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Besides the energy-intensive secondary metallurgical recycling route, aluminum chips can alternatively be extruded to final profiles by extrusion. The mechanical properties of the extruded profiles have a dependency on the quality of the weldments of the chips, which differs locally due to the batch process. To characterize the influence of this dependency on the mechanical properties, round pre-compacted chip blocks consisting of EN AW-6060 were pre-heated for six hours at 550 °C, extruded with flat-face dies at a recipient temperature of 450 °C and divided into three zones: profile, transition and contact zone. A micro-computed tomographic defect analysis was performed on the samples. It has been shown that the profile samples of both geometries have a very low defect quantity and volume, while towards the contact zone the number and volume increases significantly and small delaminations occur on the surface. For the determination of the hardness distribution, a macro hardness mapping was performed. The coarse grain edge in the outer region of the specimens, which has resulted from increased temperature as a result of the recipient friction and shear stress, shows a slightly increased hardness. Round profiles show a concentric hardness decrease and square profiles a linear drop towards the center of the cross section of the specimens.

Micro-CT defect analysis and hardness distribution of flat-face extruded EN AW6060 aluminum chips