Examining mechanical properties of profiles manufactured aluminium extrusion dies using powder bed fusion

Abstract

The present study investigated the effect of the mechanical properties and the extrusion die manufacturing of AA 6063 alloy on the surface appearance of Eloxal extrusions. The aim of this study was to benefit from the novel manufacturing freedom of powder bed fusion (PDF) in order to change the existing design concept of extrusion dies and solve the restrictions in die manufacturing. In this study, the designed aluminium extrusion dies were manufactured both by the traditional method using DIN 1.2344 hot-work tool steel and by a direct metal laser sintering (DMLS) process using EOS© maraging steel material. In the field experiments of the solid die a 1460 US ton extrusion press was used. Tensile, hardness tests, and surface roughness values were nominated to specify the mechanical properties of the AA 6063 alloy profiles. The microstructure of the aliminium profiles was analysed using both an optical microscope and a scanning electron microscope (SEM). The results showed that the mechanical properties of AA 6063 are highly dependent on the Mg2Si content. While the mechanical properties were improved by the increase in Mg2Si content, the extrudability has been decreased. It was also shown that the manufacturing of high-quality aliminium profiles was possible using dies by manufactured by DMLS directly from production.