Equal channel angular pressing (ECAP) and multi-axial compression deformation (MAC) are severe plastic deformation (SPD) processes that produce bulk nanostructured materials with ultrafine grains. The grains could be observably refined by multi-pass of ECAP and MAC. This research proposed new routes of cyclic equal channel compression (CECC), which combines ECAP and MAC to increase the mechanical properties of 6061 aluminum alloy. The tests, which are conducted through electron backscattered diffraction (EBSD) and transmission electron microscope (TEM), were performed on the grain size, recrystallization distribution, misorientation distributions, dislocations, and secondary phase distributions of CECC-processed 6061 aluminum alloys on the purpose of exploring the mechanism of grain refinement. MEM is the short form for the CECC processing route of MAC + ECAP + MAC, which is one ECAP pass between two MAC passes. The tests results showed that the average grain size could reach to as much as 1.1 μm after two MEM deformation circles named MEM-MEM, with the non-annealing average grain size being 21 μm and recrystallization annealed average grain size being 28 μm. The dislocation cells, which could be transformed into sub-grains with the increase of the strain, were formed by the slip and the accumulation of dislocations. The secondary phase was Mg₂Si, which could prevent the refined grains from growing up again by pinning at the grain boundaries. Above all, the dislocation proliferation and secondary phases will both lead to the grain refinement.

This paper reviewed the research progress of studies on the crystal rotation of single crystals that were deformed by tension and shear and the influences of crystal rotation and dislocation evolution on strain hardening behavior in crystals that were deformed with different initial orientations. The crystal rotation is entirely different depending on whether the single crystal was deformed by tension or shear. A three-stage work hardening behavior, which is not one of the intrinsic properties of materials, is generated when FCC metallic single crystals are deformed by tension along unstable oriFigurFigurentations, but single crystals do not exhibit this three-stage hardening behavior when they are deformed by simple shear at room temperature. Under tension, crystal rotation causes the transition from work hardening stage I to stage II, while the transition from work hardening stage II to III is caused by dislocation evolution. The evolution of the dislocation structure is related to deformation loading and can be classified into three types when a crystal is deformed by tension. Different from tension, shear stress can directly act on one of the 12 slip systems when a crystal is deformed by simple shear. When FCC single crystals are deformed by shear along the (1$\overline{1}$1)[110], (111)[11$\overline{2}]$ and (001)[110] orientations, the single slip system, co-planar slip systems and co-directional slip systems are activated, respectively, and the crystals hardly rotate under the shear conditions. The slip direction of [110] forces the crystal to rotate toward the shear direction under simple shear. The dislocation tangles tend to form the dislocation cells and wall structures when multiple slip systems are activated under simple shear.