Rotary-die equal channel angular pressing (RD-ECAP) is a specially designed continuous processing technique to prepare bulk ultrafine-grained/nanostructure (UFG/NS) materials. In this article, an Al-7wt.% Si-0.35wt.% Mg alloy was processed by up to four RD-ECAP passes. The deformation behavior was studied by experiments and FEM simulation, including the observation of the scribed deformation patterns, the macrostructures, the simulated flow lines feature, and the equivalent stain distribution after different RD-ECAP passes. The results show that the shear deformation can accumulate effectively all over the entire billet via multi-pass RD-ECAP. The observed zigzag shape metal flow is formed after three ECAP passes, and the structure homogeneity can be achieved by RD-ECAP with more processing passes.

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