Feasibility study and stress analysis of friction stir extruded rods and pipes: a simulative model

The traditional aluminium recycling process consumes a lot of energy and adversely affects the metallurgical quality of the secondary alloys produced. With the increasing need for resolving this problem, Friction Stir Extrusion (FSE) has been patented. FSE is a new solid-state recycling process through which parts can be extruded directly from waste. In this research, the analysis was focused on different process parameters, process set ups and geometries of the extruded parts. The traditional setup, where the tool rotates and advances while the chamber remains stationary, was considered, and a new one was introduced. In this configuration, the tool has only an advance feed, while rotation is performed through the chamber. Moreover, for each combination of process parameters the bonding phenomena occurrence, considering both the thermal and the stress conditions generated by the parameters, was analysed. For this purpose, the Piwnik and Plata criterion was chosen.