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extrusion defects
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Published: 31 December 2017
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Published: 30 November 2018
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Published: 31 December 2017
Fig. 9 Examples of defects in extrusion. (a) Chevron cracking in round steel bars during extrusion. Unless the part is inspected, such internal detects may remain undetected and possibly cause failure of the part in service. (b) Deformation zone in extrusion, showing rigid and plastic zones
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Series: ASM Handbook
Volume: 18
Publisher: ASM International
Published: 31 December 2017
DOI: 10.31399/asm.hb.v18.a0006385
EISBN: 978-1-62708-192-4
... of extrusion as well as thermodynamics. The finite-element method suitable for simulation of metal forming processes is explained. The article examines the extrusion defects that are divided into three different categories including surface, subsurface, and internal type. It includes information on friction...
Abstract
This article discusses two basic forms of extrusion: cold and hot. It provides information on three types of extrusion processes, namely, direct extrusion, reverse extrusion, and hydrostatic extrusion. The article also discusses the mechanics, analysis, tooling and die design of extrusion as well as thermodynamics. The finite-element method suitable for simulation of metal forming processes is explained. The article examines the extrusion defects that are divided into three different categories including surface, subsurface, and internal type. It includes information on friction and lubrication modeling of extrusion processes. The article also discusses the fundamentals of extrusion technology of titanium alloys and aluminum. It concludes with information on two forms of wear in extrusion, namely, adhesive and abrasive wear.
Series: ASM Handbook
Volume: 2A
Publisher: ASM International
Published: 30 November 2018
DOI: 10.31399/asm.hb.v02a.a0006534
EISBN: 978-1-62708-207-5
... and exit temperature, and their effect on product quality. The article also provides information on extrusion presses, press dies, and tooling, and addresses quality issues such as surface defects, blistering, and internal cracking. It concludes with a discussion on the drawing of solid section...
Abstract
This article describes the direct hot extrusion process and the typical sequence of operations for producing extruded aluminum shapes from soft and medium-grade aluminum alloys, hard alloys, and aluminum-matrix composites. It discusses key process variables, including extrusion speed and exit temperature, and their effect on product quality. The article also provides information on extrusion presses, press dies, and tooling, and addresses quality issues such as surface defects, blistering, and internal cracking. It concludes with a discussion on the drawing of solid section and aluminum tube.
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Published: 15 May 2022
Fig. 43 SEM fractographs of a polyvinyl chloride specimen fractured by impact at ambient temperature, showing the presence of an extrusion defect. (a) Original magnification: 500×. (b) Original magnification: 1500×
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Published: 01 January 2005
Fig. 37 Extrusion-type defect in centrally located rib (top), and die-design modification used to avoid defect (bottom). w , width; h , height; t , thickness. Source: Ref 2
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Published: 01 January 2005
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Published: 01 January 2002
Fig. 22 Extrusion-type defect in (a) centrally located rib and (b) die-design modification used to avoid defect
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Published: 01 November 2010
Series: ASM Handbook
Volume: 14A
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v14a.a0009006
EISBN: 978-1-62708-185-6
... Abstract Workability is the ability of the workpiece metal to undergo extrusion or drawing without fracture or defect development. This article describes the limits of workability in extrusion and drawing in terms of fracture and flaw development and presents some comments on fracture...
Abstract
Workability is the ability of the workpiece metal to undergo extrusion or drawing without fracture or defect development. This article describes the limits of workability in extrusion and drawing in terms of fracture and flaw development and presents some comments on fracture mechanisms. It discusses the empirical projections of absolute workability from various mechanical tests. The article concludes with a discussion on extrusion and drawing process design implications.
Book Chapter
Series: ASM Desk Editions
Publisher: ASM International
Published: 01 November 1995
DOI: 10.31399/asm.hb.emde.a0003015
EISBN: 978-1-62708-200-6
... extrusion, chill-roll film extrusion, pipe or tube extrusion, wire and cable coverings, extrusion coating, and profile extrusion, and provides some discussion on multiple-screw extruders. The article describes the dimensional accuracy of extrusion products, and lists common defects that occur frequently...
Abstract
This article describes the extrusion process, which converts soft, plastic material into a particular form using an extruder, or screw conveyer. It discusses the two main types of plastic extruders, twin-screw and single-screw, estimation of extruder capacity, and design and operations (heating, cooling, downstream sizing, corrugating, and crossheading) of the screw, the most important component of any extruder. It discusses the shapes produced by screw extrusion and the types of extrusion products produced by extrusion processes, including blown-film extrusion, flat-film or sheet extrusion, chill-roll film extrusion, pipe or tube extrusion, wire and cable coverings, extrusion coating, and profile extrusion, and provides some discussion on multiple-screw extruders. The article describes the dimensional accuracy of extrusion products, and lists common defects that occur frequently in the extrusion process.
Series: ASM Handbook
Volume: 14A
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v14a.a0004006
EISBN: 978-1-62708-185-6
... into the extruded product, because defects can result. Nevertheless, this process has the ability to produce very complex sections with excellent surface finishes and low dimensional tolerances. Flat-face (shear-face) dies and hollow dies with flat shear faces are typically used in nonlubricated hot extrusion...
Abstract
Hot extrusion is a process in which wrought parts are formed by forcing a heated billet through a shaped die opening. This article discusses nonlubricated and lubricated hot extrusion. The two nonlubricated hot extrusion methods are forward or direct extrusion and backward or indirect extrusion. The article illustrates the significance of extrusion speeds and temperatures in hot extrusion. It describes the basic types of presses used in the hot extrusion of metals. The article provides information on the characterization of extruded shapes and explains the operating parameters, including extrusion velocity, amount of pressure required, and type of lubricant, for successful and efficient hot extrusion. The article concludes with a discussion on applications and design methodology that provides insight into CAD/CAM of extrusion dies.
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Published: 01 June 2012
Fig. 8 Scanning electron microscopy images of the inside surface of a blow-molded nylon balloon showing an elliptical-shaped defect oriented with the long axis parallel to the extrusion direction. Lighter arrows point to a particulate contaminant embedded in the surface of the defect. Courtesy
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Series: ASM Handbook
Volume: 14A
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v14a.a0009004
EISBN: 978-1-62708-185-6
... of stress and strain states in various regions of workpieces suggests a convenient method of classifying cracking defects. Figures 2 , 3 , 4 in this article illustrate the locations at which free surface cracks occur in forging and rolling, as well as at the nose ends of billets in extrusion or rolling...
Abstract
This article focuses on the effects of mechanical plasticity on workability; that is, process control of localized stress and strain conditions to enhance workability. It describes the nature of local stress and strain states in bulk forming processes, leading to a classification scheme, including testing procedures and specific process measurements, that facilitate the application of workability concepts. Using examples, the article applies these concepts to forging, rolling, and extrusion processes. The stress and strain environments described in the article suggest that a workability test should be capable of subjecting the material to a variety of surface strain combinations. By providing insights on fracture criteria, these tests can be used as tools for troubleshooting fracture problems in existing processes, as well as in the process development for new product designs.
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Published: 01 January 2005
Fig. 69 Use of finite-element modeling software to predict the formation of a suck-in defect in extrusion. Source: Ref 74
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Published: 01 December 2009
Fig. 17 Use of finite-element modeling software to predict the formation of a suck-in defect in extrusion. Source: Ref 74
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in Models for Fracture during Deformation Processing
> Fundamentals of Modeling for Metals Processing
Published: 01 December 2009
Fig. 1 Sketches of processing defects form a basis for early models. (a) Forging or compression test specimen. (b) Extrusion. (c) Drawing. (d) Forging with no horizontal constraint at die surface Source: Ref 1
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Book Chapter
Series: ASM Desk Editions
Publisher: ASM International
Published: 01 November 1995
DOI: 10.31399/asm.hb.emde.a0003053
EISBN: 978-1-62708-200-6
... pressing, cold isostatic pressing, slip casting, tape casting, roll compaction, extrusion, and injection molding. It describes the advantages, equipment and tooling, and material requirements of green machining, the machining of ceramics in an unfired state with the intent of producing parts as close...
Abstract
Ceramic-forming processes usually start with a powder which is then compacted into a porous shape, achieving maximum particle packing density with a high degree of uniformity. This article compares and contrasts several forming processes, including mechanical consolidation, dry pressing, cold isostatic pressing, slip casting, tape casting, roll compaction, extrusion, and injection molding. It describes the advantages, equipment and tooling, and material requirements of green machining, the machining of ceramics in an unfired state with the intent of producing parts as close to as possible to their final shape. The article also provides useful information on drying methods, shrinkage, and defects as well as the removal of organic processing aids such as dispersants, binders, plasticizers, and lubricants.
Series: ASM Handbook
Volume: 24A
Publisher: ASM International
Published: 30 June 2023
DOI: 10.31399/asm.hb.v24A.a0006968
EISBN: 978-1-62708-439-0
... Abstract Additive manufacturing (AM) is a revolutionary technology that fabricates parts layerwise and provides many advantages. This article discusses polymer AM processes such as material extrusion, vat photopolymerization (VPP), powder-bed fusion (PBF), binder jetting (BJ), material jetting...
Abstract
Additive manufacturing (AM) is a revolutionary technology that fabricates parts layerwise and provides many advantages. This article discusses polymer AM processes such as material extrusion, vat photopolymerization (VPP), powder-bed fusion (PBF), binder jetting (BJ), material jetting (MJ), and sheet lamination (SL). It presents the benefits of online monitoring and process control for polymer AM. It also introduces the respective monitoring devices used, including the models and algorithms designed for polymer AM online monitoring and control.
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