Development of a Generic Tribological Methodology for Aluminium Extrusion Die Contact Simulation: Experimental Validation Through Lubricant Evaluation

The premature degradation of aluminium extrusion dies remains one of the major challenges affecting process efficiency, product quality, and tooling costs. Although numerous studies have investigated wear mechanisms and proposed solutions such as surface treatments, coatings and lubrication, the absence of a generic and reproducible laboratory methodology for evaluating tribological performance under representative extrusion die contact conditions limits the objective and systematic comparison of alternative tribological solutions. This study proposes and experimentally validates a generic tribological methodology for laboratory simulation of aluminium extrusion die contacts. Rather than reproducing the complete extrusion process, the methodology isolates the dominant physical mechanisms governing die degradation and reproduces their essential characteristics under controlled laboratory conditions, providing a representative platform for systematic tribological investigations. The methodology was developed through the selection and scaling of representative contact parameters, including contact geometry, normal load, sliding velocity and operating temperature. The experimental programme incorporated physical similarity principles, a controlled run-in procedure and repeated use of the same hardened steel counterface to reproduce cumulative die exposure under successive aluminium contacts. Two aluminium alloys (AA6063 and AA6082) were evaluated using a small ring-on-disc configuration against a hardened GCr15 steel counterface. Experimental validation was carried out using two extrusion lubricant systems, complemented by three additional commercial lubricants to assess the robustness and general applicability of the proposed methodology. The experimental results demonstrate that the proposed methodology provides repeatable and sufficiently sensitive measurements of friction and wear, allowing clear differentiation between lubricant systems and aluminium alloy–lubricant combinations while maintaining representative contact conditions. The study also demonstrates that steady-state friction should be identified from the actual friction evolution rather than by applying a fixed averaging interval. Although lubricant evaluation is employed here as the experimental validation case, the proposed methodology is intended as a generic experimental framework applicable to the assessment of surface treatments, coatings, tool materials, lubrication systems, and other tribological strategies aimed at extending extrusion die service life.