Extruded aluminum alloys, which are highly versatile, have relatively modest prototyping
cost, good strength and corrosion resistance. Because there is no weld seam, the circumferential
mechanical properties may be uniform and advantageous for hydroforming. However, surface defects
such as die lines and pick-up can be generated during the extrusion especially due to imperfections on
the die surface. In this study, the extent of the crack propagation caused by die lines is evaluated
according to the deformed shape of the tube in hydroforming process. And when forming a extruded
aluminum tube, the deformed surface of the tube frequently becomes rougher with increasing plastic
strain. This is well known as orange peel phenomenon and it has a significantly effect not only on the
surface quality of a final product but also on the forming limit. To evaluate the effects of the orange
peel on the hydroformability, the inter-stage polishing has been performed. Through the several tests
including hydroforming test, the effect of surface defects on the hydroformabilities are well defined.