Cross-sectional microstructural and textural inhomogeneities in a Mg–Zn–Al–Ca (ZAX210) wire produced by the conform process

The Conform process (Continuous Rotary Extrusion, CRE) enables the production of magnesium alloy wires like Mg-Zn-Al-Ca (ZAX210) with refined microstructures and tailored textures, but also introduces cross-sectional inhomogeneities that affect the final material response. In this work, a combined experimental and finite element (FE) simulation approach was used to analyse these inhomogeneities in terms of microstructure, texture, and deformation conditions. Optical and electron backscatter diffraction (EBSD) analyses revealed an overall fine grain structure (∼5.7 μm), with slightly smaller grains in the surface layers due to enhanced dynamic recrystallization. Texture development is governed by extrusion- and shear-induced deformation, resulting in a rotated B-fibre (basal plane parallel to shear plane) as the global texture component. Local variations include a B-fibre with weak C 1 -fibre component (c-axis is fibre axis first rotated 90° in shear direction, then 30° in shear plane direction) in the upper region, a strong B-fibre in the middle region, and C 1 /C 2 -fibres in the lower region caused by shear reversal. A fiber texture describes preferred crystallographic orientation, where most grains align a specific crystal direction with a common axis. Twinning activity reflects the heterogeneous deformation state, with ( tension twins dominating overall but being suppressed in high-shear regions. FE simulations confirmed the asymmetric shear stress distribution and complex flow near the abutment, providing a mechanistic link between local strain, recrystallization, and texture evolution. The middle region, representing ∼62 % of the cross-sectional area, was found to dominate the global microstructure and texture.