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Andrew Paul
What Is Indirect Extrusion?

Indirect extrusion is a process that uses a die to create a profile. Its advantages include more consistent work and less variation in temperature over the length of the extruded profile. It also produces products with more consistent dimensions, grain structure, and mechanical properties. However, it comes with some drawbacks. One of these is that it requires the removal of an as-cast surface layer, which can contain oil or dirt. In addition, the die needs to be supported during the extrusion process, which reduces the profile's size.

Flow pattern


Aluminum extrusion differs from direct extrusion in the flow pattern of metals. The pressure on the extrusion profile die is higher in the front of the extrusion. As the process proceeds, the pressure on the billet and the container decreases. This change in force causes deflection of the die. This change in force affects the opening of the die and changes the dimensions of the billet from the front to the rear of the extrusion.


The microstructure of magnesium-aluminium wrought alloys is dependent on the process. Direct extrusion is characterized by coarser grains. Hydrostatic extrusion, on the other hand, yields finer grains. However, it is less observable compared to indirect extrusion.

Forces involved


Indirect extrusion is a process that reduces friction in the metal extrusion process. Indirect extrusion results in a more consistent workpiece and less variation in temperature throughout the entire extruded length. Indirect extrusion also produces a more uniform grain structure and mechanical properties. However, it comes with trade-offs. For instance, the process requires the removal of a surface layer, which may be dirt or oil. It also involves supporting the die during the extrusion process, which reduces the size of the finished profile.


Another advantage of indirect extrusion is its ability to form hollow parts. Indirect extrusion, a billet is kept within a closed chamber while the die is stationary. During this process, a ram applies force from one end of the chamber to the other, while a billet is held in place by a "stem" that is longer than the container. This stem is necessary in indirect extrusion because it acts as a force to push the billet through the die.

Mechanics of the process


Indirect extrusion is a process that uses a pull-action to draw the extrudate. It then undergoes a cooling process, typically through blown air or water. The process requires good downstream control, especially when the final product must be within a tight tolerance. This can be achieved with more precise control of the pull speed.


Several process parameters influence the quality of the product and are critical to the process' success. To determine the relative importance of these parameters, a central composite experimental design was applied. Four runs were modeled using finite element method (FEM) software DEFORM 2D, and were evaluated in terms of product quality (represented by four response variables). The statistical analysis of the results identified five significant process parameters and predicted an overall optimum value for each.

Microstructure of the product


The indirect extrusion process has a great influence on the microstructure of a material. This process involves deformation and dynamic recrystallization, which result in a large number of changes to the material's microstructure. These changes may affect the material's mechanical performance and properties.


The microstructure of an indirect extrusion product varies depending on its composition, speed, and other factors. For instance, the content of aluminium influences the homologous processing temperature, the ratio of Tm to Tm, and the presence of intermetallic compounds such as Mg 17Al12. Different speeds of indirect extrusion also affect the kinetics of grain growth and microstructure development.

Typical applications


Indirect extrusion is a process in which a material is forced through a die. It is usually performed with a hot or cold material. Common materials extruded through this process include metals, polymers, ceramics, and concrete. The extruded material is called an extrudate.


Indirect extrusion produces a more consistent work piece due to less temperature variation along the extrusion profile. It also results in more consistent dimensions, grain structure, and mechanical properties. However, the process has its trade-offs. It requires the removal of an as-cast surface layer, dirt, and oil, and requires the die to be supported during extrusion. These tradeoffs can reduce the overall profile size.


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