Analysis of Strain Inhomogeneity in Extruded Al 6061-T6 Processed by ECAE

This paper presents an analysis of the test and simulation of the equal channel angular extrusion (ECAE) of a commercial Al 6061-T6 alloy previously extruded. Special emphasis is given to the analysis and comparison of the simulated values and distribution of equivalent plastic strain with those calculated with analytical models across the height of the middle section of the deformed billet. The results reveal the limitations of the analytical models when the effects of the inner die corner and curvature of the outer wall on the material response during the test are considered for the ECAE device used in this work. Specifically, in the simulations performed in this work, the plastic deformation zone, far from being uniform, extends along with the height of the billet where, in particular, near the inner wall over the inlet and outlet channels, even in the central region of the billet, the equivalent plastic strain is not homogeneous or discontinuous, varying mainly due to the effect of the curvature of the outer channel.