Sören Müller

Simulation of the Co-Extrusion of Hybrid Mg/Al Profiles

Extrusion of composite materials can offer big advantages. In this work the manufacturing of a hybrid metal profile in a single production step was investigated. A porthole die was used, thus producing profiles with extrusion seams. Along the seams a material mix up was visible. The extrusion process was simulated with the Finite Element Method to investigate the material flow in die and welding chamber in order to understand the cause for the defects at the seams.

Characterization of weld seam properties of extruded magnesium hollow profiles

Extrusions of hollow profiles with weld seams were conducted using the magnesium alloy ME21 applying various extrusion ratios. Subsequent analysis of the profiles’ microstructure was performed comparing weld free with weld seam containing material using (polarized) light optical microscopy (LOM). Additionally, the local texture and microstructure in the weld-free material as well as in the weld seam region has been examined with a scanning electron microscope coupled with electron backscatter diffraction technique (SEM-EBSD). The weld-free material and the weld seam are characterized by recrystallized microstructures, whereas few residual cast grains were identified. The local texture distinctively changes from the weld-free material to the weld seam. The texture of the weld-free material is comparable with the typical ME21 sheet texture. In the weld seam area, a pole density is found, which is distributed towards the transverse direction (TD) combined with a split and broadening of the pole density in the extrusion direction (ED). This texture influences the mechanical anisotropy due to the dependence of the activation of basal 〈a〉-slip and

Advanced frictional models for extrusion application

\{ 10\bar{1}2\} \;\langle 10\bar{1}1\rangle

Extrusion of AZ31 Magnesium Sheet

{101¯2}⟨101¯1⟩-extension twinning on the loading direction in favorably oriented grains.

Modifications of the Extrusion Process of Magnesium Alloys for Improved Mechanical Properties

Implantation is a frequent procedure in orthopedic surgery, particularly in the aging population. However, it possesses the risk of infection and biofilm formation at the surgical site. This can cause unnecessary suffering to patients and burden on the healthcare system. Pure Mg, as a promising metal for biodegradable orthopedic implants, exhibits some antibacterial effects due to the alkaline pH produced during degradation. However, this antibacterial effect may not be sufficient in a dynamic environment, for example, the human body. The aim of this study was to increase the antibacterial properties under harsh and dynamic conditions by alloying silver metal with pure Mg as much as possible. Meanwhile, the Mg-Ag alloys should not show obvious cytotoxicity to human primary osteoblasts. Therefore, we studied the influence of the microstructure and the silver content on the degradation behavior, cytocompatibility, and antibacterial properties of Mg-Ag alloys in vitro. The results indicated that a higher silver content can increase the degradation rate of Mg-Ag alloys. However, the degradation rate could be reduced by eliminating the precipitates in the Mg-Ag alloys via T4 treatment. By controlling the microstructure and increasing the silver content, Mg-Ag alloys obtained good antibacterial properties in harsh and dynamic conditions but had almost equivalent cytocompatibility to human primary osteoblasts as pure Mg.

Influence of Nd in Extruded Mg10Gd Base Alloys on Fatigue Strength

During the extrusion processes, very complex adhesion and friction effects between the die surface and the extruded material occur. They have a strong influence on the velocity distribution in the profile, as well as on the life-term behavior of the tools. In the framework of the virtual process modeling usually the Coulomb or the Shear Friction models are applied. The practical experience shows, that those simplified descriptions of the frictional behavior result in poor FEM results. The present work relates to experimentally evaluated tribological behavior of the Torsion-Tribo-test and shows how those data can be transferred to different new friction models.

Extrusion of Hollow Magnesium Profiles and Investigation of Extrusion Seams

In this work a numerical method for the simulation of extrusion processes with modeling of microstructure is presented. Extensive testing was done to provide a basis for the verification of simulation results. Circular rods of AA6005A were extruded by backward and forward extrusion with different extrusion ratios, billet temperatures and product velocities. The extruded rods were cooled either by water or at air to distinguish between dynamic and static recrystallization. Temperature and strain-rate dependent yield stresses were determined from hot compression tests. Special friction tests on cylindrical specimens under high hydrostatic stresses at high temperatures have been performed and the parameters of a friction model were identified from the experiments. The recrystallized volume fraction and grain sizes in the extruded rods were analyzed by means of optical micrographs. The obtained results were used to determine the parameters of a recrystallization model which was implemented in the FE code HyperXtrude. The transferability of the numerical model was checked by simulating forward extrusion tests using the model parameters obtained from backward extrusion tests.

Formability of Extruded Magnesium Alloy Sheets with Different Textures

Due to the increasing demand of deep drawing applications for magnesium alloys in the future magnesium sheets with good mechanical and forming properties are required. These properties depend on the processing route of the sheet material. The deformation behavior of magnesium alloys is strongly influenced by the texture. Extruded magnesium sheets exhibit a different texture than rolled magnesium sheets. Therefore, the forming properties of the extruded magnesium sheets are supposed to be different compared to rolled sheets. Thin extrusion of the magnesium alloy AZ31 with a thickness of 1.5 and 2 mm were performed. Adjacent the extruded sheets were tested for their microstructure, texture and mechanical properties. The texture stability and evolution after the rolling of extruded magnesium sheets were investigated. Thus some of the 1.5 mm sheets were rolled to 1.0 mm and analyzed by OIM, X-Ray and mechanical testing. Concluding the results were compared to the properties of the just extruded 1.5 mm sheet and conventionally rolled sheet of 1 mm thickness.