Charge Weld Characteristics in Multi-hollow Aluminum Profiles for Automotive Bumper Applications

Charge welds occur in aluminumAluminumextrusionExtrusion when the leading end of a new billet encounters the trailing end of the previous billet, potentially forming regions of reduced bonding qualityQuality along the extrusionExtrusion length. These areas are critical for safetySafety-related components such as automotiveAutomotivebumperBumperprofilesProfile, especially in complex multi-hollow geometries where material flow paths are intricate. This study investigates the charge weld characteristics in extruded multi-hollow aluminumAluminumprofilesProfileproduced from 6xxxAl-Mg-Si alloys (6xxx) series alloys. Macrostructural analysis, optical microscopy, and hardnessHardness testing were performed to examine the integrity of the charge weld zones along the extruded profileProfile. The investigation enabled the identification of reliable profileProfile lengths beyond the charge weld transition. The findings provide essential knowledge on charge weld development and qualityQuality, which is crucial for determining cut-off lengths that directly impact the safetySafety and performance of automotiveAutomotivebumperBumperprofilesProfile.