Aluminum extrusion finds extensive application in the construction, automobile and aerospace industries. Because of high pressures, elevated temperatures, complicated section geometries, and repeated mechanical and thermal stresses in the die and affiliated tooling, the process is quite complex. Process aberrations and tooling related problems directly contribute to extrusion defects and affect product quality. This monograph is based on a comprehensive investigation of the entire operation: deformation process, dies and tooling, and product defects. Following aspects of aluminum extrusion are discussed in detail: variation of extrusion pressure and its relationship to profile complexity; metal flow through the deformation chamber; modes and mechanisms of die failure; probabilistic study of die life and complexity; fracture toughness evaluation of die materials; simulation-based scheme for prediction of die life; defect morphology, mechanisms, and remedial measures; and statistical analysis of product defects in a typical large-size aluminum extrusion plant.