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Quality Issues of Hollow Extrusions for Aerospace Applications

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Quality Issues of Hollow Extrusions for Aerospace Applications

Pradip K. Saha, The Boeing Company, USA

Track: EXTRUSION/DIE, PRACTICAL - Hollow Profiles and Heat Exchanger Profiles

ABSTRACT --- The quality of Type II (seam) hollow extrusions in aerospace
applications becomes a critical issue from time to time. Because of the difficulty
and higher cost in producing Type I (seamless) hollow extrusions of certain
geometry, Type II extrusions are being used for manufacturing secondary
structural and other nonstructural aerospace components. This paper will provide
some useful fundamental information about Type II hollow extrusion quality
issues from two different case studies – one from a high extrudable 6063 alloy,
and the other from a low extrudable, harder 7075 alloy. Proper metallurgical
bonding of billet material, like 7075 at the seam, is the most critical factor for
achieving adequate bond strength of the seam joint. Improper bonding could
cause developing cracks, the separation of the joint at the seam, and finally
failure in fabrication, or on the assembly line. Quality check measurement
systems have been developed to help extrusion manufacturers to produce Type II
hollow extrusion as defect free as possible. This paper will also highlight an
analytical model to calculate the length of the transition zone in the Type II
extrusion for bonding of old and new billet materials inside the hollow die.

© 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.