Crystallographic orientation and slip behavior of powder metallurgy Ti–6Al–4V via multi-directional forging

In this study, we present a microstructural and mechanical analysis of Ti–6Al–4V alloys processed by low-temperature multi-directional forging at 900 °C, achieving near-theoretical density (99.9%), with a tensile strength of 1070 MPa and elongation of 14.9%. The microstructure is defined by both continuous and discontinuous dynamic recrystallization occurring simultaneously, related to an increase in dislocation density. Significantly, this study reveals the interaction between crystallographic orientation and spheroidization during the forging process. Specifically, changes in crystallographic orientation include the asynchronous formation of new subgrains/grains, the disruption of the Burgers orientation relationship, and rotation around the <11 2 ‾ 0>axis, which not only increases the orientation differences between α lamellae but also enhances the spheroidization process. Moreover, our findings demonstrate that during deformation, the activation of basal and pyramidal slip systems is favored over prismatic slip, indicating that the forging process has enhanced slip activity. The average misorientation angle and the fraction of high-angle grain boundaries are quantified, providing a detailed characterization of the evolved microstructure. This study adopts a new perspective to examine the microstructural evolution during the multidirectional forging process in powder metallurgy, presenting findings that elucidate how multidirectional forging effectively controls. • The asynchronous rotation of the α phase is related to spheroidization. • Subgrain formation, Burger's loss, and Schmid factors modulate crystal orientation. • Continuous dynamic recrystallization is predominant in α phase. • Basal and pyramidal slips are more easily activated than prismatic slip in α phase.