A review of current research related to the understanding of extrusion welding phenomena is presented. Two types of extrusion welds: the transverse and longitudinal welds are discussed. Metal flow and die design optimization is needed in order tominimize the amount of scrap metal as a result of transverse welding taking place during the billet-to-billet extrusion process. The importance of understanding of longitudinal weld performance and its metallurgical characteristics as a function of theextrusion process parameters is presented. Results of the preliminary tests for a longitudinal weld obtained when a special test die was utilized are shown. An outline of proposed study involving laboratory simulation techniques to physically model thewelding that occurs during extrusion of aluminum alloys through porthole dies is discussed. Mechanical properties of the welded samples need to be determined to investigate the influence of the extrusion parameters such as temperature, speed and dieorifice location on weld quality. The relative performance of the welded region compared to adjacent regions needs to be addressed as well. A necessity for mechanical evaluation of weld integrity both in the aswelded and in the aged condition is alsodiscussed.
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