Production of Wire From AA7277 Aluminum Chips via Friction-Stir Extrusion (FSE)
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ALUMINUM and its alloys have received much attention as important materials in aerospace, automobile, and construction industries because of their high strength-to-weight ratio and good formability.[1] Manufacturing operations, especially traditional machining, usually produce considerable amounts of aluminum waste in the form of chips (approximate amount of 3 to 5 pct of the casting weight). Traditionally, aluminum wastes are sold to scrapers and remelters, but this choice is inadvisable because the selling price is roughly 30 pct of the purchase price of the commercial second melt raw aluminum.[2] In addition, the remelting operation consumes a large amount of energy, e.g., 16 to 19 GJ/t for aluminum,[3] and it is unfavorable from an economic viewpoint. In today’s competitive market for the aluminum foundry, chip recycling requires an efficient pretreatment system to attain a high metal recovery with rapid return of investment and hence to drive down fixed cost and to increase productivity without compromising the metal quality. In the last years, various REZA ABDI BEHNAGH, Lecturer, is with the Department of Mechanical Engineering, Urmia University of Technology, 5716693187 Urmia, Iran, and with the School of Mechanical Engineering, College of Engineering, University of Tehran, 1417965463 Tehran, Iran. Contact e-mail: [email protected] RAMEZANALI MAHDAVINEJAD, Associate Professor, and MORTEZA NARVAN, MSc. Student, are with the School of Mechanical Engineering, College of Engineering, University of Tehran. AMIN YAVARI, MSc. Student, is with the Mechanical Engineering Department, Sahand University of Technology, 5197817169 Tabriz, Iran. MASOUD ABDOLLAHI, BSc. Student, is with the Department of Mechanical Engineering, Urmia University of Technology. Manuscript submitted October 7, 2013. Article published online April 17, 2014. 1484—VOLUME 45B, AUGUST 2014
recycling methods of machining swarfs and other aluminum wastes have been reported.[2–10] The direct recycling of machining swarf into bulk materials using severe plastic working without remelting has been conducted by many authors for the purposes of improving recycling efficiency, energy use, and expense. Compared with the remelting process, solid-state recycling is an efficient method because it can avoid oxidation loss in the remelting process and save energy without the needs of special environmental protection.[11] Recently, Chiba et al. investigated the possibility of solid-state recycling of aluminum alloy machining swarf and they produced recycled materials that have mechanical properties comparable to the original ingot.[12] In 1993, the friction-based process of friction-stir extrusion (FSE) was patented by The Welding Institute.[13] The extrusion process follows the same principle of the friction stir welding (FSW), in which a rapidly spinning tool is applied to the metal and is heated until it becomes soft, but not melted. Because the material is still in its solid state when it is extruded, it undergoes none of the degradation or phase t
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