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Extrusion experiments and 3D numerical modeling were conducted to investigate the dynamic recrystallization and welding quality of a 6063 aluminum alloy hollow square tube extruded by a porthole die at the ram speeds of 3 mm/s, 7 mm/s, 9 mm/s and 11 mm/s. The results showed that average grain size of hollow square tube extruded at the ram speed of 7 mm/s was the smallest. The profile extruded at the ram speed of 3 mm/s exhibited the highest expansion ratio. Dynamic recrystallization (DRX) fractions were highly variable at different ram speeds. DRX fractions in the matrix zones were higher than those in the welding zones, resulting in smaller grain sizes in the matrix zones. Mechanical properties in the welding zones and matrix zones was different. A local strain concentration would occurred during expansion, which would affect the welding quality. Finally, it was found that the uniform microstructure near the welding line would also affect the welding quality.

Microstructure and Its Influence on the Welding Quality of 6063 Aluminum Alloy Porthole Die Extrusion