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We also think so. Thank you for your input.

Reading into extruding it looks as if it could be a transverse weld that didn't get removed.

EdStainless, since this is cast billet, can it be that the butt weld could have got surface oxide < say from moisture from air line> and did not weld correctly? Even with that said, i have reviewed their process documents and the butt weld is supposed to be removed and scrapped.

Is there a possibility there was a problem with the billet before extruding?

One was found. Because of this the entire lot (5k pcs) have been quarantined. Those have not been gone through.

EdStainlessn, This is our concern. Agreed that a "no" answer tells us nothing about the process nor helps to find rootcause. Sadly if we dropped our inquires then they would not proceed with investigation. This is the reason i have turned to forums for help. We have a team member flying to this...

EdSTainless, Thank you for your inquires. See below Per the the extruder- Are the billets worked before extrusion?-NO Have they changed extrusion dies?- No Have they changed extrusion ratio? -NO Temperature? -NO speed?-NO

Stick, I can push it out with my fingers.

Hardness is in spec for 6061. Hardness between both pieces match. Surface structure match. We tried to recreate with another part on our shear tester. Our molding machine maxes out at 9kn, the shear test was done at 90kn damaged our tooling and did not press out. We are of the mind that this...

3dDAve, Thank you. Below are some picture of the failed part. The first image is what it is supposed to be. The second image is the plug out. The aluminum part is supposed to be one solid piece But as you see the core plug easily came out.

Hello, We had a part fail in an odd way. The part is 6061 aluminum. The same company cast, Hot extrudes and machines. During our process a center core plug of the aluminum popped out. Being this was extruded from a billet, this is not supposed to happen. The company that makes the part has run a...