Contents

Volume I
Extrusion Process
Extrusion Equipment
Management Issues

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EXTRUSION PROCESS
Isothermal Extrusion of Aluminum Alloys
Masaya Takahashi and Takeshi Yoneyama .............................................................................. 1

Control of Grain Structure in Al-Mg-Si Extrusions

Nick Parson, Simon Barker, Ann Shalanski, and Christopher W. Jowett ................................. 11

METAL FLOW

Upset
Christopher W. Jowett, Gary Hay, and Nick Parson ................................................................ 23

Measurement of Pressure and Friction on the Container Surface

During Aluminum Hot Extrusion
Takeshi Yoneyama and Masaya Takahashi ........................................................................... 39

Study on Metal Flow in Extruded Billet

Hideo Sano, Takashi Ishikawa, and Yoshinori Yoshida ........................................................... 47

Metal Flow in Billets of Thin-Walled Extrudates

Steven R. Claves, Kinga Janiszewska, Wojciech Z. Misiolek, and Wojciech Libura ............... 55

An Investigation of Size Effects in Miniature Hot Extrusion

Fahad Al-Mufadi, Jay S. Gunasekera, and Frank F. Kraft ....................................................... 69

PERIPHERAL COARSE GRAIN

Prediction of Static Recrystallization During Shaped Extrusion

Zhi Peng and Terry Sheppard .................................................................................................. 79
Application of FEM to Modeling of Multi-Hole Die Extrusion
Zhi Peng and Terry Sheppard .................................................................................................. 93

Analysis of Peripheral Coarse Grain Recrystallization in 6xxx Aluminum Alloy Extrusion

William Van Geertruyden, Wojciech Z. Misiolek, and Paul T. Wang ...................................... 107

Effects of Extrusion Parameters on Coarse Grain Surface Layer in 6xxx-Series Extrusions

Elizabeth D. Sweet, Sally K. Caraher, Natalia V. Danilova, and Xinquan Zhang ................... 115

Microstructural Gradients Near the Surface of Large 6xxx Aluminum Extrudates

Steven R. Claves and Wojciech Z. Misiolek ........................................................................... 127

Thermomechanical Modeling of Coarse Grain Formation of Al-Mg-Si Alloy During Extrusion

Paul T. Wang, William H. Van Geertruyden, and Wojciech. Z. Misiolek ................................ 137

Prediction of Flow Stress and Recrystallization by the Finite Element Method During the Hot
Extrusion of Aluminum Alloys
Xianjian Duan, Terry Sheppard, and Xavier Velay ................................................................. 149

Prediction of Extruded Microstructures Using Experimental and Numerical Modeling

Techniques
Christopher Harris, Qiang Li, and Mark Jolly ......................................................................... 159

METALLURGY/MEASUREMENT

A Methodology for Quantitative Three-Dimensional Comparison of Experimental and

Computer Simulated Microstructural Textures of 6xxx Aluminum Alloys
Alexander R. Bandar, Steven R. Claves, Wojciech Z. Misiolek, Jing Lu,
Antoinette M. Maniatty, and Karel Matous ............................................................................ 169

Thermomechanical Effects of the Presence of Magnesium–Silicide in 6xxx

Alloys at Extrusion Temperatures
Roger N. Wright and Stephen Bartolucci ............................................................................... 177

The Process of Gaining Extrusion Speed in 6xxx-Series Alloy

Srimay Basu, Modar Al Mekdad, and Robert J. Todd ............................................................ 183

The Role of Metallography in the Characterization of Aluminum Extrusion Defects and Failures
William L. Phillipson ............................................................................................................... 197

TEMPERATURE MEASUREMENT

Thermal Management Practices for Aluminum Extrusion

Bill Barron and Tom Larrick ................................................................................................... 209

Integrated Extrusion Thermometry and the Measurement of Quench Rate

Stuart F. Metcalfe ................................................................................................................... 217

Real Temperature Parameters for Isothermal Extrusion

Boris Shtarker, Eduard Hodos, and Ofer Yoely ..................................................................... 225
EXTRUSION PROCESS

HyperXtrude/Process – Extrusion Process Optimization Software

Mahender P. Reddy, Henry Bertolini, and Bob W. Biel .......................................................... 231

Effect of Section Thickness on Magnitude of Shape Variations During

Cooling of Flat, Extruded Sections
Martin Kristoffersen, Bjorn Andersson, and Artem Pilipenko ................................................. 237

Studies of the Effects of Flow Imbalance on Shape Variations in Aluminum Extrusion by

use of Lagrangian FEM Software
Frode Halvorsen and Trond Aukrust ...................................................................................... 243

Evaluation of the Applicability of a Thermomechanical Model to Industrial Extrusion

Experiments of AA6063
J. van de Langkruis, W. H. Kool, and S. van der Zwaag ........................................................ 253

A Manufacturing Flow-Path Simulation of the Microstructure Evolution of 6260

Aluminum Alloy During Extrusion Processing
Lawrence A. Lalli and Ralph T. Shuey ................................................................................... 259

Temperature Changes and Their Effect on Deformation During Extrusion Using FEM
Isacc Flitta and Terry Sheppard ............................................................................................. 269

Results of an Investigation of Forward and Backward Extrusion with FEM Program QForm
Sergei Stebunov, Nikolai Biba, Boris Moroz, and K. Müller ................................................... 285

EXTRUSION EQUIPMENT
The Analysis of a Fatigue Failure of a Large Indirect Aluminum
Extrusion Press Container Mantle
Gerry J. Dail ........................................................................................................................... 295

CONTAINER

Tool Steel and Design of Modern Containers for Extrusion of Light Metal
Werner Hähnel and Manfred Herder ...................................................................................... 303

New Developments in the Design and Production of Container Assemblies

Volker Wieser, Christof Sommitsch, Kurt Haberfellner, and Paul Lehofer ............................. 309

Thermal Control of the Extrusion Press Container

Dennis Van Dine, Nazmi Gilada, Paul Robbins, Veikko I. Johannes, and Shigeyoshi Takagi ... 317

PRESSES

Catastrophic Failure: A 48-Hour Remedy

Adam Cramlet and Rick Colden ............................................................................................. 323

Building a “Green Field” Extrusion Plant in the 21st Century

Franco Libera and Chip Dollins .............................................................................................. 329
Front-Loading Technology with Tandem Cylinder Design for High Precision Extrusions
Jürgen Sturm .......................................................................................................................... 335

Special Purpose Extrusion Press for the Production of Curved Profile

Markus Konig and Uwe Muschalik ........................................................................................ 339

The Extrusion Press Line for 2024: A Forecast

J.A. Kennedy .......................................................................................................................... 345

The Maintenance of Extrusion Presses With Specific Reference to Press Tooling

Paul Robbins, Roger A.P. Fielding, and Veikko I. Johannes ................................................. 353

CONTROLS

Upgrading Extrusion Presses with Variable Frequency Drives

Richard J. Rutkowski .............................................................................................................. 361

Practical Non-Contact Temperature Measurement for Gas-Fired Billet Heating Furnaces

David Jenista .......................................................................................................................... 367

Automation System for Production Optimization in Aluminum Extruder Plants,

Based on Temperature Measurement and Control
M. Pandit, W. Deis , T. Heger, H. Hengen, V. Rothweiler, and C. Jԁnsson ........................... 371

INDUCTION/BILLET TEMPERATURE

Process Control Improvements for Single Billet Induction Heaters

Stefan Beer ............................................................................................................................ 381

Induction Heating of Aluminum Billets Using Superconductors

Niklas Magnusson and Magne Runde ................................................................................... 389

Progress in Single-Billet Induction Heaters for Light-Metal Extrusions Works

Willi Johnen ............................................................................................................................ 395

Improvements in Modern Heating Techniques for the Extruder

Mike Whisken ......................................................................................................................... 405

Influence of Log and Billet Temperature Gradients on the Productivity of Extrusion Plants –
Theoretical Considerations and Practical Results
Bruno Mancini, Carl Kramer, and Werner Strehmel ............................................................... 411

QUENCH

Advantages of a “Special Nozzles” Cooling Tunnel

Enrico Freri ............................................................................................................................. 421

High Performance Quenching: Maximum Performance in the Minimum Space

David Jenista .......................................................................................................................... 427

A New Horizontal Plant Concept for the T6 Treatment of Hard Alloy Extrusions
Carl Kramer and Bruno Mancini ............................................................................................. 433
HANDLING

Flying Cut Puller Without Hand-Off

Francesco Gramaticopolo ...................................................................................................... 439

Technical Textiles for Extrusion Handling Systems: Introducing High Tech While Avoiding
Basic Mistakes
Doris Gaube ........................................................................................................................... 443

Innovative F.T.S. Three Puller – Automatic Stretcher System

Mauro Spizzo ......................................................................................................................... 449

AGE OVENS

Continuous Aging Oven for Extruded Profiles in Aluminum Extrusion Plants

Josep Barceló, Luis Las Heras, and Joan Delgado ............................................................... 453

“Moby Dick” Innovative Continuous Aging Oven for Extruded Profiles

Mauro Spizzo ......................................................................................................................... 459

MANAGEMENT ISSUES
The Effects of Globalization on the Aluminum Extrusion Industry
Bruno G. Rüttimann ............................................................................................................... 463

GLOBALIZATION

Business Opportunities for Aluminum Extrusions in China

Benson Wu ............................................................................................................................. 479

Aluminum Profile Industry in China

Wang Zitao and Liu Jingru ..................................................................................................... 487

High Quality Extrusions for Railway and Urban Transit Applications in China
Walter Engelmann, Guenther Uetz, and Jiang Sha ............................................................... 501

Aluminum Extrusion Industry in India – Challenges & Opportunities

S. S. Chokhani ....................................................................................................................... 509

Extrusion Equipment Upgrades for Maintaining Leadership Status in India

Jitendra Pal Singh .................................................................................................................. 517

Aluminum Industry Standards for Extrusions

Pete Pollak ............................................................................................................................. 523

SAFETY AND EDUCATION

Extrusion Hazards and Risk Reduction

Alan Bartelt ............................................................................................................................. 531
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 Contents

Volume II
Billet Process and Equipment
Die Design and Technology
Value-Added Processes

How To Use This Index: Scroll down or use the bookmarks in the navigation pane at left to move to a new location
in this index. Click on a blue paper title to view that paper. To return to this index after viewing a paper, click the
“Previous Menu” bookmark in the navigation pane.

BILLET PROCESS AND EQUIPMENT

New Technology – Improving Billet Casting and Extrusion Performance
David Schloz, Richard Kelly, and Gary Jones ............................................................................ 1

BILLET CASTING

Advantages of Vertical Bonded Particle Filter Technology in Extrusion Billet Casting

David V. Neff ............................................................................................................................ 15

The Ultimate Extrusion Scrap Remelt and Casting System

Roger A.P. Fielding, D. Hugh Barnard, and George E. Macey ................................................ 21

METALLURGY

Extrudability and Mechanical Properties of Alcan’s High Performance Al-Mg-Si Alloy

Ram Ramanan, Alex Brassard, Greg Lea, Gary Hay, Christopher W. Jowett,
and Nick Parson ....................................................................................................................... 27

Predictive Metallographic Assessment of Extrudability and Comparative

Testing of 6xxx Aluminum Alloy Billets
Richard M. Kelly, Paul F. Chaveriat, Kelly P. Wardlow, Steven R. Claves, and Wojciech Z.
Misiolek .................................................................................................................................... 39

Performance of 6xxx Series Alloys Designed for Improved Extrudability and Strength
Malcolm Couper, Barbara Rinderer, Xinquan Zhang, and John Heathcock ............................ 51
HOMOGENIZATION

A Model of the ȕ-AlFeSi to Į-Al(FeMn)Si Transformation During Homogenization in 6xxx Alloys

F.J. Vermolen, N.C.W. Kuijpers, C. Vuik, S. van der Zwaag, P.T.G. Koenis,
and K.E. Nilsen ......................................................................................................................... 57

A Modern View of the Thermodynamics and Kinetics of the Magnesium-Silicide

Presence in 6xxx Alloys
Roger N. Wright, Metin Usta, and Stephen Bartolucci ............................................................. 67

BILLET PROCESSING

Use of Boron Nitride Coatings with Aluminum Casting Technology

Stephan Rudolph, and Frank Reusch ....................................................................................... 77

Almech: A Computer Program for Alloy Selection and Extrusion Process Improvement
Jostein Røyset, Jan Anders Saeter, Ulf Tundal, Oddvin Reiso, Tanja Nyborg,
Elin Beate Bjørnbakk, Anne Lise Dons, and Thomas Hagelien ............................................... 81

Features of Extrusion of Al and Mg Alloys for Production of Billets with Improved Strength,
Plastic and Technological Properties
Rafail Shcherbel, Rustem Muratov, Valery Rybin, Vasily Kuchkin, and Ekaterina
Korzhavina ............................................................................................................................... 93

MOLTEN METAL TREATMENT

The Pechiney Jetcleaner – New Equipment Technology for “In-Line” Treatment

of Molten Aluminum Alloys
John V. Griffin .......................................................................................................................... 97

Techniques for Removing Sodium from Molten Aluminum

Martin B. Taylor ...................................................................................................................... 103

Benefits with Electromagnetic Pumping Technology in Extrusion Alloy Melting Furnaces

Paul S. Campbell, Chris T. Vild, and Alan M. Peel ................................................................ 113

The Casthouse Safety Program

Michael Craig ......................................................................................................................... 121

EQUIPMENT

Traveling Billet Homogenizing Furnace

William R. Weyand ................................................................................................................. 127

Compact Type Remelt Plant for Contaminated Scrap Using Latest Melting Technology
Franz Niedermair ................................................................................................................... 135

DIE DESIGN AND TECHNOLOGY

Effect of the Convex Die Geometry on the Process Parameters During Extrusion
Pawel Kazanowski, Wojciech Libura, and Romana Sliwa ..................................................... 143
FINITE ELEMENT METHOD

Finite Element Method (FEM) Investigations for Practical Extrusion

Issues -- Extrusion Process for Complex 3-D Geometries; Pocket
Die Designs; Transverse Weld Phenomenon
Qiang Li, Chris Harris, and Mark R. Jolly ............................................................................... 151

Analysis and Design Optimization of Aluminum Extrusion Dies

Mahender P. Reddy, Ravisankar Mayavaram, David Durocher, Håkan Carlsson, and
Ola Bergqvist .......................................................................................................................... 171

Prediction of Material Flow Pattern in the Hot Extrusion of

Aluminum Alloys by the Finite Element Method
Xavier Velay, Terry Sheppard, and Xinjian Duan ................................................................... 179

Microstructural Evaluation of Convex Die Extrudates

Heather M. Browne, Steven Claves, Pawel Kazanowski, and Wojciech Z. Misiolek ............. 185

Experimental and Numerical Investigations of Aluminum Extrusion Through Pocket Dies

Dariusz LeĞniak, Wojciech Libura, Józef ZasadziĔski, Buntoro,
Klaus Müller, and Jeffrey Fluhrer ............................................................................................ 191

Numerical Simulation of Behavior of Weld-Pocket Dies during Extrusion of

Thin-Walled Solid Sections
Igor Duplancic, Zeljan Lozina, Dar Kostovic, Jere Prgin, and Zoran Bracic ........................... 199

Consideration of Surface Formation and Cracking and Control by Isothermal Extrusion;

Simulation of These Factors by the Finite Element Method (FEM)
Xavier Velay, Terry Sheppard, and Xinjian Duan ................................................................... 209

Evaluation of a New Finite Element Method (FEM) Criterion for Seam Welds Quality
Prediction in Aluminum Extruded Profiles
Lorenzo Donati, Luca Tomesani, and Vincenzo Giacomelli ................................................... 221

3-D Finite Element Method (FEM) Simulation System for Optimization of Profile Extrusion
Nikolai Biba, Sergei Stebunov, and Andrey Lishny ................................................................ 237

Integration of 3-D Finite Element Flow Modeling in Extrusion Tool

Conception and Fabrication
B. Bourqui, Y. Krähenbühl, and N. Fiétier .............................................................................. 241

PRACTICAL DESIGN

Die Design - The Next Generation

Rick Liscomb .......................................................................................................................... 247

The Effect of Die Type and Die Design on Heat Generation and Productivity
when Extruding AlMgSi Alloys
Gregory Lea and Chris Jowett ............................................................................................... 251

Integrated Computer-Aided Extrusion Hollow Die Design Methodology

Yean-Jenq (Henry) Huang ..................................................................................................... 261
Introducing Simulation Technology to Die Design
Hidekazu Sakihama, Hirozo Michisaka, Hiroyuki Eda, and Hideyo Yamasaki ...................... 269

TECHNOLOGY IN PRACTICE

Use of Tribology to Improve Performance and Quality in Aluminum Extrusion

Pradip K. Saha ....................................................................................................................... 277

The Fixed Dummy Block

Paul Robbins, Dennis Van Dine , Veikko I. Johannes, and Shigeyoshi Takagi ..................... 289

Die Heating in Production

Alan Castle, and Ian Avent...................................................................................................... 295

The Single-Cell Die Oven

Stephen Wasilenko, Roger A. P. Fielding, and George Macey ............................................. 301

Automated Polishing and Cleaning of Aluminum Extrusion Dies

Bill Fehl .................................................................................................................................. 313

Study of Cost Savings in Die Trial and Die Correction With New Inspection Technologies
Shmaya Wallfish and Piermario Locatelli ............................................................................... 319

Software Application for the Management of Profiles, Backers, and Bolsters

Rafael I. Rodriguez ................................................................................................................ 325

Weight Per Meter Control Through Accurate Die Aperture Size

Hanif Hamzah ........................................................................................................................ 329

SURFACE TREATMENTS AND MATERIALS

Deposition of Hard Films on Hot-Work-Steel Dies for Aluminum Extrusion

Klaus MĦller ........................................................................................................................... 343

CVD Coating Technology for Increased Lifetime of Aluminum Extrusion Dies

Joachim Maier ........................................................................................................................ 351

Nitriding of Extrusion Dies: Problems and Solutions

Tahar Nabil Tarfa and Andrzej Czelusniak ............................................................................ 357

Extrud-ALTM -- An Alternative Approach to Nitrogen Die Cooling

Richard Twigg and Robert Oesterreich .................................................................................. 373

Modern Extrusion Die Hardening and Nitriding

Tom Guler and Jeff Pritchard ................................................................................................ .377

Ni3Al-Based Composites as Alternative Die Materials for the Extrusion of

Hard Aluminum Alloys
Twan J. Walstock, Jie Zhou, and Jurek Duszczyk ................................................................. 383

Fundamentals of Advanced Aluminum Extrusion Processes

Józef ZasadziĔski, Wojciech Libura, and Jan Richert ............................................................ 391
 VALUE-ADDED PROCESSES
Wider Extrusions at Lower Cost by Friction Stir Welding
Kari Erik Lahti ......................................................................................................................... 399

WELDING

Friction Stir Welding Tools and Techniques for Welding Aluminum Extrusions
Wayne M. Thomas, Ian M. Norris, Edward D. Nicholas, and D. G. Staines .......................... 407

Promoting the Use of Aluminum Extrusions within the Welding Fabrication Industries
Tony Anderson ....................................................................................................................... 417

EXTRUSION

Changes to Extrusion Application Design in the Aluminum Design Manual 2005

J. Randolph Kissell and Michael H. Skillingberg .................................................................... 423

Manufacturing Process of Curved Extrusions for Aluminum

Alf Birkenstock, Karl-Heinz Lindner, and Norbert-William Sucke ........................................... 427

Production of High-Curved Extruded Profiles Directly During the Extrusion Process

Buntoro and K.B. Müller ......................................................................................................... 437

Effect of Stretching on Extrusions for Residual Stress and Distortion

M.E. Karabin and R.W. Schultz .............................................................................................. 447

Industrial Experience of Caustic Soda Recovery Integrated with Automatic Die Cleaning
Walter Dalla Barba and Fabio Vincenzi ................................................................................. 453

Enhanced Tool Lubrication Systems

James E. Dyla ........................................................................................................................ 457

FABRICATION

Manufacture of Continuously Reinforced Profiles Using Standard 6060 Billets

Matthias Kleiner, Michael Schomaecker, Marco Schikorra, and Alexander Klaus ................ 461

Improving Thermal Performance in Structural Fenestration Products

Patrick Muessig ...................................................................................................................... 469

New Advanced Automation in Extrusion Working and Assembly

Mario Conserva and Enrico Perego ....................................................................................... 475

Design and Fabrication of Aluminum Automobiles

Frank G. Armao ...................................................................................................................... 483

A CNC Machining Center for Processing Aluminum Profiles for the Train Industry
Giovanni Barbareschi ............................................................................................................. 489
ANODIZING

Outdoor Exposure Performance of Anodized Finishes

Barry Ellard ............................................................................................................................ 497

A New Economic Two-Step Coloring Process for Bronze and “Stainless Steel” Colors
Walter Dalla Barba and Fabio Vincenzi ................................................................................. 507

Anodized Architectural Aluminum Combined with an Organic Seal

Richard Porosky, Michael Turner, Douglas Penn, and Tsutomu Ito ...................................... 517

PAINT-BASED FINISHES

Chrome-Free Pretreatment: A Cost-Effective Solution to the Elimination of

Environmental and Workplace Concerns Surrounding Chromium
Charles R. Ike ........................................................................................................................ 525

Decoral System: for the Decoration of Extruded Aluminum Profiles

Enrico Piva ............................................................................................................................. 529

Process Control and Data Acquisition for Pretreatment Washer

Systems Utilizing Computerized Graphics
Timothy E. Fudge ................................................................................................................... 537

GLOSSARY ......................................................................................................................... 543

AUTHOR INDEX .................................................................................................................. 569