Deformation behavior study of multi-pass ECAE process for fabrication of ultrafine or nanostructured bulk materials

Severe plastic deformation (SPD) is an efficient approach for producing ultrafine or nanostructured bulk materials. Equal channel angular extrusion (ECAE) is the most effective SPD solution for material nanostructuring, as material billet undergoes severe and large deformation and the grains are efficiently broken up in the process. To improve material nanostructuring, the ECAE die design and process configuration are critical. The deformation behavior study through FE simulation in ECAE process provides basic and useful information for optimizing die design and process determination. In this research, the deformation behavior for three different die design scenarios is studied and the related deformation mechanisms and nanostructuring performance are investigated via FE simulation. Through multi-pass simulation, the optimal design scenario is then identified. The simulation results reveal deformation phenomena, and nanostructuring performance of the designs and the corresponding process can be recommended accordingly for improving die and process performance.