Extrusion Parameters Research Articles

Elevating alloy performance: the role of bioactive glass in Mg-9Al-Zn matrix composites through friction stir back extrusion

ABSTRACT This study investigates the impact of friction stir back extrusion (FSBE) parameters on the microstructure and mechanical properties of magnesium matrix composites reinforced with bioactive glass particles. Higher rotational speeds (1600 rpm) generate more heat and stirring, promoting finer grains and better particle dispersion, while lower speeds lead to larger grains. Conversely, slower extrusion speeds allow more time for heat dissipation and better mixing, contributing to smaller grains and a more uniform particle distribution. Key findings show that increasing the bioactive glass content enhances both hardness and ultimate tensile strength (UTS), with optimal mechanical properties achieved at 1600 rpm rotational speed, 48.97 mm/min extrusion speed, and 5 vol.% bioactive glass. The introduction of bioactive glass particles restricts grain growth and improves load transfer, thereby reinforcing the composite. Additionally, the study identifies a gradient microstructure in the composite wire, with smaller grains near the surface due to higher plastic strain and temperature, in contrast to the core, which exhibits larger grains.

Cohesin distribution alone predicts chromatin organization in yeast via conserved-current loop extrusion.

Inhomogeneous patterns of chromatin-chromatin contacts within 10-100-kb-sized regions of the genome are a generic feature of chromatin spatial organization. These features, termed topologically associating domains (TADs), have led to the loop extrusion factor (LEF) model. Currently, our ability to model TADs relies on the observation that in vertebrates TAD boundaries are correlated with DNA sequences that bind CTCF, which therefore is inferred to block loop extrusion. However, although TADs feature prominently in their Hi-C maps, non-vertebrate eukaryotes either do not express CTCF or show few TAD boundaries that correlate with CTCF sites. In all of these organisms, the counterparts of CTCF remain unknown, frustrating comparisons between Hi-C data and simulations. To extend the LEF model across the tree of life, here, we propose the conserved-current loop extrusion (CCLE) model that interprets loop-extruding cohesin as a nearly conserved probability current. From cohesin ChIP-seq data alone, we derive a position-dependent loop extrusion rate, allowing for a modified paradigm for loop extrusion, that goes beyond solely localized barriers to also include loop extrusion rates that vary continuously. We show that CCLE accurately predicts the TAD-scale Hi-C maps of interphase Schizosaccharomyces pombe, as well as those of meiotic and mitotic Saccharomyces cerevisiae, demonstrating its utility in organisms lacking CTCF. The success of CCLE in yeasts suggests that loop extrusion by cohesin is indeed the primary mechanism underlying TADs in these systems. CCLE allows us to obtain loop extrusion parameters such as the LEF density and processivity, which compare well to independent estimates.

Achieving high strength-ductility synergy in Mg-Gd-Zn-Zr alloy by controlling extrusion processes parameters

The high rare earth content in current magnesium alloys poses environmental and economic challenges. To address this issue, this study designs a Mg-7.5Gd-6Zn-0.5Zr alloy (GZ76, wt.%) with low rare earth content, high strength, and excellent ductility. The morphology of the as-cast GZ76 alloy is characterized by a dendritic structure consisting of an α-Mg matrix and interdendritic zones comprising W+I phases, interspersed with fragmentary Zn-Zr phases. Furthermore, the extrusion process is employed to meticulously control the microstructure and enhance the mechanical properties of the alloy. This research focuses on investigating the effects of extrusion parameters on magnesium alloys to optimize their extrusion processing conditions. Through systematic manipulation of the extrusion ratio and extrusion speed, a comprehensive analysis is conducted to examine their impacts on grain refinement, texture evolution, distribution of second phase, and mechanical properties of extruded magnesium alloys. The results indicate that due to the insufficient recrystallization process, the microstructure of the as-extruded GZ76 alloys exhibits a bimodal structure, encompassing both fine recrystallized grains and coarse unrecrystallized grains. At larger extrusion ratio, a faster extrusion speed leads to superior mechanical properties of the alloy. Conversely, at smaller extrusion ratio, a slower extrusion speed is more favorable for achieving higher strength. These findings provide valuable insights into optimizing the extrusion parameters for enhancing the performance of magnesium alloys in engineering applications.

Extrusion Parameters Optimization and Mechanical Properties of Bio-Polyamide 11-Based Biocomposites Reinforced with Short Basalt Fibers.

The increasing demand for sustainable materials in high-value applications, particularly in the automotive industry, has prompted the development of biocomposites based on renewable or recyclable matrices and natural fibers as reinforcements. In this context, this paper aimed to produce composites with improved mechanical and thermal properties (tensile, flexural, and heat deflection temperature) through an optimized process pathway using a biobased polyamide reinforced with short basalt fibers. This study emphasizes the critical impact of fiber length, matrix adhesion, and the variation in matrix properties with increasing fiber content. These factors influence the properties of short-fiber composites produced via primary processing using extrusion and shaped through injection molding. The aim of this work was to optimize extrusion conditions using a 1D simulation software to minimize excessive fiber fragmentation during the extrusion process. The predictive model's capacity to forecast fiber degradation and the extent of additional fiber breakage during extrusion was evaluated. Furthermore, the impact of injection molding on these conditions was investigated. Moreover, a comprehensive thermomechanical characterization of the composites, comprising 10%, 20%, and 30% fiber content, was carried out, focusing on the correlation with morphology and processing using SEM and micro-CT analyses. In particular, how the extrusion process parameters adopted can influence fiber breakage and how injection molding can influence the fiber orientation were investigated, highlighting their influence in determining the final mechanical properties of short fiber composites. By optimizing the process parameters, an increment with respect to bio-PA11 in the tensile strength of 38%, stiffness of 140%, and HDT of 77% compared to the matrix were obtained.

Enhancement of Corn Flour with Carob Bean for Innovative Gluten-Free Extruded Products.

The aim of this work is to study new, extruded products based on corn flour enriched with carob bean and the evaluation of its functional quality to develop novel gluten-free food products. Five samples based on corn flour with added carob bean flour (5 to 12.5%) were formulated. Extrusion was performed using a single-screw laboratory extruder at pilot plant scale. Extrusion parameters such as color and carbohydrate content (fiber, sucrose, and starch) were evaluated. Carob bean addition led to an increase in starch, soluble fiber, and insoluble fiber. Texture parameters related to hardness (crunchiness) were significantly reduced with the addition of CB (p < 0.05), detectable from a 5% addition of CB and not significant with more CB content. Samples became browner with the addition of CB; however, when the concentrations of CB are high (>5%) no major differences in color were observed. The extrusion process reduced the content of soluble and insoluble fiber, and sucrose in all formulated samples. Extruded samples with 5-7.5% CB seem to be the best formulation in terms of fiber content, color, and texture parameters. These innovative gluten-free foods could be considered as a source of fiber, and a healthier alternative to some commercially available snacks.

Effects of extrusion process conditions on nutritional, anti‐nutritional, physical, functional, and sensory properties of extruded snack: A review

AbstractConsumers' demand for ready‐to‐eat extruded snack is increasing due to their convenience and time saving. Extrusion cooking is the most commonly used technology for manufacturing ready‐to‐eat snack products. However, improper management of extrusion parameters such as the barrel temperature, feed moisture content, pressure, and other parameters of the extruder can influence the quality of extruded snack foods. This paper aimed to review the effects of extrusion process conditions on the quality of the extruded snack. According to this review, most of the nutritional composition and anti‐nutritional factors are sensitive to the extruder's high barrel temperature. High barrel temperature decreased the anti‐nutritional factors of the extrudates. Low feed moisture content and high barrel temperature minimize the bulk density and hardness while increasing the extruded snack's expansion ratio and water solubility index. In contrast, low barrel temperature increased the color and appearance of the extrudates while decreasing the flavor and overall acceptability of the extrudates. In general, this review indicated that extrusion processing parameters need to be optimized to deliver nutrient‐rich extruded snack with appropriate physical, functional, and sensory properties.

Texture evolution induced by extrusion parameters and its effect on strengthening-toughening mechanisms of Al-Mg-Si-Cu-Mn alloys

In this study, extrusion experiments were carried out on Al-Mg-Si-Cu-Mn alloys with different extrusion ratios (ERs), extrusion temperatures (ETs), and extrusion speeds (ESs). By using electron backscatter diffraction (EBSD) analysis, tensile testing, and other analytical means, the evolution of microstructure, texture, and properties of the extruded alloys was systematically investigated, and the strengthening-toughening mechanism induced by the extrusion parameters was revealed. It was found that the strength of the extruded alloy shows a tendency to first increase and then decrease with the increase of the ER and ES, and the ‘critical ER' and ‘critical ES' are 29.5 and 2.5 mm/s, respectively; the strength of the extruded alloy gradually increases with the increase of the ET. The alloy achieved excellent strength-toughness matching at the ER of 29.5, ET of 480 °C, and ES of 2.5 mm/s. The yield strength (YS), ultimate tensile strength (UTS), and elongation (EL) of the extruded alloy at this condition were ∼169.58 MPa, ∼314.36 MPa, and ∼16.57 %, respectively. This excellent strength-toughness matching is mainly related to the following aspects: 1) grain refinement provides high grain boundary strengthening effect and appropriate work hardening ability; 2) <111>//ED texture has a strong preferential orientation; 3) the variation trend of dislocation density is importantly related to <111>//ED and EXa{011}<111> textures; 4) Cube{001}<100> and Goss{011}<100> textures have a softening effect. The above findings provide new insights into the potential mechanisms of hot extrusion forming of aluminum alloys, which are of important guiding for the design and development of aluminum alloys with excellent strength-toughness combinations.

Optically active carbon dot/cellulose nanocrystal hydrogel printing inks with two-step authentication

The counterfeit market in field of consumer goods is still a great obstacle to financial well-being for manufacturers and consumers. Security labels with hidden images have proven to be an effective anticounterfeiting measure. Three-dimensional (3D) printing is an effective approach to fabricating labels with complex geometries using environmentally friendly and cost-effective customized inks. In this work, optically active hydrogels were made by incorporating fluorescent carbon dots (CDs) into a cellulose nanocrystal (CNC) matrix. The CD:CNC ratios were optimized to obtain inks with high viscosity and fidelity that exhibited shear-thinning behavior. The resulting inks showed good printability and the extrusion parameters were optimized to achieve high printing accuracy. When excited at different wavelengths, the printed patterns fluoresced different colors. CNC also showed shear-induced alignment upon extrusion, which is visible under polarized light, allowing hidden images to be incorporated into the printed structures for two-factor authentication.

Microstructures, mechanical properties and damping performance of wrought Mg–Cu–Ca alloys

Mg–Cu–Ca alloy sheets show good room temperature formability and excellent thermal conductivity; however, their strength is insufficient for load-bearing applications. In this study, Mg–Cu–Ca ternary alloys were subjected to a conventional extrusion process, and the microstructures and tensile properties were systematically evaluated. The addition of extremely small amounts of Cu and Ca to pure Mg (Mg–0.03Cu–0.05Ca, wt%) led to significant refinement of dynamically recrystallized (DRXed) grains while preserving a certain fraction of un-DRXed grains, which contributed to a substantial increase in tensile yield strength. Adjusting the extrusion parameters further increased the tensile yield strength to 329MPa, driven by the combined effects of further refined DRXed grains and an increased area fraction of un-DRXed grains. The damping performance of the Mg–0.03Cu–0.05Ca alloy sheet was superior to that of commercial AZ31(Mg–3Al–1Zn–0.3Mn in wt%) alloy sheet but lower than that of pure Mg, particularly at low frequencies. This revealed that the solute segregation at grain boundaries plays a crucial role in the damping performance of Mg alloys.

Effect of Hot Extrusion on Microstructure, Texture, and Mechanical Properties of Mg-Zn-Mn-0.5Ca Alloy

This paper investigates the microstructure, texture, and mechanical properties of the Mg-4Zn-1Mn-0.5Ca alloy subjected to hot extrusion under varying conditions of temperature (260 °C, 300 °C, 340 °C) and extrusion speed (0.01 mm/s, 0.1 mm/s, 1 mm/s). The primary objective is to determine the optimal extrusion parameters within the selected experimental range for achieving superior mechanical properties. The results indicate that, when extruded at a constant speed of 0.1 mm/s, the alloy exhibits optimal performance at 340 °C, with a yield strength of 202 MPa, ultimate tensile strength (UTS) of 306 MPa, and elongation at fracture of 18.9%. A decrease in extrusion temperature leads to an increase in yield strength but a reduction in ductility. Specifically, the UTS reaches its peak at 342 MPa at 300 °C, while it drops slightly to 329 MPa at 260 °C. The final results show that the comprehensive mechanical properties of the Mg-4Zn-1Mn-0.5Ca alloy obtained by hot extrusion treatment with an extrusion temperature of 300 °C and extrusion speed of 0.1 mm/s are the best and can effectively improve the mechanical properties of the alloy and provide a good choice for the preparation of other biodegradable magnesium alloy products.

Scaling-Up for the Counter-Rotating Twin Screw Extrusion of Polymers.

A novel and original computer scaling-up system for the counter-rotating twin screw extrusion of polymers was developed. In the system, each scaling parameter (scaling criterion) may be considered as an objective function to be minimized for the single parameters or the functional relationships along the length of the screw. Scaling was based on the process simulation, which was performed using the comprehensive (or global) counter-rotating twin screw extrusion program called TSEM (Twin Screw Extrusion Model). The extrusion process was scaled by applying GASESTWIN (Genetic Algorithms Screw Extrusion Scaling) software developed for this purpose using genetic algorithms. Scaling up the extrusion process was carried out to enhance extrusion process throughput according to the scaling criteria specified by the single quantities of polymer melt temperature at the die exit and relative melting length, and by distributions along the screw length of the extrusion parameters of the polymer melt temperature and polymer plasticating. The global objective function had the lowest value for the selected extrusion parameters, which means the minimal differences between the values of the scaled-up processes and extrusion throughput was significantly increased. The solution to the problem of scaling the counter-rotating process presented in this paper complements the existing solutions for optimizing and scaling basic variants of the extrusion process, i.e., flood-fed and starve (metered)-fed single-screw extrusion, as well as co-rotating and counter-rotating twin-screw extrusion.

Effects of Barrel Temperature, Screw Speed and Feed Moisture Content on the Organoleptic Properties of Aerial Yam-Soybean Flour Extruded Snacks

The effects of barrel temperature, screw speed and feed moisture content, as extrusion process parameters, on the organoleptic properties of aerial yam-soybean flour extruded snacks were investigated, using Response Surface Analysis. The extruded snacks were produced using a Laboratory scale single-screw food extruder. Results of the determination of organoleptic properties of the extruded snacks showed that: texture; taste; colour; and aroma ranged from 4.38 to 6.02; 4.68 to 6.78; 4.58 to 6.97; and 4.45 to 7.00, respectively. Response surface Analysis indicated that barrel temperature and screw speed had significant effect (p &lt; 0.05) on texture, while feed moisture had no significant effect (p &gt; 0.05) on the texture of the snacks. All the extrusion parameters had significant effect (p &lt; 0.05) on the taste of the snacks. Barrel temperature and feed moisture had significant effect (p &lt; 0.05) on colour, while screw speed showed non-significant effect (p &gt; 0.05) on the colour of the snacks. Barrel temperature had significant effect (p &lt; 0.05) on aroma, while screw speed and feed moisture had no significant effect (p &gt; 0.05) on the aroma of the snacks. The results obtained for the organoleptic properties of the snacks can attest to the fact that it is possible to obtain expanded or ready-to-eat (RTE) products from aerial yam-soybean flour blends by extrusion processing technology, that possess desirable organoleptic properties.

Multiphysics modeling and simulation of monolayer flow and die swelling in industrial tube extrusion process

AbstractIn a regular extrusion process for thermoplastic specimen, the material behavior in dies and its rheological properties have a major influence on the mechanical properties and the quality of the extruded product. This study outlines the multiphysical model, which has been adapted to address the specific issues associated with polyamide 12 polymer extrusion. A series of numerical simulations, based on the modeling of material behavior, have been conducted using the computational code Comsol Multiphysics®. These simulations have been applied to the study of polymer melt flows through an industrial extrusion die. The objective of this study is to analyze the influence of the imposed extrusion parameters on the physical field distribution and the material displacement within the die. The die swell at the exit of the extrusion die has been investigated as a function of the imposed pressure. The progression of the polymer flow front inside the extrusion tool and the swelling rates have been analyzed. In particular, the phenomenon of delayed swelling at high pressure has been highlighted at high pressure.Highlights Polymer swelling at industrial extrusion die exit is investigated. Polymer melt extrusion within industrial extrusion tool is numerically simulated. Flow front progression and extrudate swell are analyzed. Effect of extrusion pressure on instabilities and die swell is highlighted.

Solvent Minimized Synthesis of Amides by Reactive Extrusion.

Herein, we report on the translation of a small scale ball-milled amidation protocol into a large scale continuous reactive extrusion process. Critical components to the successful translation were: a) understanding how the different operating parameters of a twin-screw extruder should be harnessed to control prolonged continuous operation, and b) consideration of the physical form of the input materials. The amidation reaction is applied to 36 amides spanning a variety of physical form combinations (liquid-liquid, solid-liquid and solid-solid). Following this learning process, we have developed an understanding for the translation of each physical form combination and demonstrated a 7-hour reactive extrusion process for the synthesis of an amide on 500 gram scale (1.3 mols of product).

An analysis of the high-homogeneity preparation, thermo-mechanical deformation and recrystallization behavior of a novel superalloy with γ′ content reaching 73%

A deformed superalloy with γ′ content reaching 73% has been designed by ourselves. In this work, the problems of preparation and deformation caused by the high γ′ phase content were solved by the electron beam smelting layered solidification technique (EBS-LST) and hot extrusion. Initially, the superalloy with low segregation and fine microstructure was prepared by EBS-LST, followed by conducting hot deformation experiments at different temperatures and strain rates. The compression curves are corrected, and the constitutive model, recrystallization models and thermo-mechanical processing maps were established based on the corrected curves, and the recrystallization mechanisms were analyzed by TEM and EBSD. Finally, the suitable hot extrusion parameters were obtained indirectly through the hot processing map, and the designed alloy was hot extruded. The microstructure of the extruded alloy is free of cracks and is characterized by fine equiaxed grains.

Determination and structural analysis of process parameters for combined rolling and extrusion of rods from magnesium ingots

Determination and structural analysis of process parameters for combined rolling and extrusion of rods from magnesium ingots

Influence of Extrusion Parameters on the Mechanical Properties of Slow Crystallizing Carbon Fiber-Reinforced PAEK in Large Format Additive Manufacturing.

Additive Manufacturing (AM) enables the automated production of complex geometries with low waste and lead time, notably through Material Extrusion (MEX). This study explores Large Format Additive Manufacturing (LFAM) with carbon fiber-reinforced polyaryletherketones (PAEK), particularly a slow crystallizing grade by Victrex. The research investigates how extrusion parameters affect the mechanical properties of the printed parts. Key parameters include line width, layer height, layer time, and extrusion temperature, analyzed through a series of controlled experiments. Thermal history during printing, including cooling rates and substrate temperatures, was monitored using thermocouples and infrared cameras. The crystallization behavior of PAEK was replicated in a Differential Scanning Calorimetry (DSC) setup. Mechanical properties were evaluated using three-point bending tests to analyze the impact of thermal conditions at the deposition interface on interlayer bonding and overall part strength. The study suggests aggregated metrics, enthalpy deposition rate and shear rate under the nozzle, that should be maximized to enhance mechanical performance. The findings show that the common practice of setting fixed layer times falls short of ensuring repeatable part quality.

Optimization of Glass-Powder-Reinforced Recycled High-Density Polyethylene (rHDPE) Filament for Additive Manufacturing: Transforming Bottle Caps into Sound-Absorbing Material.

Additive manufacturing presents promising potential as a sustainable processing technology, notably through integrating post-consumer recycled polymers into production. This study investigated the recycling of high-density polyethylene (rHDPE) into 3D printing filament, achieved by the following optimal extrusion parameters: 180 °C temperature, 7 rpm speed, and 10% glass powder addition. The properties of the developed rHDPE filament were compared with those of commonly used FDM filaments such as acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) to benchmark the performance of rHDPE against well-established materials in the 3D printing industry, providing a practical perspective for potential users. The resulting filament boasted an average tensile strength of 25.52 MPa, slightly exceeding ABS (25.41 MPa) and comparable to PLA (28.55 MPa). Despite diameter fluctuations, the filament proved usable in 3D printing. Mechanical tests compared the rHPDE filament 3D printed objects with ABS and PLA, showing lower strength but exceptional ductility and flexibility, along with superior sound absorption. A life cycle analysis underscored the sustainability advantages of rHDPE, reducing environmental impact compared to conventional disposal methods. While rHDPE falls behind in mechanical strength against virgin filaments, its unique attributes and sustainability position it as a valuable option for 3D printing, showcasing recycled materials' potential in sustainable innovation.

Evaluation of the effects of extrusion parameters on the swelling of extruded filament in an innovative 3D printer containing a vertical co-rotating twin-screw extrusion unit

Evaluation of the effects of extrusion parameters on the swelling of extruded filament in an innovative 3D printer containing a vertical co-rotating twin-screw extrusion unit

Parameter Optimization in FDM Filament Fabrication via Single Screw Extruder

The presence of polymer material filaments plays a crucial role in the realm of 3D printing. These filaments are utilized in 3D printing to create prototype products efficiently and cost-effectively. However, ensuring the production of high-quality prototype products necessitates the use of superior filaments characterized by consistent diameter and a round cross-section. Filaments are typically manufactured through an extrusion process using either a single screw extruder or a twin extruder. In this research, a DIY single-screw extruder was developed specifically for filament production. The main objective of this study is to generate quality filaments by optimizing the extruder parameters for various polymer materials. Three different polymers; Ethylene-vinyl Acetate (EVA), Polypropylene (PP), and Acrylonitrile Butadiene Styrene (ABS) were employed in this study. The research aimed to assess the melt flow index (MFI) to demonstrate viscous behavior and establish the ideal parameters for each material in the extrusion process. A total of 27 EVA material filament samples, 26 PP filament samples, and 26 ABS filament samples were successfully produced. Through analysis, optimal settings were identified for EVA, PP, and ABS filaments, resulting in high-quality production. The recommended parameters for producing quality EVA filaments included a temperature of 160°C, screw speed of 400 rpm, and take-up speed of 400 rpm. For PP filaments, the optimal settings comprised a temperature of 230°C, screw speed of 700 rpm, and take-up speed of 250 rpm. Lastly, ABS filament production was optimized with a temperature of 210°C, screw speed of 300 rpm, and take-up speed of 100 rpm. This project's outcomes are anticipated to have significant implications for future advancements in filament manufacturing processes.