Microstructure Evolution and Mechanical Property Characterization of 6063 Aluminum Alloy Tubes Processed with Friction Stir Back Extrusion

Friction stir back extrusion (FSBE) is a technique for lightweight metal extrusion. The frictional heat and severe plastic deformation of the process generate an equiaxed refined grain structure because of dynamic recrystallization. Previous studies proved that the fabrication of tube and wire structures is feasible. In this work, hollow cylindrical billets of 6063-T6 aluminum alloy were used as starting material. A relatively low extrusion ratio allows for a temperature and deformation gradient through the tube wall thickness to elucidate the effect of heat and temperature on the microstructure evolution during FSBE. The force and temperature were recorded during the processes. The microstructures of the extruded tubes were characterized using an optical microscope, energy-dispersive x-ray spectroscopy, electron backscatter diffraction, and hardness testing. The process reduced the grain size from 58.2 μm to 20.6 μm at the inner wall. The microhardness of the alloy was reduced from 100 to 60–75 HV because of the process thermal cycle.