Prediction of recrystallization behavior during aluminum extrusion using physics-based modeling

作者：Oliver Schulz, Lukas Kertsch, Johannes Gebhard, Yannis P. Korkolis, A. Erman Tekkaya, Maksim Zapara · 发表于：Materials & Design · 年份：2025 · DOI：10.1016/j.matdes.2025.114530 · 被引用次数：3 · 研究领域：Metallurgy and Material Forming、Microstructure and mechanical properties、Aluminum Alloy Microstructure Properties

• Application of mean field model for prediction of recrystallization and grain size. • Mean field model was calibrated by hot upsetting and miniature hot extrusion tests. • Validation by industrial scaled hot extrusion setup. • Occurrence of recrystallization predicted satisfactorily. • Recrystallized grain size predicted qualitatively. The mechanical properties of extruded aluminum profiles depend on the microstructure after extrusion. Prediction of the microstructure is therefore necessary, especially for the design of crash-relevant lightweight components. In this paper, the physics-based mean-field model developed by Fraunhofer IWM is originally introduced to aluminum extrusion to predict the recrystallization behavior during the hot extrusion of the aluminum alloys AA6060 and AA6082. A workflow consisting of material characterization, metallography, process simulation, and microstructural prediction for hot extrusion is established. The robustness and predictive capabilities of the calibrated model are validated on a double-chamber hollow profile extruded under standard industrial conditions. The mean-field model effectively predicts recrystallization based on plastic strain, strain-rate, and temperature evolution. The recrystallized areas of the hot extruded profiles could be predicted accurately. The grain size prediction of the directly quenched outer surfaces of the profile is relatively accurate (7 %), the maximum deviation of prediction and experimental observatio...