Pembentukan Logam RS K5 EXTRUSION

17/03/2015
Direct
Indirect
Hydrostatic
Billets of Lateral
Al, Cu, Mg, Steel, Solid/Hollow
Stainless Steel Non Lubricated of Constant
Lubricated Cross Section
EXTRUSION Raw ESTRUSION
Materials PROCESS Products
AN INTRODUCTORY LECTURE Hot

Cold
Conventional
Non Conventional
R a h m a t S a p t o n o - Department of Metallurgy and Materials DoM 2008

FTUI FTUI Faculty of Engineering University of Indonesia -2
Introduction
• Hot Extrusion is the process of forcing a
heated billet to flow through a shaped
Conventional Hot Extrusion die opening.
• It is used to produce long straight metal
products of constant cross section,
such as bars, solid and hollow sections,
tubes, wires, and strips from materials that
cannot be formed by cold extrusion.
R a h m a t S a p t o n o - Department of Metallurgy and Materials DoM 2008 R a h m a t S a p t o n o - Department of Metallurgy and Materials DoM 2008
FTUI Faculty of Engineering University of Indonesia - 12
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Typical direct-drive hydraulic

extrusion press. 1. hydraulic power
unit; 2. tie rods; 3. butt shear; 4.
extrusion platen; 5. container
shifting cylinders; 6. swiveling
operator's console; 7. die slide; 8.
container; 9. container housing; 10.
billet loader; 11. press base; 12.
billet loader cylinders; 13. pressing
stem; 14. crosshead; 15. side
cylinders; 16. cylinder platen; 17.
main cylinder.
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Hot Extrusion Products DISCRETE PRODUCT

MADE BY SECTIONING.
e.g.
Gear
SOLID or HOLLOW SEMI CONTINUOUS PRODUCTS Door and
of a CONSTANT CROSS SECTION Window Handle
e.g.
Railings for sliding doors
Tubing having various cross section
Structural/architectural shapes
Door & window frames
Source: Kaiser Aluminum
Types of Conventional Hot Extrusion
Non Lubricated Lubricated
Source: The Open University's OpenLearn website
Non Lubricated Hot Extrusion

Nonlubricated hot extrusion is a relatively straightforward
process once the conditions have been defined.
However, a large number of metallurgical and processing
factors interact and affect the mechanical properties, surface
finish, and corrosion resistance of the final extruded shape.
This extrusion method uses no lubrication on the billet,
container, and die, and it can produce very complex sections,
with mirror surface finishes and close dimensional tolerances,
that are considered to be net extrusions.
A flat-face (shear-face) die is often used in nonlubricated hot
extrusion.
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Direct Extrusion Indirect Extrusion
Schematic illustration of the direct extrusion process.
A typical sequence of operations for the

forward extrusion of a solid section
• The heated billet and the dummy block are loaded into the container
• The billet is extruded by the force of the ram being pushed against it.
This upsets the billet, then forces the metal to flow through the die.
During extrusion, a thin shell of material may be left on the container
walls. Extrusion is halted in order to leave a thin disk of material
(butt) in the container
• The container is separated from the die, the extruded section with
the butt, and the dummy block
• The discard (butt) is sheared off
• The shear die, the container, and the ram are returned to their initial
(loading) positions
The sequence of operations for the Typical load versus ram displacement curves
backward extrusion of a solid section for non-lubricated extrusion processes
• The die is inserted into the press

• The billet is loaded into the container
• The billet is extruded, leaving a butt
• The die and the butt are separated from the section
Load versus ram displacement curves for (a) forward extrusion (Curve 1)
(a) and backward extrusion (Curve 2) .
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Typical load versus ram displacement curves for forward

and backward extrusion are illustrated, which shows that
the load in forward extrusion initially increases very
rapidly as the billet upsets to fill the container. This is
followed by a further increase in pressure, and extrusion
begins. A somewhat cone-shaped deformation zone then
develops in front of the die aperture.
After the maximum load has been reached, the extrusion
pressure falls as the billet length decreases until a
minimum is reached, then rapidly increases again. This
last pressure increase occurs because only a disk of the
billet remains and the metal must flow radially toward the Division of the work of deformation. A, work of upsetting; B, work needed to
die aperture. Resistance to deformation increases initiate deformation; C, work of deformation; D, work needed to overcome
considerably with decreasing thickness. friction and shearing in direct extrusion
Backward Extrusion (+) Backward Extrusion (+)
• A 25 to 30% reduction in maximum load relative to direct • No heat is produced by friction between the billet and
extrusion the container; consequently, no temperature increase
• Extrusion pressure is not a function of billet length, occurs at the billet surface toward the end of extrusion,
because there is no relative displacement between the as is typical in the direct extrusion of aluminum alloys.
billet and the container. • Therefore, in backward extrusion, there is a lesser
• Therefore, billet length is not limited by the load required tendency toward cracking of the surfaces and edges,
for this displacement but only by the length and stability and extrusion speeds can be significantly higher.
of the hollow stem needed for a given container length • The service life of the tooling is increased, especially
that of the inner liner, because of reduced friction and
temperatures
Backward Extrusion (-) Lubricated Hot Extrusion
• The disadvantage of backward extrusion is that

impurities or defects on the billet surface affect the
Generally, aluminum alloys are extruded without lubrication, but
surface of the extrusion and are not automatically
copper alloys, titanium alloys, alloy steels, stainless steels, and
retained as a shell or discard in the container. As a tool steels are extruded with a variety of graphite and glass-base
result, machined billets are used in many cases. lubricants.
• In addition, the cross-sectional area of the extrusion
Commercial grease mixtures containing solid-film lubricants, such
is limited by the size of the hollow stem. as graphite, often provide little or no thermal protection to the die.
For this reason, die wear is significant in the conventional hot
extrusion of steels and titanium alloys.
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As a lubricant, glass exhibits unique characteristics, such as its

The Sejournet process is the most commonly used for the ability to soften selectively during contact with the hot billet and,
extrusion of steels and titanium alloys (Ref 2). In this process, simultaneously, to insulate the hot billet material from the tooling.
the heated billet is rolled over a bed of ground glass or is The tooling is usually maintained at a temperature that is
sprinkled with glass powder to provide a layer of low-melting considerably lower than that of the billet. In the extrusion of
glass on the billet surface. titanium and steel, the billet temperature is usually 1000 to 1250
°C (1830 to 2280 °F), but the maximum temperature the tooling
Before the billet is inserted into the hot extrusion container, a can withstand is 500 to 550 °C (930 to 1020 °F).
suitable lubricating system is positioned immediately ahead
of the die. This lubricating system can be a compacted glass Therefore, compatibility can be attained only by using the
pad, glass wool, or both. The pre-lubricated billet is quickly appropriate lubricants, insulative die coating, and ceramic die
inserted into the container, along with the appropriate followers inserts and by designing dies to minimize tool wear. Glass
or a dummy block. The extrusion cycle is then started. lubricants have performed satisfactorily on a production basis in
extruding long lengths.
The choice between grease and glass lubricants is based mainly on the
extrusion temperature. At low temperatures, lubrication is used only to Extrusion Force
reduce friction. At moderate temperatures, there is also some insulation
between the hot billet and the tooling from the use of partially molten
lubricants and vapor formation in addition to the lubrication effect. At • Force is dependent on:
temperatures above 1000 °C (1830 °F), the thermal insulation of the
tooling from overheating is of equal importance to the lubricating effect,
– Flow Strength of the Billet Materials
particularly with difficult-to-extrude alloys. The lubrication film can also – Reduction in Area i.e. Extrusion Ratio
impede oxidation. Lubricants can be classified into two groups,
according to temperature: – Friction between the Billet and the Chamber &
the Die Surfaces
Below 1000 °C (1830 °F): Grease lubrication, such as grease, graphite,
molybdenum disulfide, mica, talc, soap, bentonite, asphalt, and plastics – Other Process Variables (Die Geometry,
(for example, high-temperature polyimides) Speed, Temperature)
Above 1000 °C (1830 °F): Glass lubrication, such as glass, basalt, and
crystalline powder
Billet
Materials Billet Process Variables
Temperature
Die
Extrusion
Pressure
Angle
• Die Angle, a
• Die Temperature, T
• Extrusion Ratio, R = A0/Af
• Billet Temperature, T
Reduction in
Cross Section • Ram Speed, v
Extrusion Lubrication • Lubricant, m
Speed
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Extrusion Constant
Extrusion Constant k
Extrusion Force
A0
F  A0 k ln
Af
Initial Cross Section
Extrusion Ratio
Extrusion constant k for various metals at different temperatures.
Source: P. Loewenstein.
Example Solution
• A round billet made of 70-30 brass is • The extrusion force is calculated using
extruded at a temperature of 675oC Force Equation in which the extrusion
(1250oF). constant, k is obtained from Extrusion
• The billet diameter is 5 in. (125 mm) and constant Diagram. For this material we
the diameter of the extrusion is 2 in.(50 find that k = 35,000 Psi (250 MPa) at the
mm). extrusion temperature. Thus,
• Calculate the extrusion force required.
Pext = 500 and 700 MPa

Aluminum Extrusion
A0
F  A0 k ln
Af
T = 450-500oC
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Metal Flow in Extrusion Types of Metal Flow in Extruding With Square Dies
• Affect the Quality and Mechanical

Properties of Final Product
• The effect of the metal flow on the Types of metal flow in extruding with square dies.
extrusion force/pressure is involved in (a) Flow pattern obtained at low friction, or in indirect extrusion.
(b) Pattern obtained with high friction at the billet-chamber interfaces.
such Classical Analysis as Upper Bound (c) Pattern obtained at high friction, or with cooling of the outer regions
of the billet in the chamber. This type of pattern, observed in metals
and Slip Line Field Theories. whose strength increases rapidly with decreasing temperature, leads to
a defect known as pipe, or extrusion defect.
Metal flow varies considerably during extrusion,

depending on:
Flow pattern S (Fig. 4a) is characterized by the maximum possible
the material, uniformity of flow in the container. Plastic flow takes place primarily in a
the material/tool interface friction, and deformation zone directly in front of the die. The major part of the nonextruded
the shape of the section. billet, pushed as a rigid body through the die, remains undeformed; therefore,
the front of the billet moves evenly into the deformation zone.
Flow pattern A (Fig. 4b) occurs in homogeneous materials when there is

Flow pattern S Flow pattern A virtually no friction between the container and the billet but significant
Flow pattern B Flow pattern C
friction at the surface of the die and its holder. This retards the radial flow
of the peripheral zones and increases the amount of shearing in this region.
The result is a slightly larger dead-metal zone than that in flow type S, along with
a correspondingly wider eformation zone. However, deformation in the center
remains relatively uniform. Flow patterns of this type are seldom observed in
nonlubricated extrusion; instead, they occur during the lubricated extrusion of
soft metals and alloys, such as lead, tin, α-brasses, and tin bronzes, and during
the extrusion of copper billets covered with oxide (which acts as a lubricant).
Flow pattern B (Fig. 4c) occurs in homogeneous materials if friction exists at

both the container wall and at the surfaces of the die and die holder (Fig. 4c). Flow pattern C (Fig. 4d) occurs in the hot extrusion of materials having
The peripheral zones are retarded at the billet/container interface, while the lower
inhomogeneous properties when the friction is high (as in flow pattern B)
resistance causes the material in the center to be accelerated toward the and when the flow stress of the material in the cooler peripheral regions of
die. The shear zone between the retarded regions at the surface and the the billet is considerably higher than that in the center. The billet surface
accelerated material in the center extends back into the billet to an extent that
forms a relatively stiff shell. Therefore, the conical deadmetal zone is much
depends on the extrusion parameters and the alloy. Therefore, the dead-metal larger and extends from the front of the billet to the back. At the start of
zone is large. At the start of extrusion, the shear deformation is concentrated in
extrusion, only the material inside the funnel is plastic, and it is severely
the peripheral regions, but as deformation continues, it extends toward the center. deformed, especially in the shear zone, as it flows toward the die. The stiff shell
This increases the danger of material flowing from the billet surface--with and the dead-metal zone are in axial compression as the billet length
impurities or lubricant--along the shear zone and finishing up under the surface of decreases; consequently, the displaced material of the outer regions follows the
the extrusion. In addition, the dead-metal zone is not completely rigid and can
path of least resistance to the back of the billet, where it turns toward the center
influence, even if to a limited degree, the flow of the metal. Flow type B is found in
and flows into the funnel.
single-phase (homogeneous) copper alloys that do not form a lubricating oxide
skin and in most aluminum alloys.
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Extrusion Practices Extrusion Practices

• Extrusion Ratio, R = 10 ~ 100 (at least 4 to • Most of Extruded Parts (particularly with small
produce wrought product) CS) require straightening and twisting 
Hydraulic Stretcher.
• Length of Extrusion Product:
• Dimensional tolerances: +/- 0.25-2.5 mm
– < 7.5 m (In some cases may be up to 30 m) (Increase with increasing Dia.)
• Circumscribed-Circle Diameter (CCD). • A small portion of the end of the billet to remain
– Al : 6 mm ~ 1 m (most are within 0.25 m) in the chamber, i.e. Scrap or Butt End. 
– Steel : < 0.15 m (due to high force) another billet or a graphite block is used to
• Ram Speeds: up to 0.5 m/s extrude it.
– Lower for Al, Mg, Cu • Coaxial billets are extruded together in Coaxial
Extrusion or Cladding provided the two metals
– Higher for Steels, Ti, Refractories are compatible (e.g. Cu clad with Ag).
Hot Extrusion Billet Temperature for Hot Extrusion
Some consequences of High Operating

Temperature
• Die Wear
– Pre heated dies
• Oxide Film
– Skull
• Flat (Shear) Dies are employed particularly for

Extrusion Temperature Ranges for Various Metals Al
– They will develop Dead Metal Zone (DMZ)  Die
Angle
– DMZ will produce extruded parts with Bright Finishes
• Die Materials
– Hot work die steels coated with Zr are often used
• Lubrication
– Glass is often used for Steels, SS, High Temp. Metals
and Alloys.
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Shape Parameters Extrusion-Die Configurations

(a) (c)
Extruded CCD (b)

Cross Section
Circumscribing-Circle Diameter (CCD) Typical extrusion-die configurations:

Source for (c): Courtesy of LTV Steel Company.
The diameter of the smallest circle into which extruded cross-section will fit (a) die for nonferrous metals; (b) die for ferrous metals; (c) die for T-shaped extrusion,
made of hot-work die steel and used with molten glass as a lubricant.
Components for Extruding Hollow Shapes

(a) An extruded 6063-T6 aluminum ladder lock for aluminum extension ladders.
This part is 8 mm (5/16 in.) thick and is sawed from the extrusion (b)-(d)
Components of various dies for extruding intricate hollow shapes.
Die Design and Die Materials
Source: for (b)-(d): K. Laue and H. Stenger, Extrusion--Processes, Machinery, Tooling.

American Society for Metals, Metals Park, Ohio, 1981. Used with permission.
R a h m a t S a p t o n o - Department of Metallurgy and Materials DoM 2008

FTUI FTUI Faculty of Engineering University of Indonesia - 70
Extruded Cross Section Design
Poor and good examples

of cross-sections to be
extruded.
Note the importance of

eliminating sharp corners
and of keeping section
thicknesses uniform.
Source: J. G. Bralla (ed.); Handbook of Product Design for Manufacturing .

New York: McGraw-Hill Publishing Company, 1986. Used with permission.
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Die Materials
• Bulk deformation process is characterized by
high interface pressure coupled with high
temperatures in hot working.
• Tools and die materials must be carefully
selected and manufactured with the greatest
care.
• Hot worked die steels are usually used for hot
extrusion. Coating is used to extend their life.
Cold Extrusion
Introduction Examples of Cold Extrusion
• It is a combination of operations, i.e. +

Forging
• Impact Extrusion
• Indirect Extrusion
Two examples of cold extrusion. Thin arrows indicate
the direction of metal flow during extrusion.
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Cold Extruded Spark Plug Impact Extrusion

Production steps for a cold extruded spark plug.
Source: National Machinery Company.
A cross-section of the metal part, showing

the grain flow pattern. Schematic illustration of the impact-extrusion process. The extruded parts are
Source: National Machinery Company. stripped by the use of a stripper plate, because they tend to stick to the punch.
Examples of Impact Extrusion Internal Defects (1)
Pipe
• Metal flow pattern tends to bring surface oxide
and impurities towards the center of the billets
much like a funnel. This is known as pipe
defects, also tailpipe or fish tailing.
• Piping can be minimized by controlling the flow
(a) Two examples of products made by impact extrusion. These parts may pattern as well as the surface quality of billets
also be made by casting, by forging, or by machining; the choice of process prior to extrusion.
depends on the dimensions and the materials involved and on the properties
desired. Economic considerations are also important in final process selection.
(b) and (c) Impact extrusion of a collapsible tube by the Hooker process.
Internal Defects (2) Chevron Cracking

(b)
Internal Cracking (a)
• Also known as center-burst, center cracking,

arrowhead fracture, or chevron cracking.
• Rupture occurs in the center of the extrude
product due to excessive longitudinal
secondary hydrostatic tensile stress.
• The tendency increases if the two plastic zones (a) Chevron cracking (central burst) in extruded round steel bars. Unless the
products are inspected, such internal defects may remain undetected, and later
do not meet. The plastic zone can be made cause failure of the part in service. This defect can also develop in the drawing
of rod, of wire, and of tubes.
larger by decreasing die angle and increasing (b) Schematic illustration of rigid and plastic zones in extrusion. The tendency
toward chevron cracking increases if the two plastic zones do not meet. Note
extrusion ratio. that the plastic zone can be made larger either by decreasing the die angle or by
increasing the reduction in cross-section (or both).
Source: B. Avitzur.
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External Defects
• Surface cracking, due to inadequate
lubrication.
• Longitudinal scratches, due to scored die,
improper lubrication, or abrasive particle
After Schey being drawn into dies.
• Slivers and seams, due to cold shuts and
blow holes.
• Surface de-colorization.
13

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17/03/2015

AN INTRODUCTORY LECTURE Hot

R a h m a t S a p t o n o - Department of Metallurgy and Materials DoM 2008

Typical direct-drive hydraulic

Hot Extrusion Products DISCRETE PRODUCT

Source: Kaiser Aluminum

Types of Conventional Hot Extrusion

Non Lubricated Lubricated

Source: The Open University's OpenLearn website

Non Lubricated Hot Extrusion

Direct Extrusion Indirect Extrusion

Schematic illustration of the direct extrusion process.

A typical sequence of operations for the

• The die is inserted into the press

Typical load versus ram displacement curves for forward

Backward Extrusion (+) Backward Extrusion (+)

Backward Extrusion (-) Lubricated Hot Extrusion

• The disadvantage of backward extrusion is that

As a lubricant, glass exhibits unique characteristics, such as its

Pext = 500 and 700 MPa

• Affect the Quality and Mechanical

Metal flow varies considerably during extrusion,

Flow pattern A (Fig. 4b) occurs in homogeneous materials when there is

Flow pattern B (Fig. 4c) occurs in homogeneous materials if friction exists at

Extrusion Practices Extrusion Practices

Hot Extrusion Billet Temperature for Hot Extrusion

Some consequences of High Operating

• Flat (Shear) Dies are employed particularly for

Shape Parameters Extrusion-Die Configurations

Extruded CCD (b)

Circumscribing-Circle Diameter (CCD) Typical extrusion-die configurations:

Components for Extruding Hollow Shapes

Die Design and Die Materials

Source: for (b)-(d): K. Laue and H. Stenger, Extrusion--Processes, Machinery, Tooling.

R a h m a t S a p t o n o - Department of Metallurgy and Materials DoM 2008

Extruded Cross Section Design

Poor and good examples

Note the importance of

Source: J. G. Bralla (ed.); Handbook of Product Design for Manufacturing .

Introduction Examples of Cold Extrusion

• It is a combination of operations, i.e. +

Cold Extruded Spark Plug Impact Extrusion

A cross-section of the metal part, showing

Examples of Impact Extrusion Internal Defects (1)

Internal Defects (2) Chevron Cracking

• Also known as center-burst, center cracking,

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