Porthole die extrusion of aluminum 6063 industrial scrap by shear assisted processing and extrusion
Scott Whalen, Brandon Scott Taysom, Nicole Overman, Md. Reza‐E‐Rabby, Qiao Yao, Thomas Richter, Tim Skszek, Massimo DiCiano
Abstract
Shear Assisted Processing and Extrusion (ShAPE) is presented as a new manufacturing technology for converting aluminum scrap directly into extruded products. In this work, a porthole die configuration is integrated within the rotating ShAPE process to extrude circular, square, trapezoidal, and two-cell trapezoidal profiles from aluminum alloy 6063 industrial scrap. Microstructural characterization is presented for a trapezoidal profile having an average grain size of 6.7 µm in the as-extruded condition. Round tubes achieved yield strength (246.9 ± 10.4 MPa), ultimate tensile strength (270.8 ± 9.6 MPa), and uniform elongation (16.5 ± 2.4%) exceeding industry standards.