Temperature and Reduction Ratio Effects on Wear Rate and Ductility of Direct Extruded Aluminium 6063: A Numerical and Experimental Investigation

Aluminium alloys are widely used in various industries due to their excellent strength-toweight ratio, corrosion resistance, and formability.However, their wear resistance and ductility can be limiting factors in certain applications.This study investigates the effects of reduction ratio and extrusion temperature on the wear rate and ductility of Al 6063 extrudates.A systematic experimental approach was employed, involving the extrusion of aluminium samples at varying reduction ratios (20%, 40%, and 60%) and temperatures (400, 450, and 500).Quadratic models were developed to predict extruded wear rate and ductility, revealing reduction ratio and temperature as significant factors (p<0.05).The results showed that increased reduction percentage led to decreased wear rate, while enhanced grain sizes were achieved with increased reduction ratio and temperature.This research provides valuable insights for optimizing extrusion parameters to improve the wear resistance and ductility of formed Al 6063, which can be applied in various industries, such as aerospace, automotive, and construction, where high-performance aluminium alloys are critical.