This study investigated high-speed air-atomized water-mist impingement cooling of 2219 aluminum alloy plates using a self-developed spray-quenching setup. Cooling intensity was controlled by varying the water loading fraction, and cooling curves were recorded using embedded thermocouples. Solution–aging treatments with conventional water quenching and mist quenching were performed, and multi-pass pre-deformation routes were applied before and/or after solution treatment. Tensile properties were evaluated at room temperature. Mist impingement cooling achieved markedly higher cooling rates than air cooling, with peak values in the order of 10³ °C/s. Higher cooling intensity improved quenching efficiency and increased strength after aging. Multi-pass pre-deformation enhanced yield strength, but reduced elongation at high deformation levels, revealing a strength–ductility trade-off. These results provide guidance for optimizing quenching and pre-deformation parameters in heat treatment of 2219 aluminum alloy components.

The deformation mechanism during the hot compression of PM nickel-based superalloy FGH99 and its micro-structural evolution, especially the evolution of γ’ phases, are the key factors affecting the final molding quality of aero-engine hot forged turbine disks. In this study, a new constitutive model of viscoplasticity with micro-structures as physical internal parameters were developed to simulate the hot compression behavior of FGH99 by incorporating the strengthening effect of the γ’ phase. The mechanical behavior of high-temperature (>1000 K) compressive deformation of typical superalloys under a wide strain rate (0.001~1 s⁻¹) is investigated using the Gleeble thermal-force dynamic simulation tester. The micro-structure after the hot deformation was characterized using EBSD and TEM. Work hardening as well as dynamic softening were observed in the hot compression tests. Based on the mechanical responses and micro-structural features, the model considered the coupled effects of dislocation density, DRX, and γ’ phase during hot flow. The model is programmed into a user subroutine based on the Fortran language and called in the simulation of the DEFORM-3D V6.1 software, thus realizing the multiscale predictive simulation of FGH99 alloy by combining macroscopic deformation and micro-structural evolution. The established viscoplastic constitutive model shows a peak discrepancy of 10.05% between its predicted hot flow stresses and the experimental values. For the average grain size of FGH99, predictions exhibit an error below 7.20%. These results demonstrate the high accuracy of the viscoplastic constitutive model developed in this study.