Extrusion Benchmark 2023: Effect of Die Design on Profile Speed, Seam Weld Quality and Microstructure of Hollow Tubes

The Extrusion Benchmark 2023 was focused on the evaluation of different die design strategies for the manufacturing of AA6082 hollow tubes (40 mm external diameter and 4 mm thickness) through a porthole die with 3 openings. The extrusion process was monitored in industrial environment in terms of press load, profiles’ speed, profiles’ exit temperature, and die temperatures under different processing conditions (air quenching, water quenching, nitrogen die cooling). Extruded profiles were then analyzed in terms of seam weld quality, charge weld extension and microstructure evolution for both air/water quench and the presence/absence of nitrogen cooling. The results of the study are aimed at validating FEM simulation outputs in the context of the International Conference on Extrusion and Benchmark (ICEB)

Experimental analysis and modeling of the recrystallization behaviour of a AA6060 extruded profile

The microstructure of Al-Mg-Si alloys is gaining nowadays an increasing industrial interest because it influences the strength, crash, corrosion and esthetic properties of the extruded profiles. In order to investigate and predict the recrystallization behaviour in the extrusion of 6XXX aluminum alloys, experimental and numerical activities are still needed. In this work, the extrusion of an industrial-scale AA6060 aluminum alloy hollow profile was carried out. An innovative recrystallization model was developed and optimized by comparing the microstructural data experimentally acquired with the outputs of the simulation performed using the Finite Element commercial code Qform Extrusion. A good correlation between numerical prediction and experimental data was found, thus proving the reliability of the proposed AA6060 recrystallization model

Investigation on the topological optimization of cooling channels for extrusion dies

During the extrusion process, high temperatures are generated, due to friction and deformation works, potentially leading to profile and die defects. Among the suggested solutions aimed at controlling the thermal field of the process, the most accredited one involves the manufacturing of cooling channels at the mating face between the die and a third plate. Despite the proven efficiency of well-designed channels, the main drawback lies in the managing of the many variables involved that strongly affect the cooling efficiency and balancing. In this frame, aim of the work is to investigate the applicability of the topological optimization tool, proposed by COMSOL Multiphysics software, for the design of cooling channels in extrusion dies. To validate the tool, an industrial case study has been selected and results compared between not optimized and optimized cooling solutions

Advancements in extrusion and drawing: a review of the contributes by the ESAFORM community

The present review paper would celebrate the 25 years anniversary of the ESAFORM association by summarizing the studies performed by the delegates of the ESAFORM conference series within mini-symposium “Extrusion and Drawing” and of the papers published in the International Journal of Material Forming in the same fields. The 160 analyzed papers have been divided in four main categories corresponding to the paper main chapters (Hot Metal Extrusion, Cold Metal Extrusion, Polymer Extrusion and Drawing) then further divided in sub-chapters in order to group them in more specific research subjects. The aim of this review paper is then to provide to the reader a complete overview of the investigated topics and of the research trends over the years within the ESAFORM associate researchers

Recent Trends in Nitrogen Cooling Modelling of Extrusion Dies

Nitrogen cooling has been identified as a powerful industrial solution for the hot extrusion process to remove heat in the die and in the profile. The complexity involved in the design of cooling channels depends on many factors, including the cooling path, its position with respect to the hottest zones as well as the nitrogen phase-change that strongly affects the heat removal capacity. However, the industrial approach is still stuck in the empirical and based-experience practices that too often strongly limit the possibilities of obtaining a performing cooling solution. In this context, this work intends to summarize and discuss the advanced recent trends in the design of cooling channels for extrusion dies proposed by the authors based on the numerical approaches, with the final aim to propose possible solutions to fill the current gaps of the suboptimal industrial approaches

Multiple cues produced by a robotic fish modulate aggressive behaviour in Siamese fighting fishes

The use of robotics to establish social interactions between animals and robots, represents an elegant and innovative method to investigate animal behaviour. However, robots are still underused to investigate high complex and flexible behaviours, such as aggression. Here, Betta splendens was tested as model system to shed light on the effect of a robotic fish eliciting aggression. We evaluated how multiple signal systems, including a light stimulus, affect aggressive responses in B. splendens. Furthermore, we conducted experiments to estimate if aggressive responses were triggered by the biomimetic shape of fish replica, or whether any intruder object was effective as well. Male fishes showed longer and higher aggressive displays as puzzled stimuli from the fish replica increased. When the fish replica emitted its full sequence of cues, the intensity of aggression exceeded even that produced by real fish opponents. Fish replica shape was necessary for conspecific opponent perception, evoking significant aggressive responses. Overall, this study highlights that the efficacy of an artificial opponent eliciting aggressive behaviour in fish can be boosted by exposure to multiple signals. Optimizing the cue combination delivered by the robotic fish replica may be helpful to predict escalating levels of aggression

Hot Torsion Tests of AA6082 Alloy

Materials characterization and the knowledge of their elastic-plastic behavior are of fundamental importance for the design of industrial manufacturing processes. Nowadays, FEM simulation is the main tool used to optimize product quality and minimize scraps, and the numerical codes have evolved over the years to obtain accurate solutions with reduced computational times. Nevertheless, in order to perform reliable simulations, it is necessary to include accurate modeling of the material flow stress. Hot torsion is a powerful method for the characterization of the material flow stress because, tests can be carried out at constant speeds and temperatures, reaching large strain values, and thus getting over the limits of compression and tensile tests. In this paper the hot torsion characterization applied to AA6082 alloy is presented: tests were performed with equivalent strain rates of 0.01, 0.1, 1, and 10 s-1, in the temperature range from 440 to 550 °C (from 713.15 to 823.15 K). The results are presented in terms of equivalent stress vs equivalent strain. Finally, the material flow stress curve was predicted by the Hyperbolic sine model and Hensel-Spittel law, and the material parameters A, m1-9 are provided for the temperature expressed in °C and K

Hot Torsion Tests of AA6082 Alloy

Materials characterization and the knowledge of their elastic-plastic behavior are of fundamental importance for the design of industrial manufacturing processes. Nowadays, FEM simulation is the main tool used to optimize product quality and minimize scraps, and the numerical codes have evolved over the years to obtain accurate solutions with reduced computational times. Nevertheless, in order to perform reliable simulations, it is necessary to include accurate modeling of the material flow stress. Hot torsion is a powerful method for the characterization of the material flow stress because, tests can be carried out at constant speeds and temperatures, reaching large strain values, and thus getting over the limits of compression and tensile tests. In this paper the hot torsion characterization applied to AA6082 alloy is presented: tests were performed with equivalent strain rates of 0.01, 0.1, 1, and 10 s-1, in the temperature range from 440 to 550 °C (from 713.15 to 823.15 K). The results are presented in terms of equivalent stress vs equivalent strain. Finally, the material flow stress curve was predicted by the Hyperbolic sine model and Hensel-Spittel law, and the material parameters A, m1-9 are provided for the temperature expressed in °C and K

Toward A Stable Alpha-cycloalkyl Amino Acid With A Photoswitchable Cationic Side Chain

The N-alkylated indanylidenepyrroline (NAIP) Schiff base 3 is an unnatural a-amino acid precursor potentially useful for the preparation of semisynthetic peptides and proteins incorporating charged side chains whose structure can be modulated via Z/E photoisomerization. Here we report that the heteroallylic protons of 3 led to partial loss of ethanol accompanied by formation of the novel heterocyclic system 4 during attempted deprotection. We also show that the same protons catalyze the thermal isomerization of 3, making the light-driven conformational control concept ineffective for times longer than a few hours. These problems are not present in the previously unreported compound 5 where the acidic methyl group is replaced by an H atom. Therefore, 5, rather than 3, constitutes a promising prototype for the design of building blocks capable to modulate the electrostatic potential of a protein in specific locations via light irradiation