Application of Response Surface Methodology in optimizing the process parameters of Twist Extrusion process for AA6061-T6 aluminum alloy

The effect of process parameters such as forming load, temperature and the number of passes on AA6061-T6 alloy subjected to severe plastic deformation by twist extrusion process has been assessed. Full factorial design was used to plan the experiments. Analysis of variance was applied to investigate the influence of process parameters and their interactions. An empirical relationship has been formulated using response surface methodology to optimize the forming characteristics. The empirical relationship indicates that the number of passes was found to be the most significant factor affecting the output parameters such as tensile strength and hardness. The experimental outcomes such as tensile strength and micro hardness indicated that there is a considerable increase in the tensile strength and hardness.