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Cracking behavior and prediction criterion of spray-deposited 2195 Al–Li alloy extrusion profile

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Abstract

Surface cracking is one of the common problems in the extrusion process of Al–Li alloys, which seriously affects the surface quality and performance of the profile. In this study, the extrusion experiments of 2195 Al–Li alloy profiles were carried out under different temperatures and speeds to reveal the influence of extrusion parameters on the profile cracking and clarify the cracking mechanism. It was found that the extrusion cracking is closely related to the profile temperature at the die outlet and the plastic work accumulation after the material flows through the die bearing. Cracking occurs when the surface temperature of the profile is too high and the tensile plastic work accumulation exceeds the critical value. Based on the cracking mechanism, a prediction criterion for the extrusion cracking was established by taking into account the influences of deformation temperature and strain rate. The extrusion cracking of the spray-deposited 2195 Al–Li alloy profile was predicted by finite element simulation coupled with the established criteria. The predicted cracking position and degree were in good agreement with the experimental results. Finally, the boundary conditions for safe extrusion without cracking were investigated, and the extrusion limit diagram of the 2195 Al–Li alloy was constructed, which can be conveniently used to guide the selection of extrusion parameters in actual production.

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The raw/processed data required to reproduce these findings cannot be shared at this time as the data also forms part of an ongoing study.

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Funding

The authors would like to acknowledge the financial supports from the National Natural Science Foundation of China (Grant No. 51735008) and the Shandong Province Major Scientific and Technological Innovation Project (Grant No. 2019TSLH0102).

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Authors and Affiliations

  1. Key Laboratory for Liquid-Solid Structural Evolution and Processing of Materials (Ministry of Education), Shandong University, Jinan, Shandong, 250061, People’s Republic of China

    Yongxiao Wang, Guoqun Zhao, Xiaoxue Chen & Xiao Xu

Authors
  1. Yongxiao Wang
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  2. Guoqun Zhao
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  3. Xiaoxue Chen
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  4. Xiao Xu
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Contributions

Yongxiao Wang: conceptualization, investigation, data curation, formal analysis, methodology, writing-original draft, preparation, and submission. Guoqun Zhao: resources, project administration, funding acquisition, writing-review and editing, and supervision. Xiaoxue Chen: investigation, formal analysis, and visualization. Xiao Xu: investigation and methodology.

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Correspondence to Guoqun Zhao.

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Wang, Y., Zhao, G., Chen, X. et al. Cracking behavior and prediction criterion of spray-deposited 2195 Al–Li alloy extrusion profile. Int J Adv Manuf Technol 120, 5969–5984 (2022). https://doi.org/10.1007/s00170-022-09103-5

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