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As a pressure vessel, a small seamless aluminum liner with inner volume of about 6.75L is made from an initial billet material of AA6061-O. To produce the aluminum liner, warm forging including backward extrusion and head nosing was numerically simulated using a billet initially pre-heated to about 480℃. Compression tests on the billet material were performed at various temperatures and strain rates, and the measured mechanical properties were used in the numerical simulations. For the backward extrusion and the head nosing, the tool geometries were designed based on the desired configuration of the aluminum liner. Furthermore, the structural integrity of the tooling was evaluated to ensure adequate tool life. The seamless aluminum liner has an endurance limit of about 1.47MPa (15Kg f /cm 2 ), estimated based on the required inner pressure. The results confirm that the small seamless aluminum liner of AA6061-O can be successfully made by using the two stage warm forging procedures without any bursting failures.

Numerical Evaluation of Backward Extrusion and Head Nosing for Producing a 6.75L Small Seamless AA6061 Liner