The Effect of Bridge Geometry on Microstructure and Texture Evolution During Porthole Die Extrusion of an Al–Mg–Si–Mn–Cr Alloy

Porthole die extrusion is used to produce complex hollow aluminum cross-sections for automotive applications. In a porthole die, the material is first divided into multiple streams which are separated by a bridge, before rejoining in the weld chamber and finally passing through the die orifice. The rejoining of the material in the weld chamber produces lines known as weld lines in the final extruded product. The microstructure along the weld line and its associated quality are strongly influenced by the thermal-mechanical history the material experiences as it passes through the portholes, the weld chamber, and the die orifice, which can be altered by die design and, in particular, the bridge geometry. To study the influence of bridge geometry on weld line microstructure and final quality, a series of porthole die extrusion experiments was conducted using an Al–Mg–Si–Mn–Cr alloy and two different types of bridge geometry (streamlined and flat). The experimental results showed that bridge geometry had a significant effect on the local microstructure and crystallographic texture at the weld line. Specifically, EBSD analysis indicated that the weld line texture associated with a streamlined bridge geometry consisted of a deformation texture (mainly the copper component), while the local texture produced by a flat bridge was a recrystallization texture consisting of Cube, Goss, and Cube_RD texture components. Simulation of the extrusion process, using DEFORM 3D, indicated that the weld line produced using a flat bridge experienced a slightly higher temperature, but much higher equivalent strains than the streamlined case. Material away from the weld line was very similar for both cases, indicating that the effect of the die bridge geometry is localized to the region close to the weld line.