Finite element modeling of Conform-HPTE process for a continuous severe plastic deformation path

Abstract A novel continuous severe plastic deformation (SPD) approach was proposed by combining continuous extrusion forming (Conform) with high pressure torsion extrusion (HPTE), which is called Conform-HPTE process. Finite element method (FEM) simulations were employed to investigate the severe plastic deformation behavior of aluminum alloys under various processing conditions. The results showed that the novel Conform-HPTE process effectively accumulated large plastic strain after a single deformation pass. During the Conform-HPTE process, the Conform machine not only provided driving power for the whole equipment, but also introduced shear deformation and heating in the specimen for subsequent HPTE process. The subsequent HPTE process further introduced severe plastic deformation in the specimen. And the severe gradient shear deformation condition could lead to the formation of refined and gradient microstructure. Therefore, the novel Conform-HPTE process could be a promising industrial SPD technique to continuously produce advanced engineering materials with the advantages of energy and cost saving and high process efficiency.