Tailoring continuous dynamic recrystallization via initial microstructure regulation through Te addition in 6016 aluminum alloy

Abstract This study investigates the effects of trace Te additions (0–0.6 wt.%) on the solidification, homogenization, and hot deformation behavior of 6016 aluminum alloys. In the as-cast state, Te disrupts the continuous interdendritic eutectic network and refines the dendrite structure, but the refinement saturates and slightly weakens above 0.4 wt.%. After homogenization, grain size first decreases and then marginally increases with Te content, with the 0.4 wt.% Te alloy exhibiting the finest and most uniform grain structure. Te is found to mainly exist in solid solution or as a highly dispersed state, indirectly optimizing the second-phase distribution. During hot compression at 450°C, all alloys show clear strain-rate sensitivity. At 0.01 s − 1 , the 0.4 wt.% Te alloy exhibits relatively lower flow stress, along with lower KAM values and a higher fraction of high-angle grain boundaries, indicating stronger dynamic softening and more pronounced continuous dynamic recrystallization. Overall, the 0.4 wt.% Te addition proves optimal, synergistically improving the microstructure and deformation behavior, which provides a valuable basis for the composition design of high-performance 6016 aluminum alloys.