Hydrostatic extrusion of annealed 1100 aluminum was investigated experimentally at ambient temperature. The principal variables studied were lubricant viscosity which was varied from less than 100 to over 76,000 SUS at 100 deg F and the diametral clearance between the follower block and the extrusion cylinder which ranged from 0.0005 to 0.0030 in. for the 1.026 in. dia. cylinder. The specimen diameter was 0.97 or 1.00 in. corresponding to an extrusion ratio of 4.75 or 5.00, respectively. The included die angle was either 60 deg or 90 deg. The results show that with a proper combination of the lubricant viscosity and the follower block clearance, hydrostatic extrusion can be accomplished without the necessity of any sealing of the container on the follower block side. The optimum clearance for minimum breakthrough pressure increases as the lubricant viscosity increases. The extrusion force increases with die angle. The paper discusses the various factors that affect the magnitude of the breakthrough pressure and the occasional uneven bamboo-type appearance of the surface. Processing conditions must be selected carefully since the lowest extrusion force does not necessarily lead to a product with the best surface finish.

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