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A study of Multi-material Die Insert Failure Mechanism in Aluminum Extrusion

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A study of Multi-material Die Insert Failure Mechanism in Aluminum

Pawel Kazanowski, Hydro Aluminum – Precision Tubing Technology Center,
Zeeland, Michigan, USA

Track: EXTRUSION/DIE PRACTICAL - Dies, Inserts, and Coatings

ABSTRACT—Performance and service life of hot aluminum extrusion dies in some cases can be
improved by the implementation of multi-material die inserts. Design, manufacturing, heat
treatment, and service conditions impact functioning of the multi-material inserts at the extrusion
press and, in the case of the insert failure, are potential sources of the problem. Initiation and
propagation of the insert failure can be caused by a number of mechanisms. Analysis of insert
failure plays an important role in prediction and prevention of the failure and subsequently in
improving process economics. Fractography analysis was used in this study to determine type,
origin, and direction of fracture observed in multi-material inserts. Mechanism of the fracture was
further studied using numerical methods. Practical and theoretical work results were used to
improve inserts design and manufacturing processes. Some of the improvements will be

© Extrusion Technology for Aluminum Profiles Foundation (ET Foundation). All rights reserved. No part of The Proceedings may be reproduced in any form without the express written permission of the ET Foundation.