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A novel one-pass integrated severe plastic deformation method, entitled extrusion compression angular pressing forward extrusion (ECAP-FE), was designed and used for fabricating a fine-grained as-cast AZ31 Mg alloy. Subsequently, mechanical (room temperature compression, tensile and microhardness) and microstructural properties of the processed sample were investigated in detail. In addition, a finite element simulation of the proposed method was carried out for evaluating the equivalent plastic strain and strain rate distribution. The results showed that the ECAP-FE method is a powerful method for processing the ultrafine-grained as-cast AZ31 Mg alloy in a single pass to achieve a uniform and fine microstructure with enhanced mechanical properties. Therefore, it appears that the proposed method has a great potential to a wide range of industrial applications.

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