EP2289641B1 - Verfahren zur Koextrusion von Metallprodukten und Matrize zur Durchführung des Verfahrens - Google Patents

Verfahren zur Koextrusion von Metallprodukten und Matrize zur Durchführung des Verfahrens Download PDF

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Publication number
EP2289641B1
EP2289641B1 EP20090168462 EP09168462A EP2289641B1 EP 2289641 B1 EP2289641 B1 EP 2289641B1 EP 20090168462 EP20090168462 EP 20090168462 EP 09168462 A EP09168462 A EP 09168462A EP 2289641 B1 EP2289641 B1 EP 2289641B1
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EP
European Patent Office
Prior art keywords
metallic material
extrusion
profile
die set
metallic
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Not-in-force
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EP20090168462
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English (en)
French (fr)
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EP2289641A1 (de
Inventor
Thomas Herding
Peter Zajonz
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ST Extruded Products Germany GmbH
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Aleris Aluminum Bitterfeld GmbH
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Priority to EP20090168462 priority Critical patent/EP2289641B1/de
Publication of EP2289641A1 publication Critical patent/EP2289641A1/de
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/22—Making metal-coated products; Making products from two or more metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C25/00—Profiling tools for metal extruding
    • B21C25/02—Dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C33/00—Feeding extrusion presses with metal to be extruded ; Loading the dummy block
    • B21C33/004—Composite billet

Definitions

  • the invention relates to a method of co-extruding at least two metallic materials, a first and a second metallic material, into an extruded profile, preferably a hollow-profile workpiece, wherein the first metallic material forms an outer shell of the extruded profile and the second metallic material forms a core or inner shell of the extruded profile, said core being bonded to the outer shell. Furthermore, the invention relates to an extrusion arrangement used in the method according to this invention.
  • alloy designations and temper designations refer to the Aluminum Association designations as published by the Aluminum Association in 2009 .
  • Alloys having a poor corrosion resistance are often coated with alloys having a better corrosion resistance to obtain a good corrosion resistance of the final product.
  • it is possible to use the good properties of alloys having a poor corrosion resistance e.g. the high strength of a 7xxx alloy can be combined with the good corrosion resistance of a 6xxx alloy or pure aluminium.
  • This also applies to hollow-profile workpieces.
  • a problem in the extrusion of hollow-profile workpieces consisting of two materials is achieving a uniform layer thickness of each material. When co-extruding two alloys, there is the problem of an advance of the inner billet.
  • the inner billet which forms the core material after the co-extrusion of the hollow-profile workpiece is thicker at the beginning of the hollow-profile workpiece than at the end of this workpiece.
  • Document EP 1 008 406 discloses a method for producing a hollow-profile workpiece of an aluminum alloy, the hollow space of which is filled with a foamable material, by co-extruding the two materials and subsequently foaming the semi-finished product.
  • Document WO 2008/107000 discloses a method for applying a metal plating material as a plating layer onto the surface of a profile made of an aluminum alloy as the base material.
  • a billet made of the base material and, in front of the billet, a disk comprising substantially the same cross section as the billet and made of the plating material is inserted into the container of an extruder press, and the billet made of the base material is pressed together with the prepositioned disk made of the plating material through the opening of a die, to give a plated profile.
  • aluminum alloy profiles can be provided with a metal plating layer, the method lacks preciseness because the thickness of the coating layer cannot be adjusted exactly.
  • plating material e.g. pure aluminum, is wasted because it is extruded at the beginning of the extrusion process.
  • Document DE 10 2007 038 923 discloses a method and a semi-finished product for joining workpieces.
  • the method is characterized by arranging a semi-finished product which consists of an expandable starting material, in a joining area of the workpiece in such a manner that the semi-finished product encloses one of the workpieces.
  • this document does not disclose the specific process steps for producing the joined workpiece.
  • Document DE 10 2007 006 156 discloses a method for producing a composite body which contains at least one component that is connected to an expandable body.
  • the method comprises the following steps: connecting a pressed body, consisting of an expandable material, with the component, the pressed body and the component being brought into loose contact, shaping the component and/or the pressed body in such a manner that the component and the pressed body are form- and/or force-locked, and expanding the press body, consisting of an expandable material, by external heat supply.
  • the method also relates to an intermediate for producing a composite body. However, in this method a pressed body of the foamable material is formed and then placed into a component having a hollow profile.
  • Document JP 03052708 which forms the basis for the preambule of independent claims 1 and 7, discloses that a branched hole 28 is provided in each bridge part 17 of a port-hole die 7.
  • a compounded billet 3 is composed of a core material 30 and a surface material 31 and the diameter of the core material 30 is formed larger than that of the core 18.
  • a portion 33 of the core material 30 is divided by the bridge part 17 and pours into the deposition room 13.
  • Another portion 34 of the core material 30 pours from the branched hole 28 into the deposition room 13, extends over divided core materials 33 and passes through a formed clearance 20 under a state continuing in the peripheral direction.
  • the inner layer is made of a hollow clad material 6 continuing in the peripheral direction and excellent in quality (see Fig. 1 ).
  • the thickness of the materials is not consistent over the length of the extruded hollow-profile workpiece. This means that at the beginning of the hollow-profile workpiece the core material is thicker than at the end the workpiece. Moreover, during extrusion, the two materials are mixed in the burr by turbulences in the die set.
  • the invention provides a method of co-extruding at least two metallic materials, a first and a second metallic material, into an extruded profile, wherein the first metallic material forms an outer shell of the extruded profile and the second metallic
  • the present invention relates to a die set used in the method of the present invention.
  • part of the extrusion process means that it is not mandatory for the method of the present invention that the first metallic material and the second metallic material are separated throughout the whole extrusion process. They will be separated for example by walls or any other separation device during the last part of the extrusion process, i.e. while the billets are pressed through the die set. In an embodiment the two materials will be separated over a length of e.g. 10 to 60% in relation to the length of the die set. Preferably, the first and second metallic material will be separated only until just before the extrusion die, e.g. until about 10 - 120 mm, preferably until about 25 to 105 mm before the die.
  • the first metallic material and the second metallic material which are to be extruded according to the method of the present invention form an outer billet of the first metallic material and an inner billet of the second metallic material, which may be put together to form together an extrusion (final) billet.
  • the inner billet of the second material is surrounded by the outer billet of the first material.
  • the extruded profile is preferably a hollow profile (e.g. tube) with e.g. an approximately circular, oval or angular, in particular rectangular cross-section which may have rounded corners.
  • the method of the invention may also be used for producing solid profiles, e.g. coated rods, wherein the profiles will preferably have a circular, oval, angular and in particular rectangular cross-section and which may have rounded corners.
  • the separation of the two metallic materials during the extrusion process is achieved by providing different compartments and inlets for the first and second metallic material in a die set which is part of an extrusion arrangement.
  • the first and second billet are inserted into different inlets of the die set, the inlets in turn being separated by walls.
  • this die set has additional brakes in the compartment of the first and/or the second metallic material whereby the metal flow of each metallic material is regulated.
  • the brakes are located only just before the extrusion die, e.g. until about 10 to 100 mm, preferably until about 19 to 70 mm before the die entry.
  • the separating device, the brakes and the extrusion arrangement are all made of the same material, preferably tool steel as known in the art.
  • the shape of the brake is designed dependent on the alloys which are used as the first and the second metallic material.
  • the brake is preferably located in the compartment of the second metallic material forming the core of the extruded profile and is suspended on radial spiders or bridges of the die set.
  • the separating device may also be held by radial spiders or bridges. For example, four bridges spand by 90° may form a spider in each case.
  • the first metallic material and/or the second metallic material can be an aluminium alloy, a magnesium alloy or a lithium containing aluminium alloy.
  • the first metallic material is a 7xxx alloy and the second metallic material is a 6xxx alloy or a 1xxx-series alloy.
  • the second metallic material is a foam pre-form (not yet a foam), which consists of an alloy having a lower melting temperature than the first metallic material, and further comprising foaming agents such as hydrides, hydroxides, and carbonates.
  • foaming agents such as hydrides, hydroxides, and carbonates.
  • a suitable foaming agent is e.g. a metal hydride, wherein the metal is selected from the group consisting of Ti, Fe, Co, Al, Cu, Mg, W, Mn, Cr, Be, or an alloy thereof.
  • the metal is selected from the group consisting of Ti, Fe, Co, Al, Cu, Mg, W, Mn, Cr, Be, or an alloy thereof.
  • the hydrides will decompose and generate the required hydrogen gas.
  • the hydrogen will lead to the formation of bubbles of the molten foamable metal, e.g. an aluminium alloy.
  • a preferred foaming agent is in the form of titanium hydride (TiH2) powder, and can be added in a quantity of from 0.02 to 8 weight percent to an aluminium alloy.
  • the present invention relates to a die set for co-extruding at least two metallic materials, a first and a second metallic material, which comprises a separating device for separating the first metallic material and the second metallic material.
  • the separating device comprises different compartments and inlets for the first and the second metallic material. Moreover, the separating device can function as a brake.
  • a brake is positioned in the compartment of the first and/or second metallic material.
  • a brake may have the form of a baffle positioned to slow down the flow of the metallic material in the extrusion direction.
  • the brake will be positioned in the compartment of the second metallic material forming the core of the extruded profile.
  • the brake may extend even closer to the die than the separating device. Alternatively, it may be closer to the inlet than the separating device.
  • the form, position and thickness of the brake will determine the amount of slow-down of the flow of the respective metallic material.
  • the present invention relates to the use of the (inventive) extrusion arrangement in the method disclosed in the present application.
  • Fig. 1 is a schematic, longitudinal sectional view of an extrusion arrangement according to the state of the art for manufacturing a hollow-profile workpiece made of two metallic materials 1, 4.
  • the extrusion arrangement comprises a container 2, which comprises a cavity 12 for receiving billets of the metallic materials 1, 4, wherein the first metallic material 1 forms the outer billet and the second metallic material 4 forms the inner billet.
  • a ram (stem) 3 is guided in the cavity 12 and can perform a longitudinal movement along the arrow 7 in order to push the metallic materials 1, 4 through the die set 16.
  • the die set 16 comprises the die 10 and the die holder 6.
  • the die 10 is preferably ring-shaped in order to produce a hollow profile 11 having an outer shell of the first metallic material 1 and an inner layer/core of the second metallic material 4.
  • the metallic materials 1, 4 are guided around a mandrel 5 positioned along the longitudinal axis of the die set/extrusion arrangement.
  • the metallic materials inserted into the cavity 12 of the container 2 are pressed by the ram 3 around the mandrel 5 through the die 10, whereby an extruded hollow profile 11 is created whose cross-section depends on the shape of the die 10.
  • Fig. 2 is a schematic, longitudinal sectional view of an extrusion arrangement for manufacturing a hollow-profile workpiece made of two metals 1, 4.
  • the extrusion arrangement comprises a container 2 having a hollow space or cavity 12 for receiving billets of the metallic materials 1, 4, a ram 3 which is guided in the container 2 and presses the metallic materials 1, 4 through the die 10, and a separating device 8 for separating the two metallic materials 1, 4, i.e. the inner billet of the first metallic material 4 and the outer billet of the second metallic material 1, in the die set 16.
  • the metallic materials in the cavity 12 are pressed by ram 3 around the mandrel 5 through the die 10 of the die set 16, whereby an extruded hollow profile 11 is created whose cross-section depends on the shape of the die 10.
  • the separating device 8 may e.g. be the separating wall between two compartments in the die set 16, i.e. one compartment for the outer billet and one compartment for the inner billet. As shown in Figures 2 and 3 , the separating device 8 is located in the die set 16 distanced from the die 10 and the mandrel 5.
  • this area 14 is designated welding chamber.
  • Fig. 3 is a schematic, longitudinal sectional view of an extrusion arrangement according to the invention for manufacturing a hollow-profile workpiece 11 made of two metals 1, 4.
  • the assembly is the same as described in Fig. 2 and further contains brakes 9 in the die set 16, positioned in the second metallic material 4 to regulate the flow of this material.
  • the extrusion arrangement functions as the extrusion arrangement described in Fig. 2 .
  • Fig. 4 is a longitudinal sectional view of a die set according to the present invention for manufacturing a hollow-profile workpiece made of two metals 1, 4 along the line A-A in Fig. 5 .
  • the section through the first metallic material 1 is shown dashed, whereas sections through the second metallic material are shown dotted.
  • the figure also shows the hollow profile 11, the cavity 12 extending through the die holders 6, and the die ring 7 holding the die 10, through which a hollow profile 11 is extruded.
  • the figure additionally shows a separation device 8 between outer billet material 1 and inner billet material 4 and a brake 9 located in the compartment of the inner billet material. In the portion between the downstream end of the separating device 8 and the die 10, the first and the second metallic materials 1, 4 are bonded together in the welding chamber 14.
  • the metallic materials are pressed through the die 10.
  • the die 10 forms the outer contour of the extruded profile while the mandrel 5 forms the inner contour of the extruded profile.
  • Fig. 5 is a cross sectional view of the extrusion arrangement of Fig. 4 .
  • This figure shows four inlets 13 for the billet of the first metallic material and four inlets 15 for the billet of second metallic material. Each inlet 13 is separated from each inlet 15 by a wall 8, which forms the separating device.
  • the brake 9 is approximately rectangular with rounded corners.
  • this figure shows the spider or bridge 17 of the die set.
  • the mandrel 5 is surrounded by the hollow profile 11 having a rectangular shape with rounded corners.
  • a 6063 alloy was co-extruded with a foam pre-form of a foamable material according to the method of the present invention wherein the 6063 alloy forms the shell of the extruded profile.
  • the tensile properties of the hollow-profile workpiece were measured by the yield strength Rp 0.2 and the tensile strength Rm.
  • the hollow-profile workpiece shows a yield strength of 169 ⁇ 1 MPa and a tensile strength of 226 ⁇ 1 MPa and an elongation A of 13.5 ⁇ 0.5%.
  • the standard requirements for a 6063 alloy with temper T6 are a yield strength of 160 MPa and a tensile strength of 215 MPa and an elongation of 10%. By using the method of the present invention these standard requirements were fulfilled, although a softer layer was used as the inner billet.
  • Table 1 shows that the tensile properties over the whole hollow-profile workpiece show very low variations in yield strength and tensile strength.
  • a 6063 alloy was co-extruded with a 7020 alloy, wherein the 6063 formed the inner billet and the 7020 the outer billet.
  • the materials were co-extruded to form a tube-like hollow profile.
  • the thickness of the inner layer was stable over the length of the workpiece, namely maximally 4.18 mm at the beginning of the workpiece and only marginally thinner, namely maximally 3.85 mm at the end of the workpiece.
  • the alloys of inner and outer layer were well-bonded together with no pores between the layer, although a few scattered oxides were visible at the interface between the layers.

Claims (8)

  1. Verfahren zur Koextrusion von wenigstens zwei metallischen Werkstoffen, einem ersten und einem zweiten metallischen Werkstoff (1, 4), zu einem extrudierten bzw. stranggepressten Profil, wobei der erste metallische Werkstoff (1) eine äußere Hülle des extrudierten Profils bildet und der zweite metallische Werkstoff (4) einen Kern des extrudierten Profils bildet, wobei der Kern mit der äußeren Hülle verbunden ist, und wobei der erste und der zweite metallische Werkstoff (1, 4) während wenigstens eines Teils des Extrusionsvorgangs getrennt werden, indem unterschiedliche Abteilungen und Einlässe in einer Matrize verwendet werden, dadurch gekennzeichnet, dass während des Extrusionsvorgangs ein Fluss des ersten und/oder des zweiten metallischen Werkstoffs mittels einer Bremse (9), welche sich in der jeweiligen Abteilung des metallischen Werkstoffs in der Matrize befindet, reguliert wird.
  2. Verfahren nach einem der vorhergehenden Ansprüche, wobei der erste und/oder der zweite metallische Werkstoff (1, 4) eine Aluminiumlegierung oder eine Magnesiumlegierung ist.
  3. Verfahren nach einem der vorhergehenden Ansprüche, wobei der erste und/oder der zweite metallische Werkstoff (1, 4) eine Aluminium-Lithium-Legierung ist.
  4. Verfahren nach einem der vorhergehenden Ansprüche, wobei der zweite metallische Werkstoff (4) eine Schaumvorform oder ein schäumbarer Werkstoff ist.
  5. Verfahren nach einem der vorhergehenden Ansprüche, wobei während des Extrusionsvorgangs die äußere Hülle aus dem ersten metallischen Werkstoff (1) und der Kern aus dem zweiten metallischen Werkstoff (4) mittels Schweißen aneinander gebunden werden.
  6. Verfahren nach Anspruch 4 oder 5, wobei nach der Koextrusion das extrudierte Profil auf auf eine Temperatur über der Temperatur, bei welcher der Kern des zweiten metallischen Werkstoffs schmilzt, erwärmt wird, um den zweiten metallischen Werkstoff (4) zu einem Schaum zu expandieren.
  7. Matrize zur Koextrusion wenigstens zweier metallischer Werkstoffe, eines ersten und eines zweiten metallischen Werkstoffs (1, 4), zu einem extrudierten Profil, wobei der erste metallische Werkstoff (1) eine äußere Hülle des extrudierten Profils bildet und der zweite metallische Werkstoff einen Kern des extrudierten Profils bildet, umfassend eine Trennvorrichtung (8) zum Trennen des ersten metallischen Werkstoffs (1) und des zweiten metallischen Werkstoffs (4), wobei die Trennvorrichtung (8) unterschiedliche Abteilungen und Einlässe für den ersten und den zweiten metallischen Werkstoff (1, 4) umfasst, dadurch gekennzeichnet, dass die Abteilung des ersten und/oder zweiten metallischen Werkstoffs eine Bremse (9) umfasst.
  8. Verwendung der Matrize nach Anspruch 7 in dem Verfahren nach einem der Ansprüche 1 bis 6.
EP20090168462 2009-08-24 2009-08-24 Verfahren zur Koextrusion von Metallprodukten und Matrize zur Durchführung des Verfahrens Not-in-force EP2289641B1 (de)

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CN103878199A (zh) * 2014-01-14 2014-06-25 中北大学 一种均质高强韧化镁合金杯形构件的旋转挤压模具
US9144833B2 (en) 2013-03-14 2015-09-29 The Electric Materials Company Dual-phase hot extrusion of metals
CN105080989A (zh) * 2015-09-24 2015-11-25 重庆盛镁镁业有限公司 日字型卡合式铝合金型材模具
DE102014109764A1 (de) * 2014-07-11 2016-01-14 Gottfried Wilhelm Leibniz Universität Hannover Verfahren zur Herstellung eines metallischen Bauteils, metallisches Bauteil und Vorrichtung zur Herstellung eines metallischen Bauteils
DE102015205829A1 (de) * 2015-03-31 2016-10-27 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Verfahren zur Herstellung von geschäumten Sandwichelementen
US9844806B2 (en) 2013-03-14 2017-12-19 The Electric Materials Company Dual-phase hot extrusion of metals

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JP5637100B2 (ja) * 2011-08-24 2014-12-10 近畿車輌株式会社 異種材料の結合形材の製作方法
CN102527764A (zh) * 2011-12-26 2012-07-04 上海瑞斯乐复合金属材料有限公司 正向挤压机制造双合金复合铝管的模具结构
TWI680052B (zh) * 2018-11-29 2019-12-21 富仕多科技有限公司 多層鋁合金物件及其製造方法
US11628497B2 (en) * 2020-10-01 2023-04-18 GM Global Technology Operations LLC Method of metal foam extrusion and articles manufactured therefrom

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US9144833B2 (en) 2013-03-14 2015-09-29 The Electric Materials Company Dual-phase hot extrusion of metals
US9486848B2 (en) 2013-03-14 2016-11-08 The Electric Materials Company Dual-phase hot extrusion of metals
US9844806B2 (en) 2013-03-14 2017-12-19 The Electric Materials Company Dual-phase hot extrusion of metals
CN103878199A (zh) * 2014-01-14 2014-06-25 中北大学 一种均质高强韧化镁合金杯形构件的旋转挤压模具
CN103878199B (zh) * 2014-01-14 2015-12-02 中北大学 一种均质高强韧化镁合金杯形构件的旋转挤压模具
DE102014109764A1 (de) * 2014-07-11 2016-01-14 Gottfried Wilhelm Leibniz Universität Hannover Verfahren zur Herstellung eines metallischen Bauteils, metallisches Bauteil und Vorrichtung zur Herstellung eines metallischen Bauteils
DE102014109764B4 (de) * 2014-07-11 2017-07-20 Gottfried Wilhelm Leibniz Universität Hannover Verfahren zur Herstellung eines metallischen Bauteils, metallisches Bauteil und Vorrichtung zur Herstellung eines metallischen Bauteils
DE102015205829A1 (de) * 2015-03-31 2016-10-27 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Verfahren zur Herstellung von geschäumten Sandwichelementen
DE102015205829B4 (de) * 2015-03-31 2017-01-05 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Verfahren zur Herstellung von geschäumten Sandwichelementen
CN105080989A (zh) * 2015-09-24 2015-11-25 重庆盛镁镁业有限公司 日字型卡合式铝合金型材模具
CN105080989B (zh) * 2015-09-24 2017-06-06 重庆盛镁镁业有限公司 日字型卡合式铝合金型材模具

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