Numerical and Experimental Investigation on the Surface Defect Generation during the Hot Extrusion of Al6063 Alloy

The surface quality control of extruded products is a critical concern in the home appliance manufacturing industry owing to the increasing need for products with a high surface quality, in addition to the essential mechanical properties of the final product. The underlying issue with achieving high...

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Autores principales:	Namsu Park, Yeonghwan Song, Seon-Ho Jung, Junghan Song, Jongsup Lee, Heejong Lee, Hyun-Min Sung, Gihyun Bae
Formato:	article
Lenguaje:	EN
Publicado:	MDPI AG 2021
Materias:	extrusion surface defect white line metallurgical analysis thermomechanical FE simulation Technology T Electrical engineering. Electronics. Nuclear engineering TK1-9971 Engineering (General). Civil engineering (General) TA1-2040 Microscopy QH201-278.5 Descriptive and experimental mechanics QC120-168.85
Acceso en línea:	https://doaj.org/article/f252cb8c2c94412899e21d9fe3695a90
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spelling	oai:doaj.org-article:f252cb8c2c94412899e21d9fe3695a902021-11-25T18:13:25ZNumerical and Experimental Investigation on the Surface Defect Generation during the Hot Extrusion of Al6063 Alloy10.3390/ma142267681996-1944https://doaj.org/article/f252cb8c2c94412899e21d9fe3695a902021-11-01T00:00:00Zhttps://www.mdpi.com/1996-1944/14/22/6768https://doaj.org/toc/1996-1944The surface quality control of extruded products is a critical concern in the home appliance manufacturing industry owing to the increasing need for products with a high surface quality, in addition to the essential mechanical properties of the final product. The underlying issue with achieving high-quality extrusion products is that surface defects, especially those resulting in surface gloss differences, called white line defects, are only observed after surface treatment. In this study, we aim to investigate the cause of white line defect generation on the surface of an extruded product. Accordingly, an experimental extrusion program is established using an L-shaped die that has a noticeable change in its bearing length along the inner corner of its cross-sectional profile. Laboratory-scale experiments were performed for the L-shaped extrusion of homogenized Al 6063 alloy at various ram speeds, in order to induce surface defects, considering the production yield rate required for mass production. Subsequently, the microstructural changes near the surface failure region were investigated using an arbitrary Lagrangian–Eulerian (ALE) technique-based thermomechanical finite element (FE) analysis. To scale-up the defect observation method from laboratory-scale to production-scale manufacturing and confirm the reproducibility of the surface defect, scaled-up L-shaped extrusions were performed in an actual industrial production line. Finally, the potential cause of white line defect generation is discussed by comparing the numerical and metallurgical analyses, including the scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD) observations.Namsu ParkYeonghwan SongSeon-Ho JungJunghan SongJongsup LeeHeejong LeeHyun-Min SungGihyun BaeMDPI AGarticleextrusionsurface defectwhite linemetallurgical analysisthermomechanical FE simulationTechnologyTElectrical engineering. Electronics. Nuclear engineeringTK1-9971Engineering (General). Civil engineering (General)TA1-2040MicroscopyQH201-278.5Descriptive and experimental mechanicsQC120-168.85ENMaterials, Vol 14, Iss 6768, p 6768 (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	extrusion surface defect white line metallurgical analysis thermomechanical FE simulation Technology T Electrical engineering. Electronics. Nuclear engineering TK1-9971 Engineering (General). Civil engineering (General) TA1-2040 Microscopy QH201-278.5 Descriptive and experimental mechanics QC120-168.85
spellingShingle	extrusion surface defect white line metallurgical analysis thermomechanical FE simulation Technology T Electrical engineering. Electronics. Nuclear engineering TK1-9971 Engineering (General). Civil engineering (General) TA1-2040 Microscopy QH201-278.5 Descriptive and experimental mechanics QC120-168.85 Namsu Park Yeonghwan Song Seon-Ho Jung Junghan Song Jongsup Lee Heejong Lee Hyun-Min Sung Gihyun Bae Numerical and Experimental Investigation on the Surface Defect Generation during the Hot Extrusion of Al6063 Alloy
description	The surface quality control of extruded products is a critical concern in the home appliance manufacturing industry owing to the increasing need for products with a high surface quality, in addition to the essential mechanical properties of the final product. The underlying issue with achieving high-quality extrusion products is that surface defects, especially those resulting in surface gloss differences, called white line defects, are only observed after surface treatment. In this study, we aim to investigate the cause of white line defect generation on the surface of an extruded product. Accordingly, an experimental extrusion program is established using an L-shaped die that has a noticeable change in its bearing length along the inner corner of its cross-sectional profile. Laboratory-scale experiments were performed for the L-shaped extrusion of homogenized Al 6063 alloy at various ram speeds, in order to induce surface defects, considering the production yield rate required for mass production. Subsequently, the microstructural changes near the surface failure region were investigated using an arbitrary Lagrangian–Eulerian (ALE) technique-based thermomechanical finite element (FE) analysis. To scale-up the defect observation method from laboratory-scale to production-scale manufacturing and confirm the reproducibility of the surface defect, scaled-up L-shaped extrusions were performed in an actual industrial production line. Finally, the potential cause of white line defect generation is discussed by comparing the numerical and metallurgical analyses, including the scanning electron microscopy (SEM) and electron backscatter diffraction (EBSD) observations.
format	article
author	Namsu Park Yeonghwan Song Seon-Ho Jung Junghan Song Jongsup Lee Heejong Lee Hyun-Min Sung Gihyun Bae
author_facet	Namsu Park Yeonghwan Song Seon-Ho Jung Junghan Song Jongsup Lee Heejong Lee Hyun-Min Sung Gihyun Bae
author_sort	Namsu Park
title	Numerical and Experimental Investigation on the Surface Defect Generation during the Hot Extrusion of Al6063 Alloy
title_short	Numerical and Experimental Investigation on the Surface Defect Generation during the Hot Extrusion of Al6063 Alloy
title_full	Numerical and Experimental Investigation on the Surface Defect Generation during the Hot Extrusion of Al6063 Alloy
title_fullStr	Numerical and Experimental Investigation on the Surface Defect Generation during the Hot Extrusion of Al6063 Alloy
title_full_unstemmed	Numerical and Experimental Investigation on the Surface Defect Generation during the Hot Extrusion of Al6063 Alloy
title_sort	numerical and experimental investigation on the surface defect generation during the hot extrusion of al6063 alloy
publisher	MDPI AG
publishDate	2021
url	https://doaj.org/article/f252cb8c2c94412899e21d9fe3695a90
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Numerical and Experimental Investigation on the Surface Defect Generation during the Hot Extrusion of Al6063 Alloy

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