• Established a quantitative DRX kinetics model for Ti-10V-2Fe-3Al alloy, linking DRX grain size and volume fraction to abnormal coarse grain (ACG) formation during solid solution.
• Identified critical DRX criteria (dDRX ≤ 2.60 μm, 72.5% ≤ XDRX ≤ 87.9%) that predict ACG occurrence, showing that both excessive and insufficient DRX suppress ACG.
• Developed a finite element simulation platform with a coarse grain criterion subroutine to visually predict macroscopic ACG distribution in die forging, validated by experiments.
• Demonstrated that deformation temperature and strain rate significantly influence DRX and ACG, providing process windows to avoid ACG defects in aerospace components.