To elucidate the hot deformation characteristics of TiAl alloys, flow stress prediction, microstructural evolution and deformation mechanisms were investigated in Ti-44Al-5Nb-1Mo-2V-0.2B alloy by isothermal compression tests. A constitutive relationship using the Arrhenius model involving strain compensation and back propagation artificial neural network (BP-ANN) model were developed. A comparison of two models suggested that the BP-ANN model had excellent capabilities and was more accurate in predicting flow stress. Based on the microstructural analysis, bending and elongation of colonies, γ and B2 grains were the main microstructural constituents at low temperature and high strain rate. Dynamic recrystallization (DRX) of γ and dynamic recovery (DRY) of β/B2 were the main deformation mechanisms. With the increase of temperature and decrease of strain rate, phase transformation played an important role. The flake-like γ precipitates in B2 grains, and a coarsening of γ lamellae via α lath dissolution during compression were observed. Additionally, the flow softening process commenced with dislocation pile-up and formation of sub-grain boundaries, followed by grain refinement, twins and nano-lamellar nucleation. Continuous DRX and phase transformation promoted the formability of Ti-44Al-5Nb-1Mo-2V-0.2B alloy.

The effects of the package materials on the hot workability and stress-strain characteristics of high-Nb TiAl alloy with a nominal composition of Ti-46Al-8Nb (in at.%) were systematically studied via “sandwich structure” hot compression. TiAl sheet fabrication was conducted by hot pack rolling, and the microstructural characteristics and deformation mechanisms were investigated. Based on the analysis of compressed samples and stress-strain curves, the stainless steel/TiAl structure showed better deformation compatibility with homogeneous deformation and decreasing resistance. However, severe interfacial reactions were inevitable. Meanwhile, for the titanium alloy/TiAl structure, few interfacial reactions happened, but wavy deformation and high resistance complicated the compression process. Finally, a package structure with an outer stainless steel isolation layer and inner titanium alloy was determined for the pack rolling process. A TiAl sheet with no crack defects was obtained with 80% reduction. The pack-rolled TiAl sheet took on alternate microstructure of the grain-boundary Al-enriched ribbons and elongated lamellar colonies ribbons. The grain-boundary recrystallized α2 phase, lumpy γ phase, and massive α2/γ lamellae could be observed, which led to the scatter microstructure. The microstructural characteristics mainly resulted from the solute segregations of as-cast Ti-46Al-8Nb alloys, which triggered the local flow softening and deformation incompatibility during hot pack rolling.