Key Takeaways & Executive Findings
- •• The Arrhenius constitutive model with coupled correction accurately predicts the flow stress of SLM-processed AlMgScZr alloy, with a correlation coefficient of 0.999 and an average absolute relative error of 2.766%. • Hot processing maps at different strains identify stable and unstable regions, guiding optimal thermal deformation conditions for the alloy. • Microstructural evolution during thermal deformation is temperature-dependent: dynamic recrystallization dominates at 300–360 °C, while dynamic recovery prevails at 390–500 °C. • The study provides a foundation for optimizing hot working processes and predicting performance of SLM-fabricated high-strength aluminum alloys in high-temperature applications.
Abstract
The AlMgScZr high-strength aluminum alloy fabricated by selective laser melting (SLM) technology exhibits a “bimodal microstructure”, resulting in significant non-uniform deformation during thermal deformation. This study investigates the flow behavior of SLM-processed AlMgScZr aluminum alloy utilizing the Gleeble-1500D thermal simulation machine. The true stress−strain curves were amended based on the friction theory. Through determining the Zener-Hollomon parameters, the correlation between flow stress, deformation temperature, and strain rate during the high-temperature thermoplastic deformation of SLM-processed AlMgScZr aluminum alloy with a “bimodal microstructure” was established. In addition, the microstructural evolution during thermal deformation was analyzed. The results indicated that the predicted flow stress values obtained from the Arrhenius constitutive equation with coupled correction of thermal deformation parameters closely matched the experimental values. The correlation coefficient and the average absolute relative error of the corrected model were 0.999 and 2.766%, respectively, accurately predicting the thermoplastic deformation behavior of SLM-processed high-strength aluminum alloy with a “bimodal microstructure”. Furthermore, hot processing maps at different strains were established, identifying stable and unstable regions under different deformation conditions. Microstructural observations revealed different thermal deformation mechanisms under various deformation temperatures. Specifically, dynamic recrystallization characteristics dominated the microstructure at lower temperatures (300−360 ℃), while dynamic recovery was dominant at higher temperatures (390−500 ℃).
1. Introduction
Selective laser melting (SLM) technology leverages the interaction between a laser and metal powder to create molten pools that rapidly melt and solidify, resulting in a refined microstructure and mechanical properties that surpass those achieved through traditional casting processes. SLM enables the rapid manufacture of high-precision customized components with complex structures, successfully applied in key components for aerospace, marine engineering, and automotive industries, including engine turbine discs, propellers, and thermostat covers [1−5].
To satisfy the lightweight requirements for industry application, extensive research has been conducted on manufacturing different series of aluminum alloys using SLM technology. An Airbus subsidiary in Germany designed a high-strength Al-Mg aluminum alloy that contains scandium and zirconium elements [6, 7]. During the SLM process, columnar and equiaxed grains alternately grow across layers due to complex thermal cycles and the precipitation of Al3(Sc, Zr) particles, maintaining a balance between strength and plasticity after heat treatment [8−13].
SLM-processed AlMgScZr alloys exhibit excellent specific strength and high-temperature creep resistance, making them promising candidates for high-temperature load-bearing structural components in aerospace applications. Under severe service conditions, high-strength aluminum alloy structural components undergo micro-scale thermal deformation when exposed to high temperatures [14]. Understanding the microstructural evolution during thermal deformation contributes to predicting performance changes in aluminum alloys and alloy design under high pressure technology [15, 16]. Flow stress is a fundamental parameter characterizing the deformation behavior of metals and alloys, and constitutive equations describe the flow stress behavior. The Arrhenius constitutive model describes the plastic deformation behavior of materials at high temperatures by using macroscopic variables to replace microstructural changes [17, 18]. The model is applicable for superalloys and aluminum alloys [19], but it primarily considers temperature and strain rate, neglecting the influence of strain on flow stress. To address
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ZHU Zeng-wei, LIU Qian-li, WANG Qiu-ping, JIANG Tao, GUAN Jie-ren (2025). Thermal compression behavior and microstructural evolution of selective laser melted AlMgScZr high-strength aluminum alloys. Journal of Central South University. https://doi.org/10.1007/s11771-025-6114-0
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Frequently Asked Questions
What is the main objective of this study?
The study investigates the thermal compression behavior and microstructural evolution of selective laser melted AlMgScZr high-strength aluminum alloys, focusing on establishing a constitutive model to predict flow stress and analyzing deformation mechanisms.
How was the flow stress behavior modeled?
The flow stress behavior was modeled using an Arrhenius-type constitutive equation with coupled correction of thermal deformation parameters, which accurately predicted experimental values with a correlation coefficient of 0.999 and an average absolute relative error of 2.766%.
What are the key microstructural changes during thermal deformation?
At lower temperatures (300–360 °C), dynamic recrystallization dominates, while at higher temperatures (390–500 °C), dynamic recovery is the primary mechanism.
What practical applications does this research support?
The findings help optimize hot working processes and predict the performance of SLM-fabricated high-strength aluminum alloys in high-temperature aerospace and other load-bearing applications.
What is the significance of the hot processing maps?
Hot processing maps at different strains identify stable and unstable regions, guiding the selection of safe deformation conditions to avoid defects and improve formability.
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