Multi-gradient structures by cold extrusion of strongly textured continuously cast commercially pure aluminum

During extrusion, the material is subjected to a heterogeneous deformation that results in the formation of gradients of microstructure and thus mechanical properties. In this study, using continuously cast commercially pure aluminum as a reference material, we show how a cast structure with coarse columnar grains affects the formation of these gradients during extrusion at room temperature. Characterization of the initial material as well as the extruded round bars by optical and electron microscopy, X-ray diffraction as well as by means of mechanical testing documents the formation of four characteristic annular sections. For extrusion along the casting direction there is a <100>/<111> double-fiber textured center with lowest hardness, followed by a <111> single-fiber textured ring with a hardness plateau, a double-fiber textured region with grains arranged alternatingly in an iris-like shape, and an (ultra-)fine grained surface layer with highest hardness. For extrusion opposite to the casting direction we find similar characteristics of the center section. With increasing distance from the center follow another double-fiber textured section with increasing hardness, a <111> single-fiber textured ring with nearly homogeneous hardness and a surface layer with a slightly rotated <111> fiber and highest hardness. The key finding is that the macroscopic anisotropy of the cast material, resulting from the grain size, crystal orientation and growth direction of the columnar grains, determines the local material flow during extrusion and thus leads to the formation of these different complex multi-gradient macrostructures that may provide unique properties for complex applications such as light-weight safety-relevant components.