Aim of the work is to investigate different strategies in balancing material flow during direct extrusion through porthole dies. Two AA6082 hollow profiles were simultaneously extruded by a single die with different portholes extrusion ratio, dissimilar welding chambers and different bearing lengths. A strict process control was realized by measuring thermal conditions in the die by means of 6 thermocouples and on the profiles by a self calibrating pyrometer for aluminum alloy applications. Several billets were extruded at different ram speeds (2 to 7 mm/sec) and the effect of die design on surface quality, profile lengths and thermal field was recorded. The profiles were then sectioned and the position of the seam welds in the profiles identified and compared also with the profiles tip.