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In this paper, the effects of material removal strategies and initial stress states on the machining deformation of aluminum alloy plates were investigated through a combination of finite element simulation and experiments. We developed different machining strategies described by Tm+Bn, which removal m mm materials form top and n mm materials from the bottom of the plate. The results demonstrate that the maximum deformation of structural components with the T10+B0 machining strategy could reach 1.94 mm, whereas with the T3+B7 machining strategy was only 0.065 mm, decreasing by more than 95%. The asymmetric initial stress state had a significant impact on the machining deformation of the thick plate. The machined deformation of thick plates increased with the increase in the initial stress state. The concavity of the thick plates changed with the T3+B7 machining strategy due to the asymmetry of the stress level. The deformation of frame parts was smaller when the frame opening was facing the high-stress level surface during machining than when it was facing the low-stress level. Moreover, the modeling results for the stress state and machining deformation were accurate and in good accordance with the experimental findings. [ABSTRACT FROM AUTHOR]

In this study, the as-cast microstructure and the evolution of the homogenized microstructure of large-scale industrialized Al-Cu-Mg-Ag heat-resistant aluminum alloy ingots were investigated by means of optical microscopy (OM), scanning electron microscopy (SEM), energy dispersive analysis (EDS), and differential scanning calorimetry (DSC). The results indicate that the dendritic segregation is evident in the ingot along the radial direction, and the grain boundaries are decorated with lots of net-shaped continuous eutectic structures. With the homogenization time extension and the homogenization temperature increase, the eutectic phases (i.e., the primary Al2Cu phase, the Al2CuMg phase, and the AlCuMgAg quaternary phase) at the grain boundaries gradually dissolve back into the matrix. Meanwhile, most of the dendritic grain boundaries gradually become sparse and thinner. Finally, it is found that the optimal homogenization regime of the Al-Cu-Mg-Ag alloy is 420 °C/5 h+480 °C/8 h+515 °C/24 h. [ABSTRACT FROM AUTHOR]