The study presents the results of research on the influence of different contents of main alloying additions, such as Mg (2 ÷ 2.5 wt.%), Cu (1.2 ÷ 1.9 wt.%), and Zn (5.5 ÷ 8 wt.%), on the strength properties and plasticity of selected Al–Zn–Mg–Cu alloys extruded on a bridge die. The test material variants were based on the EN AW-7075 alloy. The research specimens, in the form of 100 mm extrusion billets obtained with the DC casting method, were homogenized and extrusion welded during direct extrusion on a 5 MN horizontal press. A 60 × 6 mm die cross-section was used, with one bridge arranged in a way to extrude a flat bar with a weld along its entire length. The obtained materials in the F and T6 tempers were characterized in terms of their strength properties, hardness, and microstructure, using EBSD and SEM. The extrusion welding process did not significantly affect the properties of the tested materials; the measured differences in the yield strength and tensile strength between the materials, with and without the welding seam, were up to ±5%, regardless of chemical composition. A decrease in plasticity was observed with an increase in the content of the alloying elements. The highest strength properties in the T6 temper were achieved for the alloy with the highest content of alloying elements (10.47 wt.%), both welded and solid. Significant differences in the microstructure between the welded and solid material in the T6 temper were observed.

The object of this study was to develop parameter of the die forging process, such as feedstock temperature and to investigate her impact on the structure and mechanical properties of magnesium alloys in different heat treatment conditions. Tests were carried out on a 2,5MN maximum capacity vertical hydraulic press using forgings of sample (model) shapes. Then, based on the results obtained in previous work, research was carried out to develop for items forged from magnesium alloys the parameters of heat treatment to the T5 and T6 condition in the context of achieving possibly homogeneous and fine-grained structure and, consequently, high mechanical properties.

This study presents the results of research on the influence of different contents of copper in aluminium alloys based on the 6xxx series on mechanical and structural properties. The investigation started with the alloying, and casting four billet variants with different copper content—0.8% Cu; 2B—1% Cu; 3A—1.2% Cu; and 3B—1.4% Cu. The prepared materials were homogenised and extruded on a 500T horizontal press with two different process temperatures and ram speeds ranging from 1 mm/s to 9 mm/s. After heat treating to the T6 and T5 tempers, their mechanical properties were tested. On this basis, the two most promising alloys 2A and 3B were selected and subjected to further tests. After extrusion and heat treatment of the profiles (to F, T1, T2, T5, and T5510), their mechanical properties were determined to select the preferred process parameters. Finally, a structural test based on crystallographic orientation based on the EBSD technique and TEM observations allowed for the characterisation of grain size, dispersoids, and phase analysis. Bright-field (BF) analysis allowed us to compare the deformed areas for T1, T5, and T5510 temperatures. The results showed significant growth in the mechanical properties of all the subjected alloys, and the best properties were shown for a Cu content of 1.4% with a tensile strength of 460 MPa and an elongation of 16% (T5510 tempering). The structural test showed an average grain size of 18 µm to 23 µm and solid solution decomposition differences for different heat-treating parameters.

FEM numerical analyses can be indicated as a common and basic tool used in the design of processes based on the plastic forming of metals. In such simulations, the accuracy of the results strongly depends on the quality of the material constitutive data used as the input. Good understanding of metals and their alloys’ deformation behavior, especially at hot working temperatures, is the key to developing or optimizing proper and economical processes. To provide reliable FEM simulation results, it is crucial to select an appropriate experimental method describing material behavior at elevated deformation temperatures. The most commonly method used for this is hot torsion tests, which can effectively provide a basis for developing constitutive models (for example, the Hensel–Spittel equation), but also produce the material constants needed to fully describe the behavior of the metal. This paper analyzes three experimental methods, compression testing, torsion testing, and spherical probe pressing, for determining material flow stress characteristics required for FEM simulations. The study focuses on the EN AW-7075 alloy, a high-strength aluminum alloy with limited hot workability. The methods were validated by comparing FEM predictions of extrusion force and profile temperature with results from industrial extrusion trials conducted on a 5 MN horizontal press.

This paper outlines preliminary findings from studies on the possibility of using hot torsion testing for the physical modeling of microstructural evolution during aluminum alloy extrusion processes. Accordingly, two plastic deformation processes were investigated: high-temperature torsion and extrusion. The studies were conducted within the temperature range characteristic of the extrusion of 16 mm diameter round profiles made of EN AW-6060 aluminum alloy, with different cooling rates after deformation. Physical modeling of both processes was preceded by numerical modeling with the finite element method (FEM) and a detailed analysis of the deformation conditions occurring during both processes. Thanks to the careful selection of thermoplastic forming parameters, comparable values of the strain, strain rate, and temperature of profiles suitable for direct microstructural comparison were obtained. The conducted studies made it possible to determine the influence of the applied thermoplastic forming parameters on the microstructural evolution of the tested material. Finite element method simulations revealed distinct strain gradients in both the hot torsion and extrusion processes. Metallographic analysis of the EN AW-6060 alloy showed a strong dependence of grain size and the degree of recrystallization on the thermoplastic processing temperature and the local strain level. The obtained results confirm that hot torsion testing, combined with the selection of representative regions based on FEM analysis, can serve as a supporting method for modeling microstructural evolution in industrial extrusion processes, provided that the thermomechanical conditions correspond to those occurring in the modeled process.