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During hot extrusion of copper alloys, extrusion tools have to withstand cyclic thermal and mechanical loads. To enhance the service life of the tools, materials with high temperature strength are designed as well as an optimised process control is performed. To characterise the tool damage evolution during service and to improve process guiding, modelling and simulation are appropriate means. The extrusion process of copper billets at three different temperatures was simulated by an FE-program to obtain the temporal boundary conditions, i.e. stress and temperature distributions at the interface billet-liner. Those boundary conditions were used to simulate the elastic–viscoplastic behaviour of the tool steel Böhler W750 in service by means of Abaqus Standard v.6.8-3 software in conjunction with Z-Mat package. A lifetime rule was added in order to compute the lifetime consumption and the cycles to failure.
Seals used in containers for dangerous goods need to maintain leak tightness for several decades. For investigating the change in seal material properties during aging, a comprehensive aging program on both uncompressed and compressed EPDM and HNBR seals was started. In order to obtain results closely related to practical conditions, O-rings with a full-scale cord diameter of 10 mm were aged. However, this set-up can lead to heterogeneous aging caused by diffusion-limited oxidation (DLO) effects. These effects depend on material, dimensions, time and temperature. Heterogeneous aging results in distorted bulk properties such as compression stress relaxation and compression set (CS) suggesting that HNBR has better performance than EPDM at 150 °C but which is not the case at 100 °C. The presence of heterogeneous material properties was shown by hardness measurements across the seal cross-section. If DLO-affected data is excluded, extrapolations of CS data are possible using time-temperature shifts and Arrhenius graphs. Exemplary CS values of 50 % and 80 % would be reached after approx. 10 years and 29 years, respectively for HNBR and after approx. 400 years and 1100 years, respectively for EPDM.
Materials subjected to high-temperature service conditions will change their microstructure with time. Associated with this aging process is a change of mechanical properties as well as a change of damage mechanisms. Within the scope of the FVV project Aging and Lifetime, Fraunhofer IWM in Freiburg and BAM in Berlin (both Germany) experimentally characterized the widespread high-temperature aluminum alloy EN AW-2618A in different overaging states. Based on the experimental findings, models for numerical lifetime assessment with the finite-element method were implemented.