EXTRUSION SECOND EDITION. Editors. M. Bauser G. Sauer K. Siegert. Translated from German by. A.F. Castle

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1 EXTRUSION SECOND EDITION Editors M. Bauser G. Sauer K. Siegert Translated from German by A.F. Castle ASM International Materials Park, Ohio

2 Copyright 2006 by ASM International All rights reserved Originally published as Strangpressen 2001 Aluminium-Verlag, Düsseldorf, Germany No part of this book may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the written permission of the copyright owner. First printing, December 2006 Great care is taken in the compilation and production of this Volume, but it should be made clear that NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE GIVEN IN CONNECTION WITH THIS PUBLICATION. Although this information is believed to be accurate by ASM, ASM cannot guarantee that favorable results will be obtained from the use of this publication alone. This publication is intended for use by persons having technical skill, at their sole discretion and risk. Since the conditions of product or material use are outside of ASM s control, ASM assumes no liability or obligation in connection with any use of this information. No claim of any kind, whether as to products or information in this publication, and whether or not based on negligence, shall be greater in amount than the purchase price of this product or publication in respect of which damages are claimed. THE REMEDY HEREBY PROVIDED SHALL BE THE EXCLUSIVE AND SOLE REMEDY OF BUYER, AND IN NO EVENT SHALL EITHER PARTY BE LIA- BLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES WHETHER OR NOT CAUSED BY OR RESULTING FROM THE NEGLIGENCE OF SUCH PARTY. As with any material, evaluation of the material under end-use conditions prior to specification is essential. Therefore, specific testing under actual conditions is recommended. Nothing contained in this book shall be construed as a grant of any right of manufacture, sale, use, or reproduction, in connection with any method, process, apparatus, product, composition, or system, whether or not covered by letters patent, copyright, or trademark, and nothing contained in this book shall be construed as a defense against any alleged infringement of letters patent, copyright, or trademark, or as a defense against liability for such infringement. Comments, criticisms, and suggestions are invited, and should be forwarded to ASM International. Prepared under the direction of the ASM International Technical Books Committee ( ), James Foley, Chair. ASM International staff who worked on this project include Scott D. Henry, Senior Product Manager; Charles Moosbrugger; Editor, Diane Grubbs, Editorial Assistant; Bonnie Sanders, Production Manager; Madrid Tramble, Senior Production Coordinator; Diane Wilkoff, Production Coordinator; Pattie Pace, Production Coordinator; Kathryn Muldoon, Production Assistant Library of Congress Cataloging-in-Publication Data Extrusion / editors, M. Bauser, G. Sauer, K. Siegert. 2nd ed. p. cm. Includes bibliographical references and index. ISBN-13: ISBN-10: X 1. Metals Extrusion. 2. Aluminum alloys. I Bauser, M. (Martin) II. Sauer, G. (Günther) III. Siegert, Klaus. TS255.E dc SAN: ASM International Materials Park, OH Printed in the United States of America

3 Contents Foreword... xv Authors... xvi Chapter 1 Introduction Basic Principles of Extrusion...1 Historic Development of Extrusion...2 Chapter 2 Extruded Products Tin and Lead Extruded Products with a Deformation Temperature Range of 0 to 300 C Magnesium and Aluminum Extruded Products with a Working Temperature Range of 300 to 600 C Magnesium Alloy Extruded Products Aluminum Alloy Extruded Products Transport Construction Machine Manufacture, Electrical Machines, and Electrical Equipment Architecture Extruded Products from Materials with a Working Temperature Range of 600 to 1300 C Copper Alloy Extruded Products Extruded Titanium Alloy Products Extruded Products in Iron Alloys and Other Hot-Working Alloys Chapter 3 Rod and Tube Extrusion Processes Direct Extrusion Direct Hot Extrusion without Lubrication and Shell (Aluminum Alloys) Process Sequence of Direct Hot Extrusion without Lubrication or Shell Variation in the Extrusion Load with Stem Movement in Direct Hot Extrusion without Lubrication or Shell Material Flow in Direct Hot Extrusion Calculation of the Axial Loads in Direct Hot Extrusion without Lubrication and Shell (Aluminum Alloys) Thermal Changes in Direct Hot Extrusion of Aluminum Direct Hot Extrusion without Lubrication and with a Shell (Copper Alloys) Process Sequence for Direct Hot Extrusion without Lubrication and with a Shell Variation in the Stem Load over the Stem Displacement in Direct Hot Extrusion without Lubrication and with a Shell Material Flow in Direct Hot Extrusion without Lubrication and with a Shell Calculation of the Axial Forces in Direct Hot Extrusion without Lubrication and with a Shell iii

4 Thermal Conditions in Direct Hot Extrusion without Lubrication and with a Shell Direct Hot Extrusion with Lubrication and without a Shell (Steel) Process Sequence in Direct Hot Extrusion with Lubrication and without a Shell Variation in the Stem Load with Stem Displacement in Direct Hot Extrusion with Lubrication and without a Shell Material Flow in Direct Hot Extrusion with Lubrication Thermal Conditions in Direct Hot Extrusion with Lubrication Direct Cold Extrusion with Lubrication and without a Shell Process Sequence in Direct Cold Extrusion with Lubrication and without a Shell Stresses, Axial Loads, and Temperature Increase Indirect Extrusion Hot Indirect Extrusion without Lubrication and without a Shell (e.g., Aluminum Alloys) Hot Indirect Extrusion without Lubrication and with a Shell Material Flow in Indirect Hot Extrusion Axial Forces and Extrusion Exit Temperatures in the Indirect Hot Extrusion with an Initial Billet Temperature Equal to the Container Temperature (e.g., Aluminum Alloy Extrusion) Axial Loads and Exit Temperatures in Indirect Hot Extrusion with an Initial Billet Temperature Higher than the Container Temperature (e.g., in the Extrusion of Copper Alloys) Comparison of the Indirect Hot Extrusion Process with Direct Hot Extrusion Indirect Cold Extrusion Indirect Cold Extrusion with Lubrication and without a Shell Hydrostatic Extrusion Conventional Hydrostatic Extrusion Process Principles Process Sequence Axial Loads in Hydrostatic Extrusion Products Thick Film Process Special Processes Conform Process Process Principle Process Variations of the Conform Process Extrusion of Granules and Powder Combination of Casting and Conform Extrusion Fiber Cladding by Conform Extrusion Cable Sheathing with the Conform Extrusion Process Cable Sheathing General Principle of Cable Extrusion Sheathing with Lead Materials and Process Cable Sheathing with Lead Sheathing with Aluminum Aluminum as a Cable Sheathing Material General Process Discontinuous Extrusion Continuous Extrusion Tube Extrusion Process Direct Tube Extrusion iv

5 Direct Hot Tube Extrusion over a Fixed Mandrel Direct Hot Tube Extrusion with a Moving Mandrel Direct Hot Tube Extrusion with a Shell Analysis of the Axial Forces in Direct Hot Tube Extrusion Indirect Tube Extrusion Indirect Tube Extrusion over a Stationary Mandrel Chapter 4 Metallurgical Principles Introduction Structure Lattice Structure Single Phase Multiphase Structure Equilibrium Diagrams Binary Systems Intermediate Phases Multicomponent Systems Diffusion, Precipitation, Nonequilibrium Melting and Casting Processes Casting and Cast Structure, Homogenizing of Aluminum Alloys Development of the Continuous Cast Structure Peripheral Shell and Peripheral Segregation Cast Log Surface Cast Grain and Cell Structure, Intermetallic Phases Homogenizing Casting and Cast Structure of Copper Alloys Segregation and Gas Porosity Cooling and Casting Defects Cast Log Surface Interior of the Cast Log Deformation, Recovery, Recrystallization Deformation of Pure Metals at Room Temperature Dislocations Single Crystals Polycrystals Deformation of Alloys at Room Temperature Higher Temperatures with Pure Metals Annealing of Pure Metals Deformation of Pure Metals at High Temperatures Alloys at Higher Temperatures Annealing of Alloys Deformation of Alloys at Higher Temperatures Processes in Extrusion Toughness, Fracture Ductile Fracture Brittle Fracture and Mixed Types Fracture during Hot-Working Defects in Extrusion Solid-State Bonding Bonding Processes The Formation of Pressure Welds in Hollow Sections and during Billet-on-Billet Extrusion Composite Extrusion Powder Extrusion Friction between the Extruded Material and the Tooling Extrudability of Metallic Materials v

6 Appendix: Additional Information for Chapter 4 Metallurgical Principles Additional Information 1: Miller s Indices to Describe a Space Lattice Additional Information 2: Representation of Textures in Pole Figures Additional Information 3: Temperature and Speed Dependence of the Flow Stress in Hot Working Chapter 5 The Production of Extruded Semifinished Products from Metallic Materials Extrusion of Materials with Working Temperatures between 0 and 300 C Extrusion of Semifinished Products in Tin Alloys Extrusion of Semifinished Products in Lead Materials Extrusion of Tin- and Lead-Base Soft Solders Extrusion of Zinc Alloy Semifinished Products Extrusion of Materials with Deformation Temperatures between 300 and 600 C Extrusion of Semifinished Products in Magnesium Alloys Extrusion of Semifinished Products in Aluminum Alloys General Extrusion Behavior of Aluminum Alloys Flow Stress Flow Process The Dead Metal Zone In the Shape-Producing Aperture Thermal Balance and Extrusion Speed Section Surface and Surface Defects Section Surface and the Peripheral Layer Cast Structure and Anodizing Capability Surface Roughness Transverse Cracks and Peeling Procedures to Control the Thermal Balance Material Billet Temperature Heat Removal Optimization of the Extrusion Parameters Joining by Extrusion Extrusion Welding Longitudinal Welds in Hollow Sections Transverse Welds Testing of Extrusion Welds Influence of the Extrusion Weld on the Surface Appearance Suitability of the Material for Hollow Section Extrusion Materials Easily Extruded Alloys Aluminum Alloys Extruded Products Extrusion and Materials Properties Moderately Difficult Alloys Aluminum Alloys Extruded Products Extrusion and Materials Properties Difficult-to-Extrude Alloys Aluminum Alloys Extruded Products Extrusion and Materials Properties Extrusion of Materials with Deformation Temperatures of 600 to 1300 C Extrusion of Semifinished Products in Copper Alloys vi

7 General Copper, Bronze, and Brass A Long History Advantageous Physical and Chemical Properties Importance of Extrusion in the Processing The Groups of Extruded Copper Alloys Their Important Properties and Applications Alloy Groups Tooling Temperatures in Extrusion Structure Typical Extruded Semifinished Products and Applications Extrusion Properties of Copper Alloys Extrudability of Different Materials Temperature and Speed Structure of the Extrusion Extrusion to Finished or Close-to-Finished Dimensions Lubrication Extrusion with a Shell Different Material Flow Behavior Flow-Type C Piping Defect Flow-Type B Shell Defect Back End Defect Discard Length Direct Extrusion with Lubrication and without a Shell Extrusion into Water or Air Extrusion Processes and Suitable Equipment Extrusion Presses for Brass Wire and Sections Tube Extrusion Drive Die Changing Discard Separation Billet Production and Heating Continuous Casting and Homogenizing Billet Length Billet Processing Billet Quality Control Billet Heating Copper Extrusion General The Different Grades of Copper, Their Properties and Applications Hot Workability, Extrusion Temperature Copper Tube Application Production Methods Extrusion Oxide on the Billet Surface, Shell and Blister Defect Copper Rod and Section Dimensions and Shape, Further Processing Hollow Sections Extrusion of Low-Alloy Copper Materials The Materials, Properties, and Applications Extrusion Solution Treatment at the Press Extrusion of Copper-Zinc Alloys (Brass and Tombac) Binary Copper-Zinc Alloys Copper-Zinc Alloys with Alloy Additions (Special Brasses) Extrusion of Copper-Tin Alloys (Tin Bronzes) vii

8 The Different Alloys, Their Structures, Properties, and Applications Casting of Copper-Tin Alloys Extrusion of Copper-Tin Alloys Flow Type and Shell Defects Competition from Wire Casting Extrusion of Copper-Aluminum Alloys (Aluminum Bronzes) The Different Alloys, Their Properties, and Applications Binary Copper-Aluminum Alloys Copper-Aluminum Alloys with Additions (Complex Aluminum-Bronzes) Extrusion of Copper-Nickel Alloys Materials, Structure, Properties, and Applications Extrusion of Copper-Nickel Alloys Extrusion of Copper-Nickel-Zinc Alloys (Nickel-Silver) Material, Structure, Properties, and Applications Extrusion of Nickel-Silver Alloys Competition from Wire Casting Extrusion of Semifinished Products in Titanium Alloys Materials, Their Properties, and Applications The Structure and Its Influence on the Properties The Most Important Titanium Alloys and Applications Titanium Alloys Produced by Powder Metallurgy Billet Production, Extrusion Casting, Billet Preparation, Billet Heating Extrusion, Lubrication Flow Stress, Extrusion Defects Tooling, Further Processing Extrusion of Semifinished Products in Zirconium Alloys Materials, Properties, and Applications Billet Production, Extrusion Casting, Billet Preparation Extrusion, Influence of the Structure Tooling, Further Processing Extrusion of Iron-Alloy Semifinished Products General Process Basics Importance of Steel Extrusion Today Mild-Steel Tubes Use of Mechanical Presses Application of Mechanical Presses Dimensional Range and Throughput Seamless Alloy Steel Tubes Extrusion in Competition with Other Hot-Working Processes Alloys and Extrusion Properties Alloy Groups, Structure, Properties, and Applications Extrusion Properties, Defects Billet Production Melting, Casting, Hot Working Homogenizing, Billet Preparation Billet Heating, Lubrication Billet Heating Lubrication Extrusion Process Tooling Further Processing, Testing viii

9 Further Processing Testing Steel Sections General Extrusion Process, Materials Competition with Other Deformation Processes Materials, Starting Material, Process Billet Production, Extrusion, Further Processing Billet Preparation, Heating, Lubrication Further Processing Tooling Extrusion of Semifinished Products in Nickel Alloys (Including Superalloys) General Materials, Properties, and Applications Billet Production Billet Heating Extrusion Billet Preparation, Lubrication Deformation Behavior and Extrusion Data Defects and Their Prevention Tooling, Further Processing Extrusion of Semifinished Products in Exotic Alloys Beryllium Properties and Applications Billet Production Deformation Behavior, Extrusion Uranium Properties, Applications Deformation Behavior, Extrusion Molybdenum, Tungsten Molybdenum Tungsten Niobium and Tantalum Tantalum Extrusion of Powder Metals General Main Application Areas of Powder Metallurgy Advantages of Metal Powder Extrusion Powder Production Spray Compaction Powder Extrusion Processes General Shaking of Loose Powder into a Vertical, Heated Container and Direct Extrusion (Version a) Precompaction of the Powder outside the Press Encapsulation of the Powder before Extrusion (Version c) Mechanism and Flow Behavior in the Extrusion of Metal Powders Load Variation Examples of Powder Extrusion Aluminum Alloys Copper and Noble Metal-Base Alloys Titanium Alloys Iron Alloys Nickel and Cobalt-Base High-Temperature Alloys Exotic Materials ix

10 Extrusion of Semifinished Products from Metallic Composite Materials Terminology and Examples Flow Behavior in the Extrusion of Fiber Composite Materials Criterion for Homogeneous Deformation Deformation with Failure of the Composite Material Production of Metallic Composite Materials Application Examples Simple Structures and Coatings Metallic Fiber Composite Materials with Complex Structures Metallic Fiber Composite Materials with P/M Structures Chapter 6 Machinery and Equipment for Direct and Indirect Hot Extrusion Machinery and Equipment for Direct and Indirect Hot Extrusion Machinery for Direct Extrusion Extrusion Press Design Principles Main Subassemblies of the Direct-Extrusion Press Auxiliary Equipment for Direct Extrusion Hydraulic Drive and Control Systems for Direct Extrusion Electrical Drive, Control, and Regulation for Direct Extrusion Typical Operating Sequence for Direct Extrusion Machines for Indirect Extrusion Press Design Main Structural Components of Indirect-Extrusion Presses Auxiliary Equipment for Indirect Extrusion Hydraulic Drive Systems and Control for Indirect Extrusion Electric Drive and Control for Indirect Extrusion Typical Operating Sequence in Indirect Extrusion Presses and Plant for Tube Extrusion Direct Tube Extrusion Machine Construction Details of Tube Extrusion Presses Main Subassemblies and Modules of Direct Tube Extrusion Presses Auxiliary Equipment for Direct Extrusion Hydraulic Control Systems Electrical Drive, Controls, and Additional Equipment for Direct Tube Extrusion Typical Operating Sequence for Direct Tube Extrusion Indirect Tube Extrusion Machine Design Details Main Subassemblies of Indirect Tube Extrusion Presses Typical Operating Sequence for Indirect Tube Extrusion Billet Heating Systems Induction Furnaces General Single-Billet Furnace Multibillet Furnaces Induction Furnace with a Heated Holding Chamber Boost Heating Induction Furnaces with Hot Log Shear Gas-Fired Billet Preheat Furnace General Rapid-Heating Gas-Fired Preheat Furnace with Billet Preheating Combination Induction Furnace and Rapid-Heating Gas-Fired Furnace Rapid-Heating Gas-Fired Furnace with Boost Heater Rapid-Heating Gas-Fired Furnace with Hot Log Shear Temperature Measurement and Control x

11 6.3.4 Economics Extrusion Billet Transport Mechanisms Handling System Handling Gear for Aluminum Alloy Products Handling System for Copper Alloy Products Wire Lines: Brass Wire Transport with Protective Baskets Wire Line: Brass Wire Transport without Protective Baskets Wire Line: Copper Wire Transport without Protective Baskets, Cooling under Water Straight Line: Brass Transport for Rod, Tube, and Section Straight-Line: Copper Tube and Section Extrusion Cooling Systems Nitrogen Cooling Water Cooling Air Cooling Age-Hardening Ovens for Aluminum Alloys Heat Transfer by Convection Methods of Air Circulation Fans Design of the Chamber Furnace Heating Transport Mechanisms Equipment for the Production of Extrusion Billets Equipment for the Production of Aluminum Billets Design and Configuration of Modern Continuous Casting Plants Melting and Casting Furnaces Processes for Melt Refining Mold Casting Systems Casting Plants Homogenization Plants Equipment for the Production of Copper Billets Plants with Furnace-Independent Molds Melting and Casting Furnaces Melt Feed to the Mold Molds Special Mold Designs Protective Cover Cooling and Control Plants with Furnace-Dependent Molds Stimulus for the Development Asarco System Horizontal Casting Plants Continuous Casting of Steel and Other Materials Process Control in Direct and Indirect Hot Extrusion of Aluminum Alloys without Lubrication Process Control in Direct Hot Extrusion of Aluminum Alloys without Lubrication Influence of the Friction between the Billet and the Container as well as the Deformation in the Deformation Zone on the Temperature of the Extruded Material as It Enters the Die Aperture Heat Transfer in the Die Area Measurement of the Extrusion Temperatures Methods of Achieving Constant Exit Temperatures over the Length of the Extrusion or Ram Displacement in the Direct Hot Extrusion of Aluminum Alloys xi

12 6.15 Process Control in Indirect Hot Extrusion of Aluminum Alloys without Lubrication Process Control Concepts for Extrusion Plants Electrical-Electronic Control Factors that Influence the Productivity and Quality of the Products in the Extrusion Process Improvement in the Productivity and Product Quality by the Optimization of the Extrusion Process Chapter 7 Extrusion Tooling Requirements of Tooling and Tooling Material Requirements of the Extrusion Tooling Requirements of the Tooling Materials Design of Tool Sets for Direct and Indirect Extrusion Design of the Tool Set for Direct Extrusion Design of the Tool Set for Indirect Extrusion Sealing of the Shape-Producing Tooling with the Container Extrusion Tooling for Direct External and Internal Shape Production Control of Material Flow in the Shape-Forming Region of Extrusion Tooling Control of Material Flow in the Shape-Producing Regions in the Extrusion of Materials with Working Temperatures from 0 to 300 C Control of Material Flow in the Shape-Producing Regions in the Extrusion of Materials with Working Temperatures from 300 to 600 C Control of Material Flow in the Shape-Producing Regions in the Extrusion of Materials with Working Temperatures from 600 to 1300 C Dimensions of the Die Apertures in Relation to the Specified Section Dimensions at Room Temperature Tooling for the Extrusion of Materials with Deformation Temperatures in the Range of 0 to 300 C Tooling for the Extrusion of Materials with Deformation Temperatures in the Range of 300 to 600 C Tooling for the Extrusion of Magnesium Alloys Tooling for the Extrusion of Aluminum Alloys Manufacture and Operation of Aluminum Extrusion Tooling Tools for the Extrusion of Materials with Deformation Temperatures of 600 to 1300 C Tools for Copper Alloy Extrusion Construction of the Tool Set for Direct and Indirect Extrusion Extrusion Dies and Mandrels for the Production of Tubes Extrusion Dies for the Production of Solid Sections in Copper-Zinc Alloys Extrusion Dies for the Extrusion of Solid Sections in Copper and Low-Alloyed Copper Alloys Dies, Mandrels, and Bridge Dies for the Production of Hollow Sections Extrusion Dies for the Production of Rod and Wire Manufacture and Use of Copper Extrusion Dies Manufacture of the Extrusion Dies Use of the Extrusion Tools Tooling for the Glass-Lubricated Extrusion of Titanium, Nickel, and Iron Alloys Design of the Tool Set for Direct Extrusion Tooling for the Extrusion of Titanium Alloys Tooling for the Extrusion of Nickel Alloys Tooling for Extrusion of Iron Alloys Extrusion Tools for Indirect Shape Production, Auxiliary, and Support Tooling Mandrel Holder and Mandrel Cooling xii

13 7.5.2 Dummy and Cleaning Blocks for Round and Oval (Rectangular Billet) Containers Dummy and Cleaning Blocks for Direct Extrusion Dummy and Cleaning Blocks for Indirect Extrusion Extrusion Stems for Round and Oval Billet Containers Extrusion Stems for Direct Extrusion Extrusion Stems for Indirect Extrusion Calculations and Dimensions for Extrusion Stems Examples of Stem Calculations for Direct and Indirect Extrusion Thermomechanical Stressing of Stems during Extrusion Temperature-Related Maintenance and Handling of Extrusion Tooling Containers Container Construction Thermomechanical Stressing of the Container during Extrusion Container Heating and Cooling Recent Developments in Resistance Heating of Containers Induction Heating for Containers Combined Container Heating and Cooling System Design, Calculation, and Dimensioning of Containers Static- and Elastic-Based Analysis and Dimensioning of Containers Loaded in Three Dimensions Design of a Single-Piece Container Loaded in Three Dimensions Design of a Two-Part Container x x Calculation of the Prestresses rr and rt Developed in a Two-Part Container by the Interference-Fit Forces xx xx Calculation of the Working Stresses rr and rt from the Extrusion Forces in a Two-Part Container xxx xxx Determining the Operating Stresses rr and rt by Addition (Additive x x xx xx Superimposition) of rr and rt and rr and in a Two-Part Container Calculation of the Equivalent Stress r v in a Two-Part Container Design of a Three-Part Container x x Calculation of the Prestresses rr and rt Developed by the Interference-Fit Forces in a Three-Part Container xx xx Calculation of the Working Stresses rr and rt Resulting from Deformation Forces during Extrusion in a Three-Part Container xxx xxx Calculation of the Working Stresses rr and rt by the Addition of the x x 0 0 xx Prestresses rr and rt and rr and rt and the Operating Stresses rr and xx r t (Additive Superimposition) in the Three-Part Container Calculation of the Equivalent Stresses, r v, in the Three-Part Container Examples of Calculations for Different Containers, Their Stresses and Dimensions Design of a Two-Part Container with a Round Bore for Aluminum Alloys Two-Part Container for a 25 MN Extrusion Press Calculation of a Three-Part Container with an Oval Bore for Aluminum Alloys Three-Part Container for a 25 MN Extrusion Press Calculation of a Three-Part Container with a Round Bore for Copper Alloys Three-Part Container for a 25 MN Extrusion Press Influence of Axial Loading of the Container Operating Conditions from Elastic/Plastic Behavior of the Tool Material under the Influence of the Thermomechanical Working Stresses Manufacture of Containers Container Operation Maintenance of Containers xiii

14 Hot Working Materials for the Manufacture of Extrusion Tooling Hot Working Steels Classic Hot Working Steels Hardening and Tempering of the Classic Hot Working Steels Machining of Hardened and Tempered Hot Working Steels Surface Heat Treatment of Extrusion Tools in Classic Hot Working Steels Austenitic Hot Working Steels Classification of Hot Working Steels Special Materials Cobalt Alloys Molybdenum Alloys Nickel Alloys Metal-Ceramic Composite Materials Hard Metals Pure Ceramic Hot Working Materials Further Developments Hot Working Materials for Different Extruded Materials for the Manufacture of Extrusion Tooling for Direct and Indirect Forming Chapter 8 Quality Management in Extrusion Quality Quality Management Quality Management System Introduction of a QMS Process Chain Product Liability Economics Quality Control Organization Process Organization Responsibilities General Requirements Audits QMS Audit Environmental System Audit Process Audit Product Audit Inspector Audit Testing Failure Modes and Effect Analysis Inspection Planning Outlook Appendix A List of Formula Symbols Appendix B Approximate Composition of Materials Index xiv

15 Foreword The book Extrusion: Processes, Equipment, Tooling, edited by Kurt Laue and Helmut Stanger, was published in 1976 by the Aluminium-Verlag GmbH, Düsseldorf. The excellent, wide, and often deep overview enabled experienced engineers as well as students and academics to understand extrusion processes, equipment, and tooling. For a long time, this book, which was also translated into English, was the standard reference on extrusion. Because it has been out of print for several years, it made sense to republish the book Extrusion in a fully updated version. The editors have attempted to retain the character of the book as an overview of the processes, equipment, and tooling. Extruded products have been discussed in more detail to demonstrate the range of applications of extrusion and to stimulate the industrial application of extrusion beyond that used today. In addition, the metallurgical fundamentals of the extrusion process are covered in detail, because the editors believe that extrusion can only be optimized by taking the materials technology into account. The discussions on extrusion equipment, plant, and tooling attempt to extend the overview with application examples. Actual applications, however, require the cooperation of the customer, extruder, tool maker and equipment manufacturer. The book Extrusion is intended for both students and research engineers as well as engineers in extrusion plants, manufacture of machinery and plant, tool manufacture, as well as the designers, process developers, and managers of automotive companies, building industries, and plant manufacture. The book should give an introduction to and an overview of extrusion. More detailed discussions and the latest research results can be found in the technical literature. The authors thank the co-authors of this book and the numerous companies that have helped in its realization by providing the material for the figures and technical discussions. Specific mention should be made of the support from Wieland-Werke AG, Ulm, and by the companies Alusuisse Neuhausen and Alusingen. We should also thank the members of the Extrusion Technical Committee in the DGM for the valuable information they provided. These include, in particular, Dr. J. Baumgarten, Dr. G. Fischer, and Dipl.-Ing. Rethmann. Thanks are also due to Y. Ismailoglu of IFU- Stuttgart and A. Schug of Wieland-Werke Ulm for the preparation and production of numerous photographs, drawings, tables, and diagrams. The editors also give special thanks to the Aluminium Verlag for fulfilling the requests and requirements of the editors and the authors and for the careful preparation of the contributions for printing. Sadly, one of the three editors, our dear colleague and friend, Professor Dr. Ing. Günther Sauer, died on October 7, He gave a great deal of commitment and effort to the realization of this book and completed all of his promised contributions to it before his sudden death. Unfortunately, he was not allowed the pleasure of seeing this book in its final format. We would like to express our sincere thanks for being a good colleague and a friend. We hope this book fulfills the expectations of the reader and contributes to the further development of extrusion. Dr. rer. nat. Martin Bauser Prof. Dr.-Ing. Dr. H.C. Klaus Siegert xv

16 Authors Dr. Rudolf Akeret, Neuhausen, Switzerland Adolf Ames, Duchtlingen bei Singer (Hohentwiel) Dr. rer. nat. Martin Bauser, Senden bei Ulm Dr. rer. nat. Amit K. Biswas, Kaarst Dipl.-Ing. Wolfgang Eckenbach, Iserlohn Dr. rer. nat. Adolf Frei, Neu-Ulm Horst H. Groos, Mettmann Willi Johnen, Simmerath Dr.-Ing. Klaus Müller, Berlin Dr. Josef Putz, Simmerath Prof. Dr.-Ing. Günther Sauer, Kronberg/Ts. Dr.-Ing. Günther Scharf, Bonn Prof. Dr.-Ing. Wolfgang Schneider, Bonn Dr.-Ing. Gottfried Schreiter, Kleinwaltersdorf bei Freiberg Prof. Dr.-Ing. Dr. H.C. Klaus Siegert, Stuttgart Dipl.-Ing. Detlef Smolarek, Pfeffikon, Switzerland xvi

17 ASM International is the society for materials engineers and scientists, a worldwide network dedicated to advancing industry, technology, and applications of metals and materials. ASM International, Materials Park, Ohio, USA This publication is copyright ASM International. All rights reserved. Publication title Extrusion, Second Edition Product code 06998G To order products from ASM International: Online Visit /bookstore Telephone (US) or (Outside US) Fax Mail Customer Service, ASM International 9639 Kinsman Rd, Materials Park, Ohio , USA CustomerService@asminternational.org In Europe In Japan American Technical Publishers Ltd Knowl Piece, Wilbury Way, Hitchin Hertfordshire SG4 0SX, United Kingdom Telephone: (account holders), (credit card) Neutrino Inc. Takahashi Bldg., 44-3 Fuda 1-chome, Chofu-Shi, Tokyo 182 Japan Telephone: 81 (0) Terms of Use. This publication is being made available in PDF format as a benefit to members and customers of ASM International. You may download and print a copy of this publication for your personal use only. Other use and distribution is prohibited without the express written permission of ASM International. No warranties, express or implied, including, without limitation, warranties of merchantability or fitness for a particular purpose, are given in connection with this publication. Although this information is believed to be accurate by ASM, ASM cannot guarantee that favorable results will be obtained from the use of this publication alone. This publication is intended for use by persons having technical skill, at their sole discretion and risk. Since the conditions of product or material use are outside of ASM's control, ASM assumes no liability or obligation in connection with any use of this information. As with any material, evaluation of the material under end-use conditions prior to specification is essential. Therefore, specific testing under actual conditions is recommended. Nothing contained in this publication shall be construed as a grant of any right of manufacture, sale, use, or reproduction, in connection with any method, process, apparatus, product, composition, or system, whether or not covered by letters patent, copyright, or trademark, and nothing contained in this publication shall be construed as a defense against any alleged infringement of letters patent, copyright, or trademark, or as a defense against liability for such infringement.