Study on the metal flow and mechanical properties of extruded bent aluminum profile using a novel torsional channel self-bending process.

Lightweight bent aluminum profiles are widely utilized in transportation fields. In this paper, the torsional channel self-bending extrusion process (TCSE) was adopted to machine AA6063 bent aluminum profiles in a single operation to verify the process's feasibility. Effects of extrusion parameters on the curvature, microstructure, and mechanical properties of the profiles were researched, and the extrusion process was simulated. The results show that the extruded profiles had good curvature stability. The grains were equiaxed in the cross longitudinal section, and the grain size at the outside diameter (OD) position was smaller than the inside diameter (ID) position. When the difference in deformation temperature at the OD edge was above 31 K, a smaller peripheral coarse grain (PCG) layer was formed at the OD edge with a thickness of about 400 μm, resulting in reduced hardness. The Mg2Si particles served as the main strengthening phase, which increased in number and decreased in size with increasing billet temperature and extrusion speed. Increasing the billet temperature and speed improved the mechanical properties of the material, with an increase in average hardness of 55.9% and 19.5%, and ultimate tensile strength (UTS) of 12.5% and 7.1%, respectively. By comprehensively considering the factors of extrusion load, microstructure, and mechanical properties, the optimum bent profile for different curvatures was determined. When a large curvature (≥328.67 mm) was required, it was preferred to increase the billet temperature. When a smaller curvature (≤328.67 mm) was required, it was advisable to increase extrusion speed. [ABSTRACT FROM AUTHOR]