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Journal of Materials Processing Technology 60 (1996) 117-124

Materials Processing Technology

Material physical response in the extrusion process

W.Z. Misiolek Aluminum Processing Program at Rensselaer Polytechnic Institute Troy, NY 12180-3590, USA

Abstract
The mechanical properties and surface quality of the extruded profiles depend on the final microstructure which has been developed during the extrusion process. The final microstructure is a result of a billet microstructure, material deformation history and post-processing treatment. In order to understand the role of the metal flow in the deformation history both physical and numerical process modeling techniques have been applied. Physical modeling of the extrusion process using modeling materials allows quick and inexpensive evaluation of the flow conditions through different die configurations. Additional information can be obtained from the crystallographic characterization of the typical deformation zone regions such as dead metal zone, main deformation zone and recrystallized zone on the billet-container interface. The electron backscattering diffraction (EBSD) technique has been utilized to follow in detail the orientation aspects of the deformed grains in extruded aluminum. This analysis provides information which can be utilized in the die and process design to improve metal flow uniformity and therefore the microstructure of the final product. It also allows prevention of the typical extrusion defects like surface tearing.

Keywords: extrusion, metal flow, microstructure, aluminum alloys, dead metal zone
1. Introduction
The demands for improved quality of extruded products measured by their surface quality and mechanical properties require better understanding of material response to the process parameters. There are numerous studies reported in literature on this subject, however, in most cases direct, extrusion of a single profile with axisymmetric geometry have been studied. This limitation was mainly chosen due to the complexity of the metal flow. New analytical techniques such as electron backscattering diffraction (EBSD) allow better examination of deformed microstructure and its crystallographic characteristics. The metal flow is dependent on several process variable, such as: i) friction conditions, ii), die geometry, iii) material's flow stress, iv) deformation (extrusion ratio), and v) strain rate (ram speed). The microstructure of the extruded material varies across the extrusion cross section as well along its length. The main variables responsible for these microstructure gradients are the temperature-speed process parameters and extrusion ratio. The level of the microstructural gradient is a result of the certain metal flow mode which in turn is responsible for the velocity gradient for the metal "particulates" moving toward the die orifice from the various billet locations. This metal flow imperfection manifests itself as a surface tearing and significantly reduces extrusion exit speed.
0924-0136/96/$15.00 1996 Elsevier Science S.A. All rights reserved PII0924-0136 (96) 02316-3

The main factor influencing metal flow is friction on the billet and container interface which causes temperature change. Metal flow also influences the most important process variables, i.e,, extrusion pressure and maximum extrusion exit speed. Understanding and control of metal flow are very important in the engineering practice. This is especially important in the case of direct extrusion which is the most popular extrusion technology. Based on theoretical analysis, the most favorable metal flow can be described by the case when the velocity of the metal is uniform across the die orifice. Among available methods for controlling metal flow in the deformation zone the most practical ones are based on: a) die geometry and b) the thermo-mechanical history of the metal. The deformation zone(s) develop in the billet portion in the front of the die during direct extrusion. Typically, "dead" metal zones and intensive shear zones are obvious distinctions in the deformation zone.

2. Physical modeling technique

The physical modeling technique has been applied successfully to metal flow analysis in the rolling, forging and extrusion processes. The selection of the plasticine for the modeling experiments and detailed description of the press is given by Prats and Misiolek [1]. In order to observe the deformation zone evolution billets are cut longitudinally and then one half is marked with a grid pattern. The two billets halves are then reassembled and

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extruded simultaneously. The evolution of the material flow is evident in the deformation of the grid pattern lines. The change of deformation zone geometry can be monitored in more than one plane depending on the shape of the extruded profile. The grid is photographed and then scanned into the computer to store and analyze the image. The experiments are designed and performed on a modeling press using plasticine. The use of a modeling material like plasticine allows for the evaluation of many designs in a relatively short time, since the tooling can be made of an easily machinable material Such as polycarbonate plastic. The particular type of plasticine was chosen primarily due to the similarity of its flow at room temperature to that of metals at extrusion temperatures. Much research has been done regarding its use, with very many encouraging results [1]. Soft metals such as lead offer good insight to the flow, but still require a significant load, and can pose health hazards. Waxes can be extruded at pressures as low as plasticine and at room temperature, but their properties are affected more by slight variations in temperature due to changes in ambient temperature or friction. To achieve a flow pattern comparable to the studied material, the plasticine billet surface needs to be treated to change its int,=,raction with the container. A modeling press was designed for these experiments with the idea of making it as flexible as possible to allow for many different conceivable experiments to be performed. The base platform is a control unit and an hydraulic actuator with a 380 MPa capacity. With this hydraulic system, a modular design for the container and supports was chosen so that the press has capabilities for both direct and indirect extrusion studies. The billet has a diameter of 9.5 cm, and is typically 12.7 cm long. The press is instrumented to record the pressure during extrusion, and a Linear Variable Differential Transducer (LVDT) is used to constantly measure ram position. The flow patterns are examined by using the A-parameter. The A-parameter characterizes the deformation zone geometry and is defined as the ratio of the diameter of the work metal to the length of the shear contact along the dead zone. In the case of axisymmetric extrusion it is established by the following equation:

L
Figure 1. Geometry for the A-rameter. h=(2) x (radius) a) Primary, b) Secondary consideration all differences between the modeling and industrial process and to include them in the scale-up procedure. Local deformation data based on the grid distortion can be used for simulation of microstructure response. Thermo-mechanical deformation simulation of the billet material under process conditions (strain, strain rate, temperature) can provide important information on microstructure evolution.

3. Dead metal zone formation and its evolution

Dead metal zone geometry changes during extrusion, creating different extrusion deformation conditions at the beginning and end of the process. A rectangular extruded profile has been studied to allow observations and analysis in the perpendicular symmetric planes [2]. Longitudinal grid technique has been used for modeling material analysis and a metallographic macrostructure characterization technique has been utilized for the analysis of dead metal zone formation and evolution in aluminum. Dead metal zone geometry as a function of extrusion shape and billet length was analyzed. Analysis of dead metal zone evolution under more complex metal flow conditions is also reported in literature [4]. Using 6105 aluminum alloy ingot, a two-hole solid profile was extruded employing typical industrial practices. The extrusion die used was a flat-face type and the metal was stripped from the die and container during the final portions of the extrusion push for examination. A limited number of papers deals with the experimental data of the dead metal zone formation and evolution. Only a few authors have made an attempt to correlate their experimental findings with proposed analytical interpretation. Other studies reported deal with the mentioned problem from the theoretical point of view. A very detailed analysis of the subject for axisymmetric conditions is presented by Mavunda and Zasadzinski [5]. Their work involves critical literature review and also reports on their own investigations focused on the formation of the dead metal zones. Studies of the influence of the coefficient of friction at the billet/container interface on the dead metal zone angle and extrusion maximum pressure are reported.

A - sin------~a(1 1~-+-7)2 +
r

(1)

where r=(hi-he)/hi and c~ is the angle of the dead zone. Each flow pattern for the two-step die known as '~Neld plate die" has two A-values; the primary A-value is for the flow of material into the weld pocket, and the secondary A-value is for the flow of material from the weld pocket into the die as presented in Figure 1. This technique has been successfully applied to numerous metal flow studies which results were confirmed on aluminum alloys [1, 2, 3]. It is very important to take into

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The upper bound approach was used by several authors, such as Johnson and Kudo [6], Yang [7], and Avitzur [8,9] to estimate the extrusion pressure. Avitzur assumes a certain deformation zone geometry, constant values for the coefficient of friction and flow stress during the whole process, in axisymmetric, one hole, round-to-round extrusion through converging dies. He analyzes the formation of the dead metal zone and the relationship between its angle (E) and extrusion ratio (R). According to Avitzur the dead metal zone is formed when the die angle is greater than its critical value (0%,) and remains constant during the entire extrusion process [10]. Among experimental studies on this subject the most important are those reported by Shabaik and Thomsen [11], Wantuchowski and Sloniowski [12], Mavunda and Zasadzinski [5], Valberg [13] and Misiolek and Kelly [4]. Only some of the approaches deal with the problem in the case of extrusion through flat face dies [2, 3, 4, 13] and most of the research is limited to rather uncomplicated geometries. Valberg proposed a method based on measurements of metal velocity in the deformation zone and its graphical representation, called an emptying diagram, has been applied to different types of extrusion [13]. Further discussion of the extrusion process parameters influencing the shape and size of dead metal zone is presented in [3]. There is a need for a thorough analysis of metal flow in more than one plane for rather uncomplicated, however, nonaxisymmetric shape. The dead zone formation and evolution is important for understanding of metal flow, especially for long billets. In today's industrial practice the billets used already surpass an old rule of thumb where the billet length was equal to 3.5 times its diameter. The selected shape for the extrusion studies on the 12.5 MN press was a rectangular profile with dimensions of 60 x 10 mm. The extrusion ratio for this process, with the press container diameter of 135 mm, was R=23.9. The extrusion tests were performed allowing interruption of the process at certain ram positions. The ram position was described with a precision of 1 mm and billets were partially extruded in the range of 50.8 to 279.4 mm in 38 mm increments. Samples were taken from the partially extruded billets and etched for macrostructure observation and analysis in two perpendicular planes A and B. The dead metal zone height, K, is measured as the maximum linear distance along the billet axis, while the zone depth, M, is the maximum linear measurement in the direction perpendicular to the billet axis. The evolution of the height, K, of the dead metal zone in aluminum in two perpendicular planes A and B for studied rectangular profile is presented in Figure 2. The dead zone evolution is proportional in both planes representing different sides of the extruded rectangular profile. Both height and depth are decreasing with the increased "actual" length of the extruded billet. However,

while the changes are proportional in both planes, they are different for dead metal zone height and depth. The height changes by a factor of 1.65 - 1.74 while the depth changes

s b,

IS

50

100

150

200

250

300

Actual bllk~t length L[mm] c t o a lm~ion A . . . . urns sec~n B I

Figure 2. Evolution of the height of the dead metal zone K in perpendicular planes, A and B, as a function of the actual length for aluminum billet.

Figure 3. Three dimensional drawing of metal flow and dead metal zones in the back end of the billet with metal zone sphere based an the interface between billet and dummy block.

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by a factor of 1.40 - 1.50 in both planes. These observations demonstrate that dead metal zone evolution for the rectangular profile in three dimensional space is proportional within typical planes. Therefore, it is necessary to know only the initial geometry of the zones, and their evolution in three dimensional space can be predicted based on the measurements in one plane only.The above findings were confirmed for the two-hole extrusion of 6105 alloy I-beam shapes [4]. A significant change in dead metal zone geometry was observed. The macrostructures of the billets were distinct enough to observe the dead metal zones, shear zones and flow lines. The typical zones were traced on paper and then measured. Such measurements were done for several sections for the front and end billet samples and saved as separate files on a computer. These files enabled creation of three-dimensional images representing deformation conditions for extrusion. Such a three-dimensional image of metal zones present at the end of the extrusion process is shown in Figure 3. Typical dead metal zones are present on the surface of the die between die openings and between the die openings and container wall. The intensive shear zone in the shape of a '~tear" appears within the regular deformation zone. This zone is localized in the neighborhood of the dead metal zone formed close to the container wall. A recrystallized peripheral zone has also been observed which confirms other reported findings related to the formation of this zone at the end of extrusion [14].

that significant strain localization takes place and, as a consequence, material looses its continuity and creates the dead zone. As mentioned before, the shape of that zone is an important factor which influences the deformation pattern and final properties of the extrudate. The evaluation of numerical modeling techniques to simulate strain localization and dead metal zone formation in extrusion is reported in literature [15]. Authors of this work used two finite-element codes for their analysis, a commercial code FORGE2 developed in CEMEF in France and thermo-mechanical program developed by Pietrzyk and Kusiak [15]. Various criteria of detection of the dead zone boundary were investigated. The models were validated by the comparison of the numerical results with the experimental data. The experiment involved the axisymmetric extrusion of the lead billets of 60 mm diameter with the extrusion ratio of 9. The ram speed was 0.6 mm/s. The locations of the grid pattern nodes were measured and the components of the strain rate tensor were calculated using the incremental method. A very good qualitative agreement between the measurements and the calculations showing the similarity of the strain rate patterns was obtained. All theoretical results presented in the previous section were obtained for the assumption that material maintains the continuity in the whole deformation zone. However, in the real extrusion process the dead zone appears in the area close to the corners of a die [1, 2,3,4]. Computations performed assuming the conventional model of material do not allow the prediction of the formation of the dead and shear zones. According to the utilized numerical models the material flows in the area where the dead zone is observed in the experiment. It can be concluded at this stage, that the criterion for strain localization has to be defined and introduced to the finite element programs. This criterion can be based on the values of strains or stresses or the combination of both. The analysis performed using the non steady and steady state models does not show any particular concentrations of stresses in the vicinity of the boundary of the dead zone. Non steady state model does not show such concentrations for strains either (See Figure 4). Steady state model calculates the strains by the integration of strain rates along the flow lines and this method leads to the prediction of the strain concentration in the discussed area. There are no clear theoretical indications regarding the strain localization criterion suitable for the extrusion. Experimental validation shows that the finite-element models perform reasonably well as far as the kinetics of the flow is considered. The calculated strain rate fields match the experimental ones. On the other hand, a more detailed analysis of the predictive capabilities of these models for extrusion shows that they do not simulate strain localization in the deformation zone. More'over, the non steady state model does not give an indication regarding the possible localization of the shear zones. Neither

4. Numerical modeling
Finite element method has become a powerful tool in the modeling of metal forming processes. Coupled thermalmechanical models used for the prediction of metal flow and heat transfer during deformation, are becoming a helpful aid in the process design. Numerical simulation allows the elimination to certain extent of costly and time consuming experiments. It should be emphasized, however, that the accuracy of the simulation is crucial for the usefulness of the models. This accuracy depends mainly on the quality of the description of boundary conditions and material properties data. This is particularly important in the extrusion process which often involves strain instability. Thus, the simulation of plastic deformation of metals during hot extrusion presents significant difficulties, which are mainly due to the existence of the dead zone in the material. The shape of that zone is not known a priori and there are no reliable methods of prediction of that shape. Therefore, numerous publications dealing with the problem of the finite-element simulation of the extrusion process are limited to the dies with the angles below 45 , when the dead zone is not created. There are some finite-element solutions for the flat dies published in the scientific literature, but they give the continuous strain and velocity fields [15]. In all these cases only an axisymmetric process is investigated. However, it is observed during the extrusion process [2,3],

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stresses nor strains calculated by this method show concentrations in the area where discontinuity of
b'b<0.280 I I 0.280<Eb<0.560 0.560<Eb<0.841 0.841<Eb<1.121 1.121<Eb<l.401 1.401<Eb<1.681 1.681<Eb<1.961 I 1 1,961<Eb<2.24! 2.241<F-.b

in the direct extrusion process can result in a drastic change of metal flow character in the main deformation zone which can produce a metal flow mode comparable to that found in indirect extrusion. The main idea behind the convex die is to extend the semiangle of the die beyond the traditional 90 value typical for a flat face geometry. Based on the flow pattern analysis it is quite obvious that in the case of the convex die there is a very substantial metal flow in the radial direction within the main deformation zone. This kind of metal flow is characterized by the more uniform velocity profile for the material passing through the die orifice. Extrusion through the converging die shows that it is possible for the extruded material to achieve a uniform velocity profile within the die opening if the die angle is small. This case is possible only when the friction between the deformed metal and the tool is very low and when the redundant work, defined by the deformation zone geometry, is minimal. However, a typical large deformation zone which extends into the billet is observed. From a practical point of view the use of the converging dies with small angles is very undesirable and typically these dies are limited to hydrostatic extrusion only. A substantial dead metal zone is present in extrusion through the traditional flat face die and in the extreme situation the velocity of the metal flowing toward the die orifice is quite uneven. The discussed deformation zone can, under certain conditions, extend almost into the whole volume of the billet. Based on the presented discussion, it seems that the use of the convex dies allows an advantageous change in the metal flow mode within the deformation zone resulting in the imposing metal flow in the radial direction toward the die opening. This flow pattern allows higher extrusion exit speed, influences the extrusion pressure, and results in a fine final microstructure because of the change in the deformation route for the extruded metal. The metal flow studies were performed using modeling materials, such as lead and plasticine, as well as technically pure aluminum, 1050 and 2017 alloy. The modeling material was extruded through a set of dies with die angles equal 90, 100, 110, 120 and 130 for two extrusion ratios, R = 26 and R = 56. Aluminum alloys were extruded through dies with 45, 90, 105, 120 and 135 using extrusion ratio R = 5.76 and R = 36. The metal flow patterns for 1050 alloy extruded at 450 C through the dies with following semi-angles: 60, 90 and 1050 are presented in Figure 5. A very distinct differences in final microstructure are observed for studied die geometries. It is evident that material extruded through the convex die has the most uniform, fine microstructure. According to the theoretical analysis discussed before the convex die should allow higher extrusion exit speed due to more uniform velocity of the metal in the die orifice.

Figure 4. Effective strain field calculated by FORGE2.

deformation is observed in the experiments. Steady state model, which calculates the strains by an integration of strain rates along the flow lines, gives concentrations of ;he strain rates in the discussed zone. Additionally, the location and the shape of the predicted maximum strain zone are sensitive to the process conditions in the same way as the shear zone is in the experiments. Thus, a conclusion is made that the shear band formation can be based on the drawing of the equivalent strain map using the steady-state finite-element model. The problem of the description of the material's behavior in the shear zone remains still open. An attempt of the solution for the rigid plastic material which softens in the area of maximum strains shows that the localization leads to a slight decrease of the dead zone. This, however, is only qualitative observation which does not give an indication regarding quantitative description of the phenomenon. There is not enough experimental data in the literature regarding development of the deformation zone in extrusion which would allow successful numerical simulation.

5. Metal flow control

5.1. Die design

Since the deformation zone geometry, constrained by dead metal zones, has such significant influence on the metal flow and therefore on final microstructure many investigations have been focused on the studies of the new generation dies and the possibility of more efficient metal flow control. Among the new types of dies is the multi-step die [16] which is an evolution from the two-step weld plate die [1]. Completely new prospects are associated with the convex dies proposed by Libura [3]. The use of these dies

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The validation experiments were run on 25 MN industrial press with 225 mm container diameter. The 300 nTn long billets of alloy 2017 were extruded, with extrusion ratio, R=10.3) through the flat face die and convex die with 105 semi-angle into 70 mm round bars. The billets were heated

5.2. Temperature-speed process optimization

The extrusion process optimization can be achieved through temperature-speed analysis. Isothermal extrusion is a general objective in terms of process productivity and quality of extruded product [3]. This can be achieved through application of various methods which represent two major approaches: a)temperature tapered billet, and b) speed control during extrusion. A constant temperature of the extruded material is extremely important, however, in order to achieve the most uniform microstructure along the extrudate length a constant geometry of the deformation zone is also needed.

a.

6. Microstructure characterization

b.

It is extremely important to understand changes in the microstructure of the billet material exposed to the extrusion deformation. Development of the new analytic techniques such as Electron Backscattern Diffraction (EBSD) allows crystallographic analysis of very fine regions. Macrostructural observation, after etching, delineates various regions in the deformation zone, identifying the position and geometry of "dead" metal zones, intensive shear zones and other areas [4]. The crystallographic orientation of deformed grains, including coarse grains and recrystallized grains, offer an opportunity to gain further insight to flow patterns and shear forces occurring within the die. Characterization of metal flow in extrusion using the (EBSD) technique was performed, resulting in an analysis of the deformation zone's microtexture [17]. Backscattered electrons, utilized for EBSD analysis, are incident beam electrons with energies close to the e-beam accelerating voltage (in the keV range) that enter and are scattered by the specimen. The scattered electrons diffract in crystalline specimens, producing a pattern of intersecting bands, analogous to Kikuchi patterns observed in transmission electron microscopy. The angular relationship of the planes in the crystal are maintained in the bands of the pattern. The analysis of the pattern, therefore, can determine the crystallographic orientation of the individual grains and, in turn, their relationship to neighboring grains. With spatial and angular resolutions of approximately 0.5 um and 0.5 degrees, respectively, the EBSD technique is applicable to fine microstructures with subtle misorientations. A homogenized billet of the alloy 6105 was extruded as presented in Figure 3. Three significantly different regions of the deformation zone were analyzed: Region 1 containing: shear zone at the container wall and main deformation area, Region 2 containing: intensive shear zone and main deformation area, and Region 3 containing: dead metal zone.

C.

Fig. 5. Macrostructure of the 1050 aluminum extruded at 450C through different dies: a) 60 , b) 90 , c) 105

to extrusion temperature of 390 C while container temperature was 350 C. The maximum extrusion speed achieved for convex die under these process conditions was upto 100% higher than for flat face die (3.8 rn/min and 1.9 m/min respectively).

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Table I Summary of the Crystallographic Orientation for the Studied Regions Region 1 1 2 2 Grain Coarse Fine Coarse Fine Crystolla~lraphic Rotation Axis Rotation Type Free Discrete Discrete Discrete Axis Relation to Flow Direction Perpendicular Perpendicular Parallel Perpendicular

I10o}
{111} {111} {111}

The pole figures for the coarse and fine grains for three typical regions were developed and analyzed. The {100} Pole Figure shows grain rotation around a <100> axis which is perpendicular to the flow direction. At that point the angle between flow direction and "extrusion direction" along the press center line, which is marked on each figure, is approximately 20 . The {111} pole figure confirms the rotation phenomena around 1O0 pole, while {110} pole figure does not indicate any specific trend. The {100} and {111} pole figures for the small grains within the same vicinity (Region 1) display a texture with strong pole intensities. This finding corresponds with {111} texture reported for the deformed aluminum [5]. The {110} pole figure shows high 110 pole density which corresponds with the flow direction in this part of the billet. A sample taken from the intensive shear zone (Region 2) consists of both coarse and fine grains. The coarse grains from this region possess, like in Region 1, an axial texture also known as wire texture. However, in this case a rotation axis is <111> instead of <100>. Furthermore, unlike <100> rotation observed in pole figures for coarse grains in Region 1, the coarse grains in Region 2 do not demonstrate rotational freedom. Most noticeable in the {111} pole figure, there are two discrete subgroups of grains that are related by a rotation of about 20 around the (100) pole in the upper left quadrate of the figure. Also note that the rotation axes for coarse grains from Region 1 and 2 differ in their relationship to the flow direction. In Region 2 the rotation axis lies, not perpendicular, but parallel to the flow direction. Fine grains show the same crystallographic characteristics as in Region 1, however, they have been rotated due to the change in the flow direction. Note that in both Region 1 and 2, the fine grain rotation axis, <111>, is perpendicular to the corresponding coarse grain rotation axes and flow directions. Dead metal zone does not have a strong deformation texture. A symmetry of the {111} pole figure indicates some symmetry and evidence of texture. However, based on the measurements for the crystallographic projection it is very difficult to define the weak orientation trend. The crystallographic characteristics of all three analyzed regions are summarized in Table I. The analyzed regions (Regions 1-3) observed at the end of the extrusion push, are the most pronounced over the entire extrusion cycle. The coarse grains, which are present in Regions 1 and 2, experience a transition in their

rotation along the billet/container wall interface to the more complex rotation in the deformation zone. The physical constraints of the deformation zone appear to mandate the restriction on the grains following the general metal the die opening and crystallographic orientation rotation. These grains are flow changing direction toward additionally modifying their (i.e. rotation).

The textured grains are present in the intensive shear zone in the form of an "island" of clustered coarse grains surrounded by the fine grains which do not show such strong crystallographic orientation. It is important to notice that the fine grains rotate around the axis perpendicular to the coarse grain rotation axis. This demonstrates that coarse and fine grains behave quite differently even in close geometrical location. This phenomenon can be explained by the fact that they are exposed to quite different local deformation conditions described by local temperature and strain rate. Additionally, the fact that the gr.ains are of different crystallographic nature and sizes limits the possibility of the same deformation path for both grain types. In order to achieve optimum mechanical properties it is desired to avoid significant microstructure gradients in the extrudate. The formation of the coarse grain zone on the outside periphery of the extrudate, as shown in Figure 3, is usually not desired because of aesthetic or structure reasons. The recommended control and stabilization of the deformation zone geometry is possible when a more uniform deformation path is achieved for the entire extrusion push from the beginning to the end of the billet. As long coarse grains that formed in the shear zone do not reach the die orifice, a more uniform product microstructure is possible. There is some limitation to the successful restriction of the coarse grain formation in the billet end which strongly depends on the die geometry and length of the billet. The dead metal zone does not have a strong deformation texture and its surface appears to be "washed-up" by the flowing metal along its outside surface during the extrusion cycle which results in its size reduction [2,4]. 7. Summary Laboratory as well as industrial tests confirmed the influence of deformation zone geometry on metal flow which can be controlled through the extrusion process

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parameters resulting in: i) more uniform and finer microstructure on the extrusion cross section, and ii) significant increase in extrusion exit speed. Meaningful evolution of dead metal zones needs to be incorporated into the process and tool design procedures in order to improve product microstructure. The presented physical modeling technique is a very usefull method or metal flow analysis. There is a need for further studies of phenomenological interpretation of dead metal zone formationould allow development of the advanced numerical simulation techniques. The utilization of the EBSD and pole figure technique resulted in more detailed analysis of crystallographic data for certain deformation paths in extrusion. There is a strong presence of the preferred crystallographic orientation in the deformation regions in extrusion and the pole figure technique is a very valuable tool in this type of characterization. The detailed information on localized crystallographic orientation can be obtained by the EBSD technique. Coarse and fine grains behave differently in the deformation zone. These two types of grains follow the general metal flow path, however, their rotation and resulting texture are quite different. Crystallographic characterization of the deformation zones makes it possible to select process parameters yielding specific extrusion microstructure characteristics. The use of EBSD technique and pole figure analysis provides an opportunity to further optimize the die design and extrusion process.

Acknowledgments
The presented research is a result of the multi-year studies within the Aluminum Processing Program, a consortium of industrial sponsors, at the New York State Center for Advanced Technology (CAT) in Automation, Robotics and Manufacturing at RPI. The author would like to acknowledge an extensive collaboration with researchers at the University of Mining and Metallurgy in Krakow, Poland, Institute for Non-Ferrous Metals in Skawina, Poland, and the Werner Co. in Greenville, PA, USA. The financial support of the Maria Sklodowska-Curie Foundation (grant MEN/NIST 94-201) for numerical simulation studies is gratefully acknowledged.

References
[1] Prats, A. E. and Misiolek W. Z., "Analysis of Metal Flow in Weld Pocket Dies", presented at the Sixth International Aluminum Extrusion Technology Seminar, ET'96, AA & AEC, May 14-17, 1996, Chicago, IL

[2] Kialka, J., Misiolek, W.Z., "Studies of Dead Metal Zone Formation in Aluminum Extrusion", presented at the Sixth International Aluminum Extrusion Technology Seminar, ET'96, AA & AEC, May 14-17, 1996, Chicago, IL [3] Zasadzinski, J., Libura, W., Richert, J. and Misiolek, W. Z., "Convex Dies for Aluminum Extrusion", presented at the Sixth International Aluminum Extrusion Technology Seminar, ET'96, AA & AEC, May 14-17, 1996, Chicago, IL [4] Misiolek, W. Z. and Kelly, R. M., "Metal Flow and Dead Metal Zones in Extrusion of Complex Shapes", Proceedings of the Fifth International Aluminum Extrusion Seminar ET'92, May 22-24, 1992, Chicago, IL, AA & AEC, vol. I, 315-318 [5] Mavunda, F. and Zasadzinski, J., "Dead Zones in the Process of Direct Extrusion of Metals", Archiwum Hutnictwa, vol. 28, 1983, No 3, 359-403 [6] Johnson, W. and Kudos, H. K., "The Mechanics of Metal Extrusion", 1962 [7] Yang, C.T., Journal of Engineering for Industry, Trans. ASME, Serie B, vo1.84 397 (1962) [8] Avitzur, B., Handbook of Metal Forming Processes, John Wiley & Sons, New York, 1983 [9] Avitzur, B., Journal of Engineering for Industry, Trans. ASME, Serie B, vol. 2, 57 (1965) [10] Zimerman, Z. and Avitzur, B., Journal of Engineering for Industry, Trans. ASME, Serie B, vol. 2, 122 (1968) [11] Shabaik, A.H. and Thomsen, E. G., Journal of Engineering for Industry, "Trans. ASME, Serie B, vol. 5, 343 (1968) [12] Wantuchowski J. and Sloniowski, J., Archiwum Hutnictwa, vol. 20, 135, (1975) [13] Valberg, H., "Physical Simulation of Metal Extrusion by Means of Model Materials", Proceedings of the Fourth International Aluminum Extrusion Technology Seminar, ET'88, AA & AEC, April 11-14, 1988, Chicago, IL, vol. 2, 321-327 [14] Laue, K., Stenger, H., "Extrusion; Processes, Machinery, Tooling", ASM Int., Metals Park, OH., 1981. [15] Kusiak, J., Misiolek, W. Z., Libura ,W. and Pietrzyk, M., "Application of the Finite-Element Technique to the Simulation of the Aluminum Extrusion Process", presented at the Sixth International Aluminum Extrusion Technology Seminar, ET'96, AA & AEC, May 14-17, 1996, Chicago, IL [16] Rodriguez, P. and Rodriguez, A., "System to Calculate Chambers and Feeds to Obtain a Minimum Single Bearing", Proceedings of the Fifth International Aluminum Extrusion Technology Seminar ET'92, May 22-24, 1992, Chicago, IL, AA & AEC, vol. I, 283-290 [17] Trogolo, J. A., Kelly, R. M., and Misiolek, W. Z. "Materials Characterization of a 6xxx Series Aluminum Alloy in Extrusion Deformation", presented at the Sixth International Aluminum Extrusion Technology Seminar, ET'96, AA & AEC, May 14-17, 1996, Chicago, IL