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The dynamic recrystallization (DRX) features and the evolution of the microstructure of a new hot isostatic pressed (HIPed) powder metallurgy (P/M) superalloy are investigated by hot-compression tests. The sensitivity of grain dimension and DRX behavior to deformation parameters is analyzed. The results reveal that the DRX features and grain-growth behavior are significantly affected by deformation conditions. The DRX process is promoted with a raised temperature/true strain or a reduced strain rate. However, the grains grow up rapidly at relatively high temperatures. At strain rates of o.1 s−1 and 1 s−1, a uniform microstructure and small grains are obtained. Due to the obvious differences in the DRX rate at various temperatures, the piecewise DRX kinetics equations are proposed to predict the DRX behavior. At the same time, a mathematical model for predicting the grain dimension and the grain growth behavior is established. To further analyze the DRX behavior and the changes in grain dimension, the hot deformation process is simulated. The developed grain-growth equation as well as the piecewise DRX kinetics equations are integrated into DEFORM software. The simulated DRX features are consistent with the test results, indicating that the proposed DRX kinetics equations and the established grain-growth model can be well used for describing the microstructure evolution. So, they are very useful for the practical hot forming of P/M superalloy parts.

The flow behavior and microstructure change of the Ti-55511 alloy are investigated by thermal compression experiments with stepped strain rates. The phase transformation features, the dynamic recrystallization (DRX) behavior of the β matrix, the dynamic spheroidization mechanism of the lamellar α phase and the evolution of the β sub-grain size are quantitatively analyzed. A unified constitutive model is constructed to characterize the hot deformation features of the Ti-55511 alloy. In the established model, the work hardening effect is taken into account by involving the coupled effects of the equiaxed and lamellar α phases, as well as β substructures. The dynamic softening mechanisms including the dynamic recovery (DRV), DRX and dynamic spheroidization mechanisms are also considered. The material parameters are optimized by the multi-objective algorithm in the MATLAB toolbox. The consistency between the predicted and experimental data indicates that the developed unified model can accurately describe the flow features and microstructure evolution of the hot compressed Ti-55511 at stepped strain rates.

The microstructural variation and high-temperature flow features of a Ti-55511 alloy in the β region are studied by utilizing double-stage compression with a stepped strain rate. The results demonstrate that the stresses in the latter stage of hot compression markedly reduce as the strain at the previous stage or the strain rate at the previous/latter stage drops. Moreover, the annihilation/interaction of substructures is promoted, and the distinct refinement of the dynamic recrystallization (DRX) in the β grain can be found. However, the coarsening of the β grain and the consumption of dislocation substructures are accelerated at high temperatures. Furthermore, the principal DRX nucleation mechanism of the Ti-55511 alloy during double-stage compression with a stepped strain rate in the β region is discontinuous DRX. Additionally, by using the microstructural variation characteristics related to the forming parameters, a physical mechanism equation is modeled to forecast the forming features, the DRX fraction, and the size of the β grain in the investigated alloy. The forecasted results are in accordance with the tested results, indicating that the established model can accurately forecast the microstructure variation and flow features of the studied alloy.