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 paper presents a systematic study of heating effects on the hot deformation and microstructure of dual-phase titanium alloy Ti-6Al-4V (TC4) under hot forming conditions. Firstly, hot flow behaviors of TC4 were characterized by conducting tensile tests at different heating temperatures ranging from 850 °C to 950 °C and heating rates ranging from 1 to 100 °C/s. Microstructure analysis, including phase and grain size, was carried out under the different heating conditions using SEM and EBSD. The results showed that when the heating temperature was lower than 900 °C, a lower heating rate could promote a larger degree of phase transformation from α to β, thus reducing the flow stress and improving the ductility. When the temperature reached 950 °C, a large heating rate effectively inhibited the grain growth and enhanced the formability. Subsequently, according to the mechanism of phase transformation during heating, a phenomenological phase model was established to predict the evolution of the phase volume fraction at different heating parameters with an error of 5.17%. Finally, a specific resistance heating device incorporated with an air-cooling set-up was designed and manufactured to deform TC4 at different heating parameters to determine its post-form strength. Particularly, the yield strength at the temperature range from 800 °C to 900 °C and the heating rate range from 30 to 100 °C/s were obtained. The results showed that the yield strength generally increased with the increase of heating temperature and the decrease of heating rate, which was believed to be dominated by the phase transformation.

Fabrication of a newly developed high entropy alloy is an essential step to enable it to be used as an industrial structure for its potential applications, such as billets, frames and tubes. Bulk forming processes at high temperatures are preferably used requiring the hot flow behavior of the HEA, which needs to be thoroughly investigated for accurate construction of a robust constitutive model and, hence, reliable process simulation and optimizations. In this study, to compensate for the lack of modelling microstructure using conventional phenomenological models, a novel physical mechanism-based model of CoCrFeMnNi high-entropy alloy was established. Particularly, the adiabatic heat effect was taken into account for modelling the HEA for the first time. The hot flow behavior, as well as grain evolution of this alloy under different forming conditions, are well modelled. The modelling predictions obtain great agreement with the experimental results, the calculated R-value (all higher than 0.95) and AARE (all smaller than 0.05) because the different conditions provide validity to the accuracy of the model prediction. In addition, the temperature increase due to deformation heat was well predicted to further evident to the accuracy of model. Furthermore, the hardening behavior during hot deformation was also compared, enabling the provision of useful guides for process designers of hot bulk forming HEAs.

The precise characterisation of hot flow behavior of titanium alloys is of vital importance for practical hot forming processes. To precisely determine the hot flow behavior of titanium alloys under the forming conditions, Gleeble hot tensile tests are usually performed to simulate the forming processes by accurately controlling the deformation temperatures and strain rates under designed conditions. However, there exists a non-uniform temperature distribution during the Gleeble tests, which leads to inaccuracies in the determined hot flow behavior. To overcome such an issue, this paper proposed a new strain-based correction method for Gleeble hot tensile tests, enabling the mitigation of the non-uniform temperature-induced stress-strain curve inaccuracies. The non-uniform temperature zones have been successfully excluded in the calculation of the true strain levels. A series of hot uniaxial tensile tests of TA32 at temperatures, ranging from 750 °C to 900 °C, and strain rates, 0.01/s~1/s, were carried out. The obtained stress-strain correlations for a large gauge zone were characterized using the new correction method, which was further used to evaluate the hardening behavior of titanium alloys. The results have shown that the ductility, strain hardening component (i.e., n), strain rate hardening component (i.e., m) and uniform strain value (i.e., ${\epsilon }_u$) are over-estimated, compared to conventional method. Higher strain rates and lower temperature leads to enhanced hardening behavior. This research provides an alternative correction method and may achieve more accurate stress-strain curves for better guidance of the hot forming process for titanium alloys.