Extrusion die geometry effects on the energy absorbing properties and deformation response of 6063-type Al–Mg–Si aluminum alloy

The response of 6063-type Al–Mg–Si alloy to deformation via extrusion was studied using tool steel dies with 15°, 30°, 45°, 60° and 75° entry angles. Compressive loads were subjected to each sample using the AVERY DENISON machine, adapted to supply a compressive load on the punch. The ability of the extrudate to absorb energy before fracture was calculated by integrating numerically the polynomial relationship between the compressive stress and sample strains. Strain rate was calculated for each specimen and the deformation zone length was mathematically derived from the die geometry to decipher its influence on both lateral and axial deformations. Results showed that extruding with a 15° die was the fastest as a result of the low flow stress encountered. Outstanding compressive strength, plastic deformation, strain rate and energy absorbing capacity were observed for the alloy extruded with a 75° die angle. Increase in die angles led to a decrease in deformation zone length and samples deformed more in the axial direction than in the lateral except for the 45o die which showed the opposite; the sample also showed the least ductility.