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This research studies the hot deformation behavior of cast and extruded AZ80 magnesium alloys for forging applications. Uniaxial hot compression tests were carried out at a temperature of 400 °C and strain rates ranging from 0.001 to 0.1 s −1 , to various strain levels up to a true strain of 1. Detailed microstructure and texture characterizations of the deformed samples were performed using electron backscatter diffraction and x-ray diffraction techniques. The results show that multiple dynamic recrystallization (DRX) mechanisms were simultaneously active in both starting materials at all the tested deformation conditions, resulting in significant grain refinement. Cast and extruded samples showed the development of a similar microstructure, texture, and flow stress by a strain of 1, despite having very different starting microstructures. This was investigated by considering differences in DRX mechanisms and kinetics, and relative deformation mode activities. Since industrial forgings typically involve strains much higher than 1, comparable final microstructure and texture are expected in industrial-scale forgings of AZ80 at 400 °C, irrespective of the starting material state.

The dynamic recrystallization behaviors of 6082 aluminum alloy in the temperature range of 623–773 K and strain rate range of 0.01–5 s−1 were studied by electron back scattered diffraction (EBSD) and transmission electron microscopy (TEM). According to the experimental results, dynamic recrystallization occurs during hot deformation of 6082 aluminum alloy, although the true stress-strain curve has no obvious single peak characteristic, and the degree of dynamic recrystallization is closely related to the Z parameter. Hot compression with lnZ = 24.9014 (723 K, 0.1 s−1) gives rise to the highest recrystallization fraction of 38.6%. The initial critical strain of dynamic recrystallization was determined by the work hardening rate. The quantitative relationship between the critical strain and Z parameters was established: ε c = 0 . 0046 Z 0 . 1285 . Based on the EBSD analysis and measurement results, dynamic recrystallization kinetics models of 6082 aluminum alloy during hot deformation were deduced. Microstructure analysis showed that the subgrain structure formed in the original grain is coarsened by grain boundary migration, and the orientation difference increases continuously until a large-angle grain boundary forms, resulting in dynamic recrystallization of grains. The likely mechanism is continuous dynamic recrystallization.

Typically, in the manufacturing of GH4169 superalloy forgings, the multi-process hot forming that consists of pre-deformation, heat treatment and final deformation is required. This study focuses on the microstructural evolution throughout hot working processes. Considering that δ phase can promote nucleation and limit the growth of grains, a process route was designed, including pre-deformation, aging treatment (AT) to precipitate sufficient δ phases, high temperature holding (HTH) to uniformly heat the forging, and final deformation. The results show that the uneven strain distribution after pre-deformation has a significant impact on the subsequent refinement of the grain microstructure due to the complex coupling relationship between the evolution of the δ phase and recrystallization behavior. After the final deformation, the fine-grain microstructure with short rod-like δ phases as boundaries is easy to form in the region with a large strain of the pre-forging. However, necklace-like mixed grain microstructure is formed in the region with a small strain of the pre-forging. In addition, when the microstructure before final deformation consists of mixed grains, dynamic recrystallization (DRX) nucleation behavior preferentially depends on kernel average misorientation (KAM) values. A large KAM can promote the formation of DRX nuclei. When the KAM values are close, a smaller average grain size of mixed-grain microstructure is more conductive to promote the DRX nucleation. Finally, the interaction mechanisms between δ phase and DRX nucleation are revealed.

Sub-solvus dynamic recrystallization (DRX) mechanisms in an advanced γ-γ’ nickel-based superalloy GH4151 were investigated by isothermal compression experiments at 1040 °C with a strain rate of 0.1 s−1 and various true strain of 0.1, 0.3, 0.5, and 0.7, respectively. This has not been reported in literature before. The electron backscatter diffraction (EBSD) and transmission electron microscope (TEM) technology were used for the observation of microstructure evolution and the confirmation of DRX mechanisms. The results indicate that a new dynamic recrystallization mechanism occurs during hot deformation of the hot-extruded GH4151 alloy. The nucleation mechanism can be described as such a feature, that is a primary γ’ (Ni3(Al, Ti, Nb)) precipitate embedded in a recrystallized grain existed the same crystallographic orientation, which is defined as heteroepitaxial dynamic recrystallization (HDRX). Meanwhile, the conventional DRX mechanisms, such as the discontinuous dynamic recrystallization (DDRX) characterized by bulging grain boundary and continuous dynamic recrystallization (CDRX) operated through progressive sub-grain merging and rotation, also take place during the hot deformation of the hot-extruded GH4151 alloy. In addition, the step-shaped structures can be observed at grain boundaries, which ensure the low-energy surface state during the DRX process.

Dynamic recrystallization is one of the main phenomena responsible for microstructure evolution during hot forming. Consequently, obtaining a better understanding of dynamic recrystallization mechanisms and being able to predict them is crucial. This paper proposes a full-field numerical framework to predict the evolution of subgrain structures upon grain growth, continuous dynamic recrystallization, and post-dynamic recrystallization. To be able to consider a subgrain structure, two strategies are proposed. One relies on a two-step tessellation algorithm to generate a fully substructured microstructure. The second strategy enables for the simulation of the formation of new subgrains during hot deformation. Using these tools, the grain growth of a fully substructured microstructure is modeled. The influence of microstructure topology, subgrain parameters, and some remaining stored energy due to plastic deformation is discussed. The results highlight that the selective growth of a limited number of subgrains is observed only when mobility is a sigmoidal function of disorientation. The recrystallization kinetics predicted with different criteria for discrimination of recrystallized grains are quantitatively compared. Finally, the ability of the framework to model continuous dynamic and post-dynamic recrystallization is assessed upon a case study representative of the hot extrusion of a zircaloy-4 billet (T=650 °C;ε˙=1.0s−1;εf=1.35). The influence of grain boundary properties and nucleation rules are quantified to evaluate the model sensitivity and suitability. Application of these numerical tools to other thermomechanical conditions and microstructures will be presented in an upcoming article.

Microstructural analysis of hot-compressed magnesium alloys is crucial for understanding the plastic formability of magnesium alloys during thermo-mechanical processing. Thermal compression tests and finite element simulations were conducted on a low rare-earth (RE) Mg-1.8Nd-0.4Zr-0.3Ca alloy. Multiple microstructural characterization techniques were employed to analyze slip systems, twinning mechanisms, dynamic recrystallization (DRX), and precipitate phases in the hot-compressed alloy. The results demonstrated that the equivalent strain distribution within compressed specimens exhibits heterogeneity, with a larger equivalent strain in the core. After thermal compression, the original microscopic structure formed a necklace-like structure. The primary DRX mechanisms comprise continuous dynamic recrystallization (CDRX), twin-induced dynamic recrystallization (TDRX), and particle-stimulated nucleation (PSN). Pyramidal slip and recrystallization constitute primary contributors to peak texture weakening and tilting. Mg41Nd5 and α-Zr phases enhanced dislocation density by impeding dislocation motion and promoting cross-slip activation. Hot compression provided the necessary thermal activation energy and stress conditions for solute atom diffusion and clustering, triggering dynamic precipitation of Mg41Nd5 phases.

The flow behavior of the solution-treated Mg-3.2Bi-0.8Ca (BX31, wt.%) alloy was systematically investigated during hot compression at different deformation conditions. In the present study, the strain-related Arrhenius constitutive model and dynamic recrystallization (DRX) kinetic model were established, and the results showed that both two models had high predictability for the flow curves and the DRX behavior during hot compression. In addition, the hot processing maps were also made to confirm a suitable hot working range. Under the assistance of a hot processing map, the extrusion parameters were selected as 573 K and 0.5 mm/s. After extrusion, the as-extruded alloy exhibited a smooth surface, a fine DRX structure with weak off-basal texture and good strength–ductility synergy. The newly developed strong and ductile BX31 alloy will be helpful for enriching low-cost, high-performance wrought Mg alloy series for extensive applications in industries.

Continuous dynamic recrystallization (CDRX) is widely acknowledged to occur during hot forming and plays a significant role in microstructure development in alloys with moderate to high stacking fault energy. In this work, the flow stress and CDRX behaviors of the TC18 alloy subjected to hot deformation across a wide range of processing conditions are studied. It is observed that deformation leads to the formation of new low-angle grain boundaries (LAGBs). Subgrains rotate by absorbing dislocations, resulting in an increase in LAGB misorientation and the transition of some LAGBs into high-angle grain boundaries (HAGBs). The HAGBs migrate within the material, assimilating the (sub)grain boundaries. Subsequently, an internal state variable (ISV)-based CDRX model is developed, incorporating parameters such as the dislocation density, adiabatic temperature rise, subgrain rotation, LAGB area, HAGB area, and LAGB misorientation angle distribution. The values of the correlation coefficient (R), relative average absolute error (RAAE), and root-mean-square error (RMSE) between the anticipated true stress and measured stress are 0.989, 6.69%, and 4.78 MPa, respectively. The predicted outcomes demonstrate good agreement with experimental findings. The evolving trends of the subgrain boundary area under various conditions are quantitatively analyzed by assessing the changes in dynamic recovery (DRV)-eliminated dislocations and misorientation angles. Moreover, the ISV-based model accurately predicts the decreases in grain and crystallite sizes with higher strain rates and lower temperatures. The projected outcomes also indicate a transition from a stable and coarse-grained microstructure to a continuously recrystallized substructure.

The hot deformation behavior of a novel high-Zn containing Al-Zn-Mg-Cu-Zr alloy was investigated by isothermal compression tests under the conditions of 350-500 °C and 0.0001-10 s −1 . Arrhenius constitutive model and diffusion model were established to describe the flow behavior. Meanwhile, the microstructure evolution and the effect of the Zener-Hollomon parameter on dynamic recrystallization (DRX) behavior was investigated. The results show that both the Arrhenius model and diffusion model describe the flow behaviors well and the Arrhenius model shows better prediction ability. Microstructure characterization indicates that dynamic recovery (DRV) is the main dynamic softening mechanism during the entire hot deformation process, and the DRX mechanism varies at different deformation conditions. Discontinuous dynamic recrystallization and continuous dynamic recrystallization are the main DRX mechanisms under the deformation condition with moderate and low ln Z values, respectively. Moreover, at an extremely low strain rate (0.0001 s −1 ), the enhancement of DRV and particle pinning effect diminish the driving force for DRX at elevated temperature, resulting in a slight decrease in the proportion of DRX grain.

Lightweight structural alloys have broad application prospects in aerospace, energy, and transportation fields, and it is crucial to understand the hot deformation behavior of novel alloys for subsequent applications. The deformation behavior and microstructure evolution of a new Al-Zn-Mg-Li-Cu alloy was studied by hot compression experiments at temperatures ranging from 300 °C to 420 °C and strain rates ranging from 0.01 s−1 to 10 s−1. The as-cast Al-Zn-Mg-Li-Cu alloy is composed of an α-Al phase, an Al2Cu phase, a T phase, an η phase, and an η′ phase. The constitutive relationship between flow stress, temperature, and strain rate, represented by Zener–Hollomon parameters including Arrhenius terms, was established. Microstructure observations show that the grain size and the fraction of DRX increases with increasing deformation temperature. The grain size of DRX decreases with increasing strain rates, while the fraction of DRX first increases and then decreases. A certain amount of medium-angle grain boundaries (MAGBs) was present at both lower and higher deformation temperatures, suggesting the existence of continuous dynamic recrystallization (CDRX). The cumulative misorientation from intragranular to grain boundary proves that the CDRX mechanism of the alloy occurs through progressive subgrain rotation. This paper provides a basis for the deformation process of a new Al-Zn-Mg-Li-Cu alloy.