Injection forging of tubes: results of macroscopic analysis and comparison with microstructural observations

The present work deals with double-sided injection forging of commercial purity aluminium tubes. The goal is to monitor and understand the strengthening mechanisms that may influence the process, by analysing the evolution of the dislocation microstructures. Comparison between the mechanical macroscopic results obtained from numerical simulations and experimental testing with the microstructural observations show that the workability limits are related to flaws generated as a result of a dead metal zone formation.