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Productivity and Quality Trade-Offs in Aluminum Extrusion: Towards Circularity Tolerant Process Windows

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Abstract:

Aluminum extrusion plays a critical role in lightweight structural applications and circular economy strategies. However, extrusion process design is constrained by competing objectives: increasing productivity through higher ram speeds or increased die-hole count improves throughput and material utilization yet simultaneously elevates force demand and defect susceptibility. In this work, a numerical statistical framework is proposed to identify circularity-tolerant process windows, defined as multi-objective design regions that balance productivity, product quality, and sustainability performance. A three-factor Taguchi design was employed to systematically vary ram speed, billet temperature, and die-hole count in the extrusion of AA6063. Twenty-seven full 3D thermo-mechanical extrusion simulations were conducted using the DEFORM finite element platform employing an Arrhenius-type constitutive model from literature. Key extrusion responses maximum ram force, local damage indicator, and total displacement were analyzed using Principal Component Analysis (PCA) to reveal correlations and trade-offs between productivity-oriented parameters and quality-related responses. The results demonstrate a clear divergence between productivity drivers (ram speed, die-hole count) and process capability indicators, providing quantitative evidence of the inherent productivity quality trade-off. The proposed framework enables the identification of robust extrusion operating regions suitable for circular manufacturing scenarios in aluminum extrusion. The proposed framework is particularly relevant for extrusion scenarios where process robustness must be ensured under increasing material and operational variability, such as those anticipated with higher recycled content.

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Periodical:

Key Engineering Materials (Volume 1051)

Pages:

125-133

DOI:

https://doi.org/10.4028/p-rlVb3W

Citation:

Cite this paper

Online since:

April 2026

Authors:

Yohannis Solomon*, Davar Hemyari, Sotirios A. Grammatikos

Keywords:

Aluminum Extrusion, Circular Manufacturing, Multi-Hole Extrusion, Principal Component Analysis (PCA), Process Robustness

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Creative Commons CC BY 4.0

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* - Corresponding Author

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