<p>Equal Channel Angular Rolling (ECAR) is a prominent technique for enhancing the mechanical properties of metallic alloys through ultrafine grain refinement. This study investigates the influence of the ECAR process on the mechanical performance and microstructure of aluminum alloy 6061, utilizing a multi-pass forming procedure. Three passes were applied, and mechanical properties were evaluated using scanning electron microscopy (SEM), microhardness tests, and uniaxial tensile testing. The results revealed progressive increases in yield stress, tensile strength, and hardness with each pass, although the extent of improvement varied across passes. Yield stress showed an increase of 12, 23, and 33% after the first, second, and third passes, respectively, when compared to the unprocessed sample. Similar trends were observed for ultimate tensile strength and hardness. Finite element analysis (FEA) conducted using Abaqus software indicated higher plastic strain at the top and bottom regions of the mold due to boundary conditions, including friction and mold geometry. The simulations also indicated that an increase in the friction coefficient raised strain values in the aluminum sheets. This study offers a comprehensive understanding of the connection between ECAR processing parameters and mechanical properties, providing valuable insights for determining material performance in industrial applications.</p> Graphical abstract <p></p>