PNNL

Abstract

Final report for SPPSi project in Thrust One Friction extrusion is a thermomechanical process that combines conventional extrusion with the action of a rotating die. The plastic deformation of the material being sheared and extruded is the primary source of process heat and it produces strain distributions unlike those resulting from conventional extrusion. This paper proposes an improved strain analysis that evaluates three main strain components in a series of rate-controlled friction extrusions in which the steady state was achieved. Cylindrical AA1100 extrusion billets with two embedded markers were extruded to wire with a 10:1 diametral reduction. The shape change of the embedded markers was determined via serial, transverse sectioning and quantitative metallography of the extruded wires. Three mutually orthogonal strain components (longitudinal, circumferential, and radial) were calculated at different positions along each extruded wire from the marker's shape change. The development of strain from the initial transient to the steady state is discussed. The variation of the steady-state strain with different process parameters is correlated with the die advance per revolution.