To advance the T5 treatment process for Al–5.81Zn–1.65Mg alloys, this study explored the influence of deformation temperature on the solution temperature, ultrafine grain (UFG) formation via dynamic recrystallization (DRX), and strain-induced dynamic precipitation (SIDP) during thermomechanical processing at 300–500 ℃, with a 70% reduction and a strain rate of 1s−1. The flow curve exhibited pronounced work hardening (WH) at 300–350 ℃, whereas a dynamic recovery-type flow curve was observed at 450–500 ℃. As the temperature increased from 300 to 500 °C, the 1st WH rates (ε=0.2–0.4) were 55, 37.5, 20, 8.5, and 10MPa, respectively. Larger DRX grains were formed at higher temperatures. The DRX rate ranged 20%–30% at 300–400 ℃ and increased to 60% at 500 ℃. The texture gradually transitioned from Goss {011}<100> to brass {110}<112> with an increase in the deformation temperature from 300 to 500 ℃. Discontinuous DRX occurred mainly near the grain boundaries and precipitates at 300–400 ℃, shifting to continuous DRX at temperatures ranging from 400 to 500 ℃. At 300 and 400 ℃, larger precipitates (10–50nm) and smaller ones (<10nm) were observed within grains and along boundaries. Precipitates at 300 ℃ were larger and denser than those at 400 ℃, with η’, and T’ phases formed through SIDP. For this alloy, considering the formation of UFG and ensuring sufficient solubility, the appropriate deformation temperature range was 400–500 ℃.
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