Advances in microextrusion process: a comprehensive review on deformation behavior, process optimization, and characterization of metallic microcomponents
Abstract
Microextrusion has emerged as a key microforming technology for manufacturing metallic microcomponents with high dimensional accuracy, superior surface quality, and enhanced mechanical performance. This review critically examines recent developments in metallic microextrusion, emphasizing deformation mechanisms, size effects, tribological behavior, microstructural evolution, and process optimization strategies. Particular attention is given to the influence of grain size, dynamic recrystallization, die geometry, lubrication, and thermal assistance on material flow and product quality. Recent advances in finite-element simulation, crystal plasticity modeling, and data-driven optimization techniques are also reviewed. A comparative analysis of experimental and numerical studies reveals that grain refinement, friction management, and temperature-assisted forming significantly improve extrusion performance. Current challenges associated with size effects, tool wear, microstructural heterogeneity, and process scalability are discussed. Finally, future research directions involving multi-physics simulation, digital twins, sustainable lubrication systems, and intelligent process monitoring are proposed for next-generation microforming applications.