as at 4 March, 2014

Abstracts for the 5th Australasian Aluminium Extrusion Conference

Technical Program

27-28 May, 2014

2

Speaker Abstract Title

Miles Prosser The Australian Aluminium Industry

Garry Martin Overview of the Aluminium Industry in the Middle East with Particular Reference to the Extrusion Industry

Sven Gade From Project to Journey

Malcolm Couper 6xxx Series Alloy Design Breakthrough Gains Acceptance

Garry Martin Factors Affecting Optimum Extrusion Performance from AA6063 and AA6060 Alloy Billet

Mark Easton The Influence of Iron Content on the Tensile Properties and Anodising Response of AA6060 Extrusions

Scott Rogers Effect of Adding Small Amounts Mn to Al-Mg-Si Extrusion Alloys of the 6060- and 6063-type

Douglas Baker Extrusion of 6xxx Series High Performance Alloys

Bill Dixon Billet Surface Inflow and the Effects on Extrusion Surface Quality

Barbara Rinderer A Study of Discolouration of Homogenized AA6061 Extrusion Billet

Mark Easton Property Differences in Extruded A6061 Alloys

Markus Dobler Aluminium Extrusion Press-line Developments

David Turla Extrusion Equipment Innovations – Log Heater and Extrusion Press

Uwe Günter Gas-Induction Inline Oven

Gerhard Kleinert Induction Heating of Billets

Jens Magenheimer The Next Generation of Extrusion Presses

Paul Robbins Flow Stress: What it is and how to manage it

Rob Palmer Optimal Die Prefill Practices for Soft Alloy Extrusion

Rimma Lapovok Modeling of Aluminum Extrusion for High Quality Production

Aiden Beer Extrusion Facility for the Development of New Lightweight Alloys and Structures

Chris Jowett Dead Zones in Dies and their Effect on Streaking

Ivan Meng Analysis on 6060 Aluminium Alloy Extrusion Streaking

Xinquan Zhang Surface Topography of Caustic and Acid Etched Aluminium Extrusions

David Turla ADAM - Integrated Plant Management Software

Markus Dobler Aluminium Extrusion Press Down Time Monitoring & Extrusion Process Monitoring

Madhukar Pandit Automation and Data Handling in Extruder Plants

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The Australian Aluminium Industry

Miles Prosser1 1Australian Aluminium Council, PO Box 63, Dickson ACT 2602, Australia

Abstract. Australia is a significant player in global aluminium supply chains in the bauxite mining, alumina refining and aluminium smelting sectors. These sectors have a particular export

focus with approximately 80% of production destined for overseas markets. Recent investments and announcements describe the quite different current trends within each sector. The Kurri

Kurri smelter closed in September 2012 and the Point Henry smelter remains open with the assistance of a Government package. Production at the Gove alumina refinery was suspended in November 2013. Levels of bauxite mining and export have been increasing and are likely to

continue to do so. The coming years are likely to see a shift up the supply chain to greater levels of bauxite mining, lower levels of aluminium smelting and an uncertain trend for alumina refining.

These macro trends will be influenced by market and policy factors with the most significant in each sector being: Aluminium smelting: - Australian dollar, renewable energy target, carbon

pricing, electricity costs; Alumina refining: - Australian dollar, gas costs; Bauxite mining: - regulatory approval processes.

Overview of the Aluminium Industry in the Middle East with Particular Reference to the Extrusion Industry

Garry Martin1 1Bahrain Aluminium Extrusion Company (BALEXCO) PO Box 1053, Manama, Kingdom of

Bahrain

Abstract. The presentation will provide an overview of the aluminium industry in the Middle

East from primary ingot production to the extrusion industry with particular focus on the Gulf Cooperation Council (GCC) Countries. The six GCC Countries are: the Kingdom of Bahrain, Kingdom of Saudi Arabia (KSA), Kuwait, Sultanate of Oman, United Arab Emirates (UAE) and

Qatar. The Middle East, and in particular the GCC Countries, has seen an unprecedented growth in the primary aluminium production in the last 5 years with the addition of new aluminium

smelters in the region coupled with growth in the downstream sector such as the extrusion industry. This growth is continuing and during the next 5 years the Middle East will become a

major hub for primary aluminium production and downstream value added aluminium products. This expansion of the aluminium industry in the Middle East is linked to its very competitive cost

base inclusive of power, developing economies, a highly educated workforce and the innovative planning of the governments in the region with both a solid primary aluminium development

program and a focus on downstream development.

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From Project to Journey

Sven Gade1 1Capral Bremer Park, 71 Ashburn Road, Bundamba, Qld. 4304, Australia

Abstract. The Bremer Park Lean Manufacturing journey over the past 4 years has been one of Capral’s key initiatives to improve its business competitiveness. Since the start in 2009, all of its

220 manufacturing employees at the Bremer Park Plant have been trained in certificates III and IV in Competitive Manufacturing. The training commenced with simple, but invaluable tools like

business boards, where the team leaders meet with their crews to discuss the day’s events, safety, delivery, quality and cost performance trends and actions to rectify any issues. Over the years,

employees have built up a good knowledge of the business drivers and what they can do to reduce costs and improve operating efficiencies. Daily reviews and Gemba walks are now routine and include operators and team leaders alike to ensure sharing learnings and

improvements across the site. Combining the business boards with operator training in 5S, problem solving and the use of

analysis tools, has enabled Bremer Park to lower its cash break-even point by over 35%. In combination with other improvement projects, over $16m in cost savings have been achieved

over the last three years. In parallel to the Lean training, over 30 leaders have also been trained in safety leadership as well as diplomas in competitive engineering.

Capral’s employee training commitment has recently been recognised by Bremer Park winning the Manufacturing Skills Queensland Award for Large Manufacturer of the Year. The Lean

journey has transformed the Bremer operation into one of the best extrusion plants. The journey is continuing with further training of employees in Kaizen activities and Value Stream Mapping,

with the expectation to further optimise processes and increase operating efficiencies in the future.

6xxx Series Alloy Design Breakthrough Gains Acceptance

Malcolm J. Couper1 and Barbara Rinderer2 1Monash University, Wellington Rd, Clayton VIC 3800, Australia

2Consulting in Partnership Pty Ltd, Diamond Creek VIC 3089, Australia

Abstract. Almost two decades ago, new microscopy techniques led to discoveries about the

sequence and composition of strengthening precipitates in aluminium alloys containing magnesium and silicon. Comalco’s patent was filed in 1997 with a new paradigm for alloy design

of 6xxx series alloys. The traditional view of a “balanced” alloy having a ratio of Mg and Si of 1.73 based on Mg2Si precipitates was shown to be flawed, and there was a reason for the

experimental evidence of improved performance of traditional alloys with “excess Si”. The alloys showed improved extrusion performance either through improved mechanical properties with

similar extrudability, or improved extrudability with similar properties to the traditional alloys. Today, the leaner 6xxx alloys are marketed by billet suppliers as high speed alloys and targeted

compositions within the alloy 6060 designation are gaining acceptance over typical 6063 alloys even in conservative markets. The authors reflect on the implementation of this alloy design breakthrough.

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Factors Affecting Optimum Extrusion Performance from AA6063 and AA6060 Alloy Billet

Garry Martin1 1Bahrain Aluminium Extrusion Company (BALEXCO) PO Box 1053, Manama, Kingdom of

Bahrain

Abstract. This paper will outline the quality requirements for achieving the optimum extrusion

performance from AA6060 and AA6063 alloy billet. The optimum extrusion performance, linked to extrudability, is a key performance indicator, for the extrusion operation resulting in improved

production output, recovery and profitability for the operation. The alloy variants in the AA6060 and AA6063 series account for the production of the majority of extruded products worldwide.

The paper will also provide information on extrusion process control for the direct extrusion process, with particular reference to temperature balance on the press, the impact on

extrudability and obtaining optimum performance for the extruder . Finally the quality requirements of extruded products from AA6063 and AA6060 will be

summarised in terms of mill surface finish, aged mechanical properties and surface finished products, quality particularly for anodizing, that are important to maximise both recovery in the extrusion operation and resultant net production of extruded products.

The Influence of Iron Content on the Tensile Properties and Anodising Response of AA6060 Extrusions

Lisa Sweet1, Xinquan Zhang2, Nick Birbilis1 and Mark Easton3 1Monash University, Wellington Rd, Clayton VIC 3800, Australia

2Rio Tinto Alcan, 1 Research Avenue, Bundoora VIC 3083, Australia

3RMIT University, Bundoora VIC 3083, Australia

Abstract. Recycling of aluminum alloys leads to significant reductions in energy usage and greenhouse gas emissions. One way primary producers can improve the sustainability of the

aluminum industry is to increase the level of scrap introduced into alloy products. However, iron (Fe) pick-up can limit the amount of recycled material used, primarily due to its detrimental

effects on mechanical properties and anodising response. This paper explores the effect of increasing Fe content (0.17 to 0.29 weight percent (wt %)) within the AA6060 compositional

range, by measuring the changes in tensile properties and anodising response. While the changes in tensile properties were found to be small, the increased Fe content led to a reduction in gloss

of the anodized piece. These effects were related to the intermetallic number density.

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Effect of Adding Small Amounts Mn to Al-Mg-Si Extrusion Alloys of the 6060- and 6063-type

Scott Rogers1, Oddvin Reiso2, Jostein Røyset2,, Jan Anders Sæter2 and Ulf Tundal2

1Hydro Aluminium Asia Pte Ltd, 3/95 High Street, East Maitland, NSW 2323, Australia

2Hydro Aluminium a.s. R&D Materials Technology, N-6600 Sunndalsora, Norway

Abstract. It has been known for several decades that a small addition of Mn to Al-Mg-Si extrusion alloys of the 6060- and 6063-type may be beneficial for the extrudability. This effect on

extrudability has often been linked to the effect of Mn on the Fe-based particles in the alloy. After casting, the majority of the Fe in the alloy is tied up in AlFeSi particles of the type

Al5FeSi, also known as beta-AlFeSi. During homogenization, the beta-AlFeSi tends to transform to another type of particles, Al15(Fe,Mn)3Si2, known as alpha-AlFeSi. Adding a small amount of

Mn greatly accelerates this transformation. It is a common perception that the beta-AlFeSi is negative for the extrudability, and the positive effect observed on extrudability of adding Mn is often explained in terms of transforming beta-AlFeSi to alpha-AlFeSi. A common level of Mn for

this purpose in 6060- and 6063-alloys has been in the range 0.01-0.03 wt.% In the present work it is demonstrated that a positive effect of adding Mn above this range is

achieved. A positive shift in extrudability is observed when Mn exceeds values well above what is necessary to achieve 100% transformation from beta- to alpha-AlFeSi. It is observed that with

increasing Mn, there is a decreasing amount in coarse Mg2Si particles in the extrusion billets. Thus, it seems that the positive effect of Mn on the extrudability relates to the refinement of the

Mg2Si particle distribution.

Extrusion of 6xxx Series High Performance Alloys

Douglas Morris Baker1 1Companhia Brasileira de Alumínio, Rua Moraes do Rego 347 18125 000, Alumínio, Brazil

Abstract. The 6060 and 6063 alloys are the most widely used for extruded profiles and represent

80% of all aluminum extruded products. These alloys are considered to be non-structural and their usage is concentrated in the building industry, consumer durables and the transport industry. Recently alloys denominated “high performance” have been introduced to these consumers with

excellent results. These alloys are characterized by their good extrudability, and by the excellent surface quality obtained. This paper aims to relate the impact of these high performance alloys on

the key parameters of the extrusion process such as extrudability, mechanical properties and surface finish.

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Billet Surface Inflow and the Effects on Extrusion Surface Quality

Bill Dixon1 1QED Extrusion Developments Inc., Escondido, California, USA

Abstract. Surface finish effects such as pick-up, die lines, and roughness have long been associated with billet quality and have been extensively researched and published, notably regarding the influence of impurity content and how the homogenisation process effects the

favorable Fe-phase transformation. This work extends from that established knowledge base and addresses the role of inflow of the billet surface inverse segregation zone (ISZ) and its effect on

surface finish of 6061 alloy extrusions. By controlled extrusion trials, the effect of the depth of the inverse segregation layer in the billet is investigated. The effect of die design and edge

distance from die entry to the container liner is also investigated. Deeper ISZ and shallower edge distance produced extrusions with inferior surface quality. Measures to improve surface

condition based on the findings of the work are presented, and other extrusion process related factors are discussed.

A Study of Discolouration of Homogenized AA6061 Extrusion Billet

Barbara Rinderer1, Ji-Yong Yao2, Lisa Sweet3 and Mark Easton4 1Consulting in Partnership Pty Ltd, Diamond Creek VIC 3089, Australia

2University of Queensland, St Lucia QLD 4072, Australia

3Monash University, Wellington Rd, Clayton VIC 3800, Australia

4RMIT University, Bundoora VIC 3083, Australia

Abstract. Billet discolouration can be an episodic problem for the cast house. While some dulling of the surface occurs following the high temperature homogenization of extrusion billet,

discolouration is an abnormally dark surface. The discolouration may be linked to events affecting the casting cooling water or can be related to the furnace conditions, and the colour is

generally darker for more highly alloyed 6000 series compositions. While this surface discolouration has not been shown to impact subsequent extrusion performance, there is a

negative customer perception of the billet. Also the dark surface may cause difficulties with automated handling sensors which can fail to detect the presence of the billet. The surface of

homogenized billet exhibiting discolouration has been investigated using different techniques. Results are presented for 6061 billets exposed to fluoride and phosphate compounds prior to

homogenization, and the impact on the homogenized surface colour.

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Property Differences in Extruded A6061 Alloys

Mark Easton1, Katharina Strobel2, Lisa Sweet2 and Kamal Chahrouk3 1 RMIT University, Bundoora VIC 3083, Australia

2Department of Materials Engineering, Monash University, Clayton, Australia

3Capral Limited, Campbellfield, Melbourne Victoria 3061 Australia

Abstract. Two A6061 alloys with an almost identical alloy composition from different billet

suppliers were compared in extrusion trials. The alloys underwent identical processing parameters and samples were taken post extrusion, after drawing and after a T5 ageing

treatment. It was evident that particularly after ageing, although also to a lesser extent after drawing, that one alloy had a much higher yield and tensile strength and a higher elongation.

However, the alloy with the higher strength failed earlier in a limited number of low cycle fatigue tests. The strain hardening rate was also higher in the alloy with the better fatigue life. Further investigations also indicated that the alloys had different hardening responses and consequently a

different quench sensitivity with the higher strength alloy having a lower quench sensitivity. Whilst the results were not completely conclusive is appears that the reason for the differences in

properties is related to different dispersoid densities, where a higher number of finer dispersoids led to an alloy with increased quench sensitivity, lower strength and better fatigue life. The

dispersoid density is related to different homogenisation treatments and some simple homogenisation treatments were used to demonstrate this.

Aluminium Extrusion Press-line Developments

Markus Dobler1 1Manufacturing Consulting Establishment, Vaduz, Principality of Liechtenstein

Abstract. The author will present on some of the most recent hardware and software

developments in extrusion press operations. The presentation covers a wide range of areas including billet preparation, die preparation, extrusion presses, profile handling, ageing, internal

logistics packing and process control. In billet preparation, for example, developments include space saving log storage solutions, log cleaning equipment for removal of surface contaminants,

precision log saws, and billet preheating options with taper control. The positive and negative aspects of the developments presented will also be discussed.

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Extrusion Equipment Innovations – Log Heater and Extrusion Press

Davide Turla1 1Turla SRL, Via del Pavione 6/8, I-25050 Paderno Franciacorta (BS), Italy

Abstract. The STeP5 log heater has been developed for improved efficiency and reduced

emissions compared to traditional gas log heaters. Generally gas log heaters have efficiency

between 50 and 55% while the STeP5 log heater has real time measured efficiency of 81%. Higher efficiency means less gas consumption and pollution with gas consumption half that of a

traditional log heater. Temperature uniformity is also improved and is comparable to that achieved through an induction heater. The target temperature is reached two thirds the distance

to the exit door, allowing a more uniform temperature from the skin to the core of the billet when the billet exits the heater.

A number of innovations have improved the extrusion press and its performance. Establishing

foundations for a press can be costly and result in time delays to begin operation. The Turla

extrusion press does not need foundations as it is an entirely forged design making it very robust.

In addition, the front part of the press is totally flat to allow cooling of the profiles as close as possible to the die to achieve the best metallurgical performance of the extruded aluminium alloy.

The press safety is handled by extensive use of redundancy sensors, encoders and signals, and the complete press is pre-stressed and fully dry-tested with hot aluminium prior to delivery.

Gas-Induction Inline Oven

Uwe Günter1 1Extrutec GmbH, Fritz-Reichle-Ring 2, D-78315 Radolfzell, Germany

Abstract. The innovative inline gas-induction oven is an efficient and powerful heating solution,

which combines the advantages of a modern gas heater in combination with an induction furnace mounted together in one axis. Results compared to stand alone equipment are: lower space

requirements, increased heating rate, utilise existing space areas, further use of existing downstream equipment, excellent process control, and other valuable effects. The article will

describe the working principle, motivation for developing the inline concept, technical features, and operation data, and show clearly the economical potential for using this technology in existing lines, in retrofitting projects, or in lines with limited space.

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Induction Heating of Billets

Gerhard Kleinert1 1I.A.S. GmbH, Am großen Teich 27, 58640 Iserlohn, Germany

Abstract. Induction heating of aluminium extrusion billet offers a number of advantages over, or in combination with gas preheating. This includes prompt start-up with no preheating of the

furnace, precise and individual adjustable temperature profile heating, low maintenance and the equipment is easily adapted to different billet geometries. A review of billet induction heating

principles is combined with presentation of the types of heating systems. Some design highlights of state of the art induction heating systems with focus on production efficiency are presented. The challenge for induction billet heaters to achieve isothermal extrusion conditions is also

discussed. In summery the advantages of modern induction billet heating systems helps to drop the total production costs and serves for increase of the productivity in the aluminium extrusion

process chain.

The Next Generation of Extrusion Presses

Jens Magenheimer1 1SMS Meer GmbH, Ohlerkirchweg 66, 41069 Mönchengladbach, Germany

Abstract. The Australian extrusion industry fights with high energy costs and labour costs as

well as imports from China. The profit margin for standard profiles is decreasing constantly and the challenge for Australian extruders has just started. SMS Meer has developed a new

generation of extrusion presses offering machines and plants with significantly improved utilisation of resources. Sustainability and cost savings have been documented in the company’s

internal designation of such products as “ecoplants”. One example of this is the recently released HybrEx extrusion press allowing energy savings up to 55%. Recent developments and

applications are presented. The strict implementation of new approaches in the development of a new press generation

have resulted in an extrusion press that is considered to be SMS Meer’s technology carrier for future innovations. An optimised discard shear, fast tool changing, a practically deflection-free counterplaten design and alternative pump concepts are just a few examples of future options.

Proven design details that have remained unique design features of Schloemann extrusion presses until today, such as well known “unbreakable” laminated tie rod frame or the linear type guiding

system moving crosshead and container holder continues to provide the solid basis for the future.

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Flow Stress: What it is and how to manage it

Paul Robbins1 1Castool Tooling Systems, 2 Parratt Rd, Uxbridge, Ontario ON L9P 1R1, Canada

Abstract. In the process of light metal extrusion there are primarily four main variables. These are flow stress, billet temperature, ram speed, and the extrusion ratio. Likely, all extruders

understand extrusion ratio, which is the cross section area of the billet, as it leaves the container, divided by the cross section area of the extrusion as it leaves the die. Not all extruders, however,

are as familiar with flow stress, what it is, and what it does. It is well known by extruders that as temperature is increased the pressure required to extrude is reduced. Also, as speed is increased,

extrusion pressure increases. Resistance to extrusion is directly related to the flow stress of the alloy, which increases with reducing temperature and increasing strain rate – hence our everyday observations with the response of extrusion pressure to both temperature and speed.

Basically, flow stress is a measure of the aluminum alloy’s resistance to being pushed through the die at high temperatures. Flow stress is important to the extruder because in the extrusion

process the press or force to extrude is a function of part geometry, friction through both the container and the die, and the flow stress of the alloy. The flow stress of the alloy is influenced

by the following factors: the chemistry and metallurgical structure of the material; the temperature of deformation; the amount of deformation or strain; and the strain rate. Flow

stress, as well as die heating systems (Super Ovens), containers (Energy Efficient Quick Response) and visual optimizing systems (VOS) will be discussed.

Optimal Die Prefill Practices for Soft Alloy Extrusion

Rob Palmer1and Palitha Abeyasinghe1 1Capral Ltd, Stockwell & Crennis Mines Rds, Angaston, SA 5353, Australia

Abstract. The proportion of dies that are stored with residual aluminum (die prefill rate) has a

strong influence on the cost of die shop operations. Prefilled dies require less die shop labor, consume less caustic chemicals, and are not damaged in handling or maintenance. This paper

statistically examines the relationships between prefill rate, die failure rate, storage time, and die shop costs in a 4-press soft alloy (6060/6063) plant. Surface finish die failure rate was not

increased by storing dies for more than one year, prefilled or not. Prefilled dies gave a slightly higher die failure rate than non-prefilled dies, but the difference was outweighed by the cost savings from using prefill. Other influences on prefill practices are discussed, with emphasis on

how to maximize prefill rate without adversely affecting extrusion performance.

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Modeling of Aluminum Extrusion for High Quality Production

Rimma Lapovok 1 1CAHM, Materials Engineering Department,

Monash University, Clayton, Australia

Abstract. The cost-effective extrusion of aluminium products, such as cylindrical bars, hollow tubes and especially irregular cross-section profiles sets the demand on the parameters of the

process. Die design, lubrication, speed and temperature of extrusion define both mechanical properties of the final product and surface quality. The non-optimal choice of these parameters

could result not only in higher cost of production but also in appearance extrusion defects, surface cracking and chevron cracking. The FE simulation of the process can minimize the time

and effort in designing the optimal parameters for extrusion of aluminium profile without defects. In this paper, the simulation using commercial FE package in combination with damage model will be demonstrated. The damage model is tailored to each specific alloy and material properties

are defined by specially developed testing program. It is shown that this model has excellent capabilities in prediction of extrusion defects such as tailpipe, chevron cracking and others and

gives the possibility to define the extrusion parameters to avoid these defects and optimize the production cost.

Extrusion Facility for the Development of New Lightweight Alloys and Structures

Aiden Beer

Institute for Technology Research and Innovation, Deakin University, Geelong, Australia

Abstract. A research-dedicated extrusion facility has been established to support fundamental research on the development of new light metal alloys and structures. The facility, housed within

the “Proof of Concept” building at Deakin University, overcomes the limitations of Australia’s current laboratory scale extrusion equipment, particularly with respect to providing the capacity

and precision of control to accurately replicate industrial-scale billet heating and extrusion conditions. The capacity of the extrusion press (300T) is more than ten times that of current

laboratory scale extrusion equipment, making it possible to not only extrude “hard” alloys, but to do so under tailored extrusion conditions to optimise the extrudates final mechanical properties.

The facility has the advantage over current hot deformation simulation equipment in that intricately designed extrudate structures can be produced. Also, extrudates are of sufficient size

to permit realistic post-processing and mechanical property assessment, a capability vital for the development of alloys and structures with optimised properties. In terms of fundamental research, the facility is expected to lead to the development of new light metal alloys, new metal-

matrix composites, new micro-truss structures and new powder-base metals for structural and biomedical applications. The facility will also underpin applied research that can directly benefit

the aluminum extrusion industry, in areas such as the development of new die coatings and optimised processing conditions and metal flow (through die design and FE modelling) for

enhanced extrudability.

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Dead Zones in Dies and their Effect on Streaking

Chris Jowett1, Nick Parson2 and Jean-Francois Beland3 1Consultant to Rio Tinto Alcan, Kingston, Ontario, Canada

2Rio Tinto Alcan, Arvida R&D Centre, Jonquière, Québec, Canada

3Aluminium Technology Centre, Saguenay, Quebec, Canada

Abstract. It is generally accepted that the best extruded surface finish, both in the mill finish

condition and after anodizing, is produced with flat dies that do not incorporate a welding chamber. This is thought to be due to several factors: the bearings of these dies generally run at

lower temperatures, they allow increased cooling of the die bearing during the dead cycle and possibly cause more efficient removal of the aluminum build-up on the die bearings between billets. Another consideration is the effect of the material that accumulates in the welding

chambers. This material is often considered dead, but it has been shown that these zones are actually dynamic, and the contamination from the surface and ends of preceding billets can

continuously feed into the dead zones and from there into the extrusions’ surface. This paper describes work studying the dynamics of the dead zones, building on work published at ET’12. It

looks at the effect of feeder plate and shallow pocket geometry on the location and thickness of these surface layers and the resulting streaks.

Analysis on 6060 Aluminium Alloy Extrusion Streaking

J. Walker1, I C. Meng2, Z.W. Chen1, W.J (Bill) Hayward2,

S. Chen2 and J Mainwaring2

1School of Engineering, AUT University, 55 Wellesley St E, Auckland, 1010, New Zealand

2Fletcher Aluminium Ltd, 30-32 Bowden Road, Mt Wellington, Auckland 1060, New Zealand

Abstract. The very common type of streaking, which presents in locations of changing cross

sectional thickness, is considered in this study. Etching and anodising may reduce or eliminate streaking in some extrusions however it will enhance others. Noted that, evolution of streaking

after different etch durations has not been reported in literature. In this analysis work, surface features relating to streaking have been analysed by progressively removing surface material. We

will demonstrate, using one extrusion type, that a glossy streak appeared on the top surface and as more material was removed two dull parallel bands and then a single dull band streak appeared. The dull streaking was due to more pitting and the glossy streaking due to less pitting

and less densely distributed die lines. Through this analysis, considering the depth of the extrusion, it can reveal that the overall streaking occurs after a longer etch duration and larger

volume of surface material removal. Thus, streaking phenomenon is mainly a subsurface issue but only to a small depth. In this presentation, die design taking into account the changes of

thickness, extrusion speed and sand blasting to reduce/eliminate streaking and the economics of such measures will also be discussed.

14

Surface Topography of Caustic and Acid Etched Aluminium Extrusions

Natalia Danilova1 and Xinquan Zhang2 1Queensland University of Technology, 2 George Street, Brisbane QLD 4000, Australia

2Rio Tinto Alcan, 1 Research Avenue, Bundoora Vic 3083, Australia

Abstract. Caustic or acid etching is used as a pretreatment step in an anodising line for aluminium extrusions. The pretreatment is primarily for surface cleaning. However, it also

partially removes die lines, pickups and other surface imperfections present on the surface of the extruded profiles, and reduces the gloss of the substrate in order to achieve consistent surface

appearance after anodising. The current work examines commercially anodised extrusions with a focus on comparing the surface topography of caustic and acid etched extrusions. Various types

of streaking defects on caustic and acid etched extrusions are investigated, aiming to illustrate different defect formation mechanisms. It has been found that, while acid etching is significantly

less sensitive to the original extruded microstructure than caustic etching, certain types of compositional streaks and die streaks can still be observed on anodised extrusions pre-treated with acid etching.

ADAM - Integrated Plant Management Software

Davide Turla1 1Turla SRL, Via del Pavione 6/8, I-25050 Paderno Franciacorta (BS), Italy

Abstract. ADAM stands for “Advanced Data Acquisition and Management” and is a software

platform developed at Turla to allow an extrusion facility to achieve and maintain maximum productivity. The software is located on an intermediate level of the organizational pyramid

between various database ERP (Enterprise Resource Planning) management systems and the production process components and PLC. Turla has developed the software with an approach

philosophy that is extremely practical and organically integrated with machines’ PLC. ADAM consists of an expandable basic software package with different customized modules

and a server hardware which usually can be installed on the main pulpit close to the press control desk. The server contains OPC drivers to communicate in real time with PLC’s in the handling

system, and SQL database for all data management and interface with plant main server where company ERP is operated. The main functions of the software are: integration with existing customer ERP database, creating and managing orders, job assignment to multiple extrusion

presses, machine setting parameters recipes, managing dies lifetime and die shop, billet length optimization, production tuning and scrap optimization, dead cycle time report and optimization,

full production tracking from raw material to packing, managing maintenance and spare parts, single machines diagnostic and search faults aid, energy cost monitoring and logs management.

15

Aluminium Extrusion Press Down Time Monitoring & Extrusion Process Monitoring

Markus Dobler1 1Manufacturing Consulting Establishment, Vaduz, Principality of Liechtenstein

Abstract. Press productivity is an important key figure to indicate if an extrusion operation is performing well. The key drivers for this are the lost time, the scrap and the ram speed. This

paper will show a simple way to monitor time losses and the cycle time of a billet in real time. Down time monitoring: The system looks at contact pressure: when there is an interruption in

the dead cycle longer than expected, the system will highlight the buttons representing the

“cause” of the problem from which the operator must choose. Extrusion process monitoring: The Software module monitors the calculated cycle time of

each billet versus the actual cycle time online for each billet. The performance of each billet is visualized on the screen at the press.

The possibility for remote access to the system so all personnel like maintenance crew, die technicians, planning department can understand what is the current situation in production. This

will force action/support immediately.

Automation and Data Handling in Extruder Plants

Madhukar Pandit1 1MoMASTeam, University of Kaiserslautern, 67653 Kaiserslautern, Germany

Abstract. Production and process optimization are tasks which have to be continuously pursued in aluminum extruder plants. Automation and human expertise are paradigms of means for the

pursuit. In some plants optimization is performed using knowledge of material sciences for specifying the settings of the extrusion process supplemented by operator expertise for manual iteration. Process optimisation using computer based automation offers an alternative. Infra-red

pyrometers, measurement and learning control techniques implemented with a computer are employed. The learning control ensures that, starting from initial values, the settings of speeds

and temperatures are optimized and updated from cycle to cycle. For both manual and automatic iteration scenarios, computers can be installed for production automation for setting up a

database system with certain additional functions available from the domain of artificial intelligence. In the paper, a comprehensive automation system consisting of a data base system

equipped with an iterative learning function and an iterative temperature control system tailored for use in extrusion plants is presented. The function of the described Iterative Learning Database

(ILR Database) is to provide appropriate initial settings for the ram speed and the reference input for the profile temperature at die exit which ensure optimal production right from the first billet after a die change. The settings are calculated using the data related to product attributes such as

profile cross section geometry, alloy composition and application requirements based on optimal settings continuously achieved, archived and updated in the data base. A system implemented

using an MS-SQL Express Data base and the automation system MoMAS are described. Practical aspects concerning installation and application are described.