Extrusion modelling was performed for 6061 aluminium alloy and three particle reinforced MMCs (10%Al2O3/6061, 15%SiC/6061, 20%Al2O3/6061) using constitutive equations previously obtained from torsion test data. In applying the finite element software DEFORM, suitable heat transfer, friction, and velocity boundary conditions were chosen based on a direct extrusion press. Simulations were run for various extrusion conditions and the outputs for the four materials were compared. The simulation results were validated by comparison with real life extrusions and modelling of other researchers. The results showed that an increase in billet temperature, a reduction in ram speed, or a reduction in extrusion ratio had the effect of reducing the ram load. In consequence, extrusion conditions could be selected so that extrusion of the composite was carried out with the same peak ram load as the alloy.
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