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<p>The development of nano-treated filler materials has gained importance to achieve crack-free welds in joining heat-treatable aluminium alloy 7075 sheets, which are highly susceptible to solidification cracking during arc welding. For producing high-quality filler materials with minimal extrusion load, optimizing die design and process variables is essential. In the present work, a finite-element-based thermo-mechanical simulation is employed to investigate the influence of extrusion ratio, die angle, and billet temperature on the extrusion load, undersurface flow lines, and effective stress distribution. The study focuses on identifying the optimum combination of these parameters to minimize peak extrusion load, limit excessive stress concentrations to prevent damage, and ensure uniform, smooth material flow through the die exit. Finite element simulations have been carried out for the hot extrusion of AA7075 billets, and the optimized parameters were subsequently employed to produce nano-treated filler wire. The simulations revealed that the extrusion ratio and billet temperature were the significant parameters influencing the load. The peak extrusion load was found to vary from approximately 17 tons to 65 tons across the investigated parameter range, indicating a significant reduction of approximately 74% under optimized condition. A significant role of die angle was observed in controlling the metal flow pattern, with a 90º die angle resulting in smooth flow through the die exit. The experimental peak loads (17.5–19.04 tons) closely matched the simulated value (18.34 tons), with deviations within ± 5%, confirming the accuracy of the numerical model.</p>

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Optimization of Parameters for Extrusion of Nano-treated Filler Wire for Joining AA7075 Sheets by Gas Tungsten Arc Welding

  • 期刊论文

  • 发表日期：

    2026年5月22日

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  • Salman Ansari,
  • Digavalli Ravi Kumar,
  • Sivanandam Aravindan,
  • Ayan Bhowmik

摘要

The development of nano-treated filler materials has gained importance to achieve crack-free welds in joining heat-treatable aluminium alloy 7075 sheets, which are highly susceptible to solidification cracking during arc welding. For producing high-quality filler materials with minimal extrusion load, optimizing die design and process variables is essential. In the present work, a finite-element-based thermo-mechanical simulation is employed to investigate the influence of extrusion ratio, die angle, and billet temperature on the extrusion load, undersurface flow lines, and effective stress distribution. The study focuses on identifying the optimum combination of these parameters to minimize peak extrusion load, limit excessive stress concentrations to prevent damage, and ensure uniform, smooth material flow through the die exit. Finite element simulations have been carried out for the hot extrusion of AA7075 billets, and the optimized parameters were subsequently employed to produce nano-treated filler wire. The simulations revealed that the extrusion ratio and billet temperature were the significant parameters influencing the load. The peak extrusion load was found to vary from approximately 17 tons to 65 tons across the investigated parameter range, indicating a significant reduction of approximately 74% under optimized condition. A significant role of die angle was observed in controlling the metal flow pattern, with a 90º die angle resulting in smooth flow through the die exit. The experimental peak loads (17.5–19.04 tons) closely matched the simulated value (18.34 tons), with deviations within ± 5%, confirming the accuracy of the numerical model.