Altair HyperXtrude 2025.1 Release Notes

Altair HyperXtrude is a suite of finite element solvers for simulating the following manufacturing processes. These solutions have interfaces in Inspire; the HyperXtrude solver is also called the Inspire Extrude Solver.
  • Binder Jet Sintering
  • Metal Extrusion
  • Polymer Extrusion
  • Quenching
  • Calibration
  • Metal Rolling
  • Friction Stir Welding
  • Resin Transfer Molding

Highlights

  • Die filling analysis

Metal Extrusion

New Features

Die filling analysis
Simulating how the starter billet breaks through the die helps in understanding the die performance and corrects any issues in the extrusion of the profile. With the die filling analysis introduced in this release, you can observe how the billet material viscoplastically deforms and fills the die cavity before exiting from the bearing region. This simulation models both the workpiece and air regions as an immiscible two-phase flow. This simulation is stopped when more than 50% of the material leaving the exit face is the workpiece material. You can modify this stop criterion using a parameter; the default is 50%. This feature does not work with coupled OptiStruct analysis. (SLVHXT-719)
Improvements to contact heat transfer
The extrusion solver supports the computation of the tool-workpiece-contact region using:
  1. Connected mesh (where the contact faces share the nodes)
  2. Congruent mesh (where the contact faces are identical and do not share nodes)
  3. Non-congruent mesh (where the contact faces are not only disconnected, they are also dissimilar)
The recommended option is congruent; however, it is not possible to achieve this for complex models. In this release, the contact search algorithm in the die-assembly regions is rewritten to improve the accuracy of the heat transfer between the tool and workpiece regions for non-congruent contact meshes. (SLVHXT-685)

Enhancements

Friction model support for Billlet_DummyBlock
The extrusion solver is enhanced to support friction conditions at the contact interfaces of the billet and dummy block, and this allows the workpiece material to slip on the dummy block wall instead of the default stick condition. The solver now supports the slip velocity friction model for the billet dummy block boundary condition. (SLVHXT-795)

Resolved Issues

Dead cycle time heat transfer coefficient
The heat transfer coefficient used during the dead cycle time (the air HTC) is no longer non-dimensionalized. The air HTC is now set to 5.0 W/(m2-K). The reference temperature has been changed from 25 ℃ to 50 ℃. (SLVHXT 785, SLVHXT-761, SLVHXT-351)
Weld surface propagation to Bearing 3D and Profile 3D
A minor issue in propagating the weld surface result to the Bearing 3D and Profile 3D regions is resolved. (SLVHXT-792)
Parameter to perturb DCT mesh
When computing bearing gap thickness fails, a method to perturb the DCT mesh and recompute was implemented in version 2025. This was causing some unintended consequences and was turned off. This can now be activated by setting pset MeshPerturbationDCT 1 in the parameters file. This feature will be internalized and automated in version 2026. (SLVHXT-804)

Polymer Extrusion

Resolved Issues

Freeze temperature in fit material module
In the fit material module, freeze temperature had a set limit of 300 K. This limit is now lowered to 200 K. (SLVHXT-799)

Binder Jet Sintering

Resolved Issues

Grain size and particle size
Both the solver and the material data in Inspire assumed the grain size to be the same as the particle size, and the solver was computing sintering stresses using the grain diameter instead of the particle diameter. In reality, the grain size is only a fraction of the particle size (one-tenth to one-twentieth), and when the data was set correctly, this resulted in very large sintering stresses. The solver now uses particle size to compute the sintering stresses, and the grain size data is used only in the grain growth models. (GIT-0d33397c)