Alferid Hussin Shifa

12/03/2021
Prof. Makhlouf

Homework 4

Ch15: 1, 7, 8(a), 9, 17, 22, 39, 42, 43, and 53(a)

Ch17: 1, 2, 4, 7, 12, 16, 22, and 27

1. How does extrusion differ from rolling and forging?

- Extrusion is the process of squeezing a generally round billet through a die. This method
can create a variety of solid and hollow cross-sectional pieces. Unlike rolling and forging,
which can result in varying thicknesses and cross-sections throughout the pieces,
extrusion produces products with a consistent cross-section length. Furthermore, most of
the pieces created during extrusion will be semi-finished and will require additional
processing to achieve the appropriate result.

2. Why is glass a good lubricant in hot extrusion?

- Lubricants are essential in the extrusion process because they reduce friction and the
formation of dead metal zones. Those zones in the extrusion container are where the
metal does not flow through the extrusion die with hot extrusion of metals, specifically
shell extrusion. The reduction of friction is a factor to consider in order to avoid a
restriction in flow. Glass is one of the lubricants that can be utilized in hot
extrusion. Because glass is a good lubricant with a low coefficient of friction, it prevents
the metals from attaching to the container and die.

3. What types of defects may occur in (a) extrusion.

- Surface, pipe, and internal cracking are common faults in extrusion. Surface cracking
occurs when the extrusion temperature, friction, or speed is too high. The metal flow in
extrusion forces surface oxides and impurities to the core of the billet, resulting in the
pipe defect. Center cracking occurs when the extruded product develops cracks in the
center.

4. Describe the difference between direct and reverse extrusion.

- The standard extrusion process, also known as forward extrusion, is direct extrusion. The
material is inserted in a tube in the shape of a round billet. The material is then forced
into the die using a hydraulic ram or pressing stem. Reverse extrusion, on the other hand,
forces material flow in the direction opposite to the direction of ram movement; forcing it
towards the billet.
5. Explain why extrusion is a batch, or semicontinuous, process. Do you think it can be made
into a continuous process? Explain.
- Extrusion is a batch process because each billet is extruded individually from the
chamber. Any system other than hydraulics would be difficult and expensive to use in
extrusion due to the large forces involved. This method, in my opinion, could not, or at
the very least would be difficult to make continuous while maintaining the relatively low
cost.

6. Glass is a good lubricant in hot extrusion. Would you use glass for impression-die forging
also? Explain.
- No, I would not use glass as a lubricant in the forging of impression dies. For hot forging
operations, many types of glass are employed. However, because glass is incompressible,
even thin layers will prevent the pieces from forming in the desire die geometry in
impression-die forging. Thus, develop poor quality products, and may prevent successful
forging of suitable forms. Additionally, if the glass lubricant hardens in the dies, removal
will be difficult and expensive.

7. Estimate the force required in extruding 70–30 brass at 700◦C if the billet diameter is 200
mm and the extrusion ratio is 30.
A
- Given data: T = 700◦C = 1290◦F, D = 200 mm = 0.2 m, A𝑜 = 30
𝑓

70–30 brass at 1290◦F(figure 15.5) - K(aprox. extrusion constat) = 40,000psi = 275 MPa

- Find: the extrusion force, f

A𝑜 𝑝𝑖 𝑝𝑖
𝐹 = A𝑜 ∗ 𝐾𝑙𝑛 ( ) = 𝐷2 ∗ 𝐾𝑙𝑛( 30) = (0.2 𝑚)2 ∗ (275 𝑀𝑃𝑎)𝑙𝑛( 30)
A𝑓 4 4
= 29.38 𝑀𝑁

8. Calculate the extrusion force for a round billet 250mm in diameter, made of 304 stainless
steel, and extruded at 1000◦C to a diameter of 70 mm.
- Given data: T = 1000◦C = 1832◦F, D𝑜 = 250 𝑚𝑚 = 0.25 𝑚, D𝑓 = 70 mm = 0.07 m

stainless steel at 1832◦F (figure 15.5) - K(aprox. extrusion constat) = 60,000psi = 410 MPa

- Find: the extrusion force, f

A𝑜 𝑝𝑖 2 𝐷𝑜2 𝑝𝑖 2
0.252
𝐹 = A𝑜 ∗ 𝐾𝑙𝑛 ( ) = 𝐷𝑜 ∗ 𝐾𝑙𝑛 ( 2 ) = (0.25 𝑚) ∗ (410 𝑀𝑃𝑎)𝑙𝑛 ( )
A𝑓 4 𝐷𝑓 4 0.072
= 51.24 𝑀𝑁
9. A planned extrusion operation involves steel at 1000◦C with an initial diameter of 100 mm
and a final diameter of 25 mm. Two presses, one with capacity of 20 MN and the other with
a capacity of 10 MN, are available for the operation. Is the smaller press sufficient for this
operation? If not, what recommendations would you make to allow the use of the smaller
press?
- Given data: T = 1000◦C = 1832◦F, D𝑜 = 100 𝑚𝑚 = 0.1 𝑚, D𝑓 = 25 mm = 0.025 m

Cold rolled steel at 1832◦F (figure 15.5) - K(aprox. extrusion constat) = 40,000psi = 275
MPa

- Find: the extrusion force, f

A𝑜 𝑝𝑖 2 𝐷𝑜2 𝑝𝑖 2
0.12
𝐹 = A𝑜 ∗ 𝐾𝑙𝑛 ( ) = 𝐷𝑜 ∗ 𝐾𝑙𝑛 ( 2 ) = (0.1 𝑚) ∗ (275 𝑀𝑃𝑎)𝑙𝑛 ( )
A𝑓 4 𝐷𝑓 4 0.0252
= 5.988 𝑀𝑁
- Thus, the smaller press is just appropriate for this operation.
10. Assume that you are the technical director of trade associations of (a) extruders operations.
Prepare a technical leaflet for potential customers, stating all of the advantages of these
processes.
Extrusion is a manufacturing method in which metal is
contained in a closed chamber and then allowed to flow through
an opening, taking the shape of the hole. This procedure is identical
to squeezing toothpaste from the tube. Extrusion procedures can be
divided into two categories: cold and hot extrusion. Extrusion at
room temperature is known as cold extrusion, while extrusion at
recrystallization temperature is known as hot extrusion. Also,
forward (or sometimes called direct extrusion) and backward
extrusion (or indirect extrusion) are used to operate those extrusions.

Extrusion has a number of advantages, including but not limited to:

- Low cost per part, operational flexibility, high production volumes, a wide range of raw
materials can be employed, and the production rates are very cost effective. Furthermore,
each extrusion method has its unique set of
benefits. For instance,
o In hot extrusion, post execution alterations
are easy because product is still in heated
condition.
o Cold extrusion provides several
advantages over hot extrusion, including
improved mechanical properties, improved
surface finish and it has a good
dimensional tolerance control (which can
reduce the need for subsequent machining)
o Indirect extrusion has the advantage of
having no billet container friction, since there is no relative motion. As a result,
it's utilized on materials with a lot of friction, like high-strength hot extrusion and
stainless steels.
11. Briefly describe the production steps involved in making powder metallurgy parts.

- The powder metallurgy process is made up of five steps: powder production, blending,
compaction, sintering, and finishing.
o The procedure begins with a powder that can be used in a variety of ways
depending on the application. Metal powder can be made in a variety of ways,
each with its unique shape, geometry, and particle size. Atomization, reduction,
electrolytic deposition, mechanically alloying, and many other processes are
examples of Metal powder processes. Following that, adequate mixing is
required to ensure that the completed item has uniform strength properties. Even
if just one metal is utilized, blending ensures that its particle sizes are evenly
dispersed throughout the mixture. The combined powders are then compacted into
various forms in dies in the following phase. The goal of this step is to ensure that
the density, particle contact area, and shape are all correct before moving on to the
next step. The sintering process is then used to heat raw compacted powders at a
regulated rate in a controlled environment in order to bond the particles without
melting. This mechanism is extensive, and it is influenced by the metal particle
composition as well as processing conditions. Finally, a variety of procedures can
be utilized to bring the sintered item to its final useable state during the finishing
stage. Machining, plating, heat-treating, and grinding are all examples of finishing
procedures.

12. Name the various methods of powder production and explain the types of powders produced.
- Carbonyls: Carbonyls are created by combining metals with carbon monoxide and then
decomposing the carbonyl back into metal. The end result is a small, dense, and spherical
particle.
- Reduction: Metal oxides are reduced by exposing them to a reducing atmosphere such as
hydrogen or carbon monoxide, which removes the oxygen component. The outcome is
extremely small metallic particles that are porous, soft, and uniform in size, but their
sizes vary from round to angular.
- Comminution: Comminution is the process of reducing the size of metals by crushing
them or mechanically fracturing them in a ball mill. If the beginning metal is ductile, the
outcome is a flakelike powder that doesn't function well in powder metallurgy. If the
starting metal is brittle, the result is a very angular-shaped particle.
- Atomization: Particles are made by pouring liquid metal through a small hole in a die,
then shattering the jet with water or gas. If the process is water-shattered, the particles
cool quickly, resulting in big, non-uniform-sized particles. The particles are more
spherical when the jet is smashed by gas.
- Mechanical Alloying: A ball mill is utilized, and different metals are mixed together in
the mill and allowed to fold, blend, and bind. Particles made this way can occasionally
 have unique properties, such as hardening the alloy or enhancing its electrical, magnetic,
or thermal conductivity.
- Nanopowders: Nanopowders are made under strict quality control throughout production
and delivery. Because Nanopowders are extremely pure metals that react violently with
oxygen, they are only handled under reducing environments.
- Electrolytic Deposition: A salt or aqueous solution containing the desired metal in
suspension is used. The metal is separated from its anion and deposited below the
cathode using electrolysis. The end result is a powder that is extremely fine and pure.

13. Describe the methods used in metal powder compaction.

- Metal powders can be compacted using a variety of methods, including powder injection
molding. The powder is combined with a binder before going through a process similar to
die-casting. The slurry is injected into the mold at high temperatures of roughly 180°C,
then sintered in a low-temperature furnace to burn off the binder. It's utilized to make
complex shapes and is more cost effective compared to other methods.

14. Describe what occurs to metal powders during sintering.

- Metal powders are heated in furnace to a set temperature in a controlled setting during
sintering. The temperature is set to be below the melting point of the metal powder but
also high enough to allow fusing of the particle surfaces.

15. What is mechanical alloying? What are its advantages over the conventional alloying of
metals?
- Mechanical alloying is a process in which different metals are ground, crushed, and
fractured in a ball mill. The particles are continually crushed into smaller and smaller
particles as part of the process, resulting in a highly uniform distribution of alloy metals
throughout each particle. Mechanical alloying has several advantages over traditional
alloying, including the ability to form alloys of metals with widely varying melting
points, which is unachievable with conventional alloying. In addition, the traditional
alloying procedure necessitates a lot of energy to melt the metals. Mechanical alloying,
on the other hand, requires less energy because the alloy is made by sintering metal
powder created in a ball mill.

16. Why is there density variation in the compacting of powders? How is it reduced?
- Mechanical locking and friction between the particles are the main causes of density
variation in powder compacting. As a result of those causes, pressure will vary depending
on the distance between the punch and the container walls. Double-acting presses can
reduce variance by minimizing the frictional resistance of the punch and die surfaces. We
can also lower it by adding lubricants to the powders that will reduce friction..
17. What are the effects of the different shapes and sizes of metal particles in PM processing?
- In a powder metallurgy process, different metal shapes and particle sizes affect how well
the metal binds, which affects mechanical qualities such as bulk and density. Metal
particles with a wide size, purity, and surface form dispersion do not adhere evenly,
resulting in voids and impairing compaction.

18. Should green compacts be brought up to the sintering temperature slowly or rapidly? Explain
your reasoning
- Slow heating provides the advantage of allowing for more uniform heating and diffusion.
Rapid heating can produce excessive thermal stresses in the sintered part, which can lead
to distortion or breaking; nevertheless, it can shorten cycle durations.