Structure refinement and performance balance of high-strength aluminum alloys using an improved thermomechanical treatment process

The microstructure of 7A85 aluminum alloy forgings often contains coarse second-phase particles and grains. To improve the microstructures and balance the properties, we used an enhanced thermomechanical treatment process that included multiaxial hot forging, multiaxial cryoforging (MACF), and three-step aging treatment. We thoroughly investigated the effects of MACF with 1–3 passes on the evolution of microstructure, three-dimensional (3D) mechanical properties at the center and edge, fracture toughness, and corrosion resistance of the alloy. Our findings revealed that multiaxial hot forging had a limited ability to crush the coarse second-phase particles. However, the higher flow stress and compound brittleness of MACF resulted in a significant increase in particle fragmentation and driving force for precipitation. Additionally, under MACF, massive dislocations proliferated due to the inhibition of dynamic recovery, forming large orientation gradient regions, which promote static recrystallization and grain refinement during solution treatment. As the number of MACF passes increased from one to three, the effect of particle crushing initially increased and then plateaued, the 3D grain sizes first decreased and then slightly increased, and the spacing of grain boundary precipitates (GBPs) increased. The dense and uniform precipitates, finest equiaxed grains, a low fraction of coarse particles, and large GBP spacing in MACF2 resulted in the higher strength, highest elongation with minimal anisotropy, superior fracture toughness, and enhanced corrosion resistance. Ultimately, MACF2 demonstrated the best overall performance and good homogeneity, with an average 3D ultimate tensile strength, average 3D yield strength, average 3D elongation, and fracture toughness at the center of 548 MPa, 476 MPa, 13.4%, and 42.5 MPa·m1/2, respectively. These values were respectively 4.2%, 1.9%, 50.6%, and 13.9% higher than those of the uncompressed sample.