Work

Hot Deformation Behavior of 7075 Aluminum Alloy and Its Implementation in Enhanced Extrusion Simulation Accuracy

Year: 2026

Type: article

Abstract: Accurate material modeling is critical for reliable finite element simulation of aluminum extrusion processes. This work presents the development and industrial validation of a strain-compensated Arrhenius constitutive model for AA7075 aluminum alloy applied to porthole die extrusion. Isothermal compression experiments were performed using a Gleeble 3500 system at 450–500°C and 0.1–1.0 s−1. Material constants were determined as sixth-order polynomial functions of strain, yielding a model with R = 0.997 and AARE = 1.50%. The constitutive relations were incorporated into the QForm software to simulate the extrusion of a complex curtain wall profile through a six-porthole die. Factory trials on a 2100-ton press confirmed the model’s reliability, with predicted forces deviating by only 1.11% from measured values, compared to 19.16% using default database parameters. TS-GHX1 tool steel with gas nitriding treatment was employed to address die failure issues associated with conventional H13 steel, demonstrating 6–8% reduction in peak die stresses and successful extrusion of the target profile.

Source: MATERIALS TRANSACTIONS

DOI: 10.2320/matertrans.mt-ma2026007

Authors: Thanh-Cong Nguyen, Tat-Tai Truong, Yu-Xuan Lin, Quang-Cherng Hsu

Institutions: National Kaohsiung University of Science and Technology, Hanoi University of Industry, Hung Yen University of Technology and Education

Language: English

Topic: Metallurgy and Material Forming

Subfield: Mechanics of Materials

Field: Engineering

Domain: Physical Sciences

Open Access status: hybrid

Funders: Ministry of Science and Technology, Taiwan, National Science and Technology Council

Award: G4480389567