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A die setup for direct hot extrusion of extra-short aluminium alloys billets used in semi-pilot plant tests was simulated using DEFORM T 2D/3D software and results were compared with experiment. A die setup without welding chamber proved to shorten charge-weld to such extend that most of material could be recovered as usable samples. Having good agreement between simulated and experimental results of two tested die setups (with and without welding chamber) the effect of temperature on length of charge-weld was evaluated. A main drawback of die setup without welding chamber is too short and, consequently, too week charge-weld. Since many extruded profiles need to be stretched after cooling, die setup without welding chamber is not applicable for commercial production. Application of die setup without -or with shallow welding chamber is limited to flat profiles with simple and symmetrical geometry like round or rectangular bars where mixing of extruded material is not crucial for the profiles properties.

EXTRUSION OF SHORT ALUMINIUM BILLETS - SIMULATION AND SEMI-PILOT TEST