Metal Extrusion

Extrusion is a metal forming process in which a work piece of a certain length and cross section is forced to flow through a die of a smaller cross sectional area, thus forming the work to the new cross section. The length of the extruded part will vary dependant upon the amount of material in the work piece and the profile extruded. Numerous cross sections are manufactured by this method. The cross section produced will be uniform over the entire length of the extrusion. Starting work is usually a round billet, and may be formed into a round part of smaller diameter, a hollow tube, or some other profile. The basic principle of extrusion is illustrated in figure 208. Figure:208

In this case a round billet is forced through a die opening, creating a round part of reduced diameter. The ram will continue to move forward pushing more of the billet material through the die opening. As this occurs a continuous length of work will emerge from the other side of the mold at a certain velocity relative to the speed of the

ram. When manufacturing an extruded product, considerations to support and guide the length of material as it exits the die are important. As the ram reaches the end of its stroke a small portion of the billet stock can not be pushed through the die opening. This last part of the work material is called the butt end. The product is cut at the die opening to remove it from the butt end material. In manufacturing industry, methods have been developed to extrude a wide variety of different materials. Some materials are better suited for extrusion manufacture than others. Aluminum is an extremely good material for extrusion. Copper, magnesium, zinc, tin, and some softer low carbon steels can also be extruded with little complication due to the material. High carbon steels, titanium, and various refractory alloys can be difficult to extrude. Extrusion is capable of creating tremendous amounts of geometric change and deformation of the work piece, more than other forming processes. Extrusion tends to produce an elongated grain structure, usually considered favorable, in the part's material in the direction that the work is extruded. Extrusion, in many instances, can be considered a semi continuous manufacturing operation. Continuous because the process will manufacture a continuous length of the same cross section. From this length, individual discrete parts can be cut. It is semi continuous and not completely continuous, (such as continuous casting), because the length of extruded product is still limited by the amount of material in the work piece. The work piece must be reloaded at the end of every cycle. Extrusion can also be a discrete manufacturing process, producing a single part with every cycle. As in other forming operations, the forces involved and the material flow patterns that occur during extrusion are of primary concern in the analysis and development of this manufacturing process. The many factors that effect material flow will be discussed.

Cold Extrusion Or Hot Extrusion

Extrusion is a forming process, and like other forming processes it can be performed either hot or cold. The characteristics of hot forming and cold forming were discussed in detail in the fundamentals of metal forming section. Hot forming involves working a metal above its recrystallization temperature. Hot working has many advantages in the improvement of the mechanical properties of the part's material. Cast metal contains pores and vacancies throughout the material. Hot working a metal will push and redistribute material, closing up these vacancies.

Impurities in a material usually combine together in masses, forming solid inclusions within the metal. These inclusions cause weakness in the surrounding metal. Hot working causes these inclusions to break up and distributes them throughout the material. Large, irregular, columnar grain structures are usually present in cast parts. Hot working a metal will break up irregular structures and recrystallize to a finer wrought grain structure. Mechanical properties of the part such as impact resistance, ductility, and strength characteristics are improved. If a hot extrusion is performed on a cast work piece then the advantages of hot working will be imparted to the part. However, most extrusions in manufacturing industry are performed on billets that have already been hot formed, thus the mechanical advantages of hot forming have already been imparted to the material. In addition to the improved physical characteristics of the metal hot forming does offer other advantages in a manufacturing process. A metal above its recrystallization temperature is more easily manipulated than a cold metal. An increase in temperature results in a corresponding decrease in strength and an increase in ductility, factors more advantageous in the forming of the material. When metals are worked above their recrystallization temperature strain hardening does not occur, thus hot forming allows for a large amount of shape change. One of the major disadvantages of hot forming of metals is the oxidation that occurs over the surface of the hot work. This results in a layer of oxide scale build up on the external surfaces of the work piece. Scale can effect surface finish and accuracy of the part as well as increasing friction and wear at die metal interfaces. Heating to, and maintenance of, high working temperatures, decreased tolerances, and increased die wear, are all disadvantages of a hot forming manufacturing process over a cold one. Choosing between hot extrusion or cold extrusion will depend on the specific details of the manufacturing process. Some of the more difficult to form materials may have to be worked hot. Some easy to extrude materials such as aluminum can be worked either hot or cold depending upon other factors in the process. Hot extrusion is generally preferred for larger parts, more extreme changes in shape, and extrusions with more complex geometry. Cold extrusion is usually used for smaller parts, less complex shapes, more workable materials, and the manufacture of discrete extrusions that create a single part with each operation. Impact extrusion, a discrete manufacturing process, is most often performed cold. Advantages of cold extrusion over hot include not having to heat the work, higher production rate, no oxidation and scale form on surfaces, greater geometric accuracy, better surface finish, and the ability to strengthen the part by way of strain hardening. In hot extrusion, like other hot forming operations, the heat transfer between the work piece and the cooler surfaces of the die presents a problem during the manufacturing

operation. In order to mitigate this issue, die used for extruding can be preheated to lessen the temperature gradient. Lubricants also help in the reduction of heat transfer between the part and the mold. With some particularly difficult to extrude materials isothermal extrusion may be employed, this is similar in concept to isothermal forging. In these instances the mold is maintained at or slightly below the temperature of the work during the entire process.

Direct Extrusion Indirect Extrusion

Compared

With

Extrusion operations in manufacturing industry can be classified into two main categories, direct and indirect. Hollow extrusions, as well as cross sections, can be manufactured by both methods. Each method, however, differs in its application of force, and is subject to different operational factors.

Direct Extrusion
Direct extrusion is a similar extrusion method to the one illustrated in figure 208. In direct or forward extrusion the work billet is contained in a chamber. The ram exerts force on one side of the work piece, while the die through which the material is extruded is located on the opposite side of the chamber. The length of extruded product flows in the same direction that the force is applied. Figure:209

During direct extrusion, metal flow and forces required are effected by the friction between the work piece and the chamber walls. Particularly in hot forming, oxide scale buildup on the outer surfaces of the work piece can negatively influence the operation. For these reasons, it is common manufacturing practice to place a dummy block ahead of the ram. The dummy block is of slightly smaller diameter than the chamber and work piece. As the extrusion proceeds the outermost surface of the work is not extruded and remains in the chamber. This material will form a thin shell, (called skull), that will latter be removed. Much of the skull will be comprised of the surface layer of oxidized scale from the work metal. Figure:210

Hollow or semi hollow parts may be directly extruded, with the use of a mandrel attached to the dummy block. A hole is created through the work parallel to the axis over which the ram applies the force to form the extrusion. The mandrel is fitted within this hole. Once the operation begins, the ram is forced forward. The extruded material flows between the mandrel and the die surfaces, forming the part. The interior profile of the extrusion is formed by the mandrel, while the exterior profile is formed by the die. Figure:211

Indirect Extrusion
In indirect extrusion, the work piece is located in a chamber that is completely closed off at one side. The forming die are located on the ram, which exerts force from the open end of the chamber. As the manufacturing process proceeds the extruded product flows in the opposite direction that the ram is moving. For this purpose the ram is made hollow so that the extruded section travels through the ram itself. This process is advantageous in that there are no frictional forces between the work piece and the chamber walls. Indirect extrusion does present limitations. Tooling and machine set up are more complicated, hollow rams are not as strong and less ridged, and support of the length of the extrusion's profile as it travels out of the mold is more difficult.

Figure:212

Indirect extrusion can also be used to produce hollow parts. In this process a ram is forced into the work material. The ram gives the internal geometry to the tubular part, while the material is formed around it. Difficulties in supporting the ram limit this process and the length of tubular extrusions that may be manufactured. Figure:213

Extrusion Practice For Manufacturing

Extrusion practice in manufacturing industry must take into consideration a variety of factors, many of which will be specific to each particular operation. The type of material, size of work piece, geometric cross section of extruded part, ram speed, temperature of work, and type of extrusion process, are all important elements in the design and analysis of an extrusion operation. The main goal is to enact the right metal flow through the correct application of force. The force is applied through a ram powered by some sort of press. Most extrusions are performed horizontally, by hydraulic presses. Hydraulic presses can deliver a constant force at a constant speed over a long stroke, making them ideal for extruding parts; however, in some instances mechanical presses may be used. The ram's speed effects the forces involved during the operation. Ram speeds can be as low as a few feet every minute, or may be as high as 15 feet per second, though most are under 2 feet per second. The length of extruded product in common manufacturing practice is generally up to 25 feet, but much longer lengths, as high as 90 feet have been created. Many of the extruded sections produced in industry require bending or straightening after the completion of the extrusion process. When performed correctly extrusion can be very economical for both small and large batch production.

Material Flow During Extrusion

During an extrusion process, material from a work piece of a certain cross section is forced to flow through a die of smaller cross section, forming an extruded part. It is important to understand the flow of material that occurs as the part is being formed. In some ways it is similar to fluid flowing from one channel into another channel of decreasing width. The material is deformed and forced to flow together as it progresses towards and through the die. As the work travels through the die the outer layers are deformed more than the ones closer to the middle. The outer sections further from the central axis will experience greater material displacement and will have more turbulent metal flow characteristics. The material closer to the center will move faster through the mold, meaning it will have the higher velocity relative to the die. With square die, which are die with 90 degree angles sections in the material close to the mold opening but adjacent to the die may not move. These areas, termed dead zones, or dead metal zones, are indicative by stagnation of metal flow. Note that

there will be a type of shearing of the material occurring between layers, at the interfaces of dead zones.

Extrusion Ratio
The extrusion process is capable of creating a tremendous amount of metal deformation of the work. The size of the cross section of the work billet may be much larger than the size of the cross section of the extruded part. For example in figure 214 the starting work billet has a certain diameter, say 10 inches. It is formed into a round extrusion with a diameter of 5 inches. We can relate the size of the work's cross section with that of the extruded part by comparing their diameters. It can be said that the extrusion has a diameter of 1/2 the original work, thus measuring the cross sectional reduction that occurred during the process. Figure:214

This is an easy relationship to make, since both the work and the extrusion are round. If the work and the extruded part have a different profile, another means will be needed to relate their sizes. For example in figure 215 a round billet is extruded into a smaller u channel profile. Figure:215

To relate the cross section of the work piece to that of the extruded product the extrusion ratio was established. The extrusion ratio is the ratio of the area of the work's cross section (Ao) to that of the extrusion's cross section (Af). The extrusion ratio, or reduction ratio can be expressed as (Ao/Af). Figure:216

Obviously since the starting work's cross section will be greater than that of the extrusion, the extrusion ratio will always be more than 1. In manufacturing industry, extrusion ratios typically range from about 4 to 100, although they can be even higher in certain special cases.

Extrusion Shape Factor

The exact geometric profile of an extrusion's cross section will have an effect on the force required to extrude the work. A circle cross section requires the least amount of work to extrude. Generally the more complex a shape, the more force that will be need to extrude a cross section of that shape. In order to quantify the effect that different cross sectional profiles have on extrusion force requirements, the extrusion shape factor was established. The lower the shape factor, the lower the pressure needed to extrude that cross section. A circle profile has a shape factor of 1, the shape factor increases as the part becomes more complex. The actual shape factor calculation is relative to the ratio between the perimeter of the extruded cross section and the perimeter of a circle of the same area.

Circumscribing Circle Diameter

As noted, the geometry of an extruded profile is a large factor in force requirements for that manufacturing operation. As in all processes, there are always limitations on the size of parts that may be manufactured based on the physical natures of the process. The work material is an important characteristic in determining the size limitations for an extruded part. Stronger materials require more pressure to form, therefore the maximum size of an extrusion will be lower for more difficult to shape metals. Another method used in manufacturing industry to quantify the geometry of an extrusion's profile, particularly with regard to size, is the circumscribing circle diameter. The circumscribing circle diameter is simply the diameter of the smallest circle that the profile of the extruded cross section can fit. Aluminum is one of the easiest to shape metals for extrusion. The range of circumscribing circle diameters for extruded aluminum parts in industrial production, typically spans from 1/4 inch to 10 inches, although much larger aluminum parts have been extruded in certain operations. Figure 217 shows some different cross sectional profiles produced by extrusion, with their circumscribing circles and circumscribing circle diameters. Figure:217

Extrusion Die
Extrusion die used in manufacturing extruded sections must have certain mechanical characteristics. Die must be strong and hard, capable of holding their dimensional accuracy throughout the high stresses created during the process. They must also be resistant to wear, which is always an issue when extruding in large quantities. Dies for hot extrusion must have high thermal resistance and be able to maintain strength and hardness at elevated temperatures. Tool steels are a common type of material for extrusion molds. Dies may be coated to increase wear resistance. Carbides are sometimes used for a mold material, carbides do not wear easy and can provide accurate part dimensions.

Extrusion die angle is an important factor in the process, as it is a large determinant in the flow of material. The amount of force necessary to form a certain cross section will vary with different die angles. A lower angle will create more friction at the work mold interface. Friction is a factor that increases the force necessary to extrude a part. High die angles create more material movement particularly in the outer regions away from the center. The greater metal displacement gives a greater turbulence in the metal flow. Increased turbulence in the flow also increases the amount of force necessary for the operation. All factors must be calculated in the design of an extrusion process. Figure:218

The optimum die angle will balance out the more extreme friction of lower die angles with the more extreme turbulence of the higher die angles, and be somewhere between the two extremes. The exact optimum die angle is difficult to determine for any process due to the influence of other operational factors, such as temperature and lubrication. The manufacturing engineer must try to provide the best angle based on all the considerations of a given extrusion operation.

Lubrication
Lubrication is used in manufacturing industry to assist in metal flow over the work mold surfaces as a part is being extruded. Soaps, oils, graphite immersed in oil, and many other special lubricants are all used in manufacturing industry to extrude parts. Some materials can be problematic in that they tend to stick to the tooling. To prevent sticking a softer metal may be used for lubrication. In this case, the softer metal will be jacketed around a the work. For manufacturing practice, particularly in high temperature processes, molten glass is often employed as an effective lubricant in the extrusion of tougher materials.

Extrusion Design
Design of an extrusion manufacturing operation involves consideration of many different factors. The primary goal is to create a process that enacts a smooth and effective flow of material. In general, force necessary is minimized as much as possible. Higher forces require greater capacity and energy. Higher forces also increase the chances of part defects, die wear and die breakage. Friction has an important roll when extruding a part and should be maintained at an optimum level. By examining and understanding the causes of extrusion defects, the process engineer can design a particular operation to mitigate the chances of defects occurring. Defects fall into different categories and have several root causes. Most defects are similar, less specifically, in that they are created by improper material movement and stress distributions. Control of operational factors will allow for control of forces and metal flow, producing efficient, defect free extrusions. In addition to operational factors, the geometric profile of the extrusion also effects the manufacture of the part.

Troubleshooting Defects
Extrusion defects that occur during the manufacturing process generally fall into three basic categories. Internal breakage, particularly in the center, surface cracking, and piping.

Center Cracking
Internal breakage; common names used in manufacturing industry for this type of defect are center cracking, cheveron cracking, arrowhead fracture, and centerburst. As the work piece is being extruded through the die, stresses within the work break the material causing cracks to form along the central axis of the extruded section. Center cracking is a difficult defect to detect since it occurs within the material of the part. Figure 219 shows an extrusion subject to centerburst, the part has been cut in a half section so that the defect may be observed. Figure:219

To understand the causes of center cracking it is important to understand the flow of the material that is occurring while extruding a profile. As mentioned in the material flow section, the outer layer of the extrusion will experience more deformation, and also more material displacement and more turbulent flow than the areas towards the central region. The difference between the material movement of the outer regions compared to that of the central region is critical. If the material displacement occurring in the outer areas is of a much greater magnitude than that which is occurring in the central area, then the difference will cause high stresses to develop within the material. The greater the difference in flow characteristics between regions,

the greater the stresses that will occur. If the stress level becomes too high then material breakage will occur in the form of internal cracks. In manufacturing practice, selection of die angle will be a primary factor in preventing center cracking. High die angles will favor center cracking in an extrusion more than low die angles will. The reason being the greater flow turbulence created in the outer regions of the work. Higher fiction in general will tend to reduce the chances of center cracking. Cracks will propagate over inclusions, therefore the higher the amount of inclusions in the work material, the more favorable the conditions for the occurrence of this extrusion defect. High extrusion ratios are less likely to promote center cracks than lower ones.

Surface Breakage
Surface breakage defect on a metal extrusion, is breakage on the surface of the part. Most surface defects are in the form of cracks that extend from the surface, into the parts material to varying degrees. These cracks usually occur along the grain boundaries of the metal. The primary cause of surface cracking defect in extrusion manufacture is excessive stresses on the surface of the part's material. Friction is a large factor in controlling surface breakage, while manufacturing an extruded section. Increased friction will create a more favorable environment for surface cracking. Lubrication can help reduce friction, so can an increased die angle. When designing a manufacturing process it is important to balance all factors such as friction. Lower friction may create better conditions at the surfaces between the work and die. However, if friction forces are too low, a more turbulent outer flow may result in center cracking. Another important factor in surface breakage defect is the hardness of the parts material. The speed a which the part is extruded is also a consideration. Higher extrusion speeds will create conditions more favorable to material breakage. Conditions in which the work material sticks to the extrusion die can be a cause of surface cracking. Work sticking to tool surfaces can sometimes be a problem in many different kinds of manufacturing operations, especially with some specific materials. It is a common case that when the extrusion sticks to the die, pressure builds up behind the material. Enough force breaks loose the work, causing cracks in the metal.

The part shoots forward a small distance, then it sticks to the die again. This cycle repeats itself as the part is being extruded. The cracks will appear at spaced intervals around the parts peripheral. This is somewhat reminiscent of the appearance of a bamboo tree, thus this particular manufacturing defect is termed bamboo defect. Surface cracking of an extrusion need not have a mechanical cause, often the root cause of cracking of a metal being extruded will be thermal stresses. High thermal gradients between the work and die interface can cause the extrusion's surfaces to loose heat rapidly. Heating molds and lubrication can help mitigate thermal gradients at surfaces. The work billet should be heated to the best temperature considering the operational variables. Extrusion speed and friction are critical factors in controlling the thermal characteristics of this type of manufacturing process. Higher extrusion speeds can not only generate greater mechanical forces, but more heat as well. Increases in heat generation during the process can crack the part material.

Piping Defect
Piping, also called tailpipe or fishtailing is a defect common when manufacturing sections by direct extrusion. The use of a dummy block and good surface preparation of the work can help avoid piping. Piping occurs in the work material at the end opposite to the die. Piping is a result of improper metal flow during the extrusion operation. Piping manifests itself as a funnel shaped void of material at the end of the work. As mentioned before, material flow is a very important consideration in a forming operation. The way to solve a piping problem is to enact a smooth metal flow during the extrusion process. The combination of friction and thermal gradients acting at the die work interface needs to be observed, and their cumulative effect on the metal flow occurring during the process determined. The manufacturing engineer must control the different process variables to achieve the smoothest material flow possible during extrusion. Figure:220

Extrusion Design For Manufacture

When designing an extrusion process the geometric profile of the extruded section is an important factor, effecting the forces involved, metal flow, die wear, and part quality. Some cross sections, when extruded, will produce undesirable force distributions and metal flow. If possible it is desirable to design for manufacture. This section will discuss the effect of different features of a profile, and how to optimize the cross section for extrusion manufacture. First it is important to understand that the nature of the forces involved in extrusion are fundamentally different than those of other forming processes. For example, in a process such as forging, the forces acting on the operation will vary throughout the process, stress will change as the forging stroke progresses. With extrusion, (although in direct extrusion the is somewhat of a linear decrease in the necessary force, due to decreasing friction with billet length), the forces acting are generally consistent throughout the bulk of the operation. Some components need to have a very specific geometry and must be manufactured that way. If parts may be geometrically altered in such a way as to ease their manufacture without changing their ability to perform their desired function, then they should be redesigned for manufacture. Symmetry is generally preferred in extruded cross sections, particularly with regard to open areas of the cross section. Open areas in an extrusion's cross section will complicate the process by changing the forces involved. Die wear and breakage is a primary consideration of a manufacturing process designer when designing an extrusion operation. Controlling material flow is essential in metal forming manufacture. In addition the stresses applied to the die as a result of this metal flow must be calculated and the mold must be designed to handle

these forces. Some areas of the die may be subject to more stresses than others. Some areas of a die may not be able to handle as much stress as others. The geometry of the mold must be considered carefully with respect to the forces created, as the part is being extruded. Excessive stresses in places that can not handle it, can cause rapid wear and die breakage. Extrusion die tongues cause a weaker area in the die's geometry. The location of die tongues and the forces they are subject to are an important factor in die design. Figure:221

Symmetry provides for more balanced forces, and helps avoid overstressing areas of the die. Hollow areas within the cross section, in particular, should be balanced. Figure:222

Usually, larger hollow areas cause more difficulties during the extrusion operation. Reducing the area of hollow sections, if possible, may ease the manufacturing operation. If hollow sections can be eliminated completely, in favor of a single solid extrusion, it would be a better design for manufacture. Figure:223

Thin walled extrusions are often produced in manufacturing industry, however, there are limits to the minimum wall thickness. Minimum wall thickness of an extrusion depends a large part on the material being extruded. Minimum wall thickness for

aluminum manufactured extrusions is usually about .040 inches. A common steel extrusion may have a minimum wall thickness of three times that of aluminum. Standard wall thickness throughout the profile is desirable, if not, the wall thickness should be as balanced as possible. Figure:224

One way to improve the design of an extrusion process that requires a cross section of walls of different thickness, is to smooth the transition between thick to thin walls with a large radius. Figure:225

The manufacturing designer should avoid sharp corners in an extrusion's profile, if at all possible. Figure:226

As mentioned earlier, die tongues are critical areas for mold wear and breakage. Rounding certain corners of an extrusion can strengthen die tongues.

Figure:227

Impact Extrusion
Impact extrusion is a discrete manufacturing process in which a part is extruded through the impact of a die with the work piece. The part is formed at a high speed, and over a relatively short stroke. In standard extrusions, the force to form the work is commonly delivered by way of a hydraulic press. In impact extrusions, mechanical presses are most often employed. The force used to form standard extrusions is usually delivered over a horizontal vector, producing a long continuous product. Force used to form impact extrusions is usually delivered over a vertical vector, producing a single part with each impact of the punch. Impact extrusion is most often performed cold, occasionally with some metals and thicker walled structures the work is heated before impact forming it. This process is best suited for softer metals, aluminum is a great material for forming by impacting. Figure:228

The Mechanics And Design Of Impact Extrusions

During the manufacturing operation of impact extrusion, a work piece is placed in a mold and struck with great force causing the metal to rapidly flow into position in an instant. The forces acting on the machinery are very high, particularly on the punch and die. Tooling must have sufficient impact resistance, fatigue resistance, and strength for metal forming by impact. There are three types of impact extrusions, forward, reverse, and combination. The different categories are based on the kind of metal flow that occurs during the process. In forward extrusion, metal flows in the same direction that force is delivered. In backward extrusion, the metal flows in the opposite direction that the force is delivered. In combination the metal flows in both directions. Backward extrusion is shown in figure 228, forward and combination are illustrated as follows.

Figure:229

Figure:230

When designing an impact extrusion process it important that the part geometry be symmetrical about the punch. In addition it is essential to the proper forming of the extruded component, that the punch die delivers a precise blow concentric to the work. Figure:231

The end of the punch is better designed not to be completely flat, to avoid slipping at the punch work interface. Sometimes a center point recess can help keep the punch concentric to the work. Figure:232

Another factor when manufacturing by this process is the proportion between an extrusion's length and its internal diameter. Long punches with relatively small diameters may fail during manufacture. Hollow thin walled tubes, closed on one end, are often produced in manufacturing industry by backward impact extrusion. It is good practice to design the extrusion so that the bottom is at least 20% thicker than the sides, to help prevent material breakage. Figure:233

Impact Extrusion In Manufacturing Industry

Modern

Impact extrusion is used to manufacture a variety of parts, such as components for machinery and appliances. Impacted parts of complex geometries can be produced as long as the part is symmetrical over the axis by which it is formed. One of the best utilizations of this type of operation is in the production of hollow tubes with one end partially or completely closed. Hollow tubes may be formed with internal and external geometry. The wall thickness of a part manufactured by impact extrusion may vary along its length, so may its interior and exterior diameters. Extrusions created by this process do not need to have a circular cross section. Noncircular but symmetrical parts are also formed. The impact extrusion manufacturing process is very effective at forming flanges on tubular parts. Flanges with varying diameters and geometric attributes may be formed along the length of the extruded section. Bosses and hollow tubes concentric to the extrusion axis can be formed within hollow tubes by impact extrusion. Many of the parts formed by impacting in industry will require further manufacturing processes such as forging, ironing, and machining before completion. Impact

extrusion can work harden a part, this may or may not be desirable. If necessary, a component may be annealed before further processing occurs. Favorable grain structures and good surface finish are some possible advantages of manufacturing by impact extrusion.

Hydrostatic Extrusion
In hydrostatic extrusion the work piece is held in a sealed chamber surrounded by pressurized liquid. Hydrostatic extrusion is actually a form of direct extrusion. The force delivered through the ram is what pressurizes the liquid. The liquid applies pressure to all surfaces of the work billet. When the ram moves forward, it is the force from the incompressible fluid that pushes the work through the die, extruding the part. Figure:234

A critical aspect of manufacturing by this process is setup. The work billet must first be tapered to fit through the die opening, thus creating a seal. This is done before adding the liquid in, order to prevent leaking. Since the liquid is under great pressure, this taper must be precise to create a robust bond. Figure:235

Many different shapes may be produced this way, using a variety of materials. A significant advantage of hydrostatic extrusion, is that essentially all friction at the work chamber interface is eliminated. Another advantage is that the hydrostatic pressure will increase the ductility of the work, enabling brittle materials to be extruded easier. Liquid pressure from all directions also greatly decreases the chances of buckling of the work. Hydrostatic extrusion may be performed at room or elevated temperatures depending upon the process. When performed hot, the liquid will insulate the work from thermal gradients between the container and work material. An advanced variation of this process, is called fluid to fluid extrusion. This process is basically the same, except that the part is extruded into a second chamber also containing pressurized liquid. The liquid in the second chamber is of a lower pressure than the first. Several different kinds of liquids are used when manufacturing by hydrostatic extrusion, including oils, waxes, melted polymers, and molten glass. Hydrostatic extrusion has not had much use in manufacturing industry, due to the complicated equipment and procedures, work preparation, long cycle times, and dangers of working with hot, high pressure liquid.