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Department of Mechanical Engineering

Production of Flange-Shaped Components by Cold Forging of Composite Hot Extruded Semi-Finished Products

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  • Massivumformung
  • Umformtechnische Grundlagenforschung
a) Process sequence, b) Profile cross section with steel and copper as reinforcements, c) Process window aluminum − steel © IUL
a) Process sequence, b) Profile cross section with steel and copper as reinforcements, c) Process window aluminum − steel
Funding Germand Research Foundation (DFG)
Project 404239924
Contact Patrick Kotzyba M. Sc. 
Status Completed

The aim of the project was the development of a process route consisting of composite extrusion with tubular reinforcing elements and subsequent lateral extrusion to produce flange-shaped components. While the extrusion process (see Figure a) was carried out at the IUL, the Institute for Metal Forming Technology (IFU) at the University of Stuttgart took over the further processing of the semi-finished products by means of lateral extrusion. Initially, hybrid profiles were extruded from the combination of AA6060 as matrix material and AA7075 as reinforcing element. Here, the maximum diameter of the reinforcing element is limited by the shear zone during extrusion. In the case of steel and copper reinforcing elements, the length of the reinforcing elements has an influence on the success of the process. If this length exceeds a critical value, the reinforcing element experiences high tensile stresses, resulting in failure of the tube. The diameters of the tubes must not exceed the diameter of the die for these two materials.