The continuous extrusion cladding forming process of the Cu-Al wire was simulated by a two-dimensional FEM software to analyze metal flow

velocity distribution

the effective stress and strain distribution under die different diversion angle.The results show that with decreasing in diversion angle

metal flow exhibits more homogeneous

and extruding force is decreased

which is beneficial for saving energy and reducing cost.In addition

small diversion angle is helpful for improving the cladding quality of Cu-Al wire

and for decreasing stress aggregation to improve mould as well as for increasing deformation efficiency.The continuous extrusion forming of Cu-Al was conducted on TLJ400 extruded machine

and the experimental results are well in agreement with the simulated ones.