Anisotropic formability and deformation mechanism of near-α titanium alloy sheet under continuous nonlinear strain paths at high temperature

In the present study, the anisotropic formability and underlying deformation mechanism of near-α TA32 titanium alloy sheet under continuous nonlinear strain paths (CNSPs) at high temperature were investigated in depth. To achieve this goal, a new experimental method combining hot gas bulging with step-combined dies was proposed, and the hot CNSPs of metal sheets can be flexibly and conveniently realized by changing the number and shape of step-combined dies. Based on this method, the anisotropic deformation behavior and forming limits of TA32 sheet under fifteen CNSPs were tested at 800 ℃ with a strain rate of 0.001 s⁻¹. Then, two advanced constitutive models with different scales were embedded into the classical Marciniak-Kuczyński (M-K) theory to predict the forming limits of TA32 sheet under different strain paths: the macro-scale viscoplastic model coupled with Hill48 yield criterion and non-associated flow rule (NAFR) as well as the meso-scale three-dimensional crystal plasticity finite element (CPFE) model coupled with cellular automata (CA). The results demonstrate that the CPFE-CA-MK coupled model exhibits higher accuracy in predicting the forming limits of TA32 sheet under linear and continuous nonlinear strain paths. Especially for the tension-tension strain paths, the CPFE-CA-MK coupled model improves accuracy by at least 3.1 % compared to macro-scale models. Due to the material anisotropy, the initial inclination angle of the groove in the CPFE-CA-MK model is closely related to the strain path and significantly affects the prediction accuracy. Based on the CPFE simulation, the effects of anisotropy and strain path change on the dislocation slip mode of different texture components was analyzed in depth, which provides a theoretical guidance for the optimization of hot forming process of TA32 titanium alloy complex components.