Abstract
The possibility of producing profiles directly by hot extrusion of aluminum chips, normally considered as scrap, is a promising alternative to the energy-intensive remelting process. It has to be taken into account that the mechanical properties depend on the quality of the weld seams between the chips, which arise during the extrusion process. To estimate the influence of the weld seams, quasistatic and cyclic investigations were performed on chip-based profiles and finally compared with cast-based extruded profiles. In order to gain comprehensive information about the fatigue progress, different measurement techniques like alternating current potential drop (ACPD)-technique, hysteresis measurements, and temperature measurements were used during the fatigue tests. The weld seams and voids were investigated using computed tomography and metallographic techniques. Results show that quasistatic properties of chip-based specimens are only reduced by about 5%, whereas the lifetime is reduced by about a decade. The development of the fatigue cracks, which propagate between the chip boundaries, was characterized by an intermittent testing strategy, where an initiation of two separate cracks was observed.
Highlights
Because of the increasing scarcity of resources, demands with regard to lightweight construction have significantly increased in recent years [1]
There are clear differences between the defect sizes in the chip-based specimens which explain the higher scattering of the quasistatic properties
Based of on the the temperature material response caused by plastic the continuously increasing amplitude, the the courses as well as the strain amplitude andstress takes fatigue strength, as stated inaccount
Summary
Because of the increasing scarcity of resources, demands with regard to lightweight construction have significantly increased in recent years [1]. In this context, aluminum is suitable because of the excellent strength-to-weight ratio and is becoming more and more popular in lightweight-relevant fields such as the automotive and aerospace industries [2]. With a requirement of about 200 GJ per ton, the production of primary aluminum is one of the most energy-intensive production processes [3] and exceeds steel production by a factor of ten [4]. A promising alternative with significantly lower energy consumption is solid state recycling by hot extrusion, in which aluminum scrap can be formed directly into profiles
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