Multi-Hole Aluminum Pipe Extrusion for Scrap-Rich Alloy Billets
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Solution Overview
Problem
The reuse of aluminum scrap material as casting material poses challenges due to high content of elements other than aluminum, leading to increased 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 a specific chemical composition containing Si, Fe, Cu, Mn, Mg, Cr, Zn, Ti, and B, within controlled temperature and time ranges, to reduce deformation resistance during hot extrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aluminum scrap material is used as casting material, then environmental load is reduced and material cost is lowered, but deformation resistance during hot extrusion increases and extrusion speed decreases
Solution Approach 1:
The invention changes the chemical composition parameters of the aluminum alloy by strictly controlling the content of elements other than aluminum (Si: 2.00 mass % or less, Fe: 0.60 mass % or less, Cu: 0.60 mass % or less, Mn: 2.00 mass % or less, Mg: 0.40 mass % or less, Cr: 0.10 mass % or less, Zn: 1.50 mass % or less, Ti: 0.10 mass % or less, B: 0.10 mass % or less). This parameter control reduces the formation of coarse intermetallic compounds that cause high deformation resistance, enabling successful hot extrusion of complex-shaped multi-hole pipes using aluminum scrap material.
2Quantity of substance
If aluminum scrap material is used as casting material, then material cost is lowered, but extrusion speed decreases
Solution Approach 1:
The invention optimizes the chemical composition parameters to maintain low material cost while improving extrusion speed. By controlling the content of elements other than aluminum within specific ranges, the alloy achieves better extrudability without requiring expensive virgin aluminum, thus maintaining cost-effectiveness while increasing productivity.
3Adaptability or versatility
If high content of elements other than aluminum is present, then aluminum scrap material utilization is improved, but deformation resistance during hot extrusion increases
Solution Approach 1:
The invention precisely controls the parameters of elements other than aluminum to resolve the contradiction between scrap material utilization and deformation resistance. By setting specific upper limits for Si (2.00 mass %), Fe (0.60 mass %), Cu (0.60 mass %), Mn (2.00 mass %), Mg (0.40 mass %), Cr (0.10 mass %), Zn (1.50 mass %), Ti (0.10 mass %), and B (0.10 mass %), the alloy achieves optimal balance between utilizing scrap material and maintaining low deformation resistance for hot extrusion.
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
This method allows for easy hot extrusion of multi-hole pipes with complex shapes even when the content of elements other than aluminum is high, enhancing extrudability and reducing environmental load by utilizing aluminum scrap material.
Implementation Method 1
performing a first homogenizing process by holding the ingot at a temperature of 550° C. or higher and 650° C. or lower for 2 h or more; subsequently performing a second homogenizing process by holding the ingot at a temperature of 450° C. or higher and 540° C. or lower for 3 h or more
Data Source
AI summary
A method of manufacturing an extruded, multi-hole-pipe (1) includes preparing an ingot having an aluminum alloy composition that contains one or more of 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 total of the Si and Mn contents is 3.2 mass % or less, and the Si content is less than the Mn content. After performing a first homogenizing process at a temperature of 550° C. to 650° C. for 2 hours or more, a second homogenizing process is performed by holding the ingot at a temperature of 450° C. to 540° C. for 3 hours or more. Subsequently, the ingot is subjected to hot extrusion to form the multi-hole-pipe.