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The presence of a second phase in Al-Cu-MG alloys, with various sizes and supersaturation-solid-solubility, which can be changed by pre-heat-treatment, could have remarkable influence on hot workability and mechanical performance. In the present work, a continuously cast 2024 Al alloy was homogenized and then subjected to hot compression and continuous extrusion (Conform) along with the initial as-cast alloy. The results showed that the 2024 Al alloy specimen with pre-heat treatment had a higher resistance to deformation and dynamic recovery (DRV) during hot compression process compared with the as-cast sample. Meanwhile, dynamic recrystallization (DRX) was advanced in the pre-heat-treated sample. After the Conform Process, the pre-heat-treated sample also attained better mechanical properties without additional solid solution treatment. The higher supersaturation solid solubility and dispersoids generated during pre-heat treatment was proved to play a key role in restricting boundary migration, tangling dislocation motion and promoting the precipitation of S phase, which raised resistance to DRV and plastic deformation and enhanced the mechanical properties.

Extrusion speed has a significant influence on the extrusion temperature, microstructure and mechanical properties of the material in the repetitive continuous extrusion forming (RCEF) process. In this work, the mechanical properties of Al2024 were improved by adjusting the speed (with a general range of 2–10 rpm) of repetitive continuous extrusion and applying subsequent heat treatment. During the RCEF process, an increase in the extrusion speed from 4 to 8 rpm was found to increase the extrusion temperature and then enhance the solid solution function. The grain size was affected by the combined effect of deformation speed and its induced temperature. A high-strength Al2024 (ultimate tensile strength of 497.6 MPa) with good elongation (12.93%) was obtained by increasing the extrusion speed and conducting solid solution and artificial aging treatments. The main strengthening mechanisms could be attributed to finer grain size and a larger amount of S (Al2CuMg) precipitates.

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