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Manufacture of Continuously Reinforced Profiles Using Standard 6060 Billets

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Manufacture of Continuously Reinforced Profiles Using Standard 6060 Billets

Matthias Kleiner, Michael Schomaecker, Marco Schikorra, Alexander Klaus, Chair of Forming Technology (LFU), Dortmund University

Track: VALUE-ADDED PROCESSES - Fabrication

ABSTRACT --- Here a new extrusion process is presented for advanced applications
in the area of lightweight constructions. This process that allows embedded reinforcing
elements such as high-strength steel wire fused into an aluminum alloy
during direct extrusion using a modified die. The fusion of the reinforcing elements
with the basic material takes place in the welding chamber’s area for the developing
longitudinal welds. For optimal results, the choice of reinforcing material and the design
of the welding chamber to control the material flow is crucial. This paper describes
the fundamental process, the experimental set-up, and results, as well as
the simulation of FE-modeling. The subsequent use of forming methods like stretching
or bending is not applicable to (or only partially applicable to) reinforced profiles
since the reinforcing elements cannot be subjected to considerable deformations.
The bending process can cause a tearing of the reinforcing elements. Discontinuities
of the reinforcing elements have a negative effect on the mechanical properties
of the extruded profiles. The innovative process of rounding during extrusion yields
better results.

© 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.