Al Alloy Research Articles

A generalised framework for modelling anisotropic creep-ageing deformation and strength evolution of 2xxx aluminium alloys

The 2xxx aluminium alloys are extensively applied in the aerospace industry due to their lightweight and balanced performance characteristics. However, a comprehensive method for modelling both the anisotropic creep deformation and strengthening behaviour in creep age forming (CAF) for 2xxx aluminium alloys remains lacking. This paper presents a generalised framework for establishing constitutive models capable of describing the anisotropic creep deformation coupled with the microstructure and material strength evolutions during creep-ageing of both the original and the pre-deformed 2xxx series Al alloys. This framework extends the rolling direction-based material model to anisotropic scenarios at varying angles between the loading and rolling directions, by employing the non-uniform rational B-splines (NURBS). The details about the anisotropic model calibration and numerical simulation implementation are demonstrated. The feasibility of this method was verified by its application to various 2xxx series aluminium alloys with or without pre-deformation, through constitutive modelling and numerical simulation, with satisfactory agreements between prediction and experimental data. For the first time, the proposed framework provides a generalised routine for establishing anisotropic creep-ageing models for various 2xxx aluminium alloys.

Improved strength and interfacial microstructure of dissimilar Al/steel weld via combined addition of Zn and Ni

The effect of the combined addition of Zn and Ni on the mechanical properties and microstructures of an intermetallic compound (IMC) layer of dissimilar welds of Al alloy 5052 to low-carbon steel was systematically investigated. A maximum weld strength of 120 MPa was achieved with the combined addition of Zn and Ni, which was 193 % higher than that of the weld produced without the addition of Zn or Ni. The addition of Zn resulted in the formation of soft Fe–Zn IMCs in the IMC layer, which reduced the hardness of the IMC layer. Additionally, the combined addition of Zn and Ni promoted the formation of Fe–Zn IMCs, which further softened the IMC layer. Further softening of the IMC layer, reduction in the thickness of the IMC layer, and suppression of the formation of defects in the IMC layer, achieved by the combined addition of Zn and Ni, drastically improved the weld strength.

Elucidating the effect of cyclic plasticity on strengthening mechanisms and fatigue property of 5xxx Al alloys

The strength of non-heat-treatable 5xxx Al alloys is derived from solid solution strengthening and strain hardening, the absence of a precipitation strengthening response results in their lower strength. In this study, significant improvements in strength can be achieved by subjecting three different Mg concentrations 5xxx Al alloys to cyclic plasticity. A quantitative analysis of the respective contributions to the yield strength has been conducted by combining transmission electron microscopy and atom probe tomography. Additionally, the fatigue performance and fatigue mechanism of the cyclic strengthened 5xxx Al alloys have been thoroughly studied due to its transformation from non-heat-treatable to precipitation strengthening. We demonstrate that the high-cycle fatigue (HCF) strength of the cyclically strengthened state only experiences a minor improvement compared to the as-received state, which is significantly disproportionate to the enhancement in tensile strength. This disparity is primarily attributed to the changes in microstructure and fatigue mechanisms, resulting in a reduction in fatigue ratio. This study provides important insights for expanding research on cyclic plasticity methods in fatigue performance, and can aid in the development of improved processes for optimal fatigue resistance.

Effect of TiO2 content on the thermal control properties of Al2O3-xTiO2 composite coatings prepared by supersonic plasma spraying technology

The main challenge faced by spacecraft is the large temperature difference in its operating environment. Thermal control coatings prepared on spacecraft and instrument surfaces are currently the most efficient ways for heat dissipation and control. In this work, Al2O3-xTiO2 composite coatings with different TiO2 contents were prepared on 7075-Al alloy substrate by supersonic plasma spraying technology. The microstructure, phase composition, mechanical properties, thermal control properties, and corrosion resistances of the coatings were investigated. The raw stock feeds were mainly composed of α-Al2O3 and anatase TiO2, but the coatings were mainly γ-Al2O3 and rutile TiO2. The average Vickers microhardness of the coatings decreased from 1198.9 to 810.4 HV0.2 with the increase of TiO2 contents, but the elastic modulus increased from 158.5 to 244.3 GPa. The thermal control properties of the coatings were promoted with the growth of TiO2 contents, and the absorptance increased from 27.1 to 89.2% with the emittance from 83.7 to 86.5%. The corrosion potential and corrosion resistance of the coating gradually increased with TiO2 content due to its gradually improved hydrophobicity. This work broadens the application boundary of Al2O3-xTiO2 composite coating and provides an innovative idea for material selection of thermal control coatings.

Role of TiC on the microstructure, tensile property and thermal stability of laser powder bed fusion fabricated AlSi10Mg alloy

The incorporation of ceramic particles is frequently employed to enhance the printability of high-strength aluminum (Al) alloys in laser powder bed fusion (L-PBF). However, their influence on the long-term thermal stability and elevated temperature mechanical properties of the Al alloy is seldom studied. This study aims to address this gap by investigating the role of micron-sized TiC particles in the microstructure, long-term thermal stability, and elevated temperature tensile properties of an L-PBF-fabricated AlSi10Mg alloy. The results indicate that highly dense TiC/AlSi10Mg samples can be fabricated, featuring fine equiaxed grains rather than the coarse columnar grains typically formed in the AlSi10Mg alloy. This columnar-to-equiaxed transition is attributed to the residual TiC and the in-situ formation of Al3Ti particles, which act as nucleating agents. Moreover, the incorporation of TiC significantly enhances the long-term thermal stability of the AlSi10Mg alloy by improving the stability of the eutectic network and retarding the coarsening of Si particles by inhibiting Si diffusion. Compared to the AlSi10Mg counterpart, the TiC/AlSi10Mg composite exhibits a higher hardness retention ratio (56 % versus 45 %) after thermal exposure at 400 °C for 192 h. The residual TiC and in-situ formed Al3Ti have high thermal stability and can impede dislocation motion, thereby contributing to enhanced long-term thermal stability. This study offers insights into the design of L-PBF ceramic-reinforced Al alloys with improved thermal stability for high-temperature applications.

A Quantitative Phase Analysis by Neutron Diffraction of Conventional and Advanced Aluminum Alloys Thermally Conditioned for Elevated-Temperature Applications.

As the issue of climate change becomes more prevalent, engineers have focused on developing lightweight Al alloys capable of increasing the power density of powertrains. The characterization of these alloys has been focused on mechanical properties and less on the fundamental response of microstructures to achieve these properties. Therefore, this study assesses the quality of the microstructure of two high-temperature Al alloys (A356 + 3.5RE and Al-8Ce-10Mg), comparing them to T6 A356. These alloys underwent thermal conditioning at 250 and 300 °C for 200 h. Time-of-flight neutron diffraction experiments were performed before and after conditioning. The phase evolution was quantified using Rietveld refinement. It was found that the Si phase grows significantly (13-24%) in T6 A356, A356 + 3.5RE, and T6 A356 + 3.5RE alloys, which is typically correlated with a reduction in mechanical properties. Subjecting the A356 3.5RE alloy to a T6 heat treatment stabilizes the orthorhombic Al4Ce3Si6 and monoclinic β-Al5FeSi phases, making them resistant to thermal conditioning. These two phases are known for enhancing mechanical properties. Additionally, the T6 treatment reduced the vol.% of the cubic Al20CeTi2 and hexagonal ᴨ-Al9FeSi3Mg5 phases by 13% and 23%, respectively. These phases have detrimental mechanical properties. The Al-8Ce-10Mg alloy cubic β-Al3Mg2 phase showed significant growth (82-101%) in response to conditioning, while the orthorhombic Al11Ce3 phase remained stable. The growth of the beta phase is known to decrease the mechanical properties of this alloy. These efforts give valuable insight into how these alloys will perform and evolve in demanding high-temperature environments.

Additive manufacturing of novel aluminium matrix composites with enhanced strength and processability via boron nitride functionalization

The present work systematically investigates the effects of BN nanopowder functionalization on the processability, microstructure and tensile response of the custom Powder Bed Fusion Laser Beam (PBF-LB) Al alloy ‘AMALLOY3D’. The results show that a minor addition of BN (0.3% by weight) not only produces near fully dense parts (99.91%), but is also paired with improved flowability, enhancing the overall processability. Electron backscatter diffraction (EBSD) analysis revealed the transformation to a fully equiaxed grain structure in the BN-functionalized material, resulting in a 40% increase in yield strength. Energy dispersive spectroscopy using a scanning transmission electron microscope (STEM-EDS) was employed to reveal the intricate secondary phases’ arrangements. These observations coupled with the help of the CALPHAD approach led to the reconstruction of the solidification history of AMALLOY3D and the BN-functionalized material. The present study unravels the complex dynamics leading to the columnar-to-equiaxed transition in BN-reinforced AMCs, proving that such unique microstructures and exceptional tensile properties can be achieved without compromising PBF-LB processability.

Comparison of Energy Absorptive Capacities of Different Aluminum Alloy Foams Placed Inside the Crash Box

Increasing population worldwide and the resulting increasing number of automobiles increase the risk of traffic accidents. Due to this increasing risk, automobile manufacturers take various safety measures to protect drivers and passengers in case of possible accidents. Crash boxes are one of the passive safety system elements that are the first to absorb the impact in the event of a front or rear impact accident, absorbing the resulting deformation energy and ensuring that it is transmitted into the car at the least possible level. Therefore, increasing the energy absorption ability of crash boxes is an extremely important issue. In this study, it was aimed to increase the energy absorption capabilities by placing aluminum foam based materials produced by using the powder metallurgy method using three different aluminum alloys (Al2024, Al5083, and Al6061) inside the crash boxes, which are normally manufactured as hollow. In addition, the produced aluminum foams were compared in terms of pore sizes with SEM images. It can be said that Al6061 is the most ideal material among the alloys used in terms of pore structure and homogeneity. On the other hand, Al6061 alloys produced the greatest damped energy value within the parameters of the investigation, 221.711 J. This value was 169.556 J for Al2024 alloy and 214.101 J for Al5083 alloy. As a result, it was concluded that the amount of energy absorption can be increased by about 4-5 times by using metallic foams produced using aluminum materials compared to the empty crash box.

Comparison of the hardness value and microstructure of Al6061 in horizontal centrifugal casting with and without mold cooling

The object of this research is the horizontal centrifugal casting process of the Al6061 alloy. Usually, cast products experience some casting defects, so the horizontal centrifugal casting process is applied to reduce the possibility of casting defects arising. In some casting processes, especially in the production of cylindrical specimens, casting defects such as porosity are encountered. Therefore, horizontal centrifugal casting was applied to overcome this problem. The test results show that the average hardness value for aluminum 6061 specimens resulting from centrifugal casting products with water cooling was 73.3 HRE, while the average hardness value for aluminum 6061 specimens resulting from centrifugal casting products without water cooling was 86.4 HRE. The microstructure results show that the grain size of centrifugal casting products with water cooling was 82.5 µm, whereas without water cooling it was 75 µm. Higher hardness values were obtained in specimens without mold cooling, this is because the conductivity in molds without cooling was higher compared to molds that experienced water cooling. The higher the heat conductivity of the mold, the faster the cooling process of the cast product. The casting process using the horizontal centrifugal method can be carried out to produce cylindrical spare parts

An experimental process parameter study on the identification of defects in additively fabricated Al6061 with laser powder bed fusion

Additively fabricated metal parts using laser powder bed fusion (L-PBF) possess sophisticated morphology due to the recurrent use of laser-induced metal powder melting and solidification. The surface and 3D morphology of these parts often include defects in the form of protrusions, depressions, pores, voids, keyholes, or cracks that are known to be influenced by laser scanning paths and layer-to-layer processing. Such inconsistent part quality hampers the extensive adoption of L-PBF. Pores and cracks are detrimental to the fatigue life of the parts and components. Quantifying and controlling part defects and optimizing processing and scanning strategy parameters adaptively in real-time through in situ monitoring systems are highly desired. This study investigates the optimization of experimental process parameters (power, scan velocity, and hatch spacing) and their effects on the cracking and porosity of Al6061 alloy using machine learning techniques. Multi-objective optimization is formulated and conducted to determine the L-PBF parameters that minimize both porosity and crack densities.

STIR CASTING OF ALUMINUM METAL MATRIX COMPOSITE FOR AUTOMOBILE APPLICATION — A REVIEW

The development of lightweight and high-strength materials is critical for many industries, including aerospace, automotive, and electronics. Metal matrix composites (MMCs) have shown great promise in meeting these requirements. The structural and physical properties of Al6061 alloy reinforced with hybrid MMCs, including TiB2, SiC, and fly ash (FA), were investigated in this research review. The MMCs investigated were made using the stir-casting process. Their microstructure, structural characteristics, and mechanical features were examined. The inclusion of TiB2 and SiC enhanced the composite’s hardness, tensile strength, and wear resistance, while the addition of FA lowered its density and improved its thermal and corrosion resistance. However, the volume percentage, particle dimension, and arrangement of the reinforcing components all had an effect on the physical characteristics of the composite. Therefore, the optimum combination of the reinforcing materials must be carefully selected to achieve the desired properties. The result of this review provides valuable insights into the development of high-performance MMCs for various industrial applications.

Enhanced creep resistance and microstructure in 7055 Al alloy by in-situ (Al2O3 + ZrB2) nanoparticles and Al3(Er, Zr)

This work put forward a novel approach to enhancing high-temperature creep resistance of 7055 Al alloy via inducing reinforcements including in-situ (Al2O3 + ZrB2) nanoparticles and Al3(Er, Zr). Creep steady-state rates of the (Al2O3 + ZrB2)/7055 Al composites enhanced by synergistic Er, Zr were lower than the (Al2O3 + ZrB2)/7055 Al composites, indicating the values of stress component (n) and apparent activation energy (Q) were 1.05–1.15 and 1.06–1.08 times of (Al2O3 + ZrB2)/7055 Al composites. The dislocation climb mechanism was considered as the dominative creep mechanism because the suitable true stress exponent was 5. The uniform distribution of Al2O3 and Al3(Er, Zr) and their influence on improving the distribution of ZrB2 aggregates gave rise to relative uniform deformation during creep process. The built interface models that induce Al3(Er, Zr) between the nanoparticle/Al interface could lead to a more thermodynamically stable and well-bonded interface. The coupling effect of attachments containing Al2O3, ZrB2 and Al3(Er, Zr) played an enhanced role in terms of vacancy-trapping, precipitate-nucleation, dislocation motion during creep process. The nanoparticles and Al3(Er, Zr) together with nuclear sites containing solute atoms, vacancies and misfits nearby, caused an expansion-inhibiting effect on the helical dislocations. The in-grain misorientation axes (IGMA) concentration of some deformed grains associated with Schmid factor (SF) analysis were related to 〈001〉, 〈111〉 and 〈101〉 direction. The calculation of creep resistance mechanisms was quantified. Additionally, typical intergranular fracture appeared within the composites due to the relatively uniform reinforcements, resulting in the complex crack path.

Thermal and cyclic performance of aluminum alloy composite phase change microcapsules for high-temperature thermal energy storage

Al alloys are suitable for high-temperature applications such as solar thermal power generation and industrial heat utilization. However, addressing the challenges of high-temperature corrosion and material failure in Al alloys is of paramount importance. In practical industrial applications, there is a need to develop encapsulation techniques applicable to a wider range of Al alloy types and phase change temperature ranges, exploring the universality of the technology and the diversity of application scenarios. In this study, a dual encapsulation was conducted on binary and ternary Al alloys (including Al-Ni, Al-Mg, Al-Si-Mg, and Al-Mg-Zn). Aiming at thermal energy storage, four composite phase change microcapsules (CPCM) were successfully prepared and subjected to material characterization, thermal performance analysis, and thermal cyclic tests in air environments. After 2000 thermal cycles, no cracks were observed on the surface of the four CPCMs, and the microstructure remained intact. The components of the CPCMs maintained good chemical compatibility. Among the four types of CPCMs, the Al-Si-Mg CPCMs exhibited the best thermal cyclic stability, with a latent heat reduction rate of 19.5 % after 2000 cycles. The experimental results indicated that the dual encapsulation strategy was effective for various types of Al alloy PCMs, thereby expanding the application of Al alloys in high-temperature thermal storage. Furthermore, Al alloys with more regular morphology and lower active metal content exhibited better thermal performance and cyclic capability, making them more suitable candidates for high-temperature thermal storage applications.

Effect of Citric Acid Hard Anodizing on the Mechanical Properties and Corrosion Resistance of Different Aluminum Alloys.

Hard anodizing is used to improve the anodic films' mechanical qualities and aluminum alloys' corrosion resistance. Applications for anodic oxide coatings on aluminum alloys include the space environment. In this work, the aluminum alloys 2024-T3 (Al-Cu), 6061-T6 (Al-Mg-Si), and 7075-T6 (Al-Zn) were prepared by hard anodizing electrochemical treatment using citric and sulfur acid baths at different concentrations. The aim of the work is to observe the effect of citric acid on the microstructure of the substrate, the mechanical properties, the corrosion resistance, and the morphology of the hard anodic layers. Hard anodizing was performed on three different aluminum alloys using three citric-sulfuric acid mixtures for 60 min and using current densities of 3.0 and 4.5 A/dm2. Vickers microhardness (HV) measurements and scanning electron microscopy (SEM) were utilized to determine the mechanical characteristics and microstructure of the hard anodizing material, and electrochemical techniques to understand the corrosion kinetics. The result indicates that the aluminum alloy 6061-T6 (Al-Mg-Si) has the maximum hard-coat thickness and hardness. The oxidation of Zn and Mg during the anodizing process found in the 7075-T6 (Al-Zn) alloy promotes oxide formation. Because of the high copper concentration, the oxide layer that forms on the 2024-T6 (Al-Cu) Al alloy has the lowest thickness, hardness, and corrosion resistance. Citric and sulfuric acid solutions can be used to provide hard anodizing in a variety of aluminum alloys that have corrosion resistance and mechanical qualities on par with or better than traditional sulfuric acid anodizing.

Effect of Cu–Al Ratio on Microstructure and Mechanical Properties of Cu–Al Alloys Prepared by Powder Metallurgy

Cu–Al alloys are widely used in electronics, new energy, and other fields due to the combination of th excellent corrosion resistance and electrical conductivity of Cu and the light weight of Al. In this paper, the powder metallurgy and equal-channel angular pressing compound technology was used to fabricate a Cu–Al alloy joint, which can be used to replace armor. Devices such as an optical microscope, electron scanning microscope, and microhardness scale were used to characterize the microstructure and mechanical properties of the Cu–Al alloys. The finite element analysis software Abaqus was used to analyze stress distribution during equal-channel angular pressing. The results indicated that the microstructure and properties of Cu–Al alloys were closely related to the volume ratio of Cu–Al. The microhardness and tensile strength were significantly increased by increasing the volume ratio of Cu–Al. As the volume ratio of Cu–Al varied from 1:2 to 2:1, the ultimate tensile strength of the Cu–Al alloys increased from 79.9 MPa to 164.9 MPa at room temperature and the microhardness increased from 60 HV to 101 HV. However, the elongation of the Cu–Al alloys hardly changed; this was about 4.4%. Crack initiation occurred at the Cu–Al interface and spread along the bonding surface of the Cu–Al alloys during the tensile process.

Role of Si element in the IMC formation and tensile-shear property of the laser welding-brazing steel-Al dissimilar joints

A comparative investigation was conducted to explore the role of Si in the intermetallic compound (IMC) formation and tensile-shear property of steel-Al joints fabricated via laser welding-brazing (LWB) technique. Three filler wires including ER5356, ER4043 and ER4047 were employed to join the DP780 steel and 5754 Al alloy. The results exhibited that the presence of Si could improve the tensile-shear property of steel-Al joints. With increasing the Si addition, the failure locations of the joints changed from the interface, weld metal to Al alloy base metal. For the joints fabricated with ER5356 filler, the IMCs consisted of Fe2Al5 and Fe4Al13. On the contrary, Fe4(Al, Si)13 and Al8Fe2Si was detected for the joints prepared with ER4043 and ER4047 filler wires. The Si could suppress the generation of brittle Fe2Al5. In addition, Fe4(Al, Si)13 and Al8Fe2Si could resist the crack propagation, guaranteeing the qualified tensile-shear strength of the joints.

Research Status and Development Trend of Wire Arc Additive Manufacturing Technology for Aluminum Alloys

It is difficult for traditional aluminum alloy manufacturing technology to meet the requirements of large-scale and high-precision complex shape structural parts. Wire Arc additive manufacturing technology (WAAM) is an innovative production method that presents the unique advantages of high material utilization, a large degree of design freedom, fast prototyping speed, and low cast. As a result, WAAM is suitable for near-net forming of large-scale complex industrial production and has a wide range of applications in aerospace, automobile manufacturing, and marine engineering fields. In order to serve as a reference for the further development of WAAM technology, this paper provides an overview of the current developments in WAAM both from the digital control system and processing parameters in summary of the recent research progress. This work firstly summarized the principle of simulation layering and path planning and discussed the influence of relative technological parameters, such as current, wire feeding speed, welding speed, shielding gas, and so on. It can be seen that both the welding current and wire feeding speed are directly proportional to the heat input while the travel speed is inversely proportional to the heat input. This process regulation is an important means to improve the quality of deposited parts. This paper then summarized various methods including heat input, alloy composition, and heat treatment. The results showed that in the process of WAAM, it is necessary to control the appropriate heat input to achieve minimum heat accumulation and improve the performance of the deposited parts. To obtain higher mechanical properties (tensile strength has been increased by 28%–45%), aluminum matrix composites by WAAM have proved to be an effective method. The corresponding proper heat treatment can also increase the tensile strength of WAAM Al alloy by 104.3%. In addition, mechanical properties are always assessed to evaluate the quality of deposited parts. The mechanical properties including the tensile strength, yield strength, and hardness of the deposited parts under different processing conditions have been summarized to provide a reference for the quality evaluation of the deposition. Examples of industrial products fabricated by WAAM are also introduced. Finally, the application status of WAAM aluminum alloy is summarized and the corresponding future research direction is prospected.

Optimizing the mechanical and corrosion properties of an ultrafine-grained Al-Cu-Mg alloy through cyclic deformation: Clusters and lattice defects

To optimize its corrosion and mechanical properties, an Al-Cu-Mg alloy is cyclically processed by high-pressure torsion (HPT), involving a 1/2 turn clockwise and a 1/2 turn counter-clockwise per cycle. The dislocation density increases to 3.04×1014 m−2 on 1 cycle HPT and decreases gradually to 2.23×1014 m−2 for higher cyclic rotations (i.e. 5 cycle HPT). Due to the rapid elimination of the geometrically necessary dislocations, the refinement of grain size in cyclic HPT is more efficient than the monotonic HPT (i.e. it decreases from 2.48 μm to 112 nm on 1 cycle HPT). The HPT samples are electrochemically corroded in a simulated seawater environment. 1-cycle HPT process causes a strong increase in hardness (to 232 HV) and an increase in corrosion potential (to −0.517 V). The trade-off between hardness/strength and corrosion resistance is broken on cyclic HPT processing. Aided by excess vacancies induced by HPT, Cu-Mg clusters form on and near grain boundaries through a ‘vacancy-pump’ mechanism, causing solute depleted zones (SDZ) adjacent to GBs. The combined effects of ultrafine grains, solute cluster segregation and SDZs enhance the strength and corrosion resistance of the Al-Cu-Mg alloys. This study provides a potential strategy to design the microstructures of an Al alloy, and to achieve a higher hardness and a better corrosion performance of that material.

Impact of cooling methods on the corrosion behavior of AA6063 aluminum alloy in a chloride solution

Abstract In this work, the AA6063 Al alloy was processed by cooling at four different conditions. The impact of the type of cooling method on the corrosion behavior of the produced alloys after 1 and 24 h in 3.5% NaCl solutions was carried out. Various electrochemical measurements, such as cyclic potentiodynamic polarization (CPP), chronoamperometric, and electrochemical impedance spectroscopy (EIS) measurements, were employed. The CPP data revealed that the intensity of corrosion of the alloys is highly influenced by the cooling method. The change in the chronoamperometric current at −650 mV (Ag/AgCl) over time indicates the possibility of pitting corrosion, particularly after 24 h, where the recorded currents showed a continuous increase over time. The scanning electron microscopy images taken for the surfaces of the alloys after corrosion confirmed that the lowest deterioration occurring on the surface was for the AA6063 alloy that was quenched in water. The EIS plots also demonstrated that AA6063 alloy exhibits different corrosion resistances when different cooling methods are applied. All measurements indicated that the corrosion resistance increases in the following order: the quenched alloy in water > the air-cooled alloy > the furnace-cooled alloy > the as-received alloy. The exposure for 24 h decreases the corrosion damage of all alloys via the formation and thickening of a top layer of corrosion products on its surface over time.

Hot deformation behavior and microstructural evolution of a new type of 7xxx Al alloy

Optimizing the thermal deformation parameters of Al alloys is beneficial for achieving grain refinement, avoiding microscopic defects in materials, and significantly enhancing the mechanical properties of Al alloys. In this study, the hot deformation behavior of a new type of 7xxx Al alloy was investigated through hot compression tests at strain rates of 10−3-1 s−1 and temperatures of 250–420 °C. The constitutive equation was successfully established using the hyperbolic sine form of the Arrhenius equation, accurately describing the flow stress. The hot processing map was obtained by overlaying the power dissipation map and the instability map, determining the optimal hot working parameters to be in the range of 325–373 °C, 0.45–1 s−1. In the safe region, dynamic recovery (DRV) and dynamic recrystallization (DRX) were predominant. The instability in the low-temperature region was attributed to the grain boundary pinning effect caused by grain boundary precipitation, while the instability in the high-temperature region was associated with local shear bands induced by uneven plastic strain. The hot processing map establishes a good connection with the microstructural evolution of the new type of 7xxx Al alloy under different hot deformation parameters.