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In recent years, the strategy of obtaining ultra-high strength bulk Al-Zn-Mg-Cu alloys materials through implementing severe plastic deformation (SPD) has emerged as the prominent trend in structural lightweight development in aerospace and transportation fields. However, the inherent poor formability makes the SPD process of high-alloying Al-Zn-Mg-Cu alloys a great challenge. In the present work, a continuous SPD process named the Conform, utilizing a rotational speed of 4 rpm and a mold preheating temperature of 300 °C, was performed on the high-alloying 7055 Al alloy and prepared rod materials with excellent mechanical properties. The results indicated that violent shear deformation accompanied by rapid temperature rise contributes to the specific grain refinement mechanism of continuous dynamic recrystallization (CDRX) and discontinuous dynamic recrystallization (DDRX). The grain configuration formed by this cooperative mechanism is advantageous for the alloy's compatible deformation capability. As a result, a synergistic improvement in the strength and ductility of the Conformed 7055 Al alloy was obtained. Additionally, the strengthening mechanisms induced by the Conform process were quantitatively calculated, revealing that solid solution strengthening and dislocation strengthening were the primary reasons for the enhanced strength of processed alloys.

Most industrial hot working operations of heat treatable Al alloys are frequently comprised of several successive deformation stages, and therefore the in-depth understanding and better prediction of flow stress evolution during multi-stage thermomechanical processing are required in modern aluminum industries. In this work, the effects of pre-precipitation microstructures on the complicated flow stress behaviors of an Al-Cu-Mg-Zr alloy during multi-stage hot deformation were first investigated. Further, a new integrated model was developed to predict the multi-stage flow stress behaviors. Concretely, by considering dynamic microstructural evolution, a microstructure-based constitutive KM + Avrami model in which the parameters could be well described by the empirical relationship with the Zener-Hollomon parameter was developed to predict the whole flow stress evolutions of single-stage deformation. Then, a novel approach was proposed to describe the whole flow behaviors during multi-stage hot deformation by integrating the microstructure-based constitutive approaches and a physically-based recovery model for static softening. A good modeling capability and agreement between the modeled and experimental flow stress results was found for the studied alloy with three types of pre-precipitation microstructures. In addition, the in-depth dynamic and static softening mechanisms with the influences of pre-precipitation were also discussed based on modeling analysis and microstructural observations.

Understanding phase transformation behaviors and microstructural evolutions during optimized post-heat treatments is essential for tuning the mechanical performances of additively manufactured titanium alloys. In this work, distinctive dual-stage heat treatments were proposed for improving the microstructure and properties of the laser powder bed fusion processed Ti-6Al-4V alloy. The effects of the heat treatments on phase transformation behaviors, microstructural characteristics, mechanical and tribological properties of the alloy were investigated systematically. The dual-stage heat treatments combined with salt bath quenching proved to be an effective approach for obtaining fine lamellar α/β microstructures through the introduction of martensitic and massive phase transformations, as well as achieving optimized strength and ductility. The grain boundary populations of the alloy were strongly influenced by the phase transformation behaviors. Moreover, high-density dislocations were introduced during the dual-stage heat treatments, and the type dislocations were dominant. The nonadditive strengthening mixture rule between obstacles and dislocations was substantiated in this alloy. Different wear mechanisms were found in the dual-stage heat-treated alloys depending on their microstructural characteristics. Furthermore, the underlying mechanisms of phase transformation, strengthening and toughening are also discussed.

The complex precipitation evolutions of Al-Cu-Mg alloys during both non-isothermal and isothermal thermal processes have been found to work on their mechanical properties and electrical resistivity. Modeling of the precipitation kinetics, electrical resistivity and strength evolution is therefore essential for optimizing heat treatment and processing of these alloys. In this work, in situ electrical resistivity monitoring during both non-isothermal and isothermal thermal processes and microstructural characterizations were conducted on an Al-Cu-Mg-Zr alloy with different pre-precipitation microstructures to provide fundamental insights of precipitation behaviors. The results showed that precipitation behaviors of Al-Cu-Mg-Zr alloy, such as the dominant strengthening phase, were highly dependent on pre-precipitation microstructures and thermal history. A time–temperature-microstructure-properties map was established to unravel precipitation characteristics and their strengthening functions. The maximum hardness was indicated to be attributed to the combined presence of Guinier–Preston–Bagaryatsky (GPB) zones and fine S (Al2CuMg) phase. Further, in situ electrical resistivity was used as the main input data to develop an improved model based on the classical Kampmann and Wagner type numerical model (KWN model). This integrated model could not only reveal precipitation kinetics but also well predict hardness evolutions of the studied alloy during non-isothermal and isothermal processes.

The microstructural evolutions and resulted mechanical responses during isothermal holding of multipass hot deformation are essential aspects in the processing of high performance titanium alloys. In this work, isothermal holding testing was performed on a Ti-5Al-3V alloy after hot compression at temperatures of 900 °C, 930 °C and 960 °C, respectively. Stress relaxation, dilatometer measurements, and microstructure examinations (i.e. scanning electron microscope, electron backscatter diffraction and transmission electron microscope) were employed to investigate the phase transformation behaviors. The results showed a flow stress hardening phenomenon during the interrupted isothermal holding in two phase region. The post-dynamic transformation from α to β phase took place first during the early stage of isothermal holding after hot deformation. With longer isothermal holding time, the reverse transformation of meta-stable β phase to α phase was then observed. Under TEM, the reverse transformed α phases were isolated from quenched α' phases. The in-depth mechanisms of post-dynamic α to β phase transformation and reverse transformation were discussed as well. Keywords: Titanium alloys, Phase transformation, Hot deformation, Microstructure