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In order to study the multi-mode damage and fracture mechanisms of thin-walled tubular parts with cross inner ribs (longitudinal and transverse inner ribs, LTIRs), the Gurson–Tvergaard–Needleman (GTN) model was modified with a newly proposed stress state function. Thus, tension damage and shear damage were unified by the new stress state function, which was asymmetric with respect to stress triaxiality. Tension damage dominated the modification, which coupled with the shear damage variable, ensured the optimal prediction of fractures of thin-walled tubular parts with LTIRs by the modified GTN model. This included fractures occurring at the non-rib zone (NRZ), the longitudinal rib (LIR) and the interface between the transverse rib (TIR) and the NRZ. Among them, the stripping of material from the outer surface of the tubular part was mainly caused by the shearing of built-up material in front of the rollers under a large wall thickness reduction (ΔT). Shear and tension deformation were the causes of fractures occurring at the NRZ, while axial tension under a large TIR interval (l) mainly resulted in fractures on LIRs. Fractures at the interface between the TIR and NRZ were due to the shearing applied by rib grooves and radial tension during the formation of ribs. This study can provide guidance for the manufacturing of high-performance aluminum alloy thin-walled tubular components with complex inner ribs.

Deformation instability is a macroscopic and microscopic phenomenon of non-uniformity and unstable deformation of materials under stress loading conditions, and it is affected by the intrinsic characteristics of materials, the structural geometry of materials, stress state and environmental conditions. Whether deformation instability is positive and constructive or negative and destructive, it objectively affects daily life at all times and the deformation instability based on metal-bearing analysis in engineering design has always been the focus of attention. Currently, the literature on deformation instability in review papers mainly focuses on the theoretical analysis of deformation instability (instability criteria). However, there are a limited number of papers that comprehensively classify and review the subject from the perspectives of material characteristic response, geometric structure response, analysis method and engineering application. Therefore, this paper aims to provide a comprehensive review of the existing literature on metal deformation instability, covering its fundamental principles, analytical methods, and engineering practices. The phenomenon and definition of deformation instability, the principle and viewpoint of deformation instability, the theoretical analysis, experimental research and simulation calculation of deformation instability, and the engineering application and prospect of deformation instability are described. This will provide a reference for metal bearing analysis and deformation instability design according to material deformation instability, structural deformation instability and localization conditions of deformation instability, etc. From the perspective of practical engineering applications, regarding the key problems in researching deformation instability, using reverse thinking to deduce and analyze the characteristics of deformation instability is the main trend of future research.

The category and morphology of precipitates are essential factors in determining the mechanical behaviors of aluminum alloys. It is a great challenge to synthetically modulate multiple precipitates to simultaneously improve strength and ductility. In the present work, by optimizing the precipitations of the GP zone, θ’-approximant and θ’ phase for an Al-Cu-Mn alloy, a high tensile strength of 585 MPa with large elongation of 12.35% was achieved through pre-deformation and aging. The microstructure evolution pattern was revealed by detailed characterizations of scanning electron microscopy and transmission electron microscopy. It was found that such high tensile strength of the samples was due to a combination of strengthening by the high density of dispersive fine precipitates and dislocations, and the high elongation to failure was primarily attributed to the multimodal precipitates and elimination of precipitation-free zones along the grain boundaries. The strategy proposed here is a promising way of preparing ultra-strong Al-Cu-Mn alloys.