Prediction of charge-weld strength in aluminum extrusion using solid-state welding models
Eren Can Sariyarlioglu, Jun Ma, Torgeir Welo
Abstract. This paper explores the adaptation of solid-state welding models to numerically predict the charge-weld strength of tubular aluminum profiles produced by hot extrusion. A series of AA6xxx tubular profiles was conducted in an industrial operation through carefully designed billet-to-billet extrusion experiments, followed by drift-expanding tests to characterize the evolution of charge-weld integrity. The experimental results revealed a positive correlation between charge-weld progression along the extruded length between two billets, and both material integrity and charge-weld strength. A comprehensive through-process finite element (FE) model was developed using QForm-Extrusion software to simulate the thermo-mechanical history of charge-weld formation. This simulation provided valuable insights into the influence of thermo-mechanical parameters on the evolution of charge-weld strength. Using a back-tracking method, the thermo-mechanical history was subsequently integrated into the Plata-Piwnik and Cooper-Allwood welding models within the FE model. The predictions made by the adapted welding models were compared with each other and validated against experimental findings. It is concluded that this study provides valuable contributions to the field of aluminum extrusion, offering new insights into the prediction of charge-weld strength and strategies for improving process control in billet-to-billet extrusion. Our findings have the potential to reduce in-process scrap and promote more sustainable aluminum profile production.
Keywords
Aluminum Extrusion, Charge Weld, Transverse Weld, Welding Strength
Published online 5/7/2025, 10 pages
Copyright © 2025 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Eren Can Sariyarlioglu, Jun Ma, Torgeir Welo, Prediction of charge-weld strength in aluminum extrusion using solid-state welding models, Materials Research Proceedings, Vol. 54, pp 754-763, 2025
DOI: https://doi.org/10.21741/9781644903599-81
The article was published as article 81 of the book Material Forming
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
References
[1] A. J. Den Bakker, L. Katgerman, and S. Van Der Zwaag, “Analysis of the structure and resulting mechanical properties of aluminium extrusions containing a charge weld interface,” J Mater Process Technol, vol. 229, pp. 9–21, Mar. 2016. https://doi.org/10.1016/j.jmatprotec.2015.09.013
[2] E. C. Sariyarlioglu, T. Welo, and J. Ma, “On the mechanisms of charge weld evolution in aluminum extrusion,” J Manuf Process, vol. 124, pp. 377–384, Aug. 2024. https://doi.org/10.1016/j.jmapro.2024.06.022
[3] M. Plata and J. Piwnik, “Theoretical and Experimental Analysis of Seam Weld Formation in Hot Extrusion of Aluminum Alloys,” in Proceedings of the Seventh International Aluminum Extrusion Technology Seminar, Chicago, Illinois: Aluminum Association, May 2000, pp. 205–211.
[4] D. R. Cooper and J. M. Allwood, “The influence of deformation conditions in solid-state aluminium welding processes on the resulting weld strength,” J Mater Process Technol, vol. 214, no. 11, pp. 2576–2592, Nov. 2014. https://doi.org/10.1016/j.jmatprotec.2014.04.018
[5] B. Reggiani and L. Donati, “Comparison of experimental methods to evaluate seam welds quality in extruded profiles,” Transactions of Nonferrous Metals Society of China, vol. 30, no. 3, pp. 619–634, Mar. 2020. https://doi.org/10.1016/S1003-6326(20)65241-4
[6] Akeret R., “Properties of pressure welds in extruded aluminum alloy sections,” The Journal of the Institute of Metals, vol. 10, no. 202, 1972.
[7] L. Donati and L. Tomesani, “The prediction of seam welds quality in aluminum extrusion,” J Mater Process Technol, vol. 153–154, no. 1–3, pp. 366–373, Nov. 2004. https://doi.org/10.1016/j.jmatprotec.2004.04.215
[8] J. Yu, G. Zhao, and L. Chen, “Analysis of longitudinal weld seam defects and investigation of solid-state bonding criteria in porthole die extrusion process of aluminum alloy profiles,” J Mater Process Technol, vol. 237, pp. 31–47, Nov. 2016. https://doi.org/10.1016/j.jmatprotec.2016.05.024
[9] M. Plata and J. Piwnik, “Theoretical and experimental analysis of seam weld formation in hot extrusion of aluminum alloys,” in Proceedings of Seventh International Aluminum Extrusion Technology Seminar ET, 2000, pp. 205–211.
[10] S.-P. Edwards, A. J. Den Bakker, J. L. NEIJENHUIS, W. H. KOOL, and L. KATGERMAN, “The Influence of the Solid-State Bonding Process on the Mechanical Integrity of Longitudinal Weld Seams,” JSME International Journal Series A, vol. 49, no. 1, pp. 63–68, 2006. https://doi.org/10.1299/jsmea.49.63
[11] N. Bay, “Mechanisms producing metallic bonds in cold welding,” Weld J, vol. 62, pp. 137–142, 1983.
[12] G. Oberhausen and D. R. Cooper, “Modeling the Strength of Aluminum Extrusion Transverse Welds Using the Film Theory of Solid-State Welding,” SSRN Electronic Journal, 2023. https://doi.org/10.2139/ssrn.4488657
[13] F. Kolpak, A. Schulze, C. Dahnke, and A. E. Tekkaya, “Predicting weld-quality in direct hot extrusion of aluminium chips,” J Mater Process Technol, vol. 274, p. 116294, Dec. 2019. https://doi.org/10.1016/j.jmatprotec.2019.116294
[14] E. C. Sariyarlioglu, M. Negozio, T. Welo, and J. Ma, “Charge weld evolution in hollow aluminum extrusion: Experiments and modeling,” CIRP J Manuf Sci Technol, vol. 49, pp. 14–27, Apr. 2024. https://doi.org/10.1016/j.cirpj.2023.12.007
