Direct extrusion is also called forward extrusion and it is the most general extrusion process.

Its work
operation includes the placement of the billet in a container, which is heavily walled. Ram or screw is used
to push the billet through the die. In between the billet and ram, there is a dummy block, which is reusable
and is used for keeping them separated.

Disadvantages of Direct Extrusion

One of the major disadvantages of the direct extrusion process is that the force needed for the extrusion of
billet is more than what is required in the indirect extrusion process. This is because of the introduction of
frictional forces due to the requirement for the billet to move the container's entire length. Hence, greatest
force is required at the start of the process, which decreases slowly with the use up of billet. At the billet's
end, the force is largely increased as the billet is thin and the material has to flow radially for existing the
die. For this reason, the butt end of the billet is not used.

Indirect Extrusion
Indirect extrusion is also called backwards extrusion and in this process, the die is constant whereas the
billet & container move together. To keep the die stationary, a stem is used which must be longer than the
length of container. The final and maximum extrusion length is decided by the stem's column strength.As
the billet movement is along with the container, all the frictional forces are easily eliminated. This results in
following advantages:

25 to 30% reduction of friction, allowing extrusion of larger billets, enhanced speed, and an increased
ability to extrude smaller cross-sections
Less tendency for extrusions to crack as no heat formation takes place from friction
Container liner lasts longer, due to less
wear
More uniform use of billet ensures that
extrusion defects & coarse grained
peripherals zones are less likely

Disadvantages of Indirect Extrusion

There are a couple of disadvantages of the
indirect or backward extrusion. This process is
not as versatile as the process of direct
extrusions, as the cross-sectional area is
confined by the stem's maximum size. Also, the
defects and impurities on the billet's surface affect the extrusion's surface. These defects destroys the piece,
if it requires to be anodized or if its aesthetics are important. To eliminate this, the billets have to be wired
brushed, chemically cleaned or machined before being used.

Hydrostatic Extrusion

Hydrostatic extrusion is a process in which the billet is completely circumscribed by a pressurized liquid in all
the cases, with the exception being the case where billet is in the contact with die. This process can be
carried out in many ways including warm, cold or hot but due to the stability of the used fluid, the
temperature is limited. Hydrostatic extrusion has to be carried out in a completely sealed cylinder for
containing the hydrostatic medium. The fluid may be pressurized in following two ways:

1. Constant-Rate Extrusion: A ram or plunger is used for pressurizing the fluid in the container
2. Constant-Pressure Extrusion: A pump with a pressure intensifier is used for pressurizing the fluid,
which is then pumped into the container
Advantages of Hydrostatic Extrusion

No friction amidst the container and

billet. This minimizes the force
requirements, allowing higher reduction
ratios, faster speeds, & lower billet
temperatures.
Friction of the die can be largely reduced
by a film of pressurized lubricant amidst
the die surface and deforming metal.
On applying high pressures, the ductility
of material increases.
Even flow of material.
Large billets & large cross-sections are
extruded.
Uniform hydrostatic pressure inside the container eliminates the requirement of billets being
straightened and extrusion of coiled wire.
No billet residue is left on the walls of container.

Disadvantages of Hydrostatic Extrusion

The billets have to be prepared by tapering one end so that it matches the die entry angle. This is essential
for forming a seal at the starting of the cycle. Generally, the complete billet is required to be machined for
the removal of surface defects.
It can be difficult to contain the fluid, under the effects of high pressures (up to 2 GPa, or 290 ksi).

Limitations of Hydrostatic Extrusion

There are a number of limitations in the hydrostatic extrusion, especially when a large volume of fluid is
used in comparison with the billet volume, which is to be extruded. These limitations are as follows:

Increased handling for the injection and removal of the fluid for every extrusion cycle
Decreased control of speed of the billet & stopping because of potential stick-slip and enormous stored
energy in the compressed fluid
Decreased process efficiency in terms of billet-to-container volume ratio
Enhanced complications, when extrusion is done at elevated temperatures

Solutions To These Limitations

The problems related to the billet speed as well as stopping control can be minimized with the use of viscous
dampers and also with the improvement in lubrication at the billet / die interface. There is another approach
to minimize all the above mentioned problems, which is to maintain the amount of pressurizing fluid to an
absolute minimum, as in the case of Hydrafilm process.