The hot-working process extrusion is used to produce semifinished products in the form of bar, strip, and solid sections, as well as tubes and hollow sections. The first part of this chapter describes the composition, properties, and applications of tin and lead extruded products with a deformation temperature range of 0 to 300 deg C and magnesium and aluminum extruded products with a working temperature range of 300 to 600 deg C. The second part focuses on copper alloy extruded products, extruded titanium alloy products, and extruded products in iron alloys with a working temperature range of 600 to 1300 deg C.

Aluminum shapes, rod, bar, tubes, and wire may be produced directly as extrusions or by subsequent processing of continuous cast stock. This chapter describes the key aspects of aluminum extrusion and wire production focusing on the more common hot extrusion process and presenting the general types of aluminum extrusion alloys. An overview of free-machining alloys and products, and weldable 6xxx and 7xxx high-strength structural alloys is also provided.

This chapter describes the different aluminum products used to manufacture modern automobile components. It discusses how automakers use these products to reduce weight, improve performance, and manage production costs. It also reflects on the changes in the aluminum industry, automakers, and their relationships. Organized by product type—castings, sheet, and extrusions—each section of the chapter describes the relevant alloys, tempers, and properties required to meet specific needs for component parts and final assembly.

This chapter begins with a description of the requirements of tooling and tooling material for hot extrusion. It covers the processes of designing tool and die sets for direct and indirect extrusion. Next, the chapter provides information on extrusion tooling and die sets for direct external and internal shape production and tools for copper alloy extrusion. Further, it addresses design, calculation, and dimensioning of single-piece and two-part containers and describes induction heating for containers. Information on static- and elastic-based analysis and dimensioning of containers loaded in three dimensions is provided. Examples of calculations for different containers, along with their stresses and dimensions, are presented and the manufacture, operation, and maintenance of containers are described. The chapter further discusses the properties and applications of hot working materials for the manufacture of extrusion tooling and of different extruded materials for the manufacture of extrusion tooling for direct and indirect forming.

Aluminum alloy products offer architectural and building solutions that exploit the benefits inherent in this metal: light weight, excellent durability, low maintenance, and thermal management opportunities. This chapter discusses the major applications for aluminum building products and related competitive materials. The commonly used alloys and tempers and their performance benefits are outlined for extruded profiles, rolled sheet and foil, and die cast products.

Forged aluminum products vary widely in their production methods and applications. The forging process allows for control of microstructure and directional properties, and their fatigue and fracture resistance are superior to shape castings. This chapter presents the types, equipment, process steps, alloys, and products of aluminum forging.

This chapter provides basic concepts and background for customer-related manufacturing processes applied to aluminum products including forming, joining and welding, surface treatments, and machinability. It reviews the selection criteria, key testing regimes, and original equipment manufacturer (OEM) requirements. The chapter also presents examples that demonstrate the importance of choosing the correct alloy and temper to successfully meet the OEM fabrication criteria.

This chapter discusses the extrusion characteristics of hard aluminum alloys, particularly those in the 5000 and 7000 series. It begins with a review of two studies, one showing how the extrudability of 7 xxx alloys varies with the presence and amount of different alloying elements, the other relating minimum wall thickness with circumscribing circle diameter. It then explains how oxides on either the billet or container complicate the control of extrusion as well as auxiliary processes and how material flow and the movement of trapped gasses in different regions of the extrusion can lead to defects and variations in strength. It also discusses the extrusion of aluminum matrix composites and explains how composite billets are made.

This chapter describes the general characteristics of two commonly classified metalworking processes, namely hot working and cold working. Primary metalworking processes, such as the bulk deformation processes used to conduct the initial breakdown of cast ingots, are always conducted hot. Secondary processes, which are used to produce the final product shape, are conducted either hot or cold. The chapter discusses the primary objectives, principal types, advantages, and disadvantages of both primary and secondary metalworking processes. They are rolling, forging, extrusion, sheet metal forming processes, blanking and piercing, bending, stretch forming, drawing, rubber pad forming, and superplastic forming.

This article describes key processing methods and related design, manufacturing, and application considerations for plastic parts and includes a discussion on materials and process selection methodology for plastics. The discussion covers the primary plastic processing methods and how each process influences part design and the properties of the plastic part. It also includes a brief description of functional requirements in process selection; an overview of various process effects and how they affect the functions and properties of the part; and the selection of processes for size, shape, and design detail factors.

Aluminum is the second most widely used metal in the world. It is readily available, offers a wide range of properties, and can be shaped, coated, and joined using a variety of methods. This chapter discusses some of the key attributes of wrought and cast aluminum alloys and the classifications, designations, and grades of available product forms. It also explains how aluminum alloys are used in aerospace, automotive, rail, and marine applications as well as in building and construction, electrical products, manufacturing equipment, packaging, and consumer durables such as appliances and furniture.

The vast majority of beryllium products are manufactured from blocks, forms, or billets of compacted powder that are machined or worked into shape. This chapter describes the metalworking processes used, including rolling, forming, forging, extrusion, drawing, and spinning. It covers the qualitative and quantitative aspects of each process and provides examples showing how they are implemented and the results that can be achieved. The chapter also discusses the issue of beryllium’s low formability and describes some of the advancements that have been made in near-net shape processing.

Compared with other deformation processes used to produce semifinished products, the hot-working extrusion process has the advantage of applying pure compressive forces in all three force directions, enhancing workability. The available variations in the extrusion process enable a wide spectrum of materials to be extruded. This chapter focuses on the processes involved in the extrusion of semifinished products in various metals and their alloys, namely tin, lead, lead-base soft solders, tin-base soft solders, zinc, magnesium, aluminum, copper, titanium, zirconium, iron, nickel, and powder metals. It discusses their properties and applications as well as suitable equipment for extrusion. It further discusses the processes involved in the extrusion of semifinished products in exotic alloys and extrusion of semifinished products from metallic composite materials.

This chapter discusses the process of cold forging and its effect on various materials. It describes billet preparation and lubrication procedures, cold upsetting techniques, and the use of slab analysis for estimating cold forging loads. It likewise describes extrusion processes, explaining how to estimate friction and flow stress and predict extrusion loads and energy requirements. The chapter also discusses the tooling used in cold forging, the parameters affecting tool life, and the relative advantages of warm forging.

This chapter discusses the basic differences between direct and indirect extrusion, the application of plastic theory, the significance of strain and strain rate, friction, and pressure, and factors such as alloy flow stress and extrusion ratio, which influence the quality of material exiting the die and the amount of force required.