PROCEEDINGS

OF

FOURTH INTERNATIONAL ALUMINUM

EXTRUSION TECHNOLOGY SEMINAR

VOLUME II—INTERACTIONS
Technology Die
Die Lines, Surface Tearing and Metal Flow
Process Technology
Marketing
Value Addled Activities
Conform
Al-Li Alloys
April 11-14, 1988
Chicago, Illinois

The views expressed and the information, materials, processes and techniques described in the papers included in these
Proceedings represent the views and developments ot the individual authors andlor the companies or organizations
indicated Neither the Aluminum Association nor the Aluminum Extruders Council endorses the views expressed or the
materials, processes and techniques described in any of the papers Nor does the Aluminum Association or the Aluminum
Extruders Council make representations as to the accuracy of any of the information set forth in the individual papers
any

Accordingly, the Aluminum Association and the Aluminum Extruders Council assume no responsibility or liability for the use
of any information, materials, processes or techniques described No warranties, expressed or implied, by the Aluminum
Association or the Aluminum Extruders Council accompany any information included in the papers published in these
Proceedings

The nature of these proceedings and the submission process for the individual papers preclude the Aluminum Association
and the Aluminum Extruders Council, Inc from making any representations, warranties or guarantees as to the compliance of

these papers with the copyright laws of the United States TIB/UB Hannover
129 952 494
.
,
 CONTENTS

VOLUME II

DIES, PROCESS TECHNOLOGY,

INTERACTIONS, PRINT ONLY, OVERVIEW

ET '88 Overview
1
Robert I. Werner

DIES

DIE CORRECTION

The Contribution of the Die to Surface Quality 13

Gary W. Dion
Die Design and Die Correction as Affected by Pullers 17
Gunner Bilen
Die Correction, Weld Plate and Pocket Dies 21
William J. Mason

DIE MAKING TECHNOLOGY

Die Design and Construction in Europe 25

Alan Castle, Roger Flory and John Gagg
Surface Finishing with Abrasive Flow Machining 35
Tom Kohut

Extrusion Die Making in the United States 45

Luis E. Bello

Die Making in the Nineties 53

Jan Aalberts

High Technology of Extrusion Die Manufacture 57

Gary Dion

Advances in Die Making with CNC EDM 61

Jack Harbison

New High Performance EDM Wires Offer Die Shops Significant Productivity Improvements 65
Dr. D. S. Tomalin

DIE COOLING TECHNIQUES

Improved Cooled Dies for Increasing Aluminum Extrusion Productivity 79

Roger J. Fiorentino and E. Garland Smith, Jr.
Efficient Use of Liquid Nitrogen for Aluminum Extrusion Die Cooling and Inerting 83
Michael A. Marchese and John J. Coston

Pressure Swing Adsorption Reduces Aluminum Extrusion Production Cost 89

George J. Waite and Francis D. Gutowski
PSA Nitrogen for Shrouding Aluminum Extrusions 99
Dale C. Miller, Steven G. Ruoff and Robert H. Maynard

NITRIDING

Plasma Nitriding Extends Die Life 103

Sidney Dressier
Benefits of Nitrogen Addition for the Increased Wear Resistance of Aluminum Extrusion Dies by Ion Nitriding 109
R. D. Denton
NITROCARBURIZING

Ferritic Nitrocarburizing, a New Surface Treatment for Aluminum Extrusion Dies 113
Timothy A. McLaughlin
The Fluidized Bed Nitriding of Aluminum Extrusion Dies 115
Joseph Poliseo

DIE STEELS

A New Hot-Work Steel for Improved Tool Performance in Aluminum Extrusion 121
Odd Sandberg
A New Hot-Work Die Steel for Aluminum Extrusion Tooling 127
Thomas J. McCaffrey

FIXED DUMMY BLOCKS

Fixed Dummy Block Design 131

Guy Bessey
Fixed Dummy Block Extrusion 135
Alan F. Castle

SHOP OPERATIONS

Evaluation of Die Cleaning Process at R. D. Werner Co., Inc 139

Michael J. McManus

Procedures for Proper Receipt of Extrusion Dies 145

Johnie L. Adams

PROCESS TECHNOLOGY

SPL SESSION C Al-Li ALLOYS

Experience on the Extruding of Aluminum-Based Advanced Materials 149

Wolf-Dieter Finkelnburg and Gunther Scharf
Extrudability and Performance of Al-Li-Cu-X Alloys 153
Michael H. Skillingberg and Richard F. Ashton

The Effect of Processing Variables on the Properties of Al-Li-Cu-Mg-Zr Alloys AA2091 & AA8090 Prod, by Extrusion 161
T. Sheppard, M. J. Tan, Dr. H. M. Flower and A. K. Mukhopadhyay

An Experimental Design to Determine Effects of Extrusion Variables on Microstructure and Properties

AI-2.6Li-0.9Zr Alloy 179
T. H. Sanders, Jr., B. M. Hillberry and A. F. Grandt, Jr.

STATISTICAL PROCESS CONTROL AND QUALITY CONTROL

Use of Statistically Designed Experiments in an Extrusion Plant 187

Viola R. Bird

Statistical Process Control Application to the Aluminum Extrusion and Drawn Tube Process 195
Robert F. Wolf

Alcoa-Vernon Works Quality Project Teams 205

William J. Boyle

Why Waste Time Experimenting? 209

Robert W. Hains

SPC Reduces Scrap in an Aluminum Extrusion Plant 221

Nicholas P. Demos

Special Features on Process Defect in Aluminum Alloy Extrusion 227

A. K. Das

The Material Flow by the Extrusion of Hollow Section of Aluminum Through Hollow Dies 235
I. Duplancic

EXTRUSION TECHNOLOGY AND TEMPERATURE MEASUREMENT

Estimation Optima! Speed-Temperature Parameters and Maximizing Hot Extrusion Exit Speed by Their Use 241
Wojciech Misiolek and Jozef Zasadzinski
Numerical Simulation of Two-Dimensional Hot Extrusion of Aluminum 247
G. E. Macey and M. Salim

Study of Electrical Conductivity of an Al-Mg-Si Alloy 255

S. K. Mehrotra, U. Ghosh and S. K. Mukherjee
Measuring Internal Temperatures of Aluminum Extrusions
.259
M. L. Mester, A. H. Kahn and H. N. G. Wadley
Extrusion Temperature Measurement with a Radiation Thermometer 267
E. R. Pickering

Reflectance—Ratio Radiation Thermometry Applied to Aluminum Samples Status

Report 271
G. D. Nutter

Evaluation and Extension of the Spectral-Ratio Radiation

Thermometry Method 281
G. J. Dail, M. G. Fuhrman and D. P. DeWitt

SPL SESSION A DIE LINES, SURFACE TEARING AND METAL FLOW

The Effect of Billet Preheating Practice on Extrudability of Al-Mg-Si Alloys 287

Oddvin Reiso

Die Temperatures in Aluminium Extrusions

297
Martin Lefstad

Simulation of Hot Tearing of Aluminum Alloys 303

O. Lohne and N. Ryum

Surface Formation in Al—Extrusion (Direct Extrusion) 309

Henry Valberg
Physical Simulation of Metal Extrusion by Means of Model Materials 321
Henry Valberg
The Orgin of Surface Defects During Extrusion of AA6063 Alloy 329
Dr. T. Sheppard and Dr. M. P. Clode

Analysis of Metal FLow and Recrystallization Behavior in Extrusion and Application of Results to Commercial
Production
343
Shigeyuki Kikuchi, Minobu Sukimoto and Kenji Nakanishi
Control of Metal Flow in Extrusion Dies
357
Dr. Rudolph Akeret and Dr. Werner Strehmel

BILLET TECHNOLOGY AND WELDABILITY

Aluminum Quality Evaluation Using High Resolution Image Analysis 369

R. N. Dokken, T. G. Kinisky and K. B. Reuter

Melting and Casting Facilities, Using a Simulation Model to Select the Best Size and Configuration 375
Thomas H. Howell and Richard A. Penington
How Casting Methods Can Affect the Quality of 6063 Extrusion Billets 381
Dr. Johann Langerweger
Billet Consistency Via Quality Control and Comparative Evaluations 385
Clark H. Weaver

Compositional Factors Affecting Weldability of Extruded Aluminum Alloys 391

C. E. Cross and D. L. Olson

Influence of Cast Structure on Extrusion of Aluminum Alloys 395

B. K. Agrawal Sr. and J. P. Singh

Theory and Application of Liq. Stabilized Plasma Tech. and Its Application on Thermo-Deposited Bodies
Resistant to Molten Al and Zn 403
Jorge A. Morando and Werner Schultz

/A/TEflACT/ONS

MARKETING
Market Trends—Europe, Japan and North America 413
John Bridgeman
Merging Marketing and Technology 429
David T. Wilson

Marketing Planning 433

Michael J. Ott

Aerospace Materials for the Twenty-First Century 441

Dr. Peter Cannon

DESIGN AND DEVELOPMENT

The Advantages of Aluminum Extrusions Compared with Some Competitive Materials and Methods of Forming 445
Joseph J. Despoy, Richard M. Kelly and James D. McKay
The Industrial
Designers Role in New Product Development and How to Support That Activity for

Improved Sales of Extrusion 451

Emerson J. Purkapile

Tolerance for Extruded Products 455

E. T. Mackay

THE CUSTOMER'S PERSPECTIVE

What's in the Box? 457

Austin R. Baer

FINISHING OF EXTRUSIONS

Designing an Automated Extrusion Anodizing Facility 461

Glenn C. Schoener

Correlation Between Extrusion Practices and Appearance of Anodized 6063 Alloy Extrusions 465

John P. Faunce
and Their Market Advantages 469
Powder Coatings
Dr. Richard J. Higgins

Polyester Powder Coating Systems for Architectural Aluminum in Europe 475

H.-J. Alfort and Dr. E. Bodnar

BAR CODING

Bar Coding 483

Barry J. Rothschild
Bar Code Standards for the Aluminum Industry 489
John Dickinson

INTERACTIONS

for Customer Communication 493

Advances in Computer Technology
James H. Foy
in the Aluminum 497
Electronic Data Interchange (EDI) Industry
Donald H. Spiegel
Market—How Can 501
Aluminum Extrusions—A Highly Competitive Technology Help?
Victor R. Johnson

Package Design for Aluminum Extrusion Products 505

John Pesek

of Aluminum Extrusions 513

Curving
Brian Geary
Precision Cutting and Marketing of Metals to Increase Profits 519
K. Forman

SPL SESSION B CONFORM

Al Extrusions by Conform-Update on Development, Experiences and Springfields Lab. of the

U.K. Atomic Energy Authority 525
Harold Keith Slater

Recent Developments in Conform and Castex Continuous Extrusion Technology 533

Dr. Johann F. Langerweger and Brian Maddock
Metallurgical Considerations for Quality Improvements of Conform Aluminum Products 539

Uday Sinha and E. Henry Chia

The Technical Development of a New Extrusion Company Solely Using Conform Machines 545
Dr. R. D. Parkinson

Capability of a Conform Conklad Universal Machine for the Present and Future Potential 553

Roy Molyneaux

PRINT ONLY

PRINT ONLY

Saw Blade Design 563

J. Stewart

Selecting the Proper CAD/CAM Solution for Designing and Manufacturing Aluminum Extrusion Dies 569
Steve Runkel
Precision and Accuracy of Several Hardness and Tension Methods Revisited 571
Robert I. Werner

Glossary 581