Finite Element Model Prediction of Charge Weld Behaviour in AA6082 and AA6063 Extruded Profiles

Charge welds are unavoidable defects of the continuous extrusion process whose extension needs to be accurately predicted in order to avoid profile mechanical failures or to minimize unrequired scrap of material. The aim of this work was then to evaluate the accuracy of the charge welds FEM predicti...

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Bibliographic Details
Published in:Journal of materials engineering and performance 2021-06, Vol.30 (6), p.4691-4699
Main Authors: Negozio, Marco, Pelaccia, Riccardo, Donati, Lorenzo, Reggiani, Barbara, Pinter, Tommaso, Tomesani, Luca
Format: Article
Language:English
Subjects:
Characterization and Evaluation of Materials
Chemistry and Materials Science
Corrosion and Coatings
Engineering Design
Materials Science
Quality Control
Reliability
Safety and Risk
Tribology
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Summary:Charge welds are unavoidable defects of the continuous extrusion process whose extension needs to be accurately predicted in order to avoid profile mechanical failures or to minimize unrequired scrap of material. The aim of this work was then to evaluate the accuracy of the charge welds FEM predictions and their applicability in the industrial field. Two different industrial cases involving A6082 and AA6063 aluminium alloys were analysed. The data of charge welds behaviours were experimentally collected, discussed and then innovatively compared to the predicted outcomes of FEM simulations performed using QForm Extrusion® software and of theoretical formulas reported in the literature. As main results, a very good numerical-experimental matching was found, with a peak discrepancy of 122 mm in terms of charge weld extent, while theoretical formulas returned a significant underestimation.
ISSN:1059-9495
1544-1024
DOI:10.1007/s11665-021-05752-x