---
_id: '61835'
abstract:
- lang: eng
  text: <jats:p>Abstract. Saving emissions and a circular economy are key aspects
    of sustainable production and compliance global climate change targets. Friction-induced
    solid-state recycling of aluminum scrap to production endless semi-finished products.
    Scrap is fed into a continuously rotating wheel. This requires less energy compared
    to heat-based recycling processes. Different sizes, shapes and surfaces of chips
    can be used as starting material in the process. The influence of this has been
    shown in past publications. A native oxide layer is a fixed component of aluminum
    surface. This layer is broken up during the forming process, allowing the aluminum
    to bond. In addition to the geometry, the surface finishes and the thickness of
    the oxide layer are therefore also important input variables in friction-induced
    solid-state recycling. The oxide layers on the chips were determined for the investigation.
    In addition, different layer thicknesses were produced to survey their influence.
    The resulting semi-finished products were evaluated on the basis of their tensile
    strength and microstructure. The main result of the investigations is the fact
    that semi-finished products made from chips with thicker oxide layers tend to
    be more brittle. In addition, thick oxide layers cause microstructural and surface
    defects.</jats:p>
author:
- first_name: Steffen
  full_name: Gabsa, Steffen
  id: '106786'
  last_name: Gabsa
citation:
  ama: 'Gabsa S. Influence of different oxide thicknesses on the friction induced
    and continuous solid-state recycling of aluminum scrap. In: <i>Materials Research
    Proceedings</i>. Vol 54. Materials Research Forum LLC; 2025. doi:<a href="https://doi.org/10.21741/9781644903599-272">10.21741/9781644903599-272</a>'
  apa: Gabsa, S. (2025). Influence of different oxide thicknesses on the friction
    induced and continuous solid-state recycling of aluminum scrap. <i>Materials Research
    Proceedings</i>, <i>54</i>. <a href="https://doi.org/10.21741/9781644903599-272">https://doi.org/10.21741/9781644903599-272</a>
  bibtex: '@inproceedings{Gabsa_2025, title={Influence of different oxide thicknesses
    on the friction induced and continuous solid-state recycling of aluminum scrap},
    volume={54}, DOI={<a href="https://doi.org/10.21741/9781644903599-272">10.21741/9781644903599-272</a>},
    booktitle={Materials Research Proceedings}, publisher={Materials Research Forum
    LLC}, author={Gabsa, Steffen}, year={2025} }'
  chicago: Gabsa, Steffen. “Influence of Different Oxide Thicknesses on the Friction
    Induced and Continuous Solid-State Recycling of Aluminum Scrap.” In <i>Materials
    Research Proceedings</i>, Vol. 54. Materials Research Forum LLC, 2025. <a href="https://doi.org/10.21741/9781644903599-272">https://doi.org/10.21741/9781644903599-272</a>.
  ieee: 'S. Gabsa, “Influence of different oxide thicknesses on the friction induced
    and continuous solid-state recycling of aluminum scrap,” in <i>Materials Research
    Proceedings</i>, 2025, vol. 54, doi: <a href="https://doi.org/10.21741/9781644903599-272">10.21741/9781644903599-272</a>.'
  mla: Gabsa, Steffen. “Influence of Different Oxide Thicknesses on the Friction Induced
    and Continuous Solid-State Recycling of Aluminum Scrap.” <i>Materials Research
    Proceedings</i>, vol. 54, Materials Research Forum LLC, 2025, doi:<a href="https://doi.org/10.21741/9781644903599-272">10.21741/9781644903599-272</a>.
  short: 'S. Gabsa, in: Materials Research Proceedings, Materials Research Forum LLC,
    2025.'
date_created: 2025-10-15T09:03:47Z
date_updated: 2025-10-15T13:07:59Z
doi: 10.21741/9781644903599-272
intvolume: '        54'
language:
- iso: eng
publication: Materials Research Proceedings
publication_identifier:
  issn:
  - 2474-395X
publication_status: published
publisher: Materials Research Forum LLC
status: public
title: Influence of different oxide thicknesses on the friction induced and continuous
  solid-state recycling of aluminum scrap
type: conference
user_id: '106786'
volume: 54
year: '2025'
...
---
_id: '61834'
abstract:
- lang: eng
  text: <jats:title>Abstract</jats:title><jats:p>3D printing or additive manufacturing
    (AM) possesses enormous potential to benefit the manufacturing industry. Presently,
    rotary draw bending (RDB) is one of the most commonly used cold-forming industrial
    process for bending metal tubes. Pressure die is a fundamental forming tool in
    RDB processes, and it is conventionally made by various grades of comparatively
    expensive alloy steels. This research presents a novel design of a pressure die
    which can be 3D printed by using inexpensive polymeric filaments. In this research
    paper, the 3D-printed pressure die is named as “FFF-pressure die.” The material
    used to fabricate the FFF-pressure die is a thermoplastic polymer known as “ecoPLA.”
    The mechanical properties of ecoPLA are studied in relation to the process conditions
    of a RDB process. Firstly, an initial feasibility of using the FFF-pressure die
    in a RDB process is obtained by conducting a quick static stress analysis with
    actual process conditions. After initial feasibility, a complete RDB process is
    developed and simulated with actual process conditions and material properties.
    The FFF-pressure die is then practically fabricated by FFF 3D printer and experimentally
    tested on an industrial RDB machine. The results of practical experiments are
    compared with the simulation results. In order to make a comparison of the FFF-pressure
    die with the conventional metal pressure die, the simulation and practical process
    is also conducted with the conventional metal pressure die. A performance and
    cost comparison is made between the polymeric FFF-pressure die and the conventional
    metal pressure die.  Von Mises stresses, contact forces, failure risk, and elastic
    deformations are analyzed. The advantages and limitations of using the FFF-pressure
    die in a RDB process are discussed in the end. This research intends to widen
    the avenue of using cost-effective and lightweight forming tools in metal forming
    industries.</jats:p>
author:
- first_name: Muhammad Ali
  full_name: Kaleem, Muhammad Ali
  last_name: Kaleem
- first_name: Rainer
  full_name: Steinheimer, Rainer
  last_name: Steinheimer
- first_name: Peter
  full_name: Frohn-Sörensen, Peter
  last_name: Frohn-Sörensen
- first_name: Steffen
  full_name: Gabsa, Steffen
  id: '106786'
  last_name: Gabsa
- first_name: Bernd
  full_name: Engel, Bernd
  last_name: Engel
citation:
  ama: Kaleem MA, Steinheimer R, Frohn-Sörensen P, Gabsa S, Engel B. Additive manufacturing
    of polymeric pressure die for rotary draw bending process. <i>The International
    Journal of Advanced Manufacturing Technology</i>. 2024;134(3-4):1789-1804. doi:<a
    href="https://doi.org/10.1007/s00170-024-14221-3">10.1007/s00170-024-14221-3</a>
  apa: Kaleem, M. A., Steinheimer, R., Frohn-Sörensen, P., Gabsa, S., &#38; Engel,
    B. (2024). Additive manufacturing of polymeric pressure die for rotary draw bending
    process. <i>The International Journal of Advanced Manufacturing Technology</i>,
    <i>134</i>(3–4), 1789–1804. <a href="https://doi.org/10.1007/s00170-024-14221-3">https://doi.org/10.1007/s00170-024-14221-3</a>
  bibtex: '@article{Kaleem_Steinheimer_Frohn-Sörensen_Gabsa_Engel_2024, title={Additive
    manufacturing of polymeric pressure die for rotary draw bending process}, volume={134},
    DOI={<a href="https://doi.org/10.1007/s00170-024-14221-3">10.1007/s00170-024-14221-3</a>},
    number={3–4}, journal={The International Journal of Advanced Manufacturing Technology},
    publisher={Springer Science and Business Media LLC}, author={Kaleem, Muhammad
    Ali and Steinheimer, Rainer and Frohn-Sörensen, Peter and Gabsa, Steffen and Engel,
    Bernd}, year={2024}, pages={1789–1804} }'
  chicago: 'Kaleem, Muhammad Ali, Rainer Steinheimer, Peter Frohn-Sörensen, Steffen
    Gabsa, and Bernd Engel. “Additive Manufacturing of Polymeric Pressure Die for
    Rotary Draw Bending Process.” <i>The International Journal of Advanced Manufacturing
    Technology</i> 134, no. 3–4 (2024): 1789–1804. <a href="https://doi.org/10.1007/s00170-024-14221-3">https://doi.org/10.1007/s00170-024-14221-3</a>.'
  ieee: 'M. A. Kaleem, R. Steinheimer, P. Frohn-Sörensen, S. Gabsa, and B. Engel,
    “Additive manufacturing of polymeric pressure die for rotary draw bending process,”
    <i>The International Journal of Advanced Manufacturing Technology</i>, vol. 134,
    no. 3–4, pp. 1789–1804, 2024, doi: <a href="https://doi.org/10.1007/s00170-024-14221-3">10.1007/s00170-024-14221-3</a>.'
  mla: Kaleem, Muhammad Ali, et al. “Additive Manufacturing of Polymeric Pressure
    Die for Rotary Draw Bending Process.” <i>The International Journal of Advanced
    Manufacturing Technology</i>, vol. 134, no. 3–4, Springer Science and Business
    Media LLC, 2024, pp. 1789–804, doi:<a href="https://doi.org/10.1007/s00170-024-14221-3">10.1007/s00170-024-14221-3</a>.
  short: M.A. Kaleem, R. Steinheimer, P. Frohn-Sörensen, S. Gabsa, B. Engel, The International
    Journal of Advanced Manufacturing Technology 134 (2024) 1789–1804.
date_created: 2025-10-15T09:02:15Z
date_updated: 2025-10-15T13:08:16Z
doi: 10.1007/s00170-024-14221-3
intvolume: '       134'
issue: 3-4
language:
- iso: eng
page: 1789-1804
publication: The International Journal of Advanced Manufacturing Technology
publication_identifier:
  issn:
  - 0268-3768
  - 1433-3015
publication_status: published
publisher: Springer Science and Business Media LLC
status: public
title: Additive manufacturing of polymeric pressure die for rotary draw bending process
type: journal_article
user_id: '106786'
volume: 134
year: '2024'
...