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In this work the theoretical solutions based upon the upper-bound theorem recently proposed by Pérez and Luri [Mech. Mater. 40 (2008) 617] for the equal channel angular extrusion process (ECAE) are analyzed by performing a 25 central composite factorial analysis. The uniaxial mechanical properties of commercial pure aluminium are considered by assuming isotropic nonlinear work-hardening combined to von Mises and Drucker isotropic yield criteria to predict the ECAE load and the effective plastic strain. From the proposed 25 factorial analysis, the main parameters affecting the ECAE pressure may be ranked as: (1) Friction factor, (2) die channels intersection angle, (3) outer and (4) inner die corners fillet radii and lastly, (5) plunger velocity. Alternatively, the effective plastic strain is mainly controlled by the die channels intersection angle and, in a less extent, by the outer and inner die corners fillet radii.

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Samples of the Al 7075 naturally and artificially aged were processed by conventional and asymmetrical rolling with 5% of thickness reduction. The rolling processes were evaluated under room temperature and under warm condition (130°C). Mechanical properties were evaluated by uniaxial tensile and Vickers microhardness tests. Microstructure evolutions were followed by optical microscopy analysis. Naturally aged samples showed better yield strengthening under warm processing. Greater ultimate stress and ductility under room temperature processing was also noticed in naturally aged specimens. Artificially aged samples showed better mechanical properties under room temperature, softening under warm processing due to grain recovery process. Microhardness tests showed expected results for both rolling types, especially on asymmetrical rolling with the higher predictions were observed. Micrographs have shown no expressive grain changes or refinement although its flattening was observed. Precipitates were analyzed by EDS/SEM revealing the presence of MgZn 2 and CuMgAl along the matrix that provides plastic strengthening.

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