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Finite Element Model Prediction of Charge Weld Behaviour in AA6082 and AA6063 Extruded Profiles

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Abstract

Charge welds are unavoidable defects of the continuous extrusion process whose extension needs to be accurately predicted in order to avoid profile mechanical failures or to minimize unrequired scrap of material. The aim of this work was then to evaluate the accuracy of the charge welds FEM predictions and their applicability in the industrial field. Two different industrial cases involving A6082 and AA6063 aluminium alloys were analysed. The data of charge welds behaviours were experimentally collected, discussed and then innovatively compared to the predicted outcomes of FEM simulations performed using QForm Extrusion® software and of theoretical formulas reported in the literature. As main results, a very good numerical-experimental matching was found, with a peak discrepancy of 122 mm in terms of charge weld extent, while theoretical formulas returned a significant underestimation.

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Authors and Affiliations

  1. DIN Department of Industrial Engineering, University of Bologna, Viale Risorgimento 2, 40136, Bologna, Italy

    Marco Negozio, Lorenzo Donati & Luca Tomesani

  2. DISMI Department of Sciences and Methods for Engineering, University of Modena and Reggio Emilia, Via Amendola 2, 42122, Reggio Emilia, Italy

    Riccardo Pelaccia & Barbara Reggiani

  3. Almax Mori, Via Matteotti 13, 38065, Mori, Italy

    Tommaso Pinter

Authors
  1. Marco Negozio
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  2. Riccardo Pelaccia
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  3. Lorenzo Donati
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  4. Barbara Reggiani
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  5. Tommaso Pinter
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  6. Luca Tomesani
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Correspondence to Marco Negozio.

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Negozio, M., Pelaccia, R., Donati, L. et al. Finite Element Model Prediction of Charge Weld Behaviour in AA6082 and AA6063 Extruded Profiles. J. of Materi Eng and Perform 30, 4691–4699 (2021). https://doi.org/10.1007/s11665-021-05752-x

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  • DOI: https://doi.org/10.1007/s11665-021-05752-x

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