Effect of specimen size and grain size on deformation in microextrusion

Miniaturization of systems and devices continues unabated, which in turn requires the production of microscale components. Similar to the macroscale process, microextrusion provides a means to fabricate metallic micropins having characteristic dimensions on the order of 1 mm or less with a lower-cost, high-throughput process. In this paper, the effect of the specimen size and grain size on deformation during microextrusion is investigated. Microhardness, microstructure, and X-ray texture analyses show that when the grain size becomes comparable to the specimen feature size, together with miniaturization, penetration of the shear deformation occurs. As a result, the coarse-grained structure has higher hardness than the fine-grained structure, especially in the central regions of the cross-section for the two smallest size extrusion cases investigated, which have Ø0.76/0.57 mm and Ø1.5/1.0 mm dimensions before and after extrusion, respectively. For the largest size extrusion case investigated, Ø2.0/1.33 mm pins, the coarse-grained structure has a lower hardness than the fine-grained one, which is typical for macroscale processes and consistent with the Hall–Petch relationship.