Introduction of Composite Hot Extrusion with Tubular Reinforcements for Subsequent Cold Forging

Abstract

A new process is presented in which semi-finished products (AA6060) with tubular internal reinforcements of higher strength (AA7075) are produced by composite hot extrusion. Flange-shaped parts are manufactured from the extrudate by subsequent lateral extrusion and upsetting. The aim is to develop a robust process route for flange-shaped components by composite hot extrusion and subsequent cold forging. For this purpose, numerical investigations were carried out. The process can be conducted without errors if certain limits are observed, which can be shown numerically. The probability of solid state bonding can be increased by choosing the proper tube geometry, so that subsequent lateral extrusion can be carried out. The knowledge generated is to be used to expand the spectrum of components in the future to include higher strength tubular reinforcements.