Analysing the Interaction between Microscopic Deformation, Microstructure and Void Evolution of Near-α Titanium Alloys during Non-Superplastic Hot Deformation by an Integrated Crystal Plasticity Finite Element Model

High-efficiency and low-cost hot forming technologies for titanium alloys have been developed for producing complex-shaped, thin-walled tubular components under non-superplastic forming conditions. Under these forming conditions, there exist complex and highly integrated material evolution processes including microscopic heterogeneous deformation, microstructure evolution and damage behaviour. This paper presents an integrated crystal plasticity finite element model of near-α titanium alloys during non-superplastic hot deformation conditions considering grain boundary sliding (GBS), dynamic recrystallisation (DRX), as well as void evolution. The polycrystalline model of a near-α TA15 titanium alloy was established, containing α phase, β phase and grain boundary (GB) regions, in which the GB region was a visualised representation of GBS. The quantitative strength ratio between the GB regions and α phase was calculated according to the Zener–Holloman parameter Z and grain size, which determined the microscopic deformation behaviour. There were found to be two high microscopic strain regions in the α phase: intragranular deformation bands through the most favourable slipping and near the GBs through multiple slipping, which promoted continuous and discontinuous DRX, respectively. With the decrease in parameter Z or grain size, the activated dislocations accommodating GBS were found to no longer pile up inside the grain, but instead travel across the grain interior. Finally, methods to improve the macroscopic plastic formability were proposed for the difficult-to-form titanium alloys experiencing non-superplastic hot deformation.