Microstructure Evolution and Constitutive Model of Spray-Formed 7055 Forging Aluminum Alloy

The thermal deformation behaviour of a spray-formed 7055 as-forged aluminium alloy was studied using isothermal hot-press tests under different deformation conditions (strain rates of 0.01, 0.1, 1, and 10 s^-1, temperatures of 340, 370, 400, 430, and 460 °C). An Arrhenius constitutive model was developed using flow stress data corrected for friction and temperature, yielding a correlation coefficient (R) of 0.9877, an average absolute relative error (AARE) of 4.491%, and a deformation activation energy (Q) of 117.853 kJ/mol. Processing maps integrating instability criteria and power dissipation efficiency identified appropriate processing parameters at 400-460 °C/0.08-0.37 s^-1. Furthermore, this study investigated how strain rate and temperature influence microstructural evolution. Microstructural characterization revealed that both dynamic recovery (DRV) and dynamic recrystallization (DRX) occur simultaneously during thermal deformation. At low temperatures (≤400 °C), DRV and continuous dynamic recrystallization (CDRX) dominated; at 430 °C, deformation microstructures and recrystallized grains coexisted, whereas abnormal grain growth prevailed at 460 °C. The prevailing mechanism of dynamic softening was influenced by the applied strain rate. At lower strain rates (≤0.1 s^-1), discontinuous dynamic recrystallization (DDRX) was the primary mechanism, whereas CDRX became dominant at higher strain rates (≥1 s^-1), and dislocation density gradients developed within adiabatic shear bands at 10 s^-1.