Schomäcker, M.; Schikorra, M.; Kleiner, M.:
In: Konferenzbeitrag Aluminium Two Thousand in Florence


Extruded profiles made of aluminum are essential components in lightweight space frame constructions in modern automotive and transport applications. The reinforcement of such aluminum profiles with high strength materials offers a high potential in terms of weight reduction and improvement of mechanical and functional properties. In comparison to conventional composite extrusion processes using particle or fibre reinforced billets, the developed alternative process for the embedding of continuous reinforcing elements, like e.g. wires, offers great advantages concerning necessary extrusion forces and load-adapted reinforcement. Within this process, modified porthole dies are used to feed the reinforcing elements from the outside of the pressing tool and to embed them in the material flow during the extrusion process of conventional billets. This composite extrusion process is part of the research work within the scope of the Collaborative Research Center SFB/TR 10, which was initiated in 2003. In this paper, an overview of the experimental investigations and the simulation using the Finite Element Method is given. The projects include analysis of influencing parameters on the positioning, the embedding, and the process stability. In basic research experiments high strength steel wires were embedded in different profiles made of alloy EN AW 6060. The number of reinforcing elements and the complexity of the cross-section geometry were gradually enhanced during this basic research stage. Furthermore, simulations were carried out to analyze the material flow and the occurring stresses during the composite extrusion process.