Microstructure evolution and mechanical properties of AZ80 Mg alloy during annular channel angular extrusion (350 °C) and heat treatment with varying parameters were investigated, respectively. The results showed that dynamic recrystallization of Mg grains was developed and the dendritic eutectic β-Mg₁₇Al₁₂ phases formed during the solidification were broken into small β-phase particles after hot extrusion. Moreover, a weak texture with two dominant peaks formed owing to the significant grain refinement and the enhanced activation of pyramidal slip at relative high temperature. The tension tests showed that both the yield strength and ultimate tensile strength of the extruded alloy were dramatically improved owing to the joint strengthening effect of fine grain and β-phase particles as compared with the homogenized sample. The solution treatment achieved the good plasticity of the alloy resulting from the dissolution of β-phases and the development of more equiaxed grains, while the direct-aging process led to poor alloy elongation as a result of residual eutectic β-phases. After solution and aging treatment, simultaneous bonding strength and plasticity of the alloy were achieved, as a consequence of dissolution of coarse eutectic β-phases and heterogeneous precipitation of a large quantity of newly formed β-phases with both the morphologies of continuous and discontinuous precipitates.

Annular channel angular extrusion has been recently developed as a new single-pass severe plastic deformation method suitable for producing large size cup-shaped parts from cylindrical billets. In this study, the novel technology was successfully applied to commercial AZ80 Mg alloy at 300 °C, and microstructure, texture evolution, and mechanical properties were investigated. Due to severe shear deformation, the initial microstructure, including the coarse grains and large eutectic β-phases, was greatly refined. The strong basal texture formed during the initial deformation stage was modified into a weak tilted dynamic texture. During the deformation process, fine β-particles separated from eutectic phases effectively hindered the grain boundary migration and rotation, enhancing the grain refinement and texture weakening. More than 63% of the microhardness increase was achieved in this extruded part. Also, tensile tests showed the yield strength and elongation in both directions (transverse and longitudinal) of extruded part were improved more than 2.5 times, and the ultimate tensile strength was improved more than 2 times, compared to the initial material state. The improved material properties were mainly attributed to microstructure (grain and phase) refinement and texture weakening. It was demonstrated that the annular channel angular extrusion process can be considered as a novel and effective single-pass severe plastic deformation method.