AAEC 2025 Abstracts
Abstracts below do not appear in speaking order
Marghanita Johnson
Australian Aluminium Council, Dickson ACT 2602, Australia
Abstract. Australia has played a key role in the global aluminium industry since 1955. Aluminium is critical to the transition to clean energy, with global demand expected to nearly double by 2050. While recycling will meet part of this demand, primary aluminium production and increased bauxite mining and alumina refining will still be necessary.
Australia’s historical advantage comes from its large bauxite reserves, early industry investment, and skilled workforce. With the right policy settings, bauxite, alumina and aluminium will have a central role in Australia’s transformation to a clean energy superpower, with policy support to be commercially and environmentally sustainable.
Opportunities for the industry include high-quality raw materials, proximity to growing markets, and political stability, but rising domestic energy costs and competition from regions with lower production costs, faster approval timelines and more attractive industry policy pose challenges. Sustainability is increasingly important, and Australian producers are investing in lower-carbon and renewable energy sources, which will require strong policy support.
Tri Dung Phan1, Maciej Mazur1, Thomas Dorin2, Andrey Molotnikov1,
and Mark Easton1
1Centre for Additive Manufacturing, School of Engineering, RMIT University, Australia
2Institute for Future Materials, Deakin University, Australia
Abstract. Conventional manufacture of aluminium hot extrusion tooling typically relies on subtractive manufacturing methods, which can limit the feasible geometry of the die profile and associated extrudates. Furthermore, once the die geometry wears it is difficult to repair. Combining subtractively manufactured substrates with additive manufactured (AM) sections in a single hybrid tool, can enable the manufacture of dies with increased complexity and the repair of critical geometry to extend die life. Several studies have explored the manufacture of hybrid injection moulding tools composed of maraging steel, using Laser Powder Bed Fusion (L-PBF). However, maraging steel is generally not suitable for more demanding tooling application such as aluminium extrusion where H13 tool steel is commonly preferred due to higher service temperatures. The hybrid manufacture of H13 tools with L-PBF has not been previously comprehensively demonstrated in the literature. In this work, H13 steel was successfully built on wrought and machined H13 substrates using optimised L-PBF processing parameters resulting in a robust interfacial bond and minimum porosity. Mechanical properties of the hybrid parts were quantified and compared to wrought H13 counterparts. A trial extrusion tool was subsequently manufactured and tested successfully demonstrating the feasibility of hybrid L-PBF additive manufactured H13 tooling.
Paul C Wong1 and Damir Medovic2
1Applied Robotics Pty Ltd, 15 Egerton St, Silverwater, NSW 2128, Australia
2Capral Aluminium, Bremer Park, Queensland 4304, Australia
Abstract. The wide-spread adoption of ‘off-the-shelf’ robotic manipulators in industry in general has prompted the consideration of using this technology for hot billet loading into aluminium extruders. Potential advantages are cost effectiveness, flexibility to change press-loading motion by software only, improved access around the billet cutter and the extrusion press, employs servo electrical actuators instead of hydraulic cylinders, and utilises a fully developed, flexible off-the-shelf technology package (ie the robot) for reducing risk in efforts to innovate more productive extruder loading solutions.
This paper will provide case studies describing two robot extruder loading installations at Capral Aluminium – a simple system in 2011, and a more complex system in 2019.
Paul Robbins1, Shah Imani1 and Richard Dickson1
1Castool Tooling Systems, Uxbridge, Ontario, Canada
Abstract. This paper explores how process parameters affect exit temperature and ram force in extrusion. Using three-dimensional Finite Element Analysis (FEA) and full factorial statistical analysis, the research aims to derive prediction equations for these variables based on parameters like billet temperature, length, diameter, and ram speed. Moreover, the effect of container heat dissipation on productivity will be investigated.
Paul Robbins1, Yahya Mahmoodkhani, Chris Jowett2 and Richard Dickson1,
1Castool Tooling Systems, Uxbridge, Ontario, Canada
2Rio Tinto Aluminium, Kingston, Ontario, Canada
Used with permission from the Proceedings of the Twelfth International Aluminum Extrusion Technology Seminar (ET ’22), published by the Extrusion Technology for Aluminum Profiles Foundation and Aluminum Extruders Council.
Abstract. This paper studies the impact of process parameters on press productivity. In particular, 3D simulations have been performed to determine the effect of billet geometry (that is primarily billet length and diameter) on press load, extrusion temperature and mode of deformation in the billet. Such simulations are shown to be invaluable to the extruder to allow optimisation of the container dimensions, tooling, and die design, which leads to maximising productivity.
Jerome Fourmann1, Richard Dickson2, Paul Robbins2 and Craig Werner3
1Rio Tinto Aluminium, Chicago, Illinois, USA
2Castool Tooling Systems, Uxbridge, Ontario, Canada
2Werner Extrusion Solutions LLC, Lake Forest, Illinois, USA
Used with permission from the Proceedings of the Thirteenth International Aluminum Extrusion Technology Seminar (ET ’24), published by the Extrusion Technology for Aluminum Profiles Foundation and Aluminum Extruders Council.
Abstract. The main audience of this paper are the management and other team members leading and operating extrusion companies and operations. The extrusion process and industry are relatively simple to understand and inexpensive to enter. The ability to serve markets is often controlled by the equipment, process and technical capabilities possessed; many companies possess sufficient levels of some but are lacking other key “connective tissue” that allows achievement of customer requirements and extruder needs. Uptime / Recovery / Productivity / Costs are important but gaps in capabilities or understanding key linkages between elements results in suboptimal performance. This paper addresses many key requirements from data to process, tooling and others required to achieve efficient operations and to progress from local optimisations to true global optimisations, moving the company from average toward “Superextruder” performance. Data and technical understanding are core achievements and once achieved, it is far too easy to slide backwards by losing just a few key aspects. The paper documents many key aspects like temperature, flow stress and pressures through the lens of data and discloses why excellent tooling or processes alone cannot lead to excellence.
Cameron Keast1 and Dallas Edwards1
1Tomago Aluminium Company, 638 Tomago Rd, Tomago NSW 2322, Australia
Abstract. Billet distortion, a common defect from casting and heat treatment in a casthouse, presents significant challenges for online measurement, particularly in determining both overall and per metre distortion. To address this, Tomago Aluminium Company has developed and implemented an innovative in-house billet measurement system at the sawing stage. Utilising advanced 3D laser scanning technology, the system features a 3D line scanning laser mounted on a linear actuator, which scans the entire surface of each billet entering the saw. This process generates a detailed point cloud, which is then analysed by an algorithm to interpret the billet’s centre of mass in 3D space. The resulting full profile of each billet enables extensive data analysis, facilitating continuous process improvement and effective billet rejection.
Marco Schreiber1, Torsten Schäfer2 and André Schulze3
1OMAV S.p.a, Via Stacca 2, 25050 Rodengo Saiano, Brescia, Italy
2IAS GmbH, Am großen Teich 16+27, 58640 Iserlohn, Germany
3SMS group GmbH, Am SMS Campus 1, 41069 Mönchengladbach, Germany
Abstract. In lightweight metal extrusion, the heating of the billets is, excluding the raw material production, the second most energy-intensive process step and hence affects the carbon footprint of a product. In order to turn metals ‘green’, one approach is to improve the heating process by lowering energy consumption and greenhouse gas emissions through electrification.
A detailed comparison of the heating technologies, burners, resistors and electromagnetics is presented, highlighting their efficiency and the impact of different improvement measures such as heat recovery systems, efficiency enhancements of gas furnaces, and electric convection furnaces, alongside traditional induction heating methods. Moreover, cutting-edge innovations such as permanent magnetic induction and novel coil designs in induction heating are investigated which promise significant advancements in energy efficiency by 30% and provides the potential of full carbon neutrality. By analysing the carbon footprint of these technologies, considering energy consumption and operational efficiency, a comprehensive overview of their influence on the environmental impact of the final products is provided. Thus, the most effective strategies and technologies for reducing the carbon footprint of profiles in aluminium extrusion are identified.
Andrea Trevisan1 and Alessandro Corrà1
1SAT Surface Aluminium Technologies SRL, Via Antonio Meucci 4, 37135 Verona, Italy
Abstract. In the last few years, cost and difficulty of finding qualified manpower is becoming an always thornier problem. This aspect has led to the study and research of automated systems for all the aluminium related production processes, especially the part related with powder coating application.
The control of the aluminium profile coating process with the introduction of AI represents a fundamental step in the automation of vertical powder coating lines, since it permits the reduction of manpower and an increase of consistency and quality in the production. The paper deeply analyses the Vision Recognition System developed specifically for vertical coating plants, its working principles and the main advantages related to this new technology.
Valentin Gala1, Felix Lang1 and André Schulze1
1SMS group GmbH, Am SMS Campus 1, 41069 Mönchengladbach, Germany
Abstract. In the past years, developments in light metal extrusion presses have focused on improving energy consumption and achieving peak performance by minimising dead cycle times. As machine and component designs have been highly optimised, there is only limited room for further improvement without new innovations. The next generation of presses must aim to maintain these high standards while offering something new and unprecedented.
The development of a next generation press is presented, which includes simplifying the hydraulic system, electrifying and de-risking the hot working zone of the press. All new key components of this newly developed press and their advantages are analysed. The main parts are a fully electromechanical shear, complete separation of oil free working area and hydraulic drives and a multi-acting cylinder. The press has a reduced fire risk, no oil tank and valves above the press, reduced piping and reduction in maintenance effort. With this, there is 30% less oil in circulation, reducing the hydraulics footprint by 15%. In addition, the installation space for the press and drive units is reduced up to 8% while also offering flexibility.
Moustafa A.N.A. Ali1 and Sammy Diasinos1
1School of Engineering, Macquarie University, Sydney, NSW 2109, Australia
Abstract. Uniformity of metal outflow for aluminium extrusion has been conventionally controlled through bearing modifications. As die designs increase in complexity to accommodate more complex shapes, complete reliance on bearing modifications may be unfeasible. This motivates exploring additional control elements upstream of the bearings. Such die modifications would aim to effectively alter the topology of the dead metal zone that affects subsequent metal flow through die. However, aluminium flow in dies is highly non-linear and a combination of different parametric variations of die design can yield unpredictable results. This study leverages finite element analysis to numerically study the effect of two parametric variations in conventional porthole dies on the topology of the dead metal zone within the die and the resulting effects on metal outflow uniformity, die stresses, and weld seams. The variations explored include the depth of the welding chamber and the geometry of the second step leading up to the die outlet. The trends observed in the results should help better equip designers navigate flow balancing in more elusive dies, improve the quality of extruded metal, and prolong die longevity.
Bill Wyllie1 and Joseph Kalarickal1
1Australian Aluminium Finishing (AAF), 23 Frank St, Wetherill Park NSW 2029, Australia
Abstract. Architectural aluminium is a growing and vital part of our built environment, providing a compelling building material for growing cities and regional areas due to its lightweight and strength properties and being infinitely recyclable. Starting with ‘low-carbon’ aluminium reduces carbon (dioxide) emissions from manufacturing.
This paper reviews the opportunities to further optimise sustainability of aluminium after manufacture. With Life Cycle Assessment (LCA), extended serviceable life will maximise the sustainability benefit calculations before the next recycling process. Finishing condition plays a key role in the serviceable life of aluminium, not only from a corrosion point of view, but also in maintaining the original aesthetic design and appearance of the building or structure. Warranty on finishes can provide a guide to serviceable life. However, empirical studies, such as the World Aluminium study Aluminium and Durability and several heritage buildings in Australia, provide some remarkable examples of life well beyond the warranty period. Reviewing highlights from the world study, this paper provides some examples of CO2-e calculations by comparing finishes to assist in optimising the sustainability benefits of low-carbon aluminium to its full life cycle potential.
Paul Rometsch1, Nick C. Parson1 and Jerome Fourmann2
1Rio Tinto Aluminium, Saguenay, Quebec, Canada
2Rio Tinto Aluminium, Chicago, Illinois, USA
Used with permission from the Proceedings of the Thirteenth International Aluminum Extrusion Technology Seminar (ET ’24), published by the Extrusion Technology for Aluminum Profiles Foundation and Aluminum Extruders Council.
Abstract. Among the many 6xxx-series aluminium extrusion alloys on the market today, AA6063 and AA6061 are well known as high-volume soft- and medium-strength alloys, respectively. For a given one of these alloys, different mechanical properties can be achieved depending on, i) how well the extrusion process parameters are controlled on a given press line; and ii) the extent of a process deviation in the event of an unforeseen problem such as a delay on the press. This work explores how the peak-aged tensile properties, hardness and VDA bend performance of an extruded strip are influenced by deviations in key process parameters such as billet preheating rate, billet presoak time and press delay duration over a wide range of billet temperatures, tooling temperatures and extrusion speeds. The work reveals processing windows where the mechanical properties of each alloy are relatively robust to process deviations.
Nikolay Biba1, Ivan Kulakov2, Stanislav Kanevskiy2 and
Alessandro Ferrari3
1MICAS Simulations Ltd, 107 Oxford Road, Oxford, OX4 2ER, UK
2QForm Group FZ LLC, Fujairah-Creative Tower, P.O. Box 4422, Fujairah, UAE
3Austek Dies, 13 Montore Rd, Minto NSW 2566, Australia
Abstract. Streaking lines in extruded aluminium profiles are visual imperfections that appear as linear marks, bands, or discolouration along the extruded product. These streaks can present aesthetic issues and often indicate underlying process or material inconsistencies. The causes of streaking lines still need to be thoroughly investigated through both experimental and theoretical approaches. Numerical simulation is a powerful tool for predicting and mitigating streaking lines in extruded aluminium profiles. Simulations can analyse the flow of aluminium through the die to identify the combination of thermo-mechanical and microstructural parameters that cause streaking while also optimising process parameters before physical production. This paper presents the development of a streaking line prediction criterion, which indicates the probability of their appearance and its implementation in practical tasks. With this prediction criterion, it becomes possible to test various die geometries to achieve a more uniform material flow, thereby reducing the likelihood of surface imperfections. A practical case is discussed where the developed criterion was used to predict the appearance of streaking lines. The simulation further helped identify a die geometry where streaking was eliminated. The newly developed die design was validated through practical extrusion, which successfully confirmed the absence of streaking lines.
Paul C Wong1 and Warren R Davison2
1Applied Robotics Pty Ltd, 15 Egerton St, Silverwater, NSW 2128, Australia
2Argyle Advisory Pty Ltd, 65 O’Connell St, North Parramatta, NSW 2151, Australia
Abstract. This paper explores key processes from scoping and business case development through to project delivery. It discusses creating a sustainable competitive advantage and the culture required to be successful. It examines options of green field and brown field solutions and the full range from proven existing solutions to innovative first mover solutions. In particular, the balance between risk and return on a project and how to maximise success. The role of senior management will be discussed from concept to delivery and common failures.
Several specific case studies will be discussed and the lessons presented with specific learnings that apply to most capital projects and specifically to those with high levels of automation. Applied Robotics have installed over 650 robotic solutions covering around 60% of their projects with the balance through non robotic automation applications.
Raffaele D’Andrea1
1Emmebi Srl, Via della Tecnologia 12 (ZIU), Pavia di Udine (UD) 33037, Italy
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
1Emmebi Srl, Via della Tecnologia 12 (ZIU), Pavia di Udine (UD) 33037, Italy
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
1Presezzi Extrusion S.p.A., Via Rovereto 1/D, Vimercate (MB), Italy
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
1Hydro Aluminium RTD Sunndal, Romsdalsvegen 1, 6600 Sunndalsøra, Norway
2Hydro Aluminium Asia Pte Ltd, 150 Beach Road #25-06/07, Singapore 189720
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
1Hydro Aluminium Metal, Drammensveien 264, 0283 Oslo, Norway
2Hydro Aluminium Asia Pte Ltd, 150 Beach Road #25-06/07, Singapore 189720
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
1Rio Tinto Aluminium, Kingston, Ontario, Canada
2National Research Council Canada, Saguenay, Québec, Canada
3Rio Tinto Aluminium, Chicago, Illinois, USA
Used with permission from the Proceedings of the Thirteenth International Aluminum Extrusion Technology Seminar (ET ’24), published by the Extrusion Technology for Aluminum Profiles Foundation and Aluminum Extruders Council.
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
1Rio Tinto Aluminium, Saguenay, Québec, Canada
2Rio Tinto Aluminium, Chicago, Illinois, USA
Used with permission from the Proceedings of the Thirteenth International Aluminum Extrusion Technology Seminar (ET ’24), published by the Extrusion Technology for Aluminum Profiles Foundation and Aluminum Extruders Council.
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
1Capral Limited, 71 Ashburn Road, Bundamba QLD 4304, Australia
2Aluminium Bahrain, King Hamad Highway, Askar, Bahrain
3Deco Australia, 67-77 Airds Road, Minto NSW 2566, Australia
4Desarrollo y Control Tecnologico, C/ Argentina 2, Nave B-3, Parque Empresarial Casarrubios, 28806-Alcala dr Henares- (Madrid), Spain
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
1AMCOL Corporation, 21435 Dequindre, Hazel Park, MI, 48030, USA
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.
Jan Günter1
1Extrutec GmbH, Feldstraße 25, D-78345, Moos, Germany
Abstract. Extrusions for various applications require properties only achievable with a modern high-pressure profile spray quench. One of the features of a modern extrusion quench is that the amount of cooling can be precisely controlled. Modulating the heat transfer coefficient allows response to the cooling requirements of a large variety of profiles. Using multiple nozzles with different flow rates in combination with modulating the water pressure provides the widest range of products can be quenched with one and the same equipment, while minimising distortion. This paper will introduce the patented Alpha Flex Technology. By using a two-cavity aluminium extrusion, different nozzles can be used in one nozzle stock increasing the range of the achievable heat transfer coefficients.
Dennis Nordmeyer1
1Extrutec GmbH, Feldstraße 25, D-78345, Moos, Germany
Abstract. In response to the changing market situation due to energy shortages and the need to substitute fossil energy sources, a high speed convection furnace equipped with electric resistance heating elements has been developed. The idea of operating the oven exclusively with electricity opens up the possibility of completely avoiding CO2 emissions, provided that the oven is operated with ‘green’ electricity. The high convection furnace can achieve efficiencies of 87%, but cannot produce a sufficient taper, and hence it is necessary to integrate an induction module. The induction oven can be combined either as a ‘stand-alone’ version or a patented ‘inline’ version. The combination of electrical resistance with induction heating provides maximum energy efficiency with state-of-the-art taper heating and at the same time make it possible to take the step towards CO2-free production of extrusions.
Anirban Giri1, Dushyant Kumar Gupta1 and Ram Sandipam Adhikary1
1Vedanta Limited, Jharsuguda, Odisha, India
Abstract. This paper explores key advancements in alloy solutions, focusing on their properties, applications, and development processes. It highlights a high-strength 6063 alloy designed for structural, defence, and marine applications, offering mechanical performance, durability, and corrosion resistance. Additionally, a highly machinable, environmentally compliant alloy comparable to 6082 that has been tailored for automotive and industrial applications, enhancing manufacturability while maintaining structural integrity is presented.
The study discusses material composition, microstructural characteristics, and processing techniques that contribute to these enhanced properties. By analysing their performance and development methodologies, this paper provides insights into the role of advanced alloys in engineering applications, supporting stronger, more efficient, and sustainable material solutions. Further research is underway to develop next-generation alloys with enhanced thermal stability, lightweight properties, and improved wear resistance, catering to emerging demands across aerospace, energy, and industrial sectors.