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<p>Hot-extruded aluminum alloy profiles with complex cross-sectional characteristics are widely used in new energy vehicles, rail transportation and aerospace industries. By optimizing the structure of die, a uniform flow rate at the profile die outlet is obtained, thereby reducing the possibility of defects. Subsequently, the extrusion transient simulation is performed by setting the billet skin. The two flow modes of the billet skin during the extrusion process are explained through transient simulation, and the front- end defect of the profile and the rear-end defect of the billet are simulated and determined. An extrusion experiment is carried out based on the process parameters in the simulation, and EBSD tests are performed on the as-cast billet, the as-cast billet after homogenization treatment, the rear-end defect, the front-end defect and the normal profile. By analyzing the ODF of the as-cast billet, it is found that the billet cast by low-frequency electromagnetic casting formed a &lt;110&gt; // ND texture and &lt;110&gt; // TD texture due to characteristics similar to directional solidification. Homogenization treatment can effectively alleviate the segregation and slightly increase the grain size. The flow pattern of the billet skin in the simulation is verified by analyzing the grain size and fiber texture of the back-end defect. By analyzing the grain size of the profile and combining it with simulation, the extrusion coarse-grained ring effect is revealed. By comparing the front-end defect and the texture of the profile, the reason why the front-end defect is difficult to reach the normal profile usage standards is explained from a microscopic perspective.</p>

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The formation mechanism and microevolution of front and rear end defects based on die structure optimization for the extrusion of a 6063 aluminum alloy profile with complex cross-section

  • 期刊论文

  • 发表日期：

    2025年12月10日

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  • Dewei Zhang,
  • Haijie Xu,
  • Sheng Xu,
  • Kai Chen,
  • Zixuan Li,
  • Jinrong Zuo,
  • Xuedao Shu

摘要

Hot-extruded aluminum alloy profiles with complex cross-sectional characteristics are widely used in new energy vehicles, rail transportation and aerospace industries. By optimizing the structure of die, a uniform flow rate at the profile die outlet is obtained, thereby reducing the possibility of defects. Subsequently, the extrusion transient simulation is performed by setting the billet skin. The two flow modes of the billet skin during the extrusion process are explained through transient simulation, and the front- end defect of the profile and the rear-end defect of the billet are simulated and determined. An extrusion experiment is carried out based on the process parameters in the simulation, and EBSD tests are performed on the as-cast billet, the as-cast billet after homogenization treatment, the rear-end defect, the front-end defect and the normal profile. By analyzing the ODF of the as-cast billet, it is found that the billet cast by low-frequency electromagnetic casting formed a <110> // ND texture and <110> // TD texture due to characteristics similar to directional solidification. Homogenization treatment can effectively alleviate the segregation and slightly increase the grain size. The flow pattern of the billet skin in the simulation is verified by analyzing the grain size and fiber texture of the back-end defect. By analyzing the grain size of the profile and combining it with simulation, the extrusion coarse-grained ring effect is revealed. By comparing the front-end defect and the texture of the profile, the reason why the front-end defect is difficult to reach the normal profile usage standards is explained from a microscopic perspective.