An investigation into the microstructure/strain pattern relationship in backward extruded AZ91 magnesium alloy

Highlights: ► Strain pattern developed during BE is inhomogeneous throughout the cross section. ► Microstructure evolution of AZ91 alloy was studied during BE at high temperatures. ► Heterogeneous microstructure fits well by related strain pattern over the cross section. ► Size and morphology of the γ-eutectic phase have been changed after BE processing. - Abstract: The contours of equivalent plastic strain (EPS) and shear strain (SS) over the cross section of backward extruded AZ91 magnesium alloy have been modeled employing the finite element method (FEM). The results indicate that the distributions of EPS and SS are not homogenous at different regions over the products' cross section. In addition, the microstructure evolutions and strain pattern relationship have been explored through applying the backward extrusion (BE) method in the temperature range of 250–450 °C. The results indicate that the microstructural features (grain size, mechanical twins and γ-second phases) of different regions are strongly affected by applying backward extrusion, which is fairly consistent with the heterogeneous strain distribution. The obtained results are properly addressed relying on the principal deformation and restoration mechanisms, which operate under specified deformation conditions. The hardness measurements have been also employed to trace the related changes