Dynamic Response and Microstructural Characterization of Al3Zr/Al Composite Using 3D Processing Map

In the present work, Al3Zr/Al composite was fabricated through the in situ route. The fabricated composite was isothermally forged in the temperature and deformation rate range of 300-450 degrees C and 0.001-1 s(-1) to a true strain of 0.69. The flow stress behavior of the forged specimen decreased with the increase in temperature and decrease in the deformation rate. The kinetic rate calculation indicated an average hot deformation activation energy of 196 kJ/mol. The workability map showed a maximum power dissipation of 43% in a narrow working zone of 442-450 degrees C, 0.001 s(-1). Another working zone II with an efficiency value of > 34% is observed in 386-403 degrees C, 0.047-0.02 s(-1). Microstructural instabilities during hot forging are mostly observed at lower temperatures and higher strain rates regions, which are micro-crack, flow localization, particle cracking, and debonding. The EBSD analysis indicated a higher fraction (>= 55%) of strain-free grains in the peak dissipation efficiency region (400 degrees C, 0.1 s(-1), and 450 degrees C, 0.001 s(-1)). The boundary misorientation analysis confirmed the occurrence of dynamic recovery (DRV) and continuous dynamic recrystallization (CDRX) during hot forging. Dynamic softening is also supported by PSN and is dominant in the Al3Zr and matrix interface.