EP2809461A1

EP2809461A1 - Device and method for producing non-porous profiles from separation residues by means of extrusion

Info

Publication number: EP2809461A1
Application number: EP12784418.1A
Authority: EP
Inventors: Erman Tekkaya; Volkan GÜLEY
Original assignee: Technische Universitaet Dortmund
Current assignee: Technische Universitaet Dortmund
Priority date: 2012-02-03
Filing date: 2012-09-24
Publication date: 2014-12-10
Anticipated expiration: 2032-09-24
Also published as: EP2809461B1; WO2013113299A1; DE102012002009A1

Abstract

The invention relates to a device and a method for producing non-porous profiles from separation residues by means of extrusion, having an extrusion press (1) with a compression chamber (11) comprising an extrusion stamp (5), an extrusion die (6) and a vacuum chamber, into which aggregate material (2) consisting of separation residues from separating production processes or the like, such as swarf or residual materials, is poured. A covering element (3), which seals the compression chamber (11) on the extrusion die side, is arranged between extrusion die (6) and compression chamber (11), against which covering element (3) the extrusion stamp (5) compresses the aggregate material (2) made of separation residues into a blank (2), and during the process, fluid inclusions remaining in the compression chamber (11) and in the aggregate material (2) are removed and discharged, through for example a conically bulging extrusion stamp, radially to the outside in a targeted manner, whereupon the covering element (3) can be removed again and the compressed blank (2) can be extruded through the extrusion die (6) as a profile cross section. The aggregate material (2) is increasingly compressed by the extrusion stamp (5), applying heat if necessary, and the blank (2) is then held for a predeterminable period of time at consistent hydrostatic pressure, whereby fluid inclusions remaining in the aggregate material (2) and/or blank (2) are expelled almost completely in a targeted manner.

Description

Apparatus and process for the production of non-porous profiles from separation residues by means of extrusion

The invention relates to a device and a method for producing pore-free profiles from separation residues by means of extrusion molding according to the preamble of claims 1 and 15 and to a method of producing property-graded profiles from separation residues according to claim 21 and a layered heap suitable for this purpose according to claim 32 ,

In the manufacture of workpieces by means of parting manufacturing processes, such as in particular by means of cutting production with geometrically determined or by means of geometrically indeterminate cutting fall inevitably in addition to the actually produced workpiece partially large amounts of chips or the like. Separation residues. Also in processes of workpiece forming such as punching of sheets or the like can not be avoided material residues. Although such material remnants are waste in terms of the workpiece produced, nevertheless these separation residues such as chips or the like usually still have the same material properties that the machined blank or the workpiece produced therefrom and therefore are also correspondingly valuable, although not in an immediately further usable form. If in the following of separation residues, chips or the like. The speech is always remnants from processing processes such as the separation or other, non-original shape changes of workpieces should be meant.

Such separation residues such as shavings, trimmings and much more are usually collected with similar types of material waste as sorted as possible and fed to a recycling. For this purpose, for example, chips are collected separately according to material, eg in containers, and further processed when appropriate quantities of scrap metal dealers are reached. This further processing usually consists in that larger amounts, for example of chips, which due to their macrogeometry form only a loose mass or also an accumulation of free-flowing smaller particles, are either broken down into smaller particles in corresponding shredders or compacted in corresponding compactors, so that the volumetric Space required for storage and transport of chips decreases. Subsequently, the usual way of re-use of such pretreated chips and separation residues that they are transported by the recycling companies to corresponding melt companies on and melted at high temperatures and thereby recycled material. The problem hereof is the one hand, the high cost of collection, storage, transport and pretreatment of not yet or insufficiently compacted separation residues and on the other hand, the high energy consumption for melting for recycling.

For compaction of metal chips, for example from DE 10 2009 040 491 A1 or DE 202 10 144 U1 corresponding Brikettierpressen known in which light metal chips can be compacted by ram and issued in the form of briquettes. Although this considerably reduces the volume of chips to be stored and transported, the resulting light metal briquettes still have a high proportion of fluid media, such as air and cooling lubricant residues, which are trapped in the briquette and are very hindering direct further processing. Recycling of the light metal briquettes takes place exclusively by smelting.

It is also known from powder metallurgy to bake extra powdered metals or even ceramic substances under heat and high pressure with each other, so that results in a very compact material matrix whose properties depend on the mixture of powdered components and the process control can be influenced within wide limits. In this case, however, the starting material, namely the one or more material powder of small, substantially spherical particles, which are for example produced from the melt extra for the powder metallurgy further processing and their arrangement to each other before the thermal pressure treatment is very compact and designed with low air inclusions. Under the Pressure and at high temperature, these particles then clog together and form the very uniform new structure with only a small percentage of pores.

From US-PS 2 391 752 a process for the production of profiles or pipes or the like. Direct metal remnants such as chips is known, introduced in the vorkom pacted and thermally pretreated compacts in an extrusion press and further pressed into it and transferred by extrusion into conventional profile shapes become. Here, the thermally pretreated pellets are further heated in the extruder to temperatures below the melting temperature and pressed in this heated state through the die. The material properties of profiles produced in this way should essentially correspond to those which originate from profiles produced from melting materials.

However, it has been found that in the processing of metal scraps in the manner indicated in US Pat. No. 2,391,752, problems arise in that the extruded profiles have inhomogeneities and defects after the extrusion process, which at the most for subordinate purposes allow at low loads. Thus, due to the air inclusions in the compacts in the cross sections of the extruded from the pellets profiles repeatedly air pockets and non-homogeneous material areas that act under mechanical loads as already produced in the production break points and thus severely limit the scope of such profiles. As a result, on the one hand, such profiles of inferior and rather arbitrary quality can be produced, which also provide only low yields for the economically quite complex recycling.

The object of the present invention is therefore to further develop a generic extrusion process and a generic extrusion device in such a way that even profiles of high quality and load capacity can be produced reliably.

The invention relates to a generic device for the production of non-porous profiles of separating residues by extrusion, comprising an extruder with a compression chamber of a press die, a die and a recipient, in which a heap consisting of separating residues separating Manufacturing process or the like. As chips or residual materials can be filled. Such a generic device is characterized further developed in accordance with the invention, that between compression die and compression chamber, the compression chamber sealing plate a sealing element can be arranged, against which the punch compresses the heap of separating residues into a compact and thereby remaining in the compression chamber and in the heap fluid Directed enclosures removed, after which the cover is removable again and the compacted compact can be pushed through the press die as a profile cross-section. Due to the arrangement of the cover element, by which at least the opened cross sections of the die are sealed against the exit of the compact to be compacted, the heap or the resulting compact can be compressed to a much greater extent than in the method according to the US Pat. PS 2 391 752 was possible. The much stronger compaction can be used to selectively expel the inclusions of fluid media, in particular the inclusions of air in the heap or the compact and to ensure that even before the actual extrusion process no fluid media such as air more in the Heap or, better said, in the highly compressed compact. For this purpose, it is ensured, for example, by the shaping of the punch and / or covering element, that the flow of the fluid expelled by the increasing pressure, such as air, is pressed out of the interior of the compact and does not remain in the pores or cavities of the compact, for example already described negative effects on the extruded profile. Ideally, the expulsion of the fluid medium may occur radially outward from the interior of the aggregate, so that the expulsion begins first inside the compact and then progresses further outward. If the compact has been pressed in the compression chamber between the ram and the cover over a certain period of time, the pressure is then relieved for a short time and the cover is moved out between the compression chamber and the press die. Immediately thereafter, the compact thus produced can be pressed through the press die in a conventional manner and now also forms defect-free profiles due to the non-porous initial state prior to extrusion. This can significantly increase the quality of the extruded profiles that can be produced be, including to the addition of the extruder to the cover and the movement required for this device no further modifications of the extruder are required. In addition, the compression and extrusion can be carried out immediately following in the same extruder, whereby additional handling operations of the compact are avoided and also the process heat of the compression can be used directly for the temperature of the compact for extrusion. Thus, the present invention modified extrusion of separation residues directly to high-quality profiles is particularly economical and easy to implement device technology.

In a conceivable embodiment, the cover can be formed substantially disc-shaped and introduced between the compression chamber and die, preferably be swung or inserted. By such a disc-shaped cover member, which is pivoted or pushed laterally in the working space of the extruder between compression chamber and press die during compression of the heap to pore-free compact, the extruder must be modified only slightly. The covering element can be supported on the pressing die in relation to the force exerted on the heap or the compact due to the pressure of the pressing die and therefore only needs to be dimensioned such that the pressing pressures can be safely introduced into the pressing die.

It is particularly advantageous if the press die has a shaping in its press-die-side end region, by means of which a locally different pressure distribution in the pile can be set during compaction. Such an uneven pressure distribution, which deviates from the otherwise conventional design of the end face of the press ram, can be used to drive out the fluid inclusions in the pile or the pressed product, in particular the trapped air, out of the pile or the pressed piece , In the areas of the cross section in which the pressure due to the shaping of the end face of the ram in the pile or the compact first increases, for example, the air is pressed out of this area, whereas in adjacent cross-sectional areas no or not so high Pressure is built up by the press ram. Therefore, the air can be largely unhindered in these not so high pressurized areas flow. If the design of the end surface of the press ram so that, for example, starting from the inner region of the heap, such as in the region of the longitudinal axis of the compression chamber and thus the heap initially higher pressures in the heap arise and then the pressure zone gradually successively enlarged radially outward, so is achieved a directed Abstromung and thus a directed expulsion of air from the heap or the compact, so that the fluid medium such as the air can be removed almost residue-free and thus a largely pore-free compact is generated, which then after extrusion also largely non-porous profile cross-sections can be made.

For this purpose, in a particularly advantageous embodiment, the press-die-side end region of the press ram can be bulged in the region of its axis of symmetry in the direction of the press die, preferably conically or spherically or the like, at least in sections. The first contact point or the first contact area of the press ram with the pile or the compact then lies in the region of the symmetry axis of the ram and with approximately conical configuration of the end face of the ram expands in the course of the compression process, this zone of high pressure more and more radially outward until the entire cross-section of the heap or the compact is evenly subjected to high pressure.

In another embodiment, however, it is also conceivable that the design of the end face causes a non-symmetric or non-uniform pressure zone, such as by the press die-side end portion of the ram is designed such that in a partial region of the cross section of the compression chamber and thus the debris first higher pressures arise in the heap, according to which this region of higher pressures successively covers the entire cross-section of the compact, while setting an expulsion direction for the remaining in the heap fluid inclusions progressively. Thus, for example, the first contact between the press ram and the pile or compact could take place on one side of one edge of the press ram and propagate successively across the entire cross section of the press ram up to the other edge of the cross-sectional area of the press ram. This could be achieved, for example, by means of an end face design formed obliquely over the entire cross section of the press ram and would become a one-sided expulsion direction for the fluid medium. It goes without saying that many other end face design of the press ram are conceivable.

In a further embodiment, it is also conceivable that not only the ram, but also the substantially disc-shaped cover member on its the die facing end face has such a shape that in a portion of the cross section of the compression chamber, preferably in the region of its axis of symmetry, and thus the Haufwerks first arise higher pressures in the heap. For example, the cover element could be e.g. in the case of a symmetrically conically shaped press die, an inversely conical design of its end face facing the press die, which in turn influences the pressure conditions in the pile or compact and the expulsion of the fluid medium, such as the air, can be further improved. Similar to the above-described possibilities for the design of the end face of the press ram, corresponding variations can also be made in the design of the end face of the cover element, which variations should be adapted to the particular design of the end face of the press ram.

Furthermore, it is advantageous if a heating device is provided, with which the pre-compressed aggregate can be heated and, under the action of the press ram, preferably compressed isostatically to the compact. The densification of the aggregate towards the non-porous compact can be substantially improved if this compaction takes place under the action of thermal energy, whereby on the one hand the deformability of the separating residues is improved and on the other hand welding operations of the fractions forming the aggregate are simplified. Also, metallurgical and chemical-physical processes within the pile or the compact will run faster and easier, such as flow processes of the fluid medium. In addition, the conventional extrusion takes place anyway at elevated temperatures, so that the pre-tempering facilitates the subsequent extrusion when pressing the bulk material or compact. If the compact is set under maximum pressure after compaction of the aggregate, keeping the pellet in this state of high pressure at the required pressing temperature for a predeterminable period of time improves structuring processes of the pellet matrix such as flow processes of the fluid. the medium or welding processes. Thus, such a holding of the compact in this state of high pressure at the required pressing temperature before the actual extrusion, as is done similarly in hot isotatic pressing, the quality of the matrix of the compact and thus the subsequent extruded profile significantly improve. Keeping the compact in this condition for a few seconds may be sufficient.

It is furthermore advantageous if openings or channels or the like are arranged in the area of the compression chamber in the direction of flow of the directionally expelled fluid inclusions through which the expelled fluid inclusions can escape from the compression chamber. This ensures that the expelled fluids such as in particular the expelled air can actually drive out completely from the compact and also near the surface of the compact do not form cavities within the compression chamber, in which the air then collects and in the following extrusion process again in the cross section of Profiles can be pressed into it. It is sufficient for this, e.g. already, to ensure such an outflow of air through the inevitable annular gaps between plunger and recipient. In a further embodiment, however, it is also conceivable that in the region of the compression chamber, a pressure lower than the ambient pressure can be set by which fluid inclusions in the debris and / or the compact can be removed during the pressing process. Such a negative pressure additionally facilitates the outflow of the fluid expelled from the heap or the compact.

Constructively simplest to implement is the present invention working cover when the conventional extrusion on frequently existing shear of the extruder for separating press residue has an additional cover and / or is designed as a cover and this cover is movable into the region between compression chamber and press die. For example, the knife-like working shear of the extruder, which is retracted between the compression chamber and press die, slightly modified constructively used as a cover for the compaction of the heap or the compact. In this case, such a cover be arranged mechanically, electrically, pneumatically or hydraulically movable between the compression chamber and press die.

The invention further relates to a process for the production of non-porous profiles from separating residues by extrusion, wherein in a compacting press in a compression chamber from a press die, a die and a recipient a heap consisting of separating residues separating manufacturing process or the like. As chips or residual materials is filled. Such a generic method can be further developed according to the invention by the heap of separation of separating manufacturing processes in the compression chamber between the die and a compression chamber on the sealing messe side sealing cover member under heating from the ram increasingly compressed into a compact and then the compact via a predetermined period of time is kept under constant hydrostatic pressure, whereby in the heap and / or compact remaining fluid inclusions are directed and largely expelled completely, and immediately thereafter removed the cover and the compact is pushed through the press die to an extruded profile. Due to the increasing and spatially directed running compaction of the heap or compact a safe expulsion of fluid inclusions in the heap or the compact is guaranteed, so that even after the so-called compaction forms a largely non-porous compact, which then immediately following and in the same extruder and can be extruded in a single workflow to high-quality profiles. Keeping the compact loaded at the highest pressure below a corresponding compaction temperature facilitates the forming and flow processes within the compact and results in a substantial improvement in the homogeneity of the material of the compact, in particular a high freedom from pores. In this way, it is also possible to produce pore-free and therefore defect-free, highly loadable profiles directly from corresponding separating residues, without having to melt off the separating residues as is customary for these applications. The method according to the invention is therefore particularly economical and profiles can be produced directly from separating residues Characteristics of those are in no way inferior from profiles produced from freshly formed compacts.

It is advantageous if the bulk material consisting of separation residues separating manufacturing process or the like. As chips or residual materials in pre-compacted form with limited degree of compression of the compression chamber of the extruder is supplied. Thus, e.g. Part of the compression of the material of the heap in corresponding compacting devices such as known Brikettierpressen or the like. Take place and thereby directly and easily be introduced into the extruder feed materials without thermal interference. In the extruder operated according to the invention, the compression of the precompacted aggregate to the non-porous compact prior to the actual extrusion is then carried out under thermal influence.

It is particularly advantageous if the fluid inclusions remaining in the heap are driven out of the heap and / or the compact by the shaping of the die and / or cover element, preferably radially outwards, and are removed from the compression chamber. The retention of pores in the pellet and thus the extruded profile-inducing Fluidrests such as trapped air is characterized largely prevented as described above and it results despite the very heterogeneous starting material separation residue or chip a very homogeneous matrix of extruded compact.

A further simplification and improvement can be achieved in that the compact compacted in compressing and expelling the fluid inclusions with heat, preferably similar to the hot isostatic pressing over a holding period at a constant temperature, preferably at the necessary temperature for extrusion is pressed. In this holding period, similar to the hot isostatic pressing flow processes such as the exiting fluid or structuring processes within the compact completely and undisturbed by changing pressure conditions, whereby the quality of the compact and thus the quality of extruded from the compact profiles is significantly improved. The invention furthermore relates to a process for the production of property-graded profiles from separating residues by means of extrusion molding according to claim 21, wherein in an extrusion press in a compression chamber comprising a press die, a press die and a recipient a heap consisting of separation processes of separating production processes or the like, such as chips or Residual materials is filled. Such a method is further formed according to the invention in that the heap is formed from an arrangement of individual, in the subsequent flow direction in the press die successive layers of separating residues separating manufacturing process or the like. As chips or residual materials, wherein the heap of each layer forming separating residues or the like within each layer have material properties that are different from the material properties of the clippings of adjoining layers forming scraps or the like, and the thus stratified heap is processed by the method according to claim 15. The coating according to the invention of individual layers of separating residues or the like of different material properties makes it possible, during the subsequent extrusion of the individual layers, to produce regions within the profiles produced which follow one another in the pressing direction and likewise have correspondingly different material properties. The advantageous properties of different materials of different material properties can be combined in a profile by these layers are pressed successively and thus arranged in the pressing direction behind the other in the profile produced .. With these innovative methods, both the mechanical properties and properties such as corrosion resistance, Thermal conductivity, magnetic properties, etc. are adjusted without restriction. The nature and distribution of these areas within the profile produced allows the extruded profiles to be adapted to a wide range of technical requirements, not only by mechanical properties but also by other properties such as corrosion resistance, thermal expansion, conductivity, weldability or even magnetic properties, etc can be changed over the length of the profile. The extruded with this process profiles are distinguished from the conventional composite production by a better metallurgical compound. The transitions between the zones are longer and more precisely definable. It is also conceivable that by continuously increasing admixture other separation residues a linear change of the properties can be ensured. The separation residues may be, for example, aluminum, magnesium, copper, titanium or their alloys. Particularly advantageous is the use of such profiles produced for crash boxes in vehicle, the areas of different deformation resistances in the longitudinal direction of the crash load should have one behind the other and can be particularly easily and inexpensively manufactured by the method according to the invention.

In a first embodiment it is e.g. It is conceivable that the separation residues forming the aggregate of each layer essentially have homogeneous material properties. Then, in the later extruded profile in the extrusion direction, successive regions with homogeneous material properties are formed, the longitudinal extent of which can be adjusted by the respective layer thickness of the associated aggregate.

In another embodiment, however, it is also conceivable that the separation residues forming the bulk of each layer have material properties that change along the subsequent pressing direction, preferably continuously changing. This can e.g. be achieved by the fact that in the production of the layers, the separation residues or the like forming the aggregate have again and again slightly changed composition in the direction of the subsequent pressing direction, e.g. by repeatedly changing the mixing ratio of the separation particles of different materials that form the heap. This makes it possible to produce a sliding transition between the material properties of the extrudates formed from the aggregate formed in this way. It is also conceivable, by stratification of individual thin layers of separating remnants of homogeneous composition and mixture of different materials, to virtually produce an incremental change in the material properties of the profile produced therefrom to reach.

With regard to the later use of the property-graded profiles produced from such heaps according to the invention, it is conceivable to combine the layers of the heaps of different materials, which have regard to mechanical and / or electrical and / or thermal properties and / or others that distinguish the technical use of influencing properties from each other. In this case, all technically usable properties of the later profiles in question, such as corrosion resistance, thermal expansion, conductivity, weldability or the magnetic properties, etc. over the length of the profile, which can be influenced by appropriate composition and stratification of the layers of the heap.

For example, it is conceivable that the lamination is formed of individual layers of different alloys of the same base material. So could e.g. a profile in total consist of an aluminum material in which different alloys with differing mechanical strength have been processed by the layering according to the invention.

However, it is also conceivable that the layering is formed of individual homogeneous layers of different materials. Thus, e.g. In sections of a profile produced in this way, which are particularly subject to corrosion, particularly corrosion-resistant materials are processed, whereas in other areas of the profile other materials of completely different properties can be used.

It is also conceivable to form not only homogeneous layers, but to form the layering of individual layers of different materials, each layer changing along the subsequent pressing direction, preferably continuously changing. Has material properties. This can be achieved in a particularly simple manner if two different materials are mixed together in one layer and the composition of the particular mixture used is e.g. continuously changes within the layer.

Of particular importance for the mixture of different materials within the layers, it is that the layers of the separation of separating manufacturing processes or the like. Like shavings or residual materials in each layer have substantially equal particle sizes, since only then an unwanted segregation of the individual separation residues and thus can reliably prevent unwanted material properties of the layer. Particularly simple and economical, the stratification of the individual layers of heaps can be produced if the stratification is made in advance as a layered arrangement outside the pressing device. In this way, with appropriate devices and mixing devices, for example, in a form corresponding to the dimensions of the subsequent press dies, the layers of the pile can be formed successively. It is conceivable, in particular, that the stratification of the individual layers of heaps is introduced into the press die as a precompacted layered blank by externally pre-pressing the pre-cut pile as described and thus interlocking the separating remainders and thereby mechanically stabilizing them.

The invention further relates to a debris according to claim 32 for the production of property-graded profiles from parting residues by extrusion according to the method of claim 21, wherein the heap an arrangement of individual, in the subsequent flow direction in the press die successive layers of separating residues separating manufacturing process or the like such as chips or residual materials, wherein the separation residues or the like forming the bulk of each layer within each layer have material properties which differ from the material properties of the separation residues or the like forming the heap of adjacent layers.

A particularly preferred embodiment of the device according to the invention and of the method according to the invention is shown in the drawing.

Show it:

FIG. 1 shows a first embodiment of the device according to the invention on an extrusion press before the start of the compacting process of a heap or compact;

Figure 2 shows the embodiment of the device according to the invention according to FIG

1 during the compression process of a heap or compact, the embodiment of the device according to the invention according to Figure 1 in the extruder of the extruded profile to be produced from the compact, schematic representation of the method according to the invention on an extruder with compacting to extrusion of the extruded profile produced from the compact, schematic representation of the isobars of the distribution of the remaining fluid between ram and Cover element in the heap or the compact during the increasing compaction of the heap to the compact with a butted punch, basic flow of the compression and extrusion process according to the present invention in the form of a diagram with a plot of density of the material of the heap or the Press- lings, force of the press ram and way of the press ram over time, another embodiment of the device according to the invention with a conical configuration of the end face of the press ram and the Ab Deckelementes, a first example of a stratification of heaps for graded production of profiles with a layering of different aluminum materials with increasing in one direction strength, another example of a stratification of heaps for property graded production of profiles with a layering of different aluminum materials with a range good formability, a range of high corrosion resistance and a high strength range, FIG. 10 shows a further example of a stacking of heaps for the property-graded production of profiles with a stratification of different aluminum materials with a region of high thermal conductivity, a region of high strength and a region with ferromagnetic properties,

FIG. 11 shows a further example of a stacking of heaps for the property-graded production of profiles with a layering of different materials with increasing strength in one direction,

FIG. 12 shows a typical structure and deformation behavior of a crash box produced according to the invention from areas of different strength properties in a property-graded profile in the form of a stadia plan.

In the figure 1 is a schematic representation of an embodiment of the device according to the invention, in which a known per se and therefore only described in detail here extruder 1 is used, as is for the peculiarities of the device and the method performed with the device of concern , Such extruders 1 are commercially available and the expert therefore known in its basic structure.

Such a commercially available extrusion press 1 has a press die 5 which is linearly adjustable in the pressing direction 4 or a press die with a separate press disk 5 which pressurizes a normally block-like compact 2 in the direction of the press die 6. The compact 2 is usually brought before the extrusion process and outside of the extruder 1 or by not shown heating devices in the extruder 1 itself to a pressing temperature, which is dependent on the material of the processed compact 2 and by the extrusion of the compact 2 simplified becomes. In the press die 6, a die opening 8 is provided through which the under the pressure of the press ram 5 deforming material of the compact 2 can escape and thereby assumes the cross-sectional shape of the opening 8 of the die 6. In the present invention, however, not a homogeneous, for example urformend by casting or the like. Manufacturing method produced pressed product 2 is used, but it is a heap 2 from waste separating manufacturing processes used, such as chips machining processes or press residues remodeling manufacturing processes or mixtures such separation residues. Such separation residues have geometrically varying shapes and dimensions and, in the form used here, form a more or less loose aggregate 2, into which relatively much air and also cooling lubricant residues or the like may be trapped. It is also conceivable and possibly even preferred that such a heap 2 is pre-compressed to a certain extent in a separate device and pressed into dimensions that allows easy filling of the compression space 1 1 of the extruder 1 with the debris 2. For this purpose, however, only a part of the volume of the aggregate 2 is compressed, so that furthermore a relatively high proportion of the volume of the aggregate 2 will be filled by air. To reduce the proportion of cooling lubricant residue, it is also conceivable to clean and dry the debris 2 from waste-separating production processes, for example chemically.

If this relatively little compacted pile 2 were then pressed directly through the die opening 8 of the pressing die 6, as has been stated in the prior art, many air pockets and voids are formed in the profile 7 thus produced which affect the quality of the profile 7 greatly reduce this and make it suitable only for inferior applications.

It is therefore carried out according to the invention before the actual extrusion process of the later profile 7, a compression process of the debris 2, through which the air and any fluid residues in the debris 2 are removed from this as far as possible and thereby a pore-free compact 2 is formed, which then also for a non-porous profile 7 extrusion can.

For this purpose, before the actual extrusion process and before filling the compression space 1 1 with the debris 2 (see Figure 1) a preferably disc-shaped cover 3 so arranged in front of the opening 8 of the die 6, that the opening 8 and better still the whole cross section of the compression space 1 1 is filled in front of the die 6 by the cover 3. Thus, despite the pressure exerted later on the debris 2 pressure of the ram 5 no material of the debris 2 exit through the opening 8 and it forms a closed space for the compaction of the debris. 2

The introduction of the cover 3 can be done in the simplest case by hand by a corresponding lateral, not shown here opening in the region of the compression space 1 1, which is closed again after the introduction of the cover 3. In automatic operation of the extruder 1, a corresponding, not shown here further movement means could be provided for the cover 3, through which the cover 3 can be laterally inserted or pivoted. It is also conceivable that provided on some extruders 1 shear device for press residues, which also moves laterally between the press die 6 and compression chamber 1 1 and the remaining press residues scissors removed, so modify that this shearing device has a corresponding cover 3 or its function and the Covering function of the press die 6 described above takes over.

If the cover 3 has been arranged in the manner described between the compression space 1 1 and 4 heap, the debris 2 can be compacted under the increasing pressure of the ram 5 in the manner described. In this case, the volume of the bulk material 2 increasingly decreases (Figure 2), wherein in the manner described above, the trapped in the debris 2 air and any other fluid residues such as cooling lubricant or the like gradually displaced from the debris 2 and, for example via not shown Can drain channels to the outside of the compression space 1 1. As a result, with the steadily increasing compression of the aggregate 2, a homogenous structure of the aggregate 2 gradually forms, until the largely nonporous compact 2 forms under the highest predetermined pressure, which then after removal of the covering element 3 (FIG can emerge again known manner through the opening 8 of the die 6 and the profile 7 can form. This profile 7 is then also largely free of pores and, despite the very inhomogeneous and the fluid inclusions having starting material of the heap 2 na The qualities that can be achieved when using homogeneous, eg cast starting materials.

Prior to the actual extrusion of the compact 2, to further improve the quality of the compact 2, a type of hot isostatic pressing operation may be interposed, during which the compacted compact 2 is kept under constant pressure and temperature for some time, e.g. held for a few seconds. In this hot isoatic holding time, residual flow processes of the exiting fluid or else restructuring processes can take place within the forming matrix of the compact 2, which further increase the degree of freedom from pores and thus the quality of the compact 2.

In FIGS. 4a to 4d, the basic sequence of this compaction and extrusion process, which was shown in FIGS. 1 to 3 within the extrusion press 1, can be seen again in a cutaway view. The designations of the compression space 11 and the components of the extruder 1 have been omitted.

In FIG. 4 a, the initial state of ram 5, uncompacted or precompressed mass 2, covering element 3 and pressing die 6 can be seen (corresponding to the state in FIG. 1). FIG. 4b shows the state after completion of the compression, in which the bulk material 2 has been compressed to a maximum and occupies its smallest volume. FIG. 4c shows the process of hot isostatic pressing, in which the compacted compact 2 is kept below the pressure reached and the predeterminable temperature for the proceeding of remaining restructuring processes. In Figure 4d finally the actual extrusion process is shown, in which the cover 3 was removed between the compact 2 and the die 6 and the compact 2 is pushed through to the profile 7 through the opening 8 of the die 6.

In the figure 6 the basic sequence of the compression and extrusion process according to the present invention is shown in the form of a diagram. Here, the changing density of the aggregate 2, the course of the stamping force of the ram 5 and the path of the press ram 5 are plotted over the time t. Time period a corresponds to the time of increasing seal of the pile 2, the period b of the time of hot isostatic pressing similar pressing of the compact 2 and the time c of the time of full compression of the compact 2 in a hot isostatic pressing similar presses before the actual extrusion of the profile 7, in the figure 6 not shown. As you can see, the density of the heap 2 initially increases sharply, consolidates in the transition from period a to time period b and reached immediately before the end of the period b and thus before the extrusion of the highest value. The stamping force of the ram 5 increases only slightly, since only the remaining cavities within the bulkhead 2 are pressed together, to which only lower forces are required. Subsequently, the punch force increases sharply, is held relatively constant during the period b for forming metallurgical compounds in the heap 2 under high pressure and high temperature and falls because of the relief of the ram 5 for the removal of the cover 3 before the start of the extrusion process from strong. The stamp path first increases linearly and remains constant during period b. In the period c then the ram 5 is driven a little back to remove the cover 3 can. Therefore, the stamping force falls off.

Of particular importance in the method according to the invention is the formation of the end face of the press ram 5 and / or the end face of the cover element 3, which points to the bulk material 2 to be compacted. In order to allow directional displacement of the fluid constituents from the aggregate 2 and thus a pore-free compression and compression of the material of the aggregate 2, the displacement must be such that the fluid constituents are completely displaced from the compact 2 out. For this purpose, according to the invention, the heap 2, starting from a starting area within the cross section of the heap 2, first compressed in the middle and successively set towards the edge region under pressure, so that the fluid constituents directed gradually from more and more areas of the Cross section of the debris 2 are displaced out. Figuratively speaking, starting from the starting region, successively and continuously running, the pressure is increased in regions adjacent to the starting region or the respective region of higher pressure, and thus an outflow direction for the fluids in the direction of the edge regions of the cross section of the compression space 1 1 given. Thus, it is prevented that amounts of fluid that have been forced out of the starting area, for example, accumulate in other cross-sectional areas of the heap 2, but can no longer flow away from there by the pressure conditions. Due to the staggered pressure curve within the cross section of the heap 2 due to the pressure on the debris 2 between the ram 5 and cover 3 is almost a pressure gradient and this pressure gradient following flow direction for the displaced fluid caused.

This targeted displacement can naturally be configured differently. Preference is given to a successive displacement of the fluid starting in the middle region of the bulk material 2 towards the edges to the outside. Such a displacement can be achieved, for example, by a fundamentally conically bulged shape of the hard surface-side end face of the press ram 5, as shown schematically in FIGS. 5a to 5d. Here, symmetrical to the central axis of the typically round press ram 5, a conical shape 9 is formed, which may have a flat central region 10. If the press ram 5 is then moved relative to the cover element 3 in the pressing direction 4, zones of different residual proportions of the fluid in the matrix of the compacting material of the bulk material 2 are formed below the conically plane end face of the press ram. These different proportions are indicated in FIG. 5 by isobaric lines of zones of equal percentage purity of the material of the aggregate 2 (95% means that there is still 5% residual fluid in the amount of material of the aggregate 2 remaining in this area). As can be seen on the basis of the increasing compression (starting from FIG. 5 a to the highest pressure in FIG. 5 d), in the illustrated conical design of the end face of the press ram 5, the fluid portions from the region of the center axis of the ram 5 escape first outwards and downwards, then further outward to a state of the compacted compact 2 in FIG. 5d, which has been almost completely freed of fluid residues.

It is of course conceivable to provide other than a conical design of the end face of the press ram 5, for example, a convex bulging shape or even over the entire face one side bevelled shape, in which the compression begins in an edge region and runs continuously towards the opposite edge region.

It is also conceivable, as indicated schematically in FIG. 7, not only to form the end face of the press ram 5 in such a curved manner, but also to profile the end face of the cover element 3 facing the press ling 2. In the figure 7 is given by way of example only, that the end face of the cover 3 is conically profiled opposite to the end face of the punch 5 and has a conical portion 9 ^' with a flat central region 10 ^' . As a result, the pressure conditions in the compacting debris 2 continue to be positively influenced and the fluid can be displaced out of the compact 2 faster and more reliably. For this purpose, the end face of the press die 6 can be adjusted according to the shape of the cover 3, so that no air between the compact 2 and the die 6 is included here.

In Figure 8, the structure of a profile according to the invention is shown schematically, in which a stratification of clumps 2 for own schgradgradierten production of profiles with a layering of different aluminum materials is realized with increasing in one direction strength. In this case, the compact 2 is made from a mixture of two aluminum alloys in five compacting stages. The first stage consists of pure EN AW-6060 aluminum turnings, to which a third EN AW-7175 aluminum turnings were mixed for the second stage. For the third and fourth stages, increasing proportions of EN AW 7175 chips (one-half and two-thirds, respectively) were mixed in. The fifth stage uses pure EN AW-7175 chips. This influences the mechanical properties of the individual zones as follows. The development of the strength properties as a function of the mixing ratio of the alloys EN AW-6060 and EN AW-7175 is given laterally and numerically defined for the individual compositions of the stages. One can clearly see the increase in tensile strength with increasing AW-7175 content. The tensile strength values are given as a function of the mixing ratio of the alloys. The extrusion molding of such property-graded aggregate 2 according to the invention leads to an aluminum profile with likewise five zones. Thus, the tensile strength in zone 1 from 145 MPa up to 395 MPa in zone 5, ie an increase in tensile strength of about 270%.

FIG. 9 shows another example of a stacking of bundles 2 for the property-graded production of profiles with a layering of different aluminum materials with a range of good formability, a region of high corrosion resistance and a region of high strength. This variant is a composite profile production from several different composite materials. For example, By adding copper chips, it has been shown that a higher thermal conductivity can be achieved. Likewise, by adding alumina particles a higher strength and by incorporating iron particles ferromagnetism could be achieved.

FIG. 10 shows a further example of a stacking of bundles for the property-graded production of profiles with a layering of different aluminum materials with a region of high thermal conductivity, a region of high strength and a region with ferromagnetic properties. With this variant, aluminum alloys with special properties can be brought together in one profile. For example, for a profile requiring additional bending and welding, a 6000 series aluminum alloy may be used because of its good formability, or where the profile encounters a particular corrosive environment, a 3000 series aluminum alloy may be used because of its high corrosion resistance , Likewise, for higher strength, a 7000 series aluminum alloy may be considered for its high strength. It is also conceivable to introduce transition zones between these zones, so that the properties can be changed in a sliding or stepless manner, and thus also a better metallurgical connection between zones is conceivable.

FIG. 11 shows in general a further example of a stacking of heaps for the graded production of profiles with a stratification of different alloys of the same base material with a strength profile produced in one direction of increasing strength. Due to the different proportions of the alloys 1 and 2 used, starting from the first stage of a pure alloy material, it is possible to use zones of different compounds. composite materials are provided, which have to the arranged at the other end of the profile stage of the other alloy 2 towards increasing strength values.

FIG. 12 shows a typical structure and the resulting deformation behavior of a crash box produced according to the invention from regions of different strength properties in a property-graded profile in the form of a staged plan. Such crash boxes are used for targeted energy reduction within the body of a vehicle in the event of a crash, the crash box should have different strength values along its longitudinal extent in the direction of the crash load. In this case, the energy absorption capacity in the post-crash least deformed region III should be greater than in the middle region II and this in turn be greater than in the first deformed region I. If a force F1 is exerted on the crash box during the accident, the area I will first fold together like a pleat and a large force will be released. The areas II and III remain because of their higher strength properties once undeformed. If the deformability of the region I is exhausted, the region II is again pushed together like a fold under the action of the force F2 until the maximum deformability has been exhausted here as well. Subsequently, the region III is deformed in an analogous manner, wherein at a designated maximum load, the deformation of the region III should not be fully exploited. In this case, then the entire initiated by the crash force has been reduced in the crash box.

Such a crash box with the described behavior can be produced with the method according to the invention for stratification of heaps of different material properties and subsequent extrusion of this heap in a particularly advantageous manner, since this exactly the material behavior of the crash box described in the crash box of Figure 12 can be produced in an extrusion process. Item number list - Extruder

- Heap or compact

- Covering element

- Pressing direction

- Press punches or pressure disc

- Press die

- profile

- die opening

9 ^' - conical section press die or cover element, 10 ^' - flat center area press die or cover element - compression space

Claims

claims

1. Apparatus for producing non-porous profiles from separating residues by means of extrusion molding, comprising an extrusion press (1) with a compression chamber (1 1) from a press ram (5), a pressing die (6) and a Rezi- pienten into which a heap (2 ) consisting of separating residues of separating production processes or the like, such as chips or residual materials can be filled, characterized in that between the press die (6) and compression chamber (1 1), the compression chamber (1 1) sealing matrizenseitig a cover (3) can be arranged, against which the press ram (5) compacts the pile (2) of separating residues into a compact (2) and thereby removes the fluid inclusions in the compacting chamber (11) and in the pile (2), after which the covering element (3) returns removable and the compacted compact (2) through the die (6) can be pushed through as a profile cross-section.

2. Apparatus according to claim 1, characterized in that the cover (3) is formed substantially disc-shaped and between the compression chamber (1 1) and the die (6) can be introduced, preferably einschwenkbar or inserted.

3. Device according to one of claims 1 or 2, characterized in that the press ram (5) in its press die-side end region has a shape through which a locally different pressure distribution in the debris (2) is adjustable during compression.

4. The device according to claim 3, characterized in that the press-die-side end region of the press ram (5) is designed such that in the region of the longitudinal axis of the compression chamber (1 1) and thus of the bulk material (2) first higher pressures in the heap ( 2) arise.

5. The device according to claim 4, characterized in that the press-die-side end region of the press ram (5) in the region of its symmetry Reached axis in the direction of the press die (6), preferably at least partially conical or convex or the like. Is formed.

6. The device according to claim 3, characterized in that the press-die-side end region of the press ram (5) is designed such that in a partial region of the cross-section of the compression chamber (1 1) and thus of the bulk material (2) first higher pressures in the heap (2), whereby this region of higher pressures gradually adjusts the entire cross-section of the compact (2) successively while adjusting an expulsion direction for the fluid inclusions remaining in the aggregate (2).

7. Device according to one of the preceding claims, characterized in that the substantially disc-shaped cover (3) on its the punch (5) facing end face has such a shape that in a portion of the cross section of the compression chamber (1 1), preferably in Area of its axis of symmetry, and thus of the heap (2) first higher pressures in the heap (2) arise.

8. Device according to one of the preceding claims, characterized in that the frontal shaping of the cover (3) and / or ram (5) is designed such that fluid inclusions in the heap (2) directed at the increasing compression, preferably radially to be driven out of the pile (2) on the outside.

9. Device according to one of the preceding claims, characterized in that a heating device is provided, with which the pre-compressed debris (2) heated and under the action of the press ram (5), preferably isostatically pressed to the compact (2).

10. Device according to one of the preceding claims, characterized in that in the region of the compression chamber (1 1) in the flow direction of the directionally expelled fluid inclusions in the heap (2) and / or the compact (2) openings or channels or the like. Are arranged through which the expelled fluid inclusions can escape from the compression chamber (1 1).

11. Device according to one of the preceding claims, characterized in that in the region of the compression chamber (11) relative to the ambient pressure lower pressure is adjustable by the fluid inclusions in the heap (2) and / or the compact (2) during the pressing process are removable.

12. Device according to one of the preceding claims, characterized in that the shearing device of the extruder (1) for separating pressing residues an additional cover (3) and / or as a cover (3) is formed and this cover (3) in the area between compression chamber (1 1) and pressing die (6) is movable.

13. The apparatus according to claim 12, characterized in that the cover (3) is mechanically, electrically, pneumatically or hydraulically between the compression chamber (1 1) and the press die (6) is movable.

14. Device according to one of the preceding claims, characterized in that the covering element (3) is supported against the pressure of the pressing ram (5) during the pressing process on the pressing die (6).

15. A process for the production of non-porous profiles from separating residues by means of extrusion molding, wherein in an extrusion press (1) in a compression chamber (11) of a press ram (5), a pressing die (6) and a recipient a heap (2) consisting of Separation residues of separating production processes or the like, such as chips or residual materials is filled, characterized in that the pile (2) separating separation of manufacturing processes in the compression chamber (11) between the die (6) and the compression chamber (11) press-die side sealing cover member (3) under heating from the ram (5) increasingly compressed into a compact (2) and the compact (2) is then maintained for a predetermined period of time under constant hydrostatic pressure, whereby in the bulk material (2) and / or compact (2) remaining fluid Addressed and inclusions are largely completely expelled, and immediately thereafter the cover (3) removed and the compact (2) by the die (6) is pressed to an extruded profile (7).

16. The method according to claim 15, characterized in that the debris (2) consisting of separating residues separating manufacturing process or the like. As chips or residual materials in pre-compacted form with limited degree of compression of the compression chamber (11) of the extruder (1) is supplied.

17. The method according to any one of claims 15 or 16, characterized in that in the heap (2) remaining fluid inclusions directed by the shape of ram (5) and / or cover (3), preferably radially outward from the heap (2) and / or the pressed body (2) are expelled and removed from the compression chamber (1 1).

18. The method according to any one of claims 15 to 17, characterized in that the aggregate (2) is increasingly reduced in compacting and expelling the fluid inclusions in its volume and compacted to the compact (2).

19. The method according to any one of claims 15 to 18, characterized in that the compact (2) compressed during compression and expulsion of the fluid inclusions under heat, preferably similar to the hot isostatic pressing over a holding period at a constant temperature, preferably at the necessary Temperature for extruding is pressed.

20. The method according to any one of claims 15 to 19, characterized in that the compression and expulsion of the fluid inclusions and the extrusion of the compact (2) in the same extruder (1) takes place immediately after one another in a uniform workflow.

21. A process for the production of property-graded profiles from separating residues by means of extrusion molding, wherein in an extrusion press (1) in a compression molding Chamber (1 1) from a press ram (5), a die (6) and a recipient of a heap (2) consisting of separation residues separating manufacturing process or the like. As chips or residual materials is filled, characterized in that the debris (2) an arrangement of individual, later in the flow direction in the press die (6) successive layers of separation of separating manufacturing processes or the like. As chips or residual materials is formed, wherein the heap (2) of each layer forming release residues or the like within each layer material properties which differ from the material properties of the separation residue or the like forming the pile (2) of adjacent layers, and the thus stratified aggregate (2) is processed by the method according to claim 15.

22. The method according to claim 21, characterized in that the heap (2) of each layer forming separation residues have substantially homogeneous material properties.

23. Method according to claim 21, characterized in that the separation residues forming the aggregate (2) of each layer have material properties that change along the subsequent pressing direction, preferably continuously changing.

24. The method according to any one of claims 21 to 23, characterized in that the layers of the heaps (2) with different materials with respect to mechanical and / or electrical and / or thermal properties and / or other, the technical use of influencing properties differ from each other.

25. The method according to any one of claims 21 to 24, characterized in that the stratification of the heaps (2) after pressing in the pressing direction (4) form successive areas of different material properties in the profile produced.

26. The method according to any one of claims 21 to 25, characterized in that the layering of individual layers of different alloys of the same base material is formed.

27. The method according to any one of claims 21 to 25, characterized in that the layering of individual homogeneous layers of different materials is formed.

A method according to claim 27, characterized in that the lamination is formed of individual layers of different materials, each layer changing, preferably continuously changing, along the later pressing direction (4). Has material properties.

29. The method according to any one of claims 21 to 28, characterized in that the separation of the layers of the bulk material (2) separating manufacturing processes or the like. As chips or residual materials in each layer have substantially equal particle sizes.

30. The method according to any one of claims 21 to 29, characterized in that the stratification of the individual layers of heaps (2) in advance outside the pressing device (1) is produced as a layered arrangement.

31. The method according to claim 30, characterized in that the stratification of the individual layers of heaps (2) is introduced as precompacted layered blank in the press die (6). ,

32. Heap (2) for the production of property-graded profiles of separation residues mitteis extrusion according to the method of claim 21, characterized in that the heap (2) an arrangement of individual, in the subsequent flow direction in the press die (6) successive layers Separating residues of separating production processes or the like, such as chips or residual materials, wherein the separation residues or the like forming the aggregate (2) of each layer have, within each layer, material properties which differ from the materials used. properties of the heap (2) adjacent layers forming separating residues or the like.

A debris (2) according to claim 32, characterized in that individual layers or each layer of the aggregate (2) can be formed from separation residues of a single material or from a substantially homogeneous mixture of separation residues of different materials.