A Novel Hybrid Die Design for Enhanced Grain Refinement: Vortex Extrusion–Equal-Channel Angular Pressing (Vo-CAP)

A novel hybrid Severe Plastic Deformation (SPD) method called Vortex Extrusion–Equal-Channel Angular Pressing (Vo-CAP) was developed and applied to AA6082 workpieces in this study. Before experimental application, a comprehensive optimization of the die design was performed considering effective strain, strain inhomogeneity, and pressing load parameters. The optimization process utilized an integrated approach combining Finite Element Analysis (FEA), artificial neural networks (ANNs), and the non-dominated sorting genetic algorithm II (NSGA-II). The optimized die successfully achieved a balance between maximizing effective strain while minimizing pressing load and strain inhomogeneity. The Vo-CAP process incorporates a unique conical die design that enables assembly without traditional fasteners. Moreover, this novel die combines VE and ECAP advantages in a single-pass operation. While VE has been previously studied, experimental work was limited to specific configurations, and its integration with ECAP had not been explored. Through the development of Vo-CAP, this research gap has been addressed. The results showed substantial enhancements in hardness values, ultimate tensile strength, and strain homogeneity. These findings demonstrate that Vo-CAP represents a significant advancement in SPD, offering an efficient single-pass process for improving the mechanical properties of aluminum alloys through grain refinement.