Metal flow behavior and energy consumption model during the extrusion process of a 6063 aluminum alloy profile with complex cross-section

Hot extruded aluminum alloy profiles are widely used in the preparation of automotive bodies and key components. In this study, the influence of extrusion parameters on the metal flow behaviors and energy consumption of a 6063 aluminum alloy profile with complex cross-section were investigated by numerical simulation and mathematical modeling. An extrusion experiment was conducted to study the microstructure and mechanical properties of the profile. The simulation results show that the standard deviation of metal flow velocity (representing the forming quality) was decreased as container temperature decreases, and the extrusion speed, billet temperature and die temperature increase. Through analyzing the energy transfer behavior during hot extrusion, a mathematical model of energy consumption was established. It was found that preparing high-quality profiles usually requires high energy consumption. Taking metal flow behavior and energy consumption into account simultaneously, reasonable extrusion process parameters were obtained, and an extruded profile without defects was prepared. By monitoring the driving motor current of the extruder, the energy consumption model was verified. The extruded profile has homogenous recrystallized grains with strong Cube and Goss textures, and yield strength distributed in the range of 75.93-89.03 MPa.