During the extrusion process it is necessary to control cosmetic, dimensional and structural features of the extrudate. The structural and cosmetic features are largely controlled by the temperature compensated strain rate ( Z) obtaining and the developed structure depends upon the local values of Z at each point in the deformation zone. The metal flow during extrusion thus very closely determines the developed structure, which in turn determines the material properties. This paper discusses the differences in metal flow which may be observed in the indirect and direct extrusion processes and traces the development of structure through the prevailing deformation zones. The variation of structure with the process variables for the two processes is also presented and it is shown that existing methods of calculating the strain rate in indirect extrusion may be in error. The communication shows that the structure in indirect extrusion is more homogenous than in the direct processes and discusses the impact of this observation on selection of process. It is also shown that, because strain rate gradients are higher in the indirect process, the structure exhibits more scatter. The two processes are compared and evaluated.
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