Investigation of the Flow Behaviour, Anisotropy and Forming Limits of 6000 Series Aluminium Extrusions with Significant Recycled Material Content

About the Project

This project seeks to, for the first time, develop a forming assessment strategy for extruded recycled 6000 series aluminium with a particular focus on roll bending. It will investigate the effect of extrusion process parameters such as alloy composition, homogenisation practice, extrusion speed and exit temperature on formability and ductility.

This PhD project will develop, for the first time, a robust forming assessment strategy for recycled 6000 series aluminium extrusions, with a particular emphasis on roll bending applications. The research addresses a critical knowledge gap associated with the increasing use of high recycled content aluminium in advanced manufacturing, where variations in processing history can significantly influence formability and mechanical performance.

The project will systematically investigate how key extrusion process parameters—including alloy composition, homogenisation practice, extrusion speed, and exit temperature—affect anisotropy, ductility, and forming limits. Experimental characterisation will be combined with advanced forming assessment methodologies to capture the complex deformation conditions experienced during roll bending. These results will be correlated with microstructural and crystallographic texture evolution to establish clear structure–property–process relationships.

The outcomes of this research will provide industry relevant tools and data to enable the reliable forming of recycled aluminium extrusions, supporting both improved manufacturing performance and sustainability objectives within the aluminium supply chain.

Project Details:

Constellium has unique facilities for recycling aluminium alloys via direct extrusion into sheet. This process has cost and sustainability benefits in support of Constellium’s long-term goal of reducing CO2 emissions to 1kg per 1kg of aluminium but potentially introduces variability into the alloy chemistry and impacts on downstream formability and final properties.

Direct extrusion results in differences in microstructure, crystallographic texture, and how they are distributed across and through the sheet compared with traditional rolled material. Forming limit diagrams and mechanical property data is not available for this extruded material which impacts the design and optimisation of subsequent forming processes such as roll bending.

This project seeks to, for the first time, develop a forming assessment strategy for extruded recycled 6000 series aluminium with a particular focus on roll bending. The main research tasks are:

1. Assessment and validation of sub-size samples for characterisation of Forming Limit Diagrams and benchmark these against standard material.
2. The use of novel forming assessment methodologies for characterising the material response to non-standard deformation conditions experienced during roll bending.
3. Correlate these with the microstructure and texture of the material.
4. In parallel with the experimental work, model the roll bending process to understand the complex deformation paths experienced to assess the suitability of forming assessment methodologies.
5. Assess A, B and C as a function of natural ageing from as extruded to 1 or 2 months.
6. Investigate batch to batch variability.

This project fits within EPSRC’s Advanced manufacturing and clean growth and Materials engineering – metals and alloys within the Manufacturing and the circular economy and Advanced materials themes

Further information: The student time will be split between the AFRC, the University of Strathclyde and Constellium UK limited. In addition, you will complete formal training leading to a Postgraduate Certificate in Researcher Professional Development (PG Cert RPD), the first UK academic award recognising postgraduate research skills. This training, combined with research, publication, presentation at conferences, and possible teaching opportunities, will provide a multidisciplinary skillset preparing you for careers in academia and industry. Studentship must commence no later than 01 August 2026.

Funding Notes

The studentship will cover UK tuition fees and has an enhanced stipend for 4 years, along with a budget for equipment/consumables and travel costs.