The reinforcement of composite aluminium extrusions offers a high potential regarding weight reduction and improvement of mechanical properties, which is essential for components in lightweight con...

Tensile behaviour of spring steel wire reinforced EN AW-6082:

In order to manufacture a workpiece fulfilling specified requirements with the lowest possible weight, it is crucial to be able to work with a variety of materials and to combine them accordingly. The production of profiles based on hybrid materials demonstrates such an approach. The continuous and selective reinforcement of aluminum profiles with metallic elements like steel wire and steel wire ropes by composite extrusion is being investigated within the scope of research of the Transregional Collaborative Research Center (SFB/TR10). A stable production process for composite profiles with embedded continuous reinforcing elements was developed during the research work. In this paper, the process principle is shown and an overview of the special tools is given. Furthermore, the temperature and the strand speed as influencing factors on the final state of the composite are analyzed, based on real size experiments using a 2.5MN and a 10 MN extrusion press.

Composite Extrusion – Determination of the Influencing Factors on the Positioning of the Reinforcing Elements

The development of new metal matrix composites for lightweight applications is aiming for an increase in specific strength and stiffness compared to conventional light metal alloys. The composite e...

Characterization of a hybrid Al2O3–aluminum matrix composite manufactured via composite extrusion

Extruded aluminum profiles are essential for lightweight constructions in contemporary transport and automotive applications. The reinforcement of such aluminum-based profiles with high-strength materials offers a high potential for weight reduction and an improvement of functional and mechanical properties. In comparison to conventional composite extrusion using fiber or particle reinforced billets, the alternatively developed process for the embedding of endless reinforcing elements provides enormous advantages regarding extrusion forces, load-adapted reinforcement, and tool abrasion. In this extrusion process with conventional billets, modified tools with portholes are used to position reinforcing elements from outside the pressing tool and to embed them into the material flow during the pressing operation. This composite extrusion process is part of the research work started in 2003 and carried out within the scope of the Collaborative Research Center SFB/TR10. To increase the potential of composite extrusion with endless reinforcing elements, the manufacture of composite extrusion profiles with high-strength non-metallic alumina wires is planned. Due to the wires' specific properties, e.g. high stiffness, their deflection behavior must be analyzed to guarantee a stable feeding-in process. In this paper the specific behavior of alumina reinforcing elements regarding the feeding-in process is analyzed by experimental investigations. The main influencing factors are determined and a process window is deduced.

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Embedding of Alumina Reinforcing Elements in the Composite Extrusion Process

Es werden Methoden zur Quantifizierung qualitativen Wissens in der Modellbildung zur multidisziplinaren Strukturoptimierung untersucht, erweitert und an praktischen Beispielen umgesetzt. Insbesondere das Wissen uber Fertigungsaufwande bei werkstoffhybriden Rahmenstrukturen wird damit in regelbasierten Typ-2-Fuzzy-Modellen abgebildet. Dadurch wird die Formulierung der Optimierungsaufgabe erweitert und vervollstandigt sowie das zugehorige Vorgehen zur Behandlung unscharfer Ziel- und Restriktionsinformationen vorgestellt. Aus diesem ganzheitlichen Prozess der Entwurfsoptimierung werden optimale Kompromisse und Hinweise bezuglich der strukturmechanischen und fertigungstechnischen Aspekte gewonnen.

M. Kleiner

Papers

Composite Extrusion of Aluminium Matrix Specimens Reinforced with Continuous Ceramics Fibres