Abstract
Based on a physically motivated weld strength model by Cooper and Allwood a weld quality model for the prediction of the process success in direct hot extrusion of aluminium chips is presented. The results are validated against a variety of literature results as well as against the results of additional hot extrusion experiments utilizing flat-face dies for the production of round bars and porthole dies for the production of hollow profiles. A procedure is presented to determine the minimum required weld quality value necessary to provide a process success by the example of chips made of the aluminium alloy AA6060. The weld model can be used to save time- and cost-consuming experimental try-outs, which may make the process an alternative to conventional hot extrusion due to its clear environmental benefits in the production of complex profiles.
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