Microstructural evolution of indirectly extruded seamless 6xxx aluminum tubes with axial variable wall thickness

For this study, seamless square tubes of aluminum alloys EN AW-6060 and EN AW-6082 were extruded with axial variable wall thickness by applying an axial moveable stepped mandrel. The microstructures in thick-walled and thin-walled sections of these tubes were investigated and correlated to the extrusion conditions. The results for EN AW-6060 revealed fibrous grains at low ram velocity (vram = 0.8 mm/s) and thus low strain rate. In these cases, peripheral coarse grains were also observed on the tube surfaces. Applying a higher vram = 3.3 mm/s lead to a fully recrystallized microstructure. For EN AW-6082 the fibrous microstructure was predominant. This was attributed to the Mn-content of this alloy, which acts as an inhibitor for recrystallization. Only at the highest values of strain, strain rate and temperature a recrystallized microstructure was observed for this alloy. EBSD analyzes of boundary misorientation angles indicate that geometric dynamic recrystallization seems to be the predominant mechanism at low strain rates. The facts that the amount of low angle boundaries significantly decreased as subgrains were removed and the amount of high angle grain boundaries is increased revealed that recrystallization occurred at higher strain rates and strains. Furthermore, the transition areas, where the wall thickness was gradually reduced were investigated. Due to increasing strain and thus increasing strain rate, thin-walled tube segments show lower grain size than thick-walled sections. It was also revealed that the PCG layer thickness remained about constant with increased strain, but since the tube wall thickness was reduced, the recrystallized fraction increased for higher strains.