Scrap assessment in direct extrusion

The continuous direct extrusion is an economic and efficient process to manufacture high-quality aluminium profiles. However, because of multiple billets processing, transient defects (coring and charge welds) can be generated affecting portions of the profiles and deteriorating their mechanical properties. In case of structural applications, the reliable prediction of the onset and extend of these portions is therefore mandatory in order to be scrapped by the commercialized length. In this context, the present work has been aimed at examining the dynamic evolution of the coring and charge weld defects in the direct extrusion of an industrial solid profile. Both experimental and numerical activities have been performed and results evaluated in terms of coring and charge welds defect evolution achieving a good agreement for both phenomena. Results have been also compared with the outcomes of the analytical models available in literature. For the charge weld extension, the analytical model returned a poor predictably while a very good match with numerical data was obtained for the coring defect.