Extreme dynamic intrusion/extrusion cycles including the increasing in the diameter of billet about 30 ~ 35% and decreasing, about 70 ~ 85%) effectively refine the grain size of the high Zn-containing (8.9 wt%) 7xxx series aluminium alloy with respct to that subjected to the traditional processes (112±36 μm → 19±13 μm). Via the multi-stage heat solution treatment subsequently followed by water quench, the formation of the inclusions is eliminated. After artificial aging (@ 120 °C for 24h), the higher density of precipitates produces ultra-high ultimate tensile strength (784 MPa) with respect to the traditional peak-aged treatments (550 MPa). Furthermore, the elongation of this alloy, subjected to extreme dynamic intrusion/extrusion cycles and subsequently followed by artificial aging, still maintains ~15%.

Extreme dynamic intrusion/extrusion cycles on high Zn containing (8.9 wt%) aluminium alloys effectively improve the tensile strength of about 40% and maintain the higher ductility (~15%). Therefore, this excellent process, i.e., the extreme dynamic intrusion/extrusion cycles, is suggested to be play an important role in the defensed materials and application of electric vehicle.

Extreme dynamic intrusion/extrusion cycles on high Zn containing (8.9 wt%) aluminium alloys effectively improve the tensile strength of about 40% and maintain the higher ductility (~15%). Therefore, this excellent process, i.e., the extreme dynamic intrusion/extrusion cycles, is suggested to be play an important role in the defensed materials and application of electric vehicle.