Influence of Hot Consolidation Conditions and Cr-Alloying on Microstructure and Creep in New-Generation ODS Alloy at 1100 °C

The coarse-grained new-generation Fe-Al-Y₂O₃-based oxide dispersion strengthened (ODS) alloys contain 5 vol.% homogeneously dispersed yttria nano-precipitates and exhibit very promising creep and oxidation resistance above 1000 °C. The alloy is prepared by the consolidation of mechanically alloyed powders via hot rolling followed by secondary recrystallization. The paper presents a systematic study of influence of rolling temperature on final microstructure and creep at 1100 °C for two grades (Fe-10Al-4Y₂O₃ and Fe-9Al-14Cr-4Y₂O₃ in wt%) of new-generation ODS alloys. The hot rolling temperatures exhibit a rather wide processing window and the influence of Cr-alloying on creep properties is evaluated as only slightly positive.     

Effect of Structure and Hydrogen on the Short-Term Creep of Titanium Ti-2.9Al-4.5V-4.8Mo Alloy

In this paper, the effect of hydrogenation, in the amount of 0.15 wt.%, on the short-term creep of a titanium Ti-2.9Al-4.5V-4.8Mo alloy in fine-grained (FG) and ultrafine-grained (UFG) states is studied at 723 K. The UFG structure was formed by the method of pressing with the change of the deformation axis and gradual temperature decrease. Creep tests are performed under conditions of uniaxial tension at a constant load for the creep rates at an interval of (10⁻⁷ ÷ 10⁻⁶) s⁻¹. The UFG alloy’s resistance to creep under the investigated conditions is revealed to be substantially lower than in the FG state. When hydrogen presents in the alloy in a solid solution, a 1.3–2.5-fold rise in the value of the steady-state creep rate for the hydrogenated FG and UFG alloys is observed. The creep of the non-hydrogenated FG and UFG alloys is described by the creep power law. The presence of dissolved hydrogen leads to a violation of the creep power law. The values of stress sensitivity indices, steady-state creep rate, and effective creep activation energy are determined. The relationships between the hydrogenation, structure, and creep mechanisms of the alloy at the steady-state are discussed.     

Nano-Mechanical Properties and Creep Behavior of Ti6Al4V Fabricated by Powder Bed Fusion Electron Beam Additive Manufacturing

Effects of scanning strategy during powder bed fusion electron beam additive manufacturing (PBF-EB AM) on microstructure, nano-mechanical properties, and creep behavior of Ti6Al4V alloys were compared. Results show that PBF-EB AM Ti6Al4V alloy with linear scanning without rotation strategy was composed of 96.9% α-Ti and 2.7% β-Ti, and has a nanoindentation range of 4.11–6.31 GPa with the strain rate ranging from 0.001 to 1 s⁻¹, and possesses a strain-rate sensitivity exponent of 0.053 ± 0.014. While PBF-EB AM Ti6Al4V alloy with linear and 90° rotate scanning strategy was composed of 98.1% α-Ti and 1.9% β-Ti and has a nanoindentation range of 3.98–5.52 GPa with the strain rate ranging from 0.001 to 1 s⁻¹, and possesses a strain-rate sensitivity exponent of 0.047 ± 0.009. The nanohardness increased with increasing strain rate, and creep displacement increased with the increasing maximum holding loads. The creep behavior was mainly dominated by dislocation motion during deformation induced by the indenter. The PBF-EB AM Ti6Al4V alloy with only the linear scanning strategy has a higher nanohardness and better creep resistance properties than the alloy with linear scanning and 90° rotation strategy. These results could contribute to understanding the creep behavior of Ti6Al4V alloy and are significant for PBF-EB AM of Ti6Al4V and other alloys.     

Substantial Improvement of High Temperature Strength of New-Generation Nano-Oxide-Strengthened Alloys by Addition of Metallic Yttrium

Oxide-dispersion-strengthened (ODS) Fe-Al-Y₂O₃-based alloys (denoted as FeAlOY) containing 5 vol. % of nano-oxides have a potential to become top oxidation and creep-resistant alloys for applications at temperatures of 1100–1300 °C. Oxide dispersoids cause nearly perfect strengthening of grains; thus, grain boundaries with limited cohesive strength become the weak link in FeAlOY in this temperature range. One of the possibilities for significantly improving the strength of FeAlOY is alloying with appropriate elements and increasing the cohesive strength of grain boundaries. Nearly 20 metallic elements have been tested with the aim to increase cohesive strength in the frame of preliminary tests. A positive influence is revealed for Al, Cr, and Y, whereby the influence of Y is enormous (addition of 1% of metallic Y increases strength by a factor of 2), as it is presented in this paper.     

A Model for Creep and Creep Damage in the γ-Titanium Aluminide Ti-45Al-2Mn-2Nb

Gamma titanium aluminides (γ-TiAl) display significantly improved high temperature mechanical properties over conventional titanium alloys. Due to their low densities, these alloys are increasingly becoming strong candidates to replace nickel-base superalloys in future gas turbine aeroengine components. To determine the safe operating life of such components, a good understanding of their creep properties is essential. Of particular importance to gas turbine component design is the ability to accurately predict the rate of accumulation of creep strain to ensure that excessive deformation does not occur during the component’s service life and to quantify the effects of creep on fatigue life. The theta (θ) projection technique is an illustrative example of a creep curve method which has, in this paper, been utilised to accurately represent the creep behaviour of the γ-TiAl alloy Ti -45Al-2Mn-2Nb. Furthermore, a continuum damage approach based on the θ-projection method has also been used to represent tertiary creep damage and accurately predict creep rupture.     

Effect of Ti Content on the Microstructure and High-Temperature Creep Property of Cast Fe-Ni-Based Alloys with High-Al Content

The cast Fe-Ni-based austenitic heat-resistant alloys with 4.5 wt% Al and varying Ti content were developed for high-temperature application. With increase in Ti content, strength of model alloys increased gradually at 700 °C and 750 °C. At 750 °C, alloys with 35Ni–(2~4)Ti composition showed a significant increase in creep rupture life compared to 30Ni–1Ti alloy, attributed to the increase in γ’-Ni₃(Al,Ti) precipitates due to higher Ni and Ti content. Among the 35Ni–(2~4)Ti alloys, increasing Ti content from 2 to 4 wt% gradually increased the creep rupture life in the as-cast condition. The creep rupture life was improved after solution annealing treatment, however, the beneficial effect of higher Ti content was not evident for 35Ni–(2~4)Ti alloys. After solution annealing, interdendritic phases were partially dissolved, but coarse B2-NiAl phases were formed. The size and amount of coarse B2-NiAl phases increased with Ti content. In the creep-tested specimens, creep void nucleation and crack propagation were observed along the coarse B2-NiAl phases, especially for high-Ti alloys. Therefore, the beneficial effect of the increase in γ’-Ni₃(Al,Ti) precipitates for high-Ti alloys on creep property was limited due to the detrimental effect of the presence of coarse B2-NiAl phases.     

Effect of Ag on Properties,Microstructure, and Thermostability of Cu–Cr Alloy

Cu–Cr-based alloys exhibit excellent electrical conductivity and strength, but their poor thermal stability limits their application in industry. In this paper, Cu–0.2Cr (at. %) and Cu–0.2Cr–0.12Ag (at. %) alloys were prepared to study the effect of Ag on the properties, microstructure, and thermal stability of the Cu–Cr alloy. Microstructure and precipitation were observed by an optical microscope (OM) and a transmission–electron microscope (TEM). After cold-drawing by 99.9% and aging at 450 °C for 2 h, the peak hardness and electric conductivity of the Cu–Cr alloy were 120.3 HV and 99.5% IACS, respectively, and those of the Cu–Cr–Ag alloy were 135.8 HV and 98.3% IACS, respectively. The softening temperature of the Cu–Cr alloy was 500~525 °C, and that of the Cu–Cr–Ag alloy was about 550 °C. The creep strains of the Cu–Cr and Cu–Cr–Ag alloys at 40 MPa and 400 ℃ for 50 h were 0.18% and 0.05%, respectively. Ag elements improved the thermal stability of the Cu–Cr alloy. Recovery and recrystallization occurred before the coarsening of precipitates during the softening process. Ag atoms mainly improved the softening resistance of the alloy by delaying recrystallization, and mainly increased creep resistance by preventing the increase in mobile-dislocation density.     

Influence of Post Weld Heat Treatment on the Grain Size,and Mechanical Properties of the Alloy-800H Rotary Friction Weld Joints

This study evaluated the microstructure, grain size, and mechanical properties of the alloy 800H rotary friction welds in as-welded and post-weld heat-treated conditions. The standards for the alloy 800H not only specify the composition and mechanical properties but also the minimum grain sizes. This is because these alloys are mostly used in creep resisting applications. The dynamic recrystallization of the highly strained and plasticized material during friction welding resulted in the fine grain structure (20 ± 2 µm) in the weld zone. However, a small increase in grain size was observed in the heat-affected zone of the weldment with a slight decrease in hardness compared to the base metal. Post-weld solution heat treatment (PWHT) of the friction weld joints increased the grain size (42 ± 4 µm) in the weld zone. Both as-welded and post-weld solution heat-treated friction weld joints failed in the heat-affected zone during the room temperature tensile testing and showed a lower yield strength and ultimate tensile strength than the base metal. A fracture analysis of the failed tensile samples revealed ductile fracture features. However, in high-temperature tensile testing, post-weld solution heat-treated joints exhibited superior elongation and strength compared to the as-welded joints due to the increase in the grain size of the weld metal. It was demonstrated in this study that the minimum grain size requirement of the alloy 800H friction weld joints could be successfully met by PWHT with improved strength and elongation, especially at high temperatures.     

The Effect of Heat Treatment on the Tribological Properties and Room Temperature Corrosion Behavior of Fe–Cr–Al-Based OPH Alloy

The microstructure, mechanical, tribological, and corrosion properties of Fe–Cr–Al–Y-based oxide-precipitation-hardened (OPH) alloy at room temperature are presented. Two OPH alloys with a composition of 0.72Fe–0.15Cr–0.06Al–0.03Mo–0.01Ta–0.02Y₂O₃ and 0.03Y₂O₃ (wt.%) were prepared by mechanical alloying with different milling times. After consolidation by hot rolling, the alloys presented a very fine microstructure with a grain size of approximately 180 nm. Such a structure is relatively brittle, and its mechanical properties are enhanced by heat treatment. Annealing was performed at three temperatures (1000 °C, 1100 °C, and 1200 °C), with a holding time from 1 to 20 h. Tensile testing, wear testing, and corrosion testing were performed to evaluate the effect of heat treatment on the behavior and microstructural properties. The grain size increased almost 10 times by heat treatment, which influenced the mechanical properties. The ultimate tensile strength increased up to 300% more compared to the initial state. On the other hand, heat treatment has a negative effect on corrosion and wear resistance.     

On the Effects of Hot Forging and Hot Rolling on the Microstructural Development and Mechanical Response of a Biocompatible Ti Alloy

Zr, Nb, and Ta as alloying elements for Ti alloys are important for attaining superior corrosion resistance and biocompatibility in the long term. However, note that the addition of excess Nb and Ta to Ti alloys leads to higher manufacturing cost. To develop low-cost manufacturing processes, the effects of hot-forging and continuous-hot-rolling conditions on the microstructure, mechanical properties, hot forgeability, and fatigue strength of Ti-15Zr-4Nb-4Ta alloy were investigated. The temperature dependences with a temperature difference (ΔT) from β-transus temperature (Tβ) for the volume fraction of the α- and β-phases were almost the same for both Ti-15Zr-4Nb-4Ta and Ti-6Al-4V alloys. In the α-β-forged Ti-15Zr-4Nb-4Ta alloy, a fine granular α-phase structure containing a fine granular β-phase at grain boundaries of an equiaxed α-phase was observed. The Ti-15Zr-4Nb-4Ta alloy billet forged at Tβ-(30 to 50) °C exhibited high strength and excellent ductility. The effects of forging ratio on mechanical strength and ductility were small at a forging ratio of more than 3. The maximum strength (σ_max) markedly increased with decreasing testing temperature below Tβ. The reduction in area (R.A.) value slowly decreased with decreasing testing temperature below Tβ. The temperature dependences of σ_max for the Ti-15Zr-4Nb-4Ta and Ti-6Al-4V alloys show the same tendency and might be caused by the temperature difference (ΔT) from Tβ. It was clarified that Ti-15Zr-4Nb-4Ta alloy could be manufactured using the same manufacturing process as for previously approved Ti-6Al-4V alloy, taking into account the difference (ΔT) between Tβ and heat treatment temperature. Also, the manufacturing equivalency of Ti-15Zr-4Nb-4Ta alloy to obtain marketing approval of implants was established. Thus, it was concluded that continuous hot rolling is useful for manufacturing α-β-type Ti alloy.     

Chemical Composition,Microstructure, Tensile and Creep Behavior of Ti60 Alloy Fabricated via Electron Beam Directed Energy Deposition

Electron beam directed energy deposition (EB-DED) is a promising manufacturing process for the fabrication of large-scale, fully dense and near net shape metallic components. However, limited knowledge is available on the EB-DED process of titanium alloys. In this study, a near-α high-temperature titanium alloy Ti60 (Ti-5.8Al-4Sn-4Zr-0.7Nb-1.5Ta-0.4Si) was fabricated via EB-DED. The chemical composition, microstructure, tensile property (at room temperature and 600 °C), and creep behavior of the fabricated alloy were investigated and compared with those of the conventional wrought lamellar and bimodal counterparts. Results indicated that the average evaporation loss of Al and Sn was 10.28% and 5.01%, respectively. The microstructure of the as-built alloy was characterized by coarse columnar grains, lamellar α, and the precipitated elliptical silicides at the α/β interfaces. In terms of tensile properties, the vertical specimens exhibited lower strength but higher ductility than the horizontal specimens at both room temperature and 600 °C. Furthermore, the tensile creep strain of the EB-DED Ti60 alloy measured at 600 °C and 150 MPa for 100 h under as-built and post-deposition STA conditions was less than 0.15%, which meets the standard requirements for the wrought Ti60 alloy. The creep resistance of the EB-DED Ti60 alloy was superior to that of its wrought bimodal counterpart.     

Effect of Oxygen Content on Microstructure and Tensile Properties of a 22Cr-5Al ODS Steel

The high tensile strength and irradiation resistance of oxide dispersion strengthened (ODS) ferritic steels is attributed to the ultrafine and dispersed oxides within the matrix. The high content of oxygen and yttrium is critical for the formation of dense Y-rich oxides. However, only few studies have reported the effect of oxygen content on the microstructure and mechanical properties of ODS steels. Herein, we employed gas atomization reactive synthesis to prepare pre-alloy powders and then hot isostatic pressing (HIP) to consolidate two 22Cr-5Al ODS steels with different oxygen content. Our results showed Y-rich precipitates at and near grain boundaries of the as-HIPed alloys. Moreover, with the oxygen content increasing from 0.04 to 0.16 wt%, more precipitates precipitated in the as-HIPed alloy, and the ultimate tensile strength of the alloy was improved. However, increasing the oxygen content to 0.16 wt% led to formation of stripe and chain precipitates at and near grain boundaries, which caused a partial intergranular fracture of the as-HIPed alloy.     

Thermal Expansion of a Multiphase Intermetallic Ti-Al-Nb-Mo Alloy Studied by High-Energy X-ray Diffraction

Intermetallic γ-TiAl-based alloys are lightweight materials for high-temperature applications, e.g., in the aerospace and automotive industries. They can replace much heavier Ni-based alloys at operating temperatures up to 750 °C. Advanced variants of this alloy class enable processing routes that include hot forming. These alloys consist of three relevant crystallographic phases (γ-TiAl, α₂-Ti₃Al, β_o-TiAl) that transform into each other at different temperatures. For thermo-mechanical treatments as well as for adjusting alloy properties required under service conditions, the knowledge of the thermal expansion behavior of these phases is important. Therefore, thermal expansion coefficients were determined for the relevant phases in a Ti-Al-Nb-Mo alloy for temperatures up to 1100 °C using high-energy X-ray diffraction.     

Study of a Modified Time Hardening Model for the Creep Consolidation Effect of Asphalt Mixtures

In the past, most researchers have explained the three-stage creep behavior of asphalt mixture in detail. Still, there is no reasonable model to describe the creep of the consolidation effect. To accurately describe the consolidation effect of an asphalt mixture during the viscoelastic deformation process, a modified time hardening model was established by using the Malthus model and the Logistic function to change its creep strain and creep compliance. According to the characteristics of asphalt mixture creep, a single penetration creep test was conducted for high-elasticity modified asphalt mixtures at different temperatures (20 °C, 40 °C, 60 °C) and various loading levels (0.55 MPa, 0.70 MPa, 0.85 MPa, 1.00 MPa). The test results showed that the effect of stress on deformation within the normal range of variation was more significant than that of temperature. In addition, the test results were simulated by the modified time hardening model using surface fitting and compared with a time hardening model and a modified Burgers model. A fitting analysis showed that the modified time hardening model more accurately represents the asphalt mixture’s consolidation effect and creep behavior. Therefore, the modified time hardening model can better show the consolidation effect in the creep process.     

Development of Machine Learning Models to Evaluate the Toughness of OPH Alloys

Oxide Precipitation-Hardened (OPH) alloys are a new generation of Oxide Dispersion-Strengthened (ODS) alloys recently developed by the authors. The mechanical properties of this group of alloys are significantly influenced by the chemical composition and appropriate heat treatment (HT). The main steps in producing OPH alloys consist of mechanical alloying (MA) and consolidation, followed by hot rolling. Toughness was obtained from standard tensile test results for different variants of OPH alloy to understand their mechanical properties. Three machine learning techniques were developed using experimental data to simulate different outcomes. The effectivity of the impact of each parameter on the toughness of OPH alloys is discussed. By using the experimental results performed by the authors, the composition of OPH alloys (Al, Mo, Fe, Cr, Ta, Y, and O), HT conditions, and mechanical alloying (MA) were used to train the models as inputs and toughness was set as the output. The results demonstrated that all three models are suitable for predicting the toughness of OPH alloys, and the models fulfilled all the desired requirements. However, several criteria validated the fact that the adaptive neuro-fuzzy inference systems (ANFIS) model results in better conditions and has a better ability to simulate. The mean square error (MSE) for artificial neural networks (ANN), ANFIS, and support vector regression (SVR) models was 459.22, 0.0418, and 651.68 respectively. After performing the sensitivity analysis (SA) an optimized ANFIS model was achieved with a MSE value of 0.003 and demonstrated that HT temperature is the most significant of these parameters, and this acts as a critical rule in training the data sets.     

Constitutive Model Parameter Identification Based on Optimization Method and Formability Analysis for Ti6Al4V Alloy

Titanium alloy is widely applied in aerospace, medical, shipping and other fields due to its high specific strength and low density. The purpose of this study was to analyze the formability of Ti6Al4V alloys at elevated temperatures. An accurate constitutive model is the basic condition for accurately simulating the plastic forming of materials, and it is an important basis for optimizing the parameters of the hot forging forming process. In this study, the optimization algorithm was used to accurately identify the high-temperature constitutive model parameters of Ti6Al4V titanium alloy, and the hot working diagram was established to optimize the hot forming process parameters. The optimal forming conditions of Ti6Al4V titanium alloy are given. Ti6Al4V alloy was subjected to high-temperature compression tests at 800–1000 °C and at strain rates of 0.01–5 s⁻¹ on a Gleeble-1500D thermal/mechanical simulation machine. Each parameter of the Hansel–Spittel constitutive model was taken as an independent variable, and the accumulated error between the stress calculated by the constitutive model and the stress obtained by experimentation was used as an objective function. Based on response surface methodology, an inverse optimization method for identifying the parameters of the high-temperature constitutive model of Ti6Al4V alloy is proposed in this paper. An orthogonal test design was adopted to obtain sample point data, and a third-order response surface approximate model was established. The genetic algorithm (GA) was applied to reversely optimize the parameters of the constitutive model. To verify the accuracy of the optimized constitutive model, the average absolute relative error (AARE) and correlation coefficient (R) were used to evaluate the reliability of optimized constitutive model. The R value of the model was 0.999, and the AARE value was 0.048, respectively, indicating that the established high-temperature constitutive model for Ti6Al4V alloy has good calculation accuracy. The flow stress behavior of the material could be accurately delineated. Meanwhile, in order to study the formability of Ti6Al4V alloy, the hot processing map of the alloy, based on a dynamic material model, was established in this paper. The optimum hot working domains of the Ti6Al4V alloy were determined within 840–920 °C/0.01–0.049 s⁻¹ and 940–980 °C/0.11–1.65 s⁻¹; the hot processing map was verified in combination with the microstructure, and the fine and equiaxed grains and a large amount of β phase could be found at 850 °C/0.01 s⁻¹.     

Optimization of the Post-Process Heat Treatment Strategy for a Near-α Titanium Base Alloy Produced by Laser Powder Bed Fusion

During the last decades, titanium alloys have been of great interest for lightweight applications due to their high strength in combination with a low material density. Current research activities focus on the investigation of near-α titanium alloys produced by laser powder bed fusion (LPBF). These alloys are known for their superior tensile strength and high creep resistance. This study focuses on the optimization of post-process heat treatments and the impact on tensile and creep strength of a LPBF produced Ti6242S alloy. Therefore, a variety of annealing steps were conducted to gain knowledge about the decomposition process of the non-equilibrium as-built microstructure and the arising influence on the mechanical properties. Components made of Ti6242S and produced by LPBF reveal an extraordinarily high ultimate tensile strength of about 1530 MPa at room temperature, but show a low elongation at fracture (A₅ = 4.3%). Based on microstructure-property relationships, this study recommends precise heat treatments on how to improve the desired mechanical properties in terms of strength, ductility as well as creep resistance. Moreover, this study shows a triplex heat treatment, which enhances the elongation at fracture (A₅) to 16.5%, while the ultimate tensile strength is still at 1100 MPa.     

Effect of Thermomechanical Treatment on Structure and Functional Fatigue Characteristics of Biodegradable Fe-30Mn-5Si (wt %) Shape Memory Alloy

The Fe-Mn-Si shape memory alloys are considered promising materials for the biodegradable bone implant application since their functional properties can be optimized to combine bioresorbability with biomechanical and biochemical compatibility with bone tissue. The present study focuses on the fatigue and corrosion fatigue behavior of the thermomechanically treated Fe-30Mn-5Si (wt %) alloy compared to the conventionally quenched alloy because this important functionality aspect has not been previously studied. Hot-rolled and water-cooled, cold-rolled and annealed, and conventionally quenched alloy samples were characterized by X-ray diffraction, transmission electron microscopy, tensile fatigue testing in air atmosphere, and bending corrosion fatigue testing in Hanks’ solution. It is shown that hot rolling at 800 °C results in the longest fatigue life of the alloy both in air and in Hanks’ solution. This advantage results from the formation of a dynamically recrystallized γ-phase grain structure with a well-developed dislocation substructure. Another important finding is the experimental verification of Young’s modulus anomalous temperature dependence for the studied alloy system, its minimum at a human body temperature, and corresponding improvement of the biomechanical compatibility. The idea was realized by lowering M_s temperature down to the body temperature after hot rolling at 800 °C.     

Enhanced Elevated-Temperature Strength and Creep Resistance of Dispersion-Strengthened Al-Mg-Si-Mn AA6082 Alloys through Modified Processing Route

In the present work, we investigated the possibility of introducing fine and densely distributed α-Al(MnFe)Si dispersoids into the microstructure of extruded Al-Mg-Si-Mn AA6082 alloys containing 0.5 and 1 wt % Mn through tailoring the processing route as well as their effects on room- and elevated-temperature strength and creep resistance. The results show that the fine dispersoids formed during low-temperature homogenization experienced less coarsening when subsequently extruded at 350 °C than when subjected to a more typical high-temperature extrusion at 500 °C. After aging, a significant strengthening effect was produced by β″ precipitates in all conditions studied. Fine dispersoids offered complimentary strengthening, further enhancing the room-temperature compressive yield strength by up to 72–77 MPa (≈28%) relative to the alloy with coarse dispersoids. During thermal exposure at 300 °C for 100 h, β″ precipitates transformed into undesirable β-Mg₂Si, while thermally stable dispersoids provided the predominant elevated-temperature strengthening effect. Compared to the base case with coarse dispersoids, fine and densely distributed dispersoids with the new processing route more than doubled the yield strength at 300 °C. In addition, finer dispersoids obtained by extrusion at 350 °C improved the yield strength at 300 °C by 17% compared to that at 500 °C. The creep resistance at 300 °C was greatly improved by an order of magnitude from the coarse dispersoid condition to one containing fine and densely distributed dispersoids, highlighting the high efficacy of the new processing route in enhancing the elevated-temperature properties of extruded Al-Mg-Si-Mn alloys.     

Analysing the Interaction between Microscopic Deformation,Microstructure and Void Evolution of Near-α Titanium Alloys during Non-Superplastic Hot Deformation by an Integrated Crystal Plasticity Finite Element Model

High-efficiency and low-cost hot forming technologies for titanium alloys have been developed for producing complex-shaped, thin-walled tubular components under non-superplastic forming conditions. Under these forming conditions, there exist complex and highly integrated material evolution processes including microscopic heterogeneous deformation, microstructure evolution and damage behaviour. This paper presents an integrated crystal plasticity finite element model of near-α titanium alloys during non-superplastic hot deformation conditions considering grain boundary sliding (GBS), dynamic recrystallisation (DRX), as well as void evolution. The polycrystalline model of a near-α TA15 titanium alloy was established, containing α phase, β phase and grain boundary (GB) regions, in which the GB region was a visualised representation of GBS. The quantitative strength ratio between the GB regions and α phase was calculated according to the Zener–Holloman parameter Z and grain size, which determined the microscopic deformation behaviour. There were found to be two high microscopic strain regions in the α phase: intragranular deformation bands through the most favourable slipping and near the GBs through multiple slipping, which promoted continuous and discontinuous DRX, respectively. With the decrease in parameter Z or grain size, the activated dislocations accommodating GBS were found to no longer pile up inside the grain, but instead travel across the grain interior. Finally, methods to improve the macroscopic plastic formability were proposed for the difficult-to-form titanium alloys experiencing non-superplastic hot deformation.