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Solid-state-recycled aluminum profile with notable fatigue and corrosion fatigue properties made by chip extrusion

Alexandros Prospathopoulos, Oliver Schulz

2026enfatiguealuminumrecyclingextrusion

Abstract

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Solid-state recycling by hot extrusion of AA6060 machining chips avoids remelting, but fatigue-critical reliability remains uncertain. This study benchmarks T6 heat-treated tubular profiles extruded from chip-based billets against cast-billet extrusions using two extrusion parameter sets. A steady-state Eulerian FE simulation coupled to a modified Bay weld model predicts spatial weld integrity and identifies defect-prone zones, showing minimum bonding of 93.8% (Batch#1) versus 98.9% (Batch#2). Experiments confirm that higher extrusion ratio, die venting during upsetting, and lower ram speed prevent post-aging chip decohesion and enable cast-like fatigue and improved corrosion-fatigue in 3.5 wt.% NaCl. Transferable process rules are provided for industry.

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Cite This Work

@article{a114b2d8-dfd7-4f61-bde8-4044c9526633,
  title={Solid-state-recycled aluminum profile with notable fatigue and corrosion fatigue properties made by chip extrusion},
  author={Alexandros Prospathopoulos and Oliver Schulz},
  year={2026},
  language={en}
}
TY  - JOUR
TI  - Solid-state-recycled aluminum profile with notable fatigue and corrosion fatigue properties made by chip extrusion
AU  - Alexandros Prospathopoulos
AU  - Oliver Schulz
PY  - 2026
LA  - en
ER  -

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