In this study, we investigated the effects of modified aging treatments on the microstructures and hardness in a commercial 6016 Al alloy through hardness tests and transmission electron microscopy (TEM) observations. The results demonstrate that many fine needle-like β″ phases contribute to the high hardness of peak-aged (T6) alloys. Over-aging treatments lead to the precipitation of lath-like β′, β″/disordered, or B′/disordered composite phases. Moderate over-aging treatment results in the coarsening of grain boundary precipitates (GBPs) and widening of the precipitate-free zone (PFZ), while heavy over-aging treatment triggers the re-precipitation of Cu-containing GBPs and increases the number density of GBPs. A retrogression and re-aging (RRA) treatment precipitates β″, lath-like β′, and disordered phases, while a two-step aging (T78) treatment precipitates β″, B′, and disordered phases. Both the T78 and the RRA treatments lead to the coarsening of GBPs and the widening of PFZs. The decreased hardness during over-aging treatments is attributed to a combination of coarsening intragranular precipitates and/or wider PFZs. The T78 and RRA tempers achieve 95.5% and 94% of the hardness values of the T6 treatment, respectively. The hardness values of the RRA and T78 treated alloys are related to the finer nano-sized precipitates formed during the high temperature process. These precipitates can compensate for the loss of hardness caused by the increase in the widths of the PFZs and the coarsening of the matrix precipitates. The relationship between the hardness and microstructures such as PFZs and precipitates in the matrix during various heat treatments is elucidated.

The investigation of thermal deformation behavior plays a significant role in guaranteeing the overall performance of alloy materials. In this manuscript, a series of isothermal compression tests at different temperatures (300, 350, 400, and 450 °C) and strain rates (0.001, 0.01, 0.1, and 1 s⁻¹) were conducted to study the thermal deformation behavior of 7075 aluminum alloy. Subsequently, processing maps at a strain from 0.4 to 1.39 were established according to the stress–strain data obtained from various deformation parameters. The microstructural evolution of the target alloy was observed with an optical microscope and transmission electron microscope. The results reveal the unstable regions are located at (360–450 °C, 0.04–1 s⁻¹) and (300–315 °C, 0.01–0.22 s⁻¹). Precipitation particles, pinned dislocations, and highly dislocated areas can be observed in the microstructure of the alloy in the unstable regions. This is a potential crack and defect formation point. The identified optimum processing parameters are located at (375–450 °C, 0.001–0.03 s⁻¹), with a maximum dissipation efficiency of 0.6.

In order to explore the hot deformation behaviors of the as-cast 7005 aluminum alloy, a number of hot tensile tests with four temperatures (100, 200, 300, and 400 °C) and three strain rates (0.001, 0.01, and 0.1 s⁻¹) were performed. The Johnson–Cook model was used to express the relationship between stress, strain, strain rate, and temperature. Scanning electron microscopy (SEM), optical microscopy (OM), and transmission electron microscopy (TEM) were selected to reveal fracture features and microstructure evolution of the studied alloy. The results indicate that the flow stress level of the alloy reduces with increases in the deformation temperature and decreases in the strain rate. The established Johnson–Cook model can be employed to characterize the thermal flow behavior of the experimental alloy. The grains near the fracture surface were elongated, and a certain number of holes were found after deformation at 400 °C. The alloy exhibits obvious ductile fracture features. The dimple is deep with high quantity. Due to the plastic deformation, a high-density dislocation structure is found in the material. High-temperature conditions promote the annihilation of dislocation, and, as a result, the dislocation density decreases gradually with the increase in temperature. In addition, a certain number of precipitates were found in the alloy after high-temperature tension.

The hot tensile behavior of an extruded 6082 alloy sheet at varying temperatures and strain rates was investigated by a Gleeble3500 thermal simulation testing machine. The optical microscope (OM), scanning electron microscope (SEM), transmission electron microscopy (TEM) and X-ray diffraction (XRD) were applied to observe the microstructure evolution. It is found that the flow stress of the studied alloy declines with increasing deformation temperature. When deformed at high temperatures, the density of dislocation decreases obviously. In addition, precipitate coarsening occurs, resulting in a decrease in deformation resistance. The dimple number of the fracture samples increases with temperature and the size of the dimple becomes deeper, exhibiting an excellent plasticity. The 6082 sheet presents anisotropy of mechanical behavior at 300 °C, this can be attributed to the fibrous grain and the Brass component {011}. The anisotropic behavior seems to be slighter with an increase in temperature. No obvious anisotropic behavior was found when tensiled at 400 °C. Because it is easier to activate the slip system at elevated temperatures, meanwhile, the recrystallization begins to occur at 400 °C.