Numerical Simulation and Experimental Study of Al/Mg Bimetallic Extrusion Shear Forming

Al/Mg alloys are extruded at different temperatures to form coated rods by extrusion shear (ES) deformation technology. The deformation behavior of the composite billet during the ES deformation process was analyzed by DEFORM-3D TM finite element simulation (FEM). Analysis of the structure and property of an extruded Al/Mg alloy using a scanning electron microscopy (SEM), microhardness tester and universal mechanical tester. The results show that the symmetrical die structure design of ES deformation can effectively coordinate the forming load, effective stress and temperature field in the deformation process of composite billets. The bimetallic composite rod prepared at 390 °C has a good metallurgical bonding effect with a thickness of approximately 32 μm. The hardness of the bonding layer is higher than that of the aluminum side and the magnesium side, approximately 221 HV, and the shear strength is 13.2 MPa.