AAEC 2025 Abstracts

Abstracts below do not appear in speaking order

Marghanita Johnson

Tri Dung Phan1, Maciej Mazur1, Thomas Dorin2, Andrey Molotnikov1,
and Mark Easton1

Paul C Wong1 and Damir Medovic2

Paul Robbins1, Shah Imani1 and Richard Dickson1

Paul Robbins1, Yahya Mahmoodkhani, Chris Jowett2 and Richard Dickson1,

Jerome Fourmann1, Richard Dickson2, Paul Robbins2 and Craig Werner3

Cameron Keast1 and Dallas Edwards1

Marco Schreiber1, Torsten Schäfer2 and André Schulze3

Andrea Trevisan1 and Alessandro Corrà1

Valentin Gala1, Felix Lang1 and André Schulze1

Moustafa A.N.A. Ali1 and Sammy Diasinos1

Bill Wyllie1 and Joseph Kalarickal1

Paul Rometsch1, Nick C. Parson1 and Jerome Fourmann2

Nikolay Biba1, Ivan Kulakov2, Stanislav Kanevskiy2  and
Alessandro Ferrari3

Paul C Wong1 and Warren R Davison2

Raffaele D’Andrea1

Abstract. The extrusion aluminium industry faces increasing demands for efficiency, flexibility, and cost-effectiveness in its logistics operations. Advanced logistics solutions are becoming essential to meet these challenges, enabling the industry to adapt to varying production volumes and customer requirements. This paper explores innovative logistics approaches tailored to the extrusion aluminium sector, focusing on automation, real-time data integration, and flexible handling systems. These solutions improve material flow, reduce lead times, and enhance operational flexibility, while addressing the complexities of managing a large variety of products. The paper also examines the impact of these solutions on operational performance, with a particular emphasis on addressing logistical challenges following the destacking of profiles. It explores potential future advancements in these areas, highlighting opportunities for further optimisation within the industry.

Raffaele D’Andrea1

Abstract. The aluminium industry is facing a shortage of available personnel, driving the adoption of automation technologies to reduce dependence on human labor. Among various solutions, robotics have emerged as a leading choice for replacing manual labor in critical processes. This paper explores two key applications of robotic automation within the aluminium industry: the packing of aluminium profiles into bundles and the hooking of profiles onto vertical powder coating plants. The discussion highlights the advantages of robotics in improving efficiency, safety, and consistency, while addressing the challenges and opportunities associated with their implementation in these specific tasks.

Massimo Pezzorgna1

Abstract. The growing environmental challenges and shrinking profit margins in the extrusion industry are driving an urgent need for innovative, sustainable, and low-impact solutions, prompting advancements that optimise energy consumption and minimise environmental impact without compromising production quality or efficiency. Traditional log furnaces incorporate energy-saving technologies, such as advanced burner designs and efficient fuel usage, ensuring precise heating and operational reliability. A revolutionary breakthrough is the ZPE billet heating system with permanent magnets, achieving over 82% energy efficiency and a 50% reduction in CO2 emissions compared to conventional induction heating. This system improves sustainability, reduces operational costs, and delivers a strong return on investment.

Additionally, extrusion presses that integrate energy-saving systems can significantly reduce energy consumption while maintaining or improving output and profile quality. Modern handling solutions further optimise production by minimising manual intervention, reducing labour costs, and enhancing operator safety and ergonomics, particularly for managing long or heavy products.

Jostein Røyset1, Scott Rogers2, Takeshi Saito2 and Ulf Tundal1

Abstract. The Al-Mg-Si alloys gain their strength from formation of nanoscale particles during artificial age hardening. In the 1990’s the composition of the hardening particles was revealed, thus making it possible to pinpoint which alloy compositions that will be most effective in bringing about a given strength. At about the same time it was discovered, and patented, that a dual rate heating procedure for the artificial ageing would give a significant strength increase, particularly for the leaner Al-Mg-Si alloys such as 6060 and 6063. Combining these findings, a series of alloys, termed High Speed Alloys, was launched with an extrudability 10-25% higher than the alloys commonly used at that time. Further advancements of these alloys include tuning the Mn content, and applying novel casting technology in combination with a non-isothermal homogenisation procedure.

Equally important as increasing the extrudability is the possibility for de-bottlenecking of extrusion plants. The limitation on productivity should be on the extrusion press itself, not on the less expensive equipment (billet heater, quench box, ageing furnaces etc.) Examples on how the High Speed Alloys can be utilised in de-bottlenecking in different scenarios are shown.

Stig Tjøtta1, Scott Rogers2 and Takeshi Saito2

Abstract. As the world moves towards a lower emission society to limit global warming to the 1.5oC target, we see that the end-markets for aluminium are influenced providing new market opportunities for the aluminium industry. In addition, we see an increasing number of end-user companies of aluminium also commit to limit their own emissions according to the 1.5oC target. Evidence of this is, for example, the Science Based Target Initiative (SBTi) that was set up by the United Nations, World Wildlife Fund, and the World Resource Institute after the Paris Accord to help companies to decarbonise. At the end of 2024 close to 10 000 companies worldwide have joined SBTi and are setting targets. SBTi not only require targets on own direct emissions, but also emissions from the supply chain.

We will discuss what impact these decarbonisation targets and strategies will have on the aluminium industry both from a market and supply chain perspectives. For example, we expect material and supplier selection will not only be based on the traditional functionality and cost, but also include sustainability targets. Furthermore, we will discuss carbon footprint of aluminium and roadmaps to decarbonise. Finally, we will point to strategies aluminium ingot and semi suppliers might adopt to create business opportunities based on end users’ decarbonisation targets.

Nick C. Parson1, Jean-François Béland2 and Jerome Fourmann3

Abstract. Al-Mg-Si extrusions are widely used in automotive structures and crash management systems. In terms of material properties, a high yield strength is desirable for downgauging combined with superior ductility to accommodate plastic deformation associated with part forming, mechanical joining and crash with minimal cracking. The role of press quench is well recognised and water spray quenching is typically applied. The authors previously established a preferred minimum quench rate of 50°C/sec. However, the size and complexity of recent profile designs, e.g., for battery enclosures, can result in excessive distortion at high quench rates. It is therefore important to understand the material performance trade-offs with sub-optimal quenching. A test program was conducted using a purpose-built “quench simulator” to study the effect of quench rates in the forced air to spray regimes for a range of commonly used automotive alloys. Strength and ductility were quantified by tensile and bend testing. 

Paul Rometsch1 and Jerome Fourmann2

Abstract. Scandium (Sc) can offer many benefits to aluminium alloys, such as significant strengthening, grain structure control and corrosion inhibition. However, Sc has rarely been used in extrusions due to cost and supply issues. Another but somewhat related challenge is that there are metallurgical aspects to be understood and exploited if maximum benefits are to be achieved from minimal Sc additions. This work explores the effects of small Sc additions (~0.1wt%) on selected extrusion alloys from among the 1xxx-, 3xxx-, 5xxx- and 6xxx-series alloys. The addition of Sc to 6xxx-series extrusion alloys is particularly challenging due to the potential loss of Sc to coarse non-hardening AlSiSc particles and due to the mismatch in aging temperatures between the Al3Sc and MgSi hardening precipitates. This work reveals possible pathways for processing different types of extrusion alloys to achieve maximum microstructure and property benefits per unit Sc addition.

Angela Schaffer1, Hussain Faqihi2 , Chan Chi-Man3  and Jose Manuel Mota4

Abstract. As the “green aluminium” sector continues to grow in prominence within Australia and globally, new opportunities are emerging. Low carbon aluminium can be produced using renewable energy in the smelting of primary aluminium. However, sustainability can be improved further by utilising recycled aluminium to support a circular economy, conserving natural resources and minimising waste. The quality of secondary aluminium billet is important for both extruders and customers as it can impact extrusion productivity and profile quality. This paper examines a 6060 alloy, containing 30% pre-consumer scrap, from the perspective of an extruder. Billet metallurgical characteristics, microstructure, extrudability, mechanical properties, surface finish and corrosion testing results are reported. Considerations when extruding secondary aluminium are discussed.

James E. Dyla1

Abstract. The use of Programmable Logic Controllers (PLCs) has gained widespread use to control, monitor, and optimise aluminium extrusion presses and related ancillary equipment (billet heater, log saw/shear, loader, extrusion press, cut-to-length saw). Over the years, automatic extrusion tool lubrication systems have typically been controlled using PLC outputs from these components. Simple lubrication systems are easily integrated with these components and require limited outputs, inputs, programming, and wiring.
Automatic lubrication systems have become more complex to improve performance and reliability. With this comes the need for PLC programming and related inputs/outputs. To ease installation and ensure proper sequencing, small pre-programmed pre-wired independent PLCs are now being employed. This is especially useful when retrofitting older equipment with limited PLC outputs and inputs. This presentation will provide an overview of how these systems are quickly evolving the concept of automatic lubrication expectations.