Comparison of Friction Extrusion Processing From Bulk and Chips of Aluminum-Copper Alloys

Friction extrusion processing describes the extrusion of metallic materials via severe plastic deformation imposed by friction-induced heat and shear strain. The process features relative rotational movement between die and feedstock material, resulting in complex shear introduction affecting local thermal and material flow conditions. While the processing of powders, chips and bulk material for improvement of extrudate properties has been studied independently, this work focuses on the direct comparison between the friction extrusion of bulk material and chips of AlCu10 under identical processing conditions. Analysis of machine response and microstructure in the extruded wires allows for first conclusions, identifying characteristics and requirements for friction extrusion processing from different feedstock materials.