FEM Modelling of the hot extrusion of the titanium alloy Ti-6Al-4V for enhanced shape, microstructure and process control. An industrial process for the direct hot extrusion of Ti-6Al-4V is modelled in the finite element package DEFORM(R). Process parameters including flow stress, friction and heat transfer were determined experimentally. The microstructure produced by the industrial process was determined via experimental work; this included the impact of the processing window on the beta grain size and the nucleation of alpha phase at prior beta grain boundaries. The residual stresses generated by water quenching an extruded profile of Ti-6Al-4V from above the beta transus temperature were determined via experimental techniques and modelled in FEM.