6 Problem

INCLUSION
DEFECTS IN 6000 Inclusions present in extruded aluminium are almost always connected
SERIES with poor surface finish, mechanical property failure and damage to
EXTRUSIONS extrusion dies.

Identification
Extrusions containing inclusions usually exhibit one of the following;
1. Heavy die lines,
2. Tearing that appears to
contain foreign particles, or
3. Severe delamination,
Figure 1.
Billets containing inclusions
may also damage die bearings
which will produce heavy die
lines, increase die mainten-
ance and result in loss of Figure 1. Example of extrusion tearing caused by an
dimensional tolerances. In inclusion defect.
some cases dies can be broken
up by large inclusions.

SUMMARY OF CAUSES
EXTRUSION 1. Extruded billet skin
DIRECTION 2. Extrusion equipment failure
3. Casting inclusions
a) Oxide inclusions
b) TiB2 clusters
c) Cast house refractories

EXTRUDED BILLET SKIN

LOCATION OF Cause
MICROGRAPH

The billet skin can enter the extrusion at any

point in the extrusion process, particularly if
the container temperature is close to or
higher than the billet temperature. Such
conditions will minimise frictional constraints
at the billet/container interface and the billet
skin can flow into the extrusion more easily,
Figure 2.

Figure 2. Optical micrograph of extrusion cross-

section exhibiting flow of skin in from edge

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 Irrespective of the type of section and billet flow,
skin will enter the extrusion if the butt section is too
thin, Figure 3.

Prevention
To avoid the extrusion of the skin, a container
temperature of at least 30°C less than billet
temperature is recommended. This will help retain
the skin in the extrusion butt.
Minimising butt thickness is desirable for good
metal recovery but is only possible if properly cast
billets with shallow segregation zones are used.
Figure 3. Butt exhibiting flow of skin from rear Large segregation zones and reductions in butt
of billet. thickness to minimise scrap may result in back-end
defects, effectively eliminating any metal savings,
Figure 4.

Segregation
zone
75-100
microns

200
microns

Air pressurised Float cast

Figure 4: Optical micrographs of segregation zones.
2. EXTRUSION EQUIPMENT FAILURE
Cause.
Pieces of steel tools are sometimes discovered in extrusions or extrusion butts. This is usually the
result of extrusion equipment failures, examples of which are die failures, shear blade chips and
container flaking.

NOTE:
The extruder should be wary of identifying steels in extrusions by appearance or colour alone.
Tool steels may be readily identified by metallographic examination or hardness measurements.
Die tool steels (H11 or H13) generally have a hardness in the range 45-52 Rockwell C, but the
bulk of old dies may soften to as much as 40 Rockwell C. Hardness of steels used in other press
components may vary greatly, so metallographic techniques are the most suitable means of
identification if the source is unknown. As a means of rapidly identifying the source of steel
inclusions a log of the different types of steel used in press components and ancillary equipment
is recommended.

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 Prevention
These failures may be minimised by the correct selection of material for press tool components and
routine maintenance of press components such as replacing chipped shear blades and inspecting
cleaned containers for damage.

3. CASTING INCLUSIONS
Inclusions cast into billet can cause expensive die failures as well as extensive extrusion surface
degradation. Examples of such inclusions are:
a. Oxide inclusions (dross).
b. Titanium diboride (TiB2 ) clusters.
c. Cast house refractories.

a) OXIDE INCLUSIONS
Cause
Oxides will form in the furnace (dross), launders and during some melt treatments. Oxide formation is
much higher in remelt operations than in smelter casting processes, due to introduced oxide from scrap.
The oxides are extremely hard and when extruded will promote die wear and pick-up, Figure 5.

Oxide
Al
Stringer

Figure 5. Scanning electron micrograph of oxide stringers.

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Prevention
The formation of oxides during billet casting is unavoidable but are reduced greatly in size and number
by the following furnace practices:

• Furnace skimming to remove dross before casting

• Allow the melt to settle after alloy mixing prior to casting.
Note that tilting furnaces have an advantage over static furnaces in this case because oxides that sink
to the bottom of the static furnace can be poured via the taphole located at the bottom of the furnace.
• Degassing the melt ( particularly using in-line techniques).
• Filtering the melt.

Aluminium
Alloy

Furnace
In Line
Degassing Casting Pit

Ram

Figure 6. Schematic of VDC casting process.

b) TIB2 CLUSTERS

Cause
TiB2 enters the melt as a TiB2/aluminium alloy grain refiner. The TiB2 does not melt, but is dispersed
in the melt as numerous fine particles. These particles act as nucleation sites for grain formation. If
the TiB2 does not evenly disperse, TiB2 clusters will form. Remelt operations are most susceptible to
TiB2 cluster formation because the molten metal is held for longer times than a primary metal casting
process. During extrusion these clusters may induce die wear, die lines and pick-up, and if the
extrusions are remelted then the inclusions will return through the cycle to be cast into billet, Figure 7.

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 B

Ti

Al

Figure 7. Optical micrograph of TiB2 cluster (500 mag).

Prevention
The size and dispersion rate of TiB2 clusters in the melt are controlled by the time that the grain
refiner remains in contact with the melt. TiB2 should not be added directly to the furnace where it
may remain for long periods. The most effective method of adding grain refiner is to add TiB2 rod to
the launder during transfer from furnace to the casting pit. This ensues maximum dispersion in the
melt with minimum contact time. Use of a ceramic foam or similar filter in-line helps trap larger TiB2
clusters.
Additions of TiB2 grain refiner to remelt scrap should be carefully monitored to avoid excess build
up due to residuals of grain refiner already in the scrap metal.

c) CAST HOUSE REFRACTORIES

Cause
Large pieces of refractory material that have broken away from furnace linings, launders or filter
boxes may be inadvertently be cast into billet. These large pieces of foreign material can cause
premature die failure, die lines and eventually tearing of the extrudate, Figure 8.

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 Al

Ca

O Si

Figure 8. Extrudate containing refractory inclusion (20x).

Prevention
Furnace practices should be reviewed to ensure that all activities likely to damage refractories are minimised. In
particular, remelt operations should take extreme care in scrap charging, alloy additions and furnace stirring,
degassing and cleaning to prevent refractory damage.
Any refractory (or other inclusion) particles that may enter the melt should be filtered from the liquid metal by
filtration. Incidences of foreign material, such as refractory, entering the melt downstream from the filter are
minimised by effective cast house maintenance.

As an aid to further understanding of the information in this brochure it is recommended that the reader refer to the Comalco brochure
entitled "THE BASIC METALLURGY OF 6000 SERIES EXTRUSION ALLOYS".

"Important Disclaimer"

This brochure has not been prepared with any particular reader in mind and therefore, although we believe that the advice and
information herein is accurate and reliable, no warranty of accuracy, reliability or completeness is given and (except insofar as
liability under any statute cannot be excluded) no responsibility arising in any other way for errors or omissions or in negligence
is accepted by the company or any director, employee or agent of the company.

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