Paper Titles

Calibrating a Lode-Parameter-Dependent Damage Evolution Equation to Cold Extrusion Experiments
p.63

Effect of Chemical Composition on Hot Extrudability and Tribological Behavior of 7000 Series Aluminum Alloys
p.73

Using Tungsten Inert Gas Welding Equipment to Locally Heat Tubes and Achieve Inhomogeneous Thickness in Tube Sinking Processes
p.83

Charge Weld Evolution in Profile Extrusion: Variability across Billets and Multi-Profile Designs
p.93

Development of a System for Ultrasonic Die Oscillations during Extrusion of Aluminum Hollow Profiles
p.109

Detection of Charge Welds in Lateral Angular Co-Extrusion Using Non-Destructive Testing
p.121

Comparative Characterization through Torsion Tests of Primary and Secondary Aluminum Alloys for the Extrusion Process
p.133

Transient Thermal Analysis of Multiple Extrusion Runs with Nitrogen Cooling by Means of Qform Code
p.151

Numerical Data-Driven Modelling of Modified Samanta Process for Cold Extrusion of Gears
p.165

HomeKey Engineering MaterialsKey Engineering Materials Vol. 1048Comparative Characterization through Torsion Tests...

Comparative Characterization through Torsion Tests of Primary and Secondary Aluminum Alloys for the Extrusion Process

Article Preview

View Pdf By email

Abstract:

In the transition to a circular economy in the automotive sector, it is essential to integrate recycled (or secondary) aluminum alloys into extrusion processes, while ensuring that their performance is as close as possible to that of primary alloys. Within the Horizon Europe ZEvRA project, this study aims to analyze and investigate the hot deformation behavior of four aluminum alloys, two primary alloys (AA6082 Primary and AA7108) and two recycled alloys (AA6082 Recycled and AA6061), in order to demonstrate their potential suitability for automotive applications. Hot torsion tests were conducted under temperature and strain rate conditions representative of industrial extrusion processes. Four different temperatures (400, 450, 500, and 550 °C) and four different strain rates (0.01, 0.1, 1, and 10 s⁻¹) were investigated, allowing the achievement of significantly higher strain levels compared to conventional standard tensile and compression tests. Subsequently, the flow stress curves obtained from the torsion tests were analyzed to evaluate the influence of temperature and strain rate on the plastic deformation behavior of the material and on the associated dynamic softening mechanisms. The results demonstrate a comparable deformation behavior between primary and secondary alloys, confirming the feasibility and full compatibility of recycled alloys for high-performance industrial extrusion applications. Furthermore, the experimental results provide a solid basis for the development of robust constitutive models to support FEM simulations aimed at optimizing metal forming pocesses within a circular manufacturing framework.

You might also be interested in these eBooks

Extrusion and Drawing

Info:

Periodical:

Key Engineering Materials (Volume 1048)

Pages:

133-150

DOI:

https://doi.org/10.4028/p-0NIiBN

Citation:

Cite this paper

Online since:

April 2026

Authors:

Nicola Lai*, Sara Di Donato, Lorenzo Donati, Riccardo Pelaccia, Barbara Reggiani, Marco Negozio

Keywords:

Aluminum Alloy, Extrusion, Flow Stress Modeling, Secondary Alloys, Torsion Tests

Export:

RIS, BibTeX

Permissions:

Creative Commons CC BY 4.0

Share:

Citation:

* - Corresponding Author

[1] V.K. Soo, J. Peeters, D. Paraskevas, P. Compston, M. Doolan, J.R. Duflou, Sustainable aluminium recycling of end-of-life products: a joining techniques perspective, J. Clean Prod. 178 (2018) 119–132.

DOI: 10.1016/j.jclepro.2017.12.235

[2] V.K. Soo, P. Compston, M. Doolan, Interaction between new car design and recycling impact on life cycle assessment, Procedia CIRP 29 (2015) 426–431.

DOI: 10.1016/j.procir.2015.02.055

[3] D. Paraskevas, K. Kellens, Renaldi, W. Dewulf, J.R. Duflou, Sustainable Metal Management and Recycling Loops: Life Cycle Assessment for Aluminium Recycling Strategies, in: A. Nee, B. Song, S.K. Ong (Eds.), Re-engineering Manufacturing for Sustainability, Springer, Singapore, 2013, p.403–408.

DOI: 10.1007/978-981-4451-48-2_66

[4] L. Donati, B. Reggiani, R. Pelaccia, M. Negozio, S. Di Donato, Advancements in extrusion and drawing: a review of the contributes by the ESAFORM community, Int. J. Mater. Forming 15 (2022) 41.

DOI: 10.1007/s12289-022-01664-w

[5] R. Pelaccia, M. Negozio, S. Di Donato, B. Reggiani, L. Donati, Numerical simulation of the extrusion process with different FEM code approaches: analysis of thermal field, profile speed, defects evolution, and microstructure of hollow tubes, in: Proceedings of ESAFORM Conference on Material Forming, 2024, p.771–780.

DOI: 10.21741/9781644903131-85

[6] S. Di Donato, R. Pelaccia, M. Negozio, N. Lai, M. El Mehtedi, B. Reggiani, L. Donati, Effect of material characterization via torsion tests on the accuracy of FEM simulations in the extrusion process, in: Material Forming – ESAFORM 2025, Mater. Res. Proc. 54 (2025) 780–791.

DOI: 10.21741/9781644903599-84

[7] M. Negozio, A. Segatori, R. Pelaccia, B. Reggiani, S. Di Donato, L. Donati, Modeling of recrystallization behaviour of AA6xxx aluminum alloy during extrusion process, Trans. Nonferrous Met. Soc. China 34 (2024) 3170–3184.

DOI: 10.1016/s1003-6326(24)66600-8

[8] M. Negozio, R. Pelaccia, L. Donati, B. Reggiani, S. Di Donato, Microstructure evolution and FEM prediction on AA6XXX alloys, Key Eng. Mater. 987 (2024) 3–10.

DOI: 10.4028/p-qo8wad

[9] S. Di Donato, R. Pelaccia, M. Negozio, M.E. Mehtedi, B. Reggiani, L. Donati, Hot torsion tests of AA6082 alloy, Key Eng. Mater. 988 (2024) 21–29.

DOI: 10.4028/p-5c0lii

[10] M. Negozio, L. Donati, A.H.A. Lutey, Smart extrusion via data-driven prediction of grain size and peripheral coarse grain defect formation, Sci. Rep. 15 (2025) 9518.

DOI: 10.1038/s41598-025-94884-4

[11] X.H. Fan, M. Li, D.Y. Li, Y.C. Shao, S.R. Zhang, Y.H. Peng, Dynamic recrystallisation and dynamic precipitation in AA6061 aluminium alloy during hot deformation, Mater. Sci. Technol. 30 (2014) 1263–1272.

DOI: 10.1179/1743284714y.0000000538

[12] D. Hu, L. Wang, H.J. Wang, Dynamic recrystallization behavior and processing map of the 6082 aluminum alloy, Materials 13 (2020) 1042.

DOI: 10.3390/ma13051042

[13] R.H. Buzolin, F. Krumphals, M.C. Poletti, Topological aspects in the microstructural evolution of AA6082 during hot plastic deformation, Eur. J. Mater. 3 (2023) 2218403.

DOI: 10.1080/26889277.2022.2125350

[14] M.C. Poletti, T. Simonet-Fotso, D. Halici, D. Canelo-Yubero, F. Montheillet, D. Piot, et al., Continuous dynamic recrystallization during hot torsion of an aluminum alloy, J. Phys.: Conf. Ser. 1270 (2019) 012049.

DOI: 10.1088/1742-6596/1270/1/012049

[15] Y.C. Lin, L.T. Li, Y.X. Fu, Y.Q. Jiang, Hot compressive deformation behavior of 7075 Al alloy under elevated temperature, J. Mater. Sci. 47 (2012) 1306–1318.

DOI: 10.1007/s10853-011-5904-y

[16] H.E. Hu, L. Zhen, B.Y. Zhang, L. Yang, J.Z. Chen, Microstructure characterization of 7050 aluminum alloy during dynamic recrystallization and dynamic recovery, Mater. Charact. 59 (2008) 1185–1189.

DOI: 10.1016/j.matchar.2007.09.010

[17] B. Wu, M.Q. Li, D.W. Ma, The flow behavior and constitutive equations in isothermal compression of 7050 aluminum alloy, Mater. Sci. Eng. A 542 (2012) 79–87.

DOI: 10.1016/j.msea.2012.02.035

[18] Q. Yang, X. Liu, Y. Liu, X. Fan, M. Shu, The flow softening behavior and deformation mechanism of AA7050 aluminum alloy, Mater. Trans. 60 (2019) 2041–2047.

DOI: 10.2320/matertrans.mt-m2019114

[19] Y.C. Lin, L.T. Li, Y.Q. Jiang, A phenomenological constitutive model for describing thermo-viscoplastic behavior of Al-Zn-Mg-Cu alloy under hot working condition, Exp. Mech. 52 (2012) 993–1002.

DOI: 10.1007/s11340-011-9546-4

[20] J. Lv, J.-H. Zheng, V.A. Yardley, Z. Shi, J. Lin, A review of microstructural evolution and modelling of aluminium alloys under hot forming conditions, Metals 10 (2020) 1516.

DOI: 10.3390/met10111516