Magnesium alloy extrusions have emerged as a key approach to achieving vehicle lightweighting, owing to their dual advantages in material properties and structural design. Therefore, figuring out the relationship between crushing deformation process, energy absorption characteristics, and thermomechanical processing state is crucial for further expanding the application of Mg extrusions. This paper mainly focuses on the deformation behavior under uniaxial tension and axial crushing with an AZ31 magnesium alloy extrusion in various treated states through mechanical tests, microscopic characterization and numerical simulation. The results show that the deformation behavior of the AZ31 magnesium alloy extrusion under uniaxial tension and axial crushing is significantly influenced by its initial microstructure determined by hot forming and subsequent heat treatment. After solution treatment, the yield strength (YS) and ultimate tensile strength (UTS) decrease from 230 MPa to 207 MPa and from 303 MPa to 295 MPa, respectively, while the elongation (EL) increases from 19.32 % to 24.08 %. Subsequent aging after solution treatment induces precipitation strengthening, which raises the YS to 234 MPa and UTS to 317 MPa, but results in a significant reduction in EL to 15.74 %. The plastic deformation of the as-extruded profile primarily relies on non-basal slip and limited twinning, with fracture surface exhibiting typical ductile-brittle mixed characteristics. After solution treatment, more tensile twins are activated to accommodate plastic deformation, resulting in a more ductile-oriented mixed fracture mode with fine distributed dimples. In contrast, the aged extrusion demonstrates the weakest deformation compatibility, with a local KAM reaching 18.88°, and exhibits a brittle-dominated mixed fracture mode. The as-extruded profile shows the highest energy absorption capacity and excellent structural strength, yet it exhibits relatively poor crushing stability. The solutionized extrusion exhibits the lowest energy absorption capacity due to its reduced strength, more pronounced load fluctuations during the initial crushing stage, and diminished deformation stability. In contrast, the aged extrusion achieves a more favorable balance between crushing load and deformation stability, thereby demonstrating relatively superior energy absorption capacity. The deformation mode and progressive evolution of the AZ31 magnesium alloy extrusion under axial crushing can be accurately captured using numerical simulation.
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