TiAl alloy is a high temperature structural material with excellent comprehensive properties in the range of 750–900 °C. However, its engineering application is limited by its poor plasticity and hot working properties at room temperature. Based on the above background, a novel three-phase Ti-40Al-6V-1Cr-0.3Ni (at.%) alloy was designed and fabricated in the present study. The as-cast ingot was subjected to near-isothermal forging, and the thermoplastic deformation behavior, microstructure evolution and mechanical properties were systematically studied. Near-isothermal forging shows excellent forming capability, and the forging disk is flawless without cracking. The core of the forging disk shows the greatest degree of deformation, and the microstructure is composed of fine equiaxed grains and residual (α2/γ) lamellae. The hardness of the B2 phase and the hardness difference between the B2 phase and γ phase are reduced by the Cr and V elements added in the alloy. The wrought alloy exhibits excellent mechanical properties at room temperature and elevated temperature, respectively. The uniform fine microstructure, low nanohardness of the B2 and γ phase and the property matching of each phase can be accounted for the excellent mechanical properties.

Aluminum-clad steel wires are widely used in ultra-high-voltage (UHV) transmission lines due to their excellent beneficial properties. To address the inadequate strength–ductility balance of aluminum-clad steel wires for UHV applications, this study investigates the effects of cold drawing and low-temperature annealing (200~330 °C) on the microstructure, aluminum/steel interface, and mechanical properties of 20SA (20.3% IACS) aluminum-clad steel wires. The results indicate that the cold-drawn steel core exhibits high strength due to its high dislocation density and strong fiber texture. Low-temperature annealing promotes overall recovery and partial recrystallization of the microstructure. Specifically, annealing at 240~280 °C significantly enhances ductility while maintaining high strength, achieving optimal strength–ductility synergy; however, higher annealing temperatures result in an unacceptably low ultimate strength, rendering them impractical for application. Interfacial characterization reveals that the as-clad and cold-drawn processes, as well as annealing below 250 °C for 10 min, maintain stable metallurgical bonding at the aluminum/steel interface, whereas annealing at 300 °C for 10 min induces the formation of brittle Fe-Al intermetallic compounds, thereby compromising service reliability. Furthermore, the precipitation of cementite (Fe₃C) with increasing temperature partially compensates for the strength loss caused by overall recovery. This study identifies the optimal heat treatment window, providing a theoretical basis for the strength–ductility design and reliable service of UHV transmission lines.