Experimental and theoretical investigation of extrusion load for AA6063/SiC extruded composite billet

Because of their great strength and stiffness with regard to their weight, extruded sections are commonly utilized as essential parts in many areas. The investigation focuses on experimental and theoretical analysis of cold extruded aluminium composites. Four types of extrusion die configurations, such as 12:8, 2:4, 12:2, and 8:4, were used to obtain the aluminium composite billets. Aluminium with 5 wt% SiC material was used for the fabrication of Ingot. The theoretical models have been used to determine the extrusion load compared with the experimental value. Moreover, the theoretical model is modified to reflect the relative significance of extrusion parameters in the extrusion process and to provide the actual value of the testing process. Also, the modified model was attributed to developing the equation for evaluating the extrusion load in the intermediate process of extrusion for all the types of extrusion die configurations. The experimentally investigated extrusion load has a 0.81% deviation with the modified model and increased with other theoretical models. Surface morphology analysis was carried out for all configurations of extruded billet components and indicated the surface quality of the extruded billet.