This study systematically investigates the influence of cooling rate on the microstructure evolution and mechanical properties of a metastable β Ti-4.5Al-6.5Mo-2Cr-2.6Nb-2Zr-2Sn-1V alloy, using multi-scale characterization combined with thermal dilatometry and nanoindentation techniques. The continuous cooling transformation diagram identifies a critical cooling rate of about 200 °C/min, below which the α phase precipitation is completely suppressed. Experimental results reveal a gradual increase in the volume fraction of the α phase, ranging from 0 % to 50.6 %, as cooling rate decreases from 200 °C/min to 5 °C/min. The increase is associated with a corresponding enhancement in nanomechanical properties, achieving peak hardness of 5.25 GPa and Young's modulus of 123 GPa, attributed to synergistic effects related to phase type, content, and morphology. Fast quenching at 200 °C/min maintains a single metastable β phase by effectively preventing α phase precipitation, whereas relatively fast cooling rates (50–100 °C/min) promote selective intragranular α nucleation and heterogeneous precipitation due to unfavorable thermodynamic conditions and uneven defect distribution. Further reduction of cooling rates to intermediate levels (10–20 °C/min) initiates competitive growth of various α variants, including intragranular α, grain boundary α, and grain boundary Widmanstätten α. At the slow cooling rate of 5 °C/min, thermodynamically favorable conditions facilitate additional precipitation and coarsening of all α variants through enhanced atomic diffusion. The established quantitative relationships between thermal processing parameters (notably the critical threshold of ∼200 °C/min), multi-scale microstructure characteristics, and mechanical performance provide fundamental insights for microstructure design engineering and offer direct guidance for optimizing industrial heat treatment processes of metastable β titanium alloys.
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