Multi-Hole Pipe Extrusion with Two-Stage Ingot Homogenizing
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Solution Overview
Problem
The reuse of aluminum scrap material as casting material leads to increased content of elements other than aluminum, causing deformation resistance and decreased extrusion speed, making it difficult to manufacture extruded multi-hole pipes with complex cross-sectional shapes.
Innovation Solution
A two-stage homogenizing process is applied to an ingot with specific chemical composition ranges, including Si, Mn, and other elements, to reduce deformation resistance during hot extrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aluminum scrap material is reused as casting material, then material cost is reduced and environmental load is lowered, but deformation resistance increases and extrusion speed decreases
Solution Approach 1:
The patent applies parameter changes by implementing a two-stage homogenizing process with specific temperature and time parameters. The first stage uses 550-650°C for 2+ hours, and the second stage uses 450-540°C for 3+ hours. This controlled parameter change transforms the ingot's internal structure, reducing deformation resistance despite high scrap content, thereby resolving the contradiction between material sustainability and manufacturing ease
Solution Approach 2:
The patent employs preliminary action through the two-stage homogenizing process performed before hot extrusion. By pre-treating the ingot with controlled heating and holding stages, the internal composition is optimized in advance, ensuring low deformation resistance during subsequent extrusion. This preliminary preparation enables successful extrusion even when using high-proportion aluminum scrap material
2Reliability
If aluminum scrap material is reused as casting material, then material cost is reduced and environmental load is lowered, but extrusion speed decreases
Solution Approach 1:
The patent uses parameter changes in the homogenizing process (temperature: 550-650°C then 450-540°C; time: 2+ hours then 3+ hours) to optimize the ingot's internal structure before extrusion. This pre-optimization ensures that even with high scrap content, the material flows smoothly during extrusion, maintaining high extrusion speed while preserving material sustainability
3Reliability
If complex cross-sectional shape is formed by extrusion, then functional performance is improved, but deformation resistance increases making extrusion difficult
Solution Approach 1:
The patent applies preliminary action through the two-stage homogenizing process that prepares the ingot's internal structure before extrusion. By controlling temperature and time parameters in advance, the material's deformation characteristics are optimized, enabling successful formation of complex cross-sectional shapes with thin partition portions while maintaining manufacturing ease
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method allows for easy production of extruded multi-hole pipes with complex cross-sectional shapes even when the content of elements other than aluminum is high, reducing environmental load and lowering material costs.
Implementation Method 1
a first homogenizing process is performed by holding the ingot at a temperature of 550°C or higher and 650°C or lower for 2 h or more; a second homogenizing process is performed by holding the ingot at a temperature of 450°C or higher and 540°C or lower for 3 h or more
Data Source
Figure 1
AI summary
In a method of manufacturing an extruded, multi-hole-pipe (1), an ingot is prepared having a chemical composition that contains one or two or more elements from among Si: 2.0 mass% or less, Fe: 0.6 mass% or less, Cu: 0.6 mass% or less, Mn: 2.0 mass% or less, Mg: 0.4 mass% or less, Cr: 0.1 mass% or less, Zn: 1.5 mass% or less, Ti: 0.1 mass% or less, and B: 0.1 mass% or less, the remainder being composed of Al and unavoidable impurities, wherein the total of the Si content and the Mn content is 3.2 mass% or less, and the Si content is less than the Mn content. After a first homogenizing process has been performed by holding the ingot at a temperature of 550°C to 650°C for 2 h or more, a second homogenizing process is performed by holding the ingot at a temperature of 450°C to 540°C for 3 h or more. Subsequently, hot extrusion is performed on the ingot.