Investigation of mechanical properties and residual stress in the combined simple shear extrusion-forward extrusion (CSSE-FE) process of 1050 aluminum alloy

The combined simple shear extrusion-forward extrusion technique was recently known as a new severe plastic deformation technique for processing bulk materials. The unique design of the die channel in this process has led to the production of samples with a regular cross-section. This study investigated the effect of the combined simple shear extrusion-forward extrusion process on the mechanical properties, micro-hardness, and residual stress of 1050 aluminum alloy samples. The residual stress was studied numerically and experimentally using the contour method. The finite element software was used to analyze process parameters numerically. After the combined simple shear extrusion-forward extrusion process, yield stress, tensile strength, and average micro-hardness values were increased by 316.28%, 147.09%, and 88.82%, respectively. Among the mechanical properties, the combined simple shear extrusion-forward extrusion technique significantly affects yield stress. In this study, after measuring the residual stress numerically and experimentally using the contour method, there was a good correlation between their results. Also, the numerical results showed that with the increase of the friction coefficient from 0 to 0.04, the compressive residual stress value is reduced by about 71.92%.