Microstructural evolution during hot forming of aluminium alloys plays a critical role in both the material flow behaviour during the deformation and the post-form mechanical properties in service. This paper presents a comprehensive review on the recrystallisation mechanisms, the interrelations between microstructures and macroscopic responses, and the associated modelling methods for aluminium alloys under hot forming conditions. Particular attention is focused on dynamic recrystallisation (DRX), which occurs during hot forming. The mechanisms, key features, and conditions of occurrence (forming temperature, strain rates, etc.) during hot forming for each type of DRX type are classified. The relationships between microstructures and macroscopic responses, including the flow behaviour, the post-form strength and ductility, are summarised based on existing experimental results. Most importantly, the associated modelling work, describing the recrystallisation and the viscoplastic behaviour under hot forming conditions, is grouped into four types, to enable a clear and concise understanding of the existing quantitative micro–macro interactions, which are particularly valuable for the future development of advanced physically based multi-scale modelling work for hot-forming processes in aluminium alloys.

Physicallybased constitutive equations are increasingly used for finite element simulations of metal forming processes due to the robust capability of modelling of underlying microstructure evolutions. However, one of thelimitations of current models is the lack of practical validation using real microstructure data due to the difficulties in achieving statistically meaningful data at a sufficiently large microstructure scale. Particularly, dislocation density and grain size governing the hardening in sheet deformation are of vital importance and need to be precisely quantified. In this paper, a set of dislocation mechanics-based plane stress material model is constructed for hot forming aluminum alloy. This material model is applied to high strength 7075 aluminum alloy for the prediction of the flow behaviorsconditioned at 300–400 °C with various strain rates. Additionally, an electron backscatter diffraction (EBSD) technique was applied to examine the average grain size and geometrical necessary dislocation (GND) density evolutions, enabling both macro- and micro- characteristics to be successfully predicted. In addition, to simulate the experienced plane stress states in sheet metal forming, the calibrated model is further extended to a plane stress stateto accuratelypredict the forming limits under hot conditions.The comprehensively calibrated material model could be used for guidinga better selection of industrial processing parameters and designing process windows, taking into account both the formed shape as well as post formed microstructure and, hence, properties.

This work focuses on quantitatively investigating the relationship between creep and stress relaxation of 7050 aluminum alloy at ageing temperatures. The creep strain rates, creep exponent, n, and activation energy were extracted from both the creep and stress relaxation curves to explore the creep mechanisms. Results showed that higher applied stress promotes the creep and stress relaxation extents. The calculated creep strain rates from creep and stress relaxation curves located in similar ranges and share similar n values (n = 3.7 for creep and n = 3.5 for stress relaxation), indicating that both tests are dominated by the dislocation slip mechanism. Additionally, the n value for creep tests is a constant throughout the tests, indicating that the dominant creep mechanism is unchanged. However, the activation energy changes from 123 kJ/mol to 139 kJ/mol, possibly due to evolved dislocations. Such a new finding could provide a supporting mechanism for building constitutive equations depending on the evolved A value. Furthermore, compared to the single-stage creep ageing, no primary creep was observed in T74 multi-stage creep ageing while similar amount of total creep strains was achieved. This suggests an alternative loading sequence for creep age forming of 7050 aluminum alloy, i.e., loading at the second stage to avoid prolonged exposure to high temperatures, extend the tool life, and achieve similar amounts of inelastic deformations. Based on all the above studies, creep and stress relaxation have a certain relationship. This paper provides a theoretical basis for future research on creep ageing forming of 7050 aluminum alloy.