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Lateral extrusion of tailor welded aluminum alloy pipes with a lost core of low temperature melting alloy

100%

Ohashi T. , Liu G.

Journal of Achievements in Materials and Manufacturing Engineering

2009

tom Vol. 32, nr 1

61-65

Purpose: In this paper, the authors employ tailor welded aluminum alloy pipes for lateral extrusion process with a lost core to perform a hollow light-weight-part. Design/methodology/approach: The pipe is welded longitudinally by YAG-laser. “The lateral extrusion process with a lost core (LELC)” consists of lateral extrusion of pipes with a soluble solid core, called the “lost core”, which serves as a plastic mandrel. The process proceeds as follows. First, the pipe cavity is filled with the liquid low temperature melting material composing the lost core. The liquid is then solidified to form the soluble core of the pipe. The material is compressed longitudinally as a composite billet as well as forging, and extruded in the lateral direction. After the pipe is deformed, the lost core is melted and removed. s. The bulge by the LELC is carried out by extruding the material for the lateral direction, however the simple bulge by hydro-forming is done by internal pressure. Findings: The LELC process can make a hollow product having uneven wall thickness without the deformation concentrating on a thinner part of the material, because the circumferential deformation of the material will be performed by its meridian strain. Practical implications: The authors have developed LELC process in which the lost core consists of low-temperature melting alloys and have tried to apply the process to perform bulge process with a tailor-welded pipe having two different wall thickness. Originality/value: Optimum volume distribution is important for light-weight-parts, and employment of tailor-welded blanks is effective technique in sheet metal forming. Combination of employment of hollow shape and tailor-welded blanks seems to be hopeful.

Badania jednooperacyjnego tłoczenia blachy bimetalowej Cu/Al

80%

Muzykiewicz W. , Rękas A.

Rudy i Metale Nieżelazne

2007

tom R. 52, nr 1

18-22

Wyznaczono graniczne możliwości tłoczenia (ciągnienia i dwuosiowego rozciągania) blachy bimetalowej Cu/Al. Próby przeprowadzono w dwóch wariantach kontaktu bimetalu z narzędziami (w układzie matryca-aluminium i matryca-miedź). Wyznaczona wartość granicznego współczynnika wytłaczania blachy Cu/Al wynosi m(gr) ≈ 0,5. Wartość wskaźnika tłoczności Erichsena dla układu Cu-Al jest większa o 0,5 mm w porównaniu z układem Al-Cu i wynosi 9,4 mm. Dokonano analizy odkształceń wytłoczki bimetalowej, mierząc rozkład zmian grubości wzdłuż jej tworzącej i rozkład wskaźnika grubości gk/g0 na obwodzie wytłoczki. Ze względu na bardzo silną anizotropię płaską tłoczonej blachy, część górną wytłoczki charakteryzuje nierównomierny rozkład grubości, rozkład przy dnie jest bardziej jednorodny.

Boundary conditions of deep drawing (drawing and two-axial stretching) of bimetallic Cu/Al sheet have been determined. Tests were made under two options of bimetal's contact with tools (die-aluminium and die-copper systems). The limiting drawing ratio determined for the Cu/Al sheet was m(gr) ≈ 0.5. The Erichsen's drawability index for the Cu-Al is by 0.5 mm higher compared to the Al-Cu system and reaches 9.4 mm. Deformation of bimetallic drawpiece was analysed by measurements of distribution of thickness changes along its generating line as well as distribution of thickness index gk/g0 on the perimeter of a drawpiece. Due to very high planar anisotropy of the sheet subjected to drawing, the top portion of a drawpiece was characterised by non-uniform distribution of thickness, whereas at the drawpiece bottom this distribution was more uniform.