From billet to extruded band: Engineering texture and properties in AA6082 through die design and billet condition

This study investigates the influence of billet condition and die design on the microstructure, texture evolution, and mechanical properties of extruded AA6082 flat bands. Using cast and pre-extruded billets, profiles were produced with a conventional flat die and a modified die featuring a different press channel geometry, thereby altering local deformation conditions. Electron backscatter diffraction (EBSD) analyses were performed on both final profiles and billet remainders to trace texture development along the extrusion path. Pre-extruded billets showed enhanced recrystallization and finer, more homogeneous grain structures, while cast billets retained deformation textures and required higher strain accumulation to activate recrystallization nucleation mechanisms. The modified die promoted Goss texture formation and reduced peripheral coarse grain zones, resulting in improved ductility and reduced anisotropy. Finite element simulations confirmed smoother strain introduction in the modified die route, facilitating dynamic recrystallization. Mechanical testing revealed that the combination of pre-extruded billets and modified die yielded the most favorable properties, including high tensile strength and uniform elongation. These findings highlight the critical role of initial microstructure and strain path engineering in tailoring texture and mechanical performance in aluminum extrusion, offering practical guidance for optimizing lightweight structural components.