Identification of processing window for extrusion of large thick-walled Inconel 625 alloy pipes using response surface methodology

Identifying suitable processing window is necessary but difficult for achieving favorable microstructure and performance in extrusion of large thick-walled pipe with difficult-to-deform Inconel 625 alloy. In this work, a method was established for identifying the extrusion process window considering temperature control using response surface methodology. Firstly, the response surface models, which correlate temperature rise and peak temperature to key extrusion parameters, have been developed by orthogonal regression based on finite element calculated data. Secondly, the coupled effects of the key extrusion parameters on the temperature rise and peak temperature have been disclosed based on the regression models. Lastly, suitable extrusion processing windows, which are described by contour map of peak temperature in the space of extrusion speed and initial billet temperature, have been established for different extrusion ratios. Using the identified process window, a suitable combination of the key extrusion parameters can be determined conveniently and quickly.