A comparative study on deformation mechanisms, microstructures and mechanical properties of wide thin-ribbed sections formed by sideways and forward extrusion

Extruded profiles/sections are increasingly used in the transport industry for lightweight structures. In this paper, a wide thin-ribbed aluminium profile with asymmetric Z-shape, was manufactured by novel sideways extrusion process proposed authors. A comparative study conducted utilising direct/forward at same temperature and speed, which different mechanics, resulting microstructures mechanical properties of profiles have been investigated experiments finite element modelling. It revealed that, compared extrusion, although design die pocket forward induces preform avoids use large-diameter billet container/press needed extruding profiles, it requires greater force due to work-piece upsetting necessary fill leads lower effective strain rib. EBSD characterisation regions an equal indicated that increased shear is more efficient obtaining fine grains higher average misorientation angle. region rib made from two processes, results grain refinement strains, slightly texture intensity found intensive deformation. Tensile tests on formed yield strength (YS) ultimate tensile (UTS) but relatively elongation failure, combined effects refinement, GND enhancement. Compared billet, has YS about 60% 79% respectively, UTS 74% 80% respectively direction, demonstrating advantage improving material under condition.