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<p>The hot deformation behavior of additively manufactured AlF357 alloy was systematically investigated through isothermal compression tests conducted over a temperature range of 200-350&#xa0;°C and strain rates of 0.1-10&#xa0;s<sup>−1</sup>. The flow stress response showed a strong dependence on deformation parameters, reflecting the competition among work hardening, dynamic recovery, and dynamic recrystallization mechanisms. Based on the experimental data, three constitutive models, namely the Johnson–Cook (JC), modified Johnson–Cook, and strain-compensated Arrhenius models (SCAM), were developed using a hybrid global–local optimization strategy that combined differential evolution and the Levenberg–Marquardt algorithms. The predictive performance of each model was evaluated using statistical indicators, including root mean square error, average absolute relative error, and coefficient of determination. The results indicate that both the modified JC model and the SCAM provide significantly improved prediction accuracy compared to the original JC model, with largely comparable performance across the deformation domain. The SCAM demonstrates slightly improved consistency, which can be attributed to its ability to account for thermally activated deformation mechanisms and nonlinear parameter interactions. Processing maps were constructed based on the dynamic materials model to identify stable and unstable deformation regimes and optimal hot-working windows. The microstructural evolution and dynamic recrystallization behavior were investigated using electron backscatter diffraction (EBSD), incorporating grain orientation spread, kernel average misorientation, grain boundary character, and texture analyses. EBSD results revealed that elevated temperatures and lower strain rates promote enhanced recovery and continuous dynamic recrystallization, leading to reduced intragranular strain and refined grain structures. The integration of constitutive modeling, processing-map analysis, and EBSD-based microstructural characterization provides a comprehensive understanding of the hot workability of the additively manufactured AlF357 alloy and offers practical guidance for thermomechanical post-processing and forming applications.</p>

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High-Temperature Compressive Response of Additively Manufactured AlF357 Alloy: Constitutive Modeling, Microstructural Evolution, and Processing Maps

  • 期刊论文

  • 发表日期：

    2026年6月18日

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  • Avinash Mohan,
  • Jayaganthan Rengaswamy

摘要

The hot deformation behavior of additively manufactured AlF357 alloy was systematically investigated through isothermal compression tests conducted over a temperature range of 200-350 °C and strain rates of 0.1-10 s−1. The flow stress response showed a strong dependence on deformation parameters, reflecting the competition among work hardening, dynamic recovery, and dynamic recrystallization mechanisms. Based on the experimental data, three constitutive models, namely the Johnson–Cook (JC), modified Johnson–Cook, and strain-compensated Arrhenius models (SCAM), were developed using a hybrid global–local optimization strategy that combined differential evolution and the Levenberg–Marquardt algorithms. The predictive performance of each model was evaluated using statistical indicators, including root mean square error, average absolute relative error, and coefficient of determination. The results indicate that both the modified JC model and the SCAM provide significantly improved prediction accuracy compared to the original JC model, with largely comparable performance across the deformation domain. The SCAM demonstrates slightly improved consistency, which can be attributed to its ability to account for thermally activated deformation mechanisms and nonlinear parameter interactions. Processing maps were constructed based on the dynamic materials model to identify stable and unstable deformation regimes and optimal hot-working windows. The microstructural evolution and dynamic recrystallization behavior were investigated using electron backscatter diffraction (EBSD), incorporating grain orientation spread, kernel average misorientation, grain boundary character, and texture analyses. EBSD results revealed that elevated temperatures and lower strain rates promote enhanced recovery and continuous dynamic recrystallization, leading to reduced intragranular strain and refined grain structures. The integration of constitutive modeling, processing-map analysis, and EBSD-based microstructural characterization provides a comprehensive understanding of the hot workability of the additively manufactured AlF357 alloy and offers practical guidance for thermomechanical post-processing and forming applications.