T6 Aging Research Articles

Microstructure and properties of a HIP manufactured B4Cp reinforced highly alloyed Al-Zn-Mg-Cu-Zr aluminum matrix composite

In this study, an aluminum matrix composite with good mechanical property and excellent corrosion resistance, B4C particles (B4Cp) reinforced highly alloyed Al-Zn-Mg-Cu-Zr matrix composite, was successfully fabricated through ball-milling, cold isostatic pressing, vacuum degassing, hot isostatic pressing (HIP), homogenization, hot extrusion, solution treatment, and aging treatment. It was found that the B4C/MgAl2O4/Al was the dominant interface structure, which was coherent and enhanced the bonding between the particles and the matrix considerably, while the B4C/Al2O3/Al was the minor interface structure. The grain boundary was very clean in both T4 and T6 aging states, without aging precipitates and O element segregation. In T4 aging state, the composite exhibited superior properties, with the mass density of 2.84 g cm−3, the elastic modulus of 119.18 GPa, the yield strength of 576.08 MPa, the ultimate tensile strength of 655.27 MPa, the tensile elongation of 1.48 %, and the very low electrochemical corrosion current density of 4.4581 × 10−8 A cm−2 in 3.5 wt% NaCl water solution. The MgAl2O4 and BO3-rich interface phases, the strengthening mechanisms and the anti-corrosion mechanisms of the composite were discussed in detail.

Effect of the over-aging degree on high cycle fatigue properties of an ultra-high strength Al-Zn-Mg-Cu alloy

An ultra-high strength Al-Zn-Mg-Cu alloy with high Zn content was subjected to T6, T79, T76, T74 and T73 ageing treatments in order to investigate the effect of the over-aging degree on the high cycle fatigue (HCF) properties of the alloy. The microstructures and fatigue fracture morphologies were analyzed. The results showed that the fatigue strengths exhibited a non-linear trend of first increasing and then decreasing from the T6 to T73 aged samples. The T79 aged sample obtained the highest fatigue strength, was 247 MPa. The Basquin equation was used to describe the changes in HCF properties. The physical meanings and causes of changes in the parameters of the fitted Basquin equation were rationalized by combining quantitative analysis of the microstructures and existing models. The combination of microstructural evolution and the trend of parameters in the fitted Basquin equation was ultimately employed to elucidate the underlying mechanism of the specific non-linear fatigue strength trend.

Influence of grain structure and precipitates on fatigue crack propagation behaviors of Al-xCu-1.2Li-X alloys

The fatigue crack propagation (FCP) rates of the Al-xCu-1.2Li-X (x=4.2, 4.5 wt%) alloys with various heat treatment states were systematically investigated and correlated crack growth mechanism was further elucidated. The finer recrystallized grains and more equivalent slip system numbers provided more beneficial conditions for crack deflection and bifurcation, leading to the decreased FCP rate in short-term natural-aged (ST-T4) MC alloy. Moreover, the crack tips hardly activated the slip system within the adjacent grains when their twist angle differences for four slip surfaces were >10°, and the crack tended to propagate along the grain boundaries. With increasing Cu content of T8-aged alloy, the number density and dimension of T1 and θ′ precipitates are simultaneously increased, and the strengthening mechanism of T1 precipitates transformed from shearing to by-passing. Thus, the crack tips required more energy for transgranular propagation, causing the tendency of propagation to the grain boundaries and increased FCP rate in T8-aged HC alloy. However, the high Cu content levels resulted in the preferential precipitation of Guinier-Preston (G.P) zones during T6 aging. The δ′ and θ′ precipitates are increased and the nucleation of by-passed T1 precipitates is suppressed in T6-aged HC alloy, leading to a significantly decreased FCP rate compared to that of MC alloy.

Generation Mechanism of Anisotropy in Mechanical Properties of WE43 Fabricated by Laser Powder Bed Fusion.

At present, no consensus has been reached on the generation mechanism of anisotropy in materials fabricated by laser powder bed fusion (LPBF), and most attention has been focused on crystallographic texture. In this paper, an analysis and test were carried out on the hardness, defect distribution, residual stress distribution, and microstructure of WE43 magnesium alloy fabricated by LPBF. The results indicate that LPBF WE43 exhibits obvious anisotropy-the hardness HV of X-Z surface (129.9 HV on average) and that of Y-Z surface (130.7 HV on average) are about 33.5% higher than that of X-Y surface (97.6 HV on average), and the endurable load is smaller in the stacking direction Z compared to the X and Y directions. The factors contributing more to the anisotropy are listed as follows in sequence. Firstly, the defect area of the X-Y projection surface is about 13.2% larger than that of the other two surfaces, so this surface shows greatly reduced mechanical properties due to the exponential relationship between the material strength and the number of defects. Secondly, for laser scanning in each layer/time, the residual stress accumulation in the Z direction is higher than that in the X and Y directions, which may directly reduce the mechanical properties of the material. Finally, more fine grains are distributed in X-Z and Y-Z surfaces when comparing them with those in an X-Y surface, and this fine-grain strengthening mechanism also contributes to the anisotropy. After T5 aging heat treatment (250 °C/16 h), a stronger crystallographic texture is formed in the <0001> direction, with the orientation density index increasing from 10.92 to 21.38, and the anisotropy disappearing. This is mainly caused by the enhancement effect of the texture in the <0001> direction on the mechanical properties in the Z direction cancelling out the weakening effect of the defects in the X-Y surface in the Z direction.

Effect of B4C and graphene on the microstructural and mechanical properties of Al6061 matrix composites

Materials that are lightweight with superior strength and improved structural properties have consistently been highly sought after in the aircraft and automobile industries for their superior performance. This study investigates the effect of graphene and boron carbide (B4C) additions on the microstructural & mechanical properties of Al6061 MMCs in fabricated and T6 heat-treated conditions. The powder metallurgy technique is used to fabricate the Al6061 hybrid composites reinforced with different volume fractions. i.e 0.5,1 wt% of graphene and 3,6 wt% of B4C. XRD, Optical microscope, FE-SEM with EDAX mapping, Hardness, and Compression tests were employed to evaluate and characterize the Al6061/Gr/B4C hybrid composites. After the T6 ageing treatment, both hardness and compressive strength were increased to 61.08% and 68.51% compared to base Al6061 matrix alloy. The sample Al6061/0.5% Gr/6%B4C-T6 exhibits the highest hardness value of 91HV and sample Al6061/1%Gr/6%B4C-T6 gives the value of higher compressive strength of 298 MPa. The higher tensile strength was observed in the sample Al6061/0.5%Gr/6%B4C-T6 which is 209.53 MPa with 8.907% elongation. The T6 heat treatment has a significant role in the strength improvement. Whereas increment in graphene has no impact on the tensile strength. The tensile strength of Al6061/0.5%Gr/6%B4C-T6 was improved by 43.56% compared to the base Al6061 alloy.

Effect of substrate microstructure on corrosion resistance of cast and forged anodised 6082 Al alloy

This work addresses the effect of the surface morphology of a 6082-aluminium alloy on the characteristics of the anodic layer generated by an anodising process using two current densities. The samples tested were horizontal direct chill (HDC), vertical direct chill (VDC) cast billets, and the same material after forged + T6 ageing treatment. Samples were anodised in a mixed citric acid‑sulphuric acid electrolyte using 0.5 A⋅dm−2 and 1.5 A⋅dm−2. D.C. current densities. The protective character of the oxide layer was studied by electrochemical impedance spectroscopy (EIS) in 0.1 M NaCl solution.Microstructural characterisation revealed that the microsegregation and forging processes have a significant effect on the growth of the oxide layer as well as on the optimum anodising conditions. The EIS study showed that the corrosion protection provided by the oxide layer on Al6082 alloy was strongly affected by the manufacturing process, with thinner oxide layers obtained for cast billets. Heat treatment and forging homogenise the microstructure, which positively affects anodising and modifies the growth rate and thickness of the oxide layer. This effect makes obtaining a thicker oxide layer with good corrosion protective properties possible by using lower current densities for forged samples.

Effect of T6 and T6I4 Aging Treatments on Microstructure and Compressive Properties of Aluminum Metal Matrix Composites Reinforced by SiCw Via Squeeze Casting

Effect of T6 and T6I4 Aging Treatments on Microstructure and Compressive Properties of Aluminum Metal Matrix Composites Reinforced by SiCw Via Squeeze Casting

Microstructure, fatigue crack growth rate and low-cycle fatigue behavior of an Al[sbnd]Li alloy sheet with different aging

The microstructures, fatigue crack growth (FCG) rates and low-cycle fatigue (LCF) behaviors of 1445 Al-Li alloy sheet with T6 aging at 170 °C, single-step T8 (S-T8) aging at 150 °C and double-step T8 (D-T8) aging at 170 °C following aging at 150 °C for 4 h were investigated. The main precipitates in T6 and S-T8 samples are δ′ phases, but strain strengthening causes 40 MPa enhancement in the S-T8 sample yield strength (YS). Due to coherent shearable δ′ precipitates, the FCG rate curves of S-T8 samples are highly coincident. With the 2nd-step aging time extension, δ′ precipitates in D-T8 sample gradually coarsen, semi-coherent S′ phases form and their amount increases. The interaction between δ′ precipitates with dislocations transites from shearing to by-passing, leading to the YS enhancement and the FCG resistance decrease. Meanwhile, cyclic-hardening decreases and transfers to cyclic-softening during LCF at starin amplitude of 0.6% ∼ 0.9%. At 0.9% strain amplitude, due to greater cyclic-softening and cleavage fracture of S′ precipitates, the D-T8 sample with 2nd-step aging time of 120 h has a shorter LCF life. The D-T8 sample with 2nd-step aging time of 24 h possesses a comprehensive property of higher strength, lower FCG rate and better LCF life.

Study on the effect of magnetic needle grinding process on the service properties of medical Mg-1.6Ca-2.0Zn alloy

Magnesium alloy, valued for its superior mechanical properties and biocompatibility in biomaterials, faces limitations such as rapid corrosion, poor wear resistance, and unfavorable cell adhesion. To address these challenges and enhance medical magnesium alloy development, this study investigates a magnetic needle grinding process on magnesium alloy. Mg-1.6Ca-2.0Zn alloy, prepared through powder metallurgy and T6 aging treatment, undergoes milling, and magnetic grinding using various needle sizes. The impact is assessed through Vickers hardness, residual stresses, surface roughness, friction and wear tests, electrochemical assessments, and contact angle tests. Results indicate a 22.59% microhardness increase, 30.43 MPa residual compressive stress, increased surface roughness, improved wear and corrosion resistance, and improved hydrophilia after magnetic needle grinding. This research provides a theoretical foundation for advancing medical magnesium alloy industrially.

The effect of T6 and T6I4 aging treatment on microstructure and compressive properties of Aluminum metal matrix composites reinforced by SiCw via squeeze casting

Исследовано влияние старения на микроструктуру и свойства при сжатии композитов с металлической алюминиевой матрицей на основе сплава серии 7ххх (Al – 12,44 Zn – 3,22 Mg – 1,13 Cu – 0,19 Zr – 0,12 Sr), армированного нитевидными кристаллами SiCw методом литья под давлением. Проведено старение по четырем различным режимам: T6-1, Т6-2, Т6I4-1, Т6I4-2. Осуществлен микроструктурный анализ с помощью световой микроскопии, сканирующей электронной микроскопии и рентгеновской дифракции. Определены твердость по Виккерсу и механические характеристики при испытаниях на сжатие при комнатной температуре. Установлено, что старение по всем исследованным режимам повышает твердость композитов, величина которой составляет после старения 325, 278, 306 и 346 HV у сплавов T6-1, Т6-2, Т6I4-1 и Т6I4-2 соответственно. Наиболее высокий комплекс механических свойств композита при испытаниях на сжатие достигается после старения T6-2. В этом случае предел прочности и относительное сжатие составляют 747 МПа и 7 % соответственно, а максимальное дислокационное упрочнение — 86,89 МПа.

Enhancing properties of Al-Zn-Mg-Cu alloy through microalloying and heat treatment

This paper aims to understand the influence of microalloying constituents (Ti, Zr, Sr and Sc), and three heat treatment conditions i.e., T6, retrogression and reaging (RRA) and high temperature aging (HTA) on mechanical and thermal characteristics of modified Al-Zn-Mg-Cu-X alloy using microstructural analyses consist of precipitation characteristics, phase fraction and phase morphology. Addition of 0.25 wt % Sc significantly refines the grain structure, reducing the grain size from 62 μm to 34 μm and increasing Al3Zr, Al3(Zr, Ti), and Al3(Sc, Zr) precipitate fraction. After T6 aging, the alloy exhibits primary precipitates of fine η and T phases, accompanied by secondary intermetallics as well as S phases. RRA treatment led to a slightly larger fraction of coarse Zn and Cu-rich phases, while HTA results in larger η, T, and S phases due to high-temperature aging. The addition of Sc reduces the cooling rate by raising the transition temperature to 532 °C with an enthalpy of 22.1 J/g. T6 treatment shows dissolution of most η phases within the matrix, although RRA and HTA exhibit higher enthalpy due to a greater fraction of η phases. The tensile strength of Al-Zn-Mg-Cu-X alloy follows the following sequence: T6 > RRA > HTA > as-cast condition, regardless of micro-alloy additions. Under T6 conditions, Sc added alloy achieves 30 % higher strength, i.e., 575 MPa, than base alloy due to fine dispersoids. RRA treatment enhances elongation without compromising mechanical properties, resulting in a shift from transgranular brittle fracture to intergranular-dominated mix-mode fracture, with the presence of secondary cracking.

Enhancing the strength of Sc-containing Al-Cu-Li alloys by modifying the precipitation behavior through plastic deformation and heat treatment

Al-Cu-Li alloys are used extensively in the aerospace manufacturing industry for their outstanding properties, however, the addition of trace Sc elements will form high-temperature insoluble (Cu, Sc)-containing phases during homogenization leads to a decrease in age-strengthening, and there is a limited investigation on how to overcome this unfavorable factor. In this work, the effects of plastic deformation coupled with heat treatment on the microstructure and mechanical properties of Sc-containing Al-Cu-Li alloy were systematically investigated by using age-hardening curves and room-temperature tensile tests combined with characterization by TEM, EBSD, and SEM/EDS. The results show that plastic deformation before high-temperature treatment fragments and promotes the dissolution of coarse phases, reduces the development of (Cu, Sc)-containing enriched phases, and simultaneously increases the content of Cu atoms within the Al matrix. Among all precipitates (GPB zones, S phases, T1 phases) after T6 aging, T1 phases act as the dominant strengthening phase of the alloy. At the same time, we found that the decrease in the Cu-containing residual phase after solid solution treatment will result in a remarkably increasing number density and volume fraction of T1 phases at the peak aging. In a word, we obtain a good strength-ductility trade-off (the yield strength is ∼500 MPa while maintaining ∼10% elongation) Al-Cu-Li alloy with Sc element by optimizing the distribution of Cu elements and modulating the aging precipitation behavior. Our proposed process is expected to provide an experimental and theoretical guide toward the development of Al-Cu-Li alloys with superior properties.

Yield strength modelling via precipitation/recovery kinetics in rapidly solidified thin-strip cast AA6005 AlMgSi sheets subjected to cold rolling and direct aging

A comprehensive and experimentally verified yield strength model of AA6005 Al–Mg–Si sheets rapidly solidified via a novel Thin Strip (TS) casting route is developed and presented. The cast sheets were cold-rolled and directly aged via a heat-treatment process (termed TSH) that effectively utilizes the increased solute supersaturation of matrix due to the high casting cooling rates experienced. The TSH conditions were optimized based on the hardness and tensile data, with the peak aging conditions found to be 160°C-4 hrs, 180°C-1 hr and 200°C-15 min. The TEM analysis revealed that, due to the presence of prior cold work, β′ precipitates formed during TSH, i.e., as opposed to the β" precipitates that form upon a typical T6 aging treatment. Also, while the total precipitate volume fraction was comparable among the three peak aging conditions, the sample aged at 200 °C exhibited a lower peak aging strength (300 MPa vs. ∼315 MPa in the other two conditions), i.e., due to a higher dislocation recovery rate and therefore a lower strengthening contribution from the remaining cold work. Interestingly, at each temperature, aging beyond the peak aging time still resulted in an increase in the precipitate volume fraction. The concurrent drop in the yield strength could be explained by the offsetting effect of the recovery of the remaining cold work. Therefore, thanks to the sufficiently high solute supersaturation of the matrix during TSH, together with the remaining cold work (as well as the formation of β′), peak aging at 180 °C is achieved after only 30 min to 1 h, i.e., as opposed to generally 4–6 h of aging needed for a traditional T6 aging. This gives the low-cost, less energy-intensive TS-cast sheets also a significantly faster response to the paint-baking process (typically performed at near 180 °C for around 30 min), thus allowing for a higher strength achieved via a typical automotive body fabrication route. Finally, a robust model of precipitation/recovery kinetics, incorporating precipitate aspect ratio evolution, was developed to simulate the yield strength during TSH. The model predicts a peak-aging time of ∼100 min, aligning well with the observed 60–120 min interval measured from the tensile test results.

Effect of the Ti addition on the corrosion behavior of newly developed AA7075-Ti alloys

In this study, the effect of Ti addition, cold rolling and T6 aging heat treatment on the corrosion behavior of newly produced AA7075–0%Ti, AA7075–2%Ti, AA7075–4%Ti and AA7075–8%Ti quality alloys was investigated. The titanium ratio in the alloys was adjusted using AlTi master alloy in the melting method, and all the alloys produced were subjected to T6 aging heat treatment and some samples were cold rolled at a rate of 6%. The investigation of the immersion and potentiodynamic corrosion behavior of the alloys was conducted in 3.5% by weight of NaCl solution. The corrosion resistance of the alloys studied here is improved by both applied cold rolling and Ti addition. On the other hand, in alloys without Ti addition, the rolling process, which increased the precipitate formation, decreased the corrosion resistance.

Effects of Stacking Number on Microstructure and Mechanical Properties for Cold Roll Bonding Process of Dissimilar Aluminum Alloy Sheets

A cold roll-bonding (CRB) process is applied to study the effects of stacking number on the microstructure and mechanical properties of roll-bonded and age-treated Al sheets. Commercial AA1050 and AA6061 sheets with a thickness of 2 mm were stacked alternately on each other to two and four layers, and roll-bonded by multi-pass cold rolling. The roll-bonded Al sheets were then subjected to natural aging (T4) and artificial aging (T6) treatments. The as roll-bonded Al sheets showed a typical deformation structure, where the grains are elongated in the rolling direction regardless of the stacking number. However, after the T4 and T6 aging treatments, the Al sheets had a recrystallization structure consisting of coarse grains in both the AA5052 and AA6061 regions with different grain sizes in each. In addition, the sheets showed an inhomogeneous hardness distribution in the thickness direction, with higher hardness in AA6061 than in AA1050 after the T4 and T6 age treatments. The tensile strength of the T6-treated specimen was higher than that of the T4-treated one for both the 2 and 4-layer CRBs. In addition, both the tensile strength and elongation of the specimens processed by the 4-layer stack CRB were higher than those of the 2-layer stack CRB for all experimental conditions.

Detailed investigation on microstructure and strengthening contribution of Al-xCu-1.3Li-X alloy sheets

The microstructure-mechanical properties connection and strengthening contribution of Al-xCu-1.3Li-X (x = 3.8, 4.2, 4.5 wt%) alloy sheets subjected to various heat treatments were systematically investigated. After solid-solution treatment, the decreased schmid factor value was the main factor for higher strength of Alloy-3 (4.5 wt% Cu). The number density and diameter of T1 precipitates simultaneously increased with rising the Cu content during T8 aging, leading to the highest strength (655.4 MPa) of T8-aged Alloy-3. However, the high Cu content level resulted in the preferential precipitation of Guinier-Preston (G.P) zones during T6 aging at 165 °C. The θ' precipitates were therefore significantly increased and the nucleation of T1 precipitates was suppressed in T6-aged Alloy-3, causing the reduced strength compared to that of T6-aged Alloy-2 (4.2 wt% Cu). Furthermore, the experimental yield strength was successfully predicted by invoking the modified precipitate strengthening model, in which the θ' precipitate-dislocation interaction was by-passing mechanism, whereas the shearable and by-passed T1 precipitates coexisted for all alloys. The strengthening transition from by-passing to shearing occurred in T1 precipitates with a thickness <1.9 nm or diameter <65 nm, and was particularly associated with the decrease in thickness of T1 precipitates.

Electron microscopic investigation of precipitation hardening in Al-Si based alloys

The present work was performed on Al-8.5%Si-1.75%Cu-0.55%Mg-0.2%Ti-0.32%Zr-0.015%Sr alloy (coded as 354 alloy) following T6 (at 160 °C) and T7 (at 240 °C) artificial aging conditions using high resolution transmission electron microscopy (HR-TEM). The main results inferred from the present study are the precipitation of GP zones in samples aged for 20 h at 160 °C along with S-Al2CuMg phase particles. Aging at 240 °C was carried out for different times, ranging between 30 min and 200 h. The quenched structures revealed a series of precipitations mainly GP zones at low aging times to Θ’-Al2Cu after 200 h together with the S-phase. No coherency was observed between the S-phase and the aluminum (Al) matrix. The growth of the S- phase takes place by precipitation of S2 type phase on the advancing S1-type phase. Mismatching was clearly observed at particle/matrix interfaces. High magnification images indicated the dissolution of some of the Θ” and Θ’ particles to enrich the nearby particles (coarsening). The start of incoherency is observed when the alloy is aged at 240 °C for 200 h.

Grain structure and co-precipitation behavior of high-Zn containing Al–Zn–Mg–Cu aluminium alloys during deformation via high-temperature upsetting-extrusion

A study on the deformation behavior with increase in strain during upsetting-extrusion (UE) was studied (i.e., No-UE, Small-UE, and Large-UE strains) at 350 °C in Al-8.9Zn-2.2Mg-2.1Cu-0.14Zr-0.02Sc (wt%) alloys to evaluate the strengthening effects of grain size/texture and co-precipitation for different ageing (i.e., as-received, T4, and T6 aging) conditions. In as-received samples, electron back-scattered diffraction observations revealed that increasing UE strain enhances the formation of continuous and discontinuous dynamic recrystallization grains. This reduces the size difference between fine and coarse grains in bimodal structure and produces stronger copper/cubic texture. In small angle X-ray scattering (SAXS), a large UE strain brings about more fraction of Y-phase and GP zones. In T4 Large-UE samples, SAXS indicated higher size stability of disk-like Y-phase. High-angle annular dark field scanning transmission electron microscopy images revealed five-layered atomic arrangement of a unit cell of Y-phase, where the center layer was composed of Al and sandwiched layers, 2Cu/2Zn/2Cu and Al/ZnCu/ZnCu/Al. In T6 Large-UE samples, it was observed that the growth of Y-phase is accompanied by intrinsic atomic shift along the [101̅0]Y-phase direction. Furthermore, SAXS quantitatively showed size evolution of η'/η precipitates and formation of a higher aspect ratio of Y-phase. The collective effects of finer bimodal grain structure, stronger fiber texture, and co-precipitation of Y-phase and η'/η precipitates provide evidence higher ultimate tensile strength (∼766 ± 5 MPa) and superior strain (∼10.9 ± 0.4) of large-UE strain samples under T6 ageing.

Performance analysis on mechanical and machinability attributes of Al6061-B4C-T6 composites processed via hot extrusion

In this study, composite materials with Al6061 alloy matrix and B4C particles reinforcement were produced by hot extrusion process. Fabricated composites were examined for the mechanical and machinability attributes. Al6061 alloy powders (&lt;100 µm) and B4C particles (&lt;10 µm) were mixed with the different weight fraction of B4C (3%, 6%, and 9% by weight) of and then cold pressed under 200 MPa pressure. The cold pressed powder metal block was extruded hot after preheating at 550°C for 1 h. Further, the composites were subjected to T6 aging heat treatment after hot extrusion. Microstructure, density, hardness, tensile strength, and wear properties were examined. The effects of cutting speed and cutting force on the machinability were also investigated. In addition, surface roughness and chips formation were examined. High density (99.6%) values were achieved with the extrusion process. With increasing B4C particles ratio, the hardness and tensile values were increased which was substantiated by the fracture morphology of the tensile specimens. It has been observed that tool smearing was high in the machining of the low-reinforced (3% B4C) composite. The highest cutting force was measured as 236 N at a feed rate of 0.27 mm/rev and a cutting speed of 250 m/min. It has also been observed that the average surface roughness decreased with increasing cutting speed and it increased with increasing feed rate.

Effect of forging pretreatment on the microstructures and mechanical properties of the Al-Cu-Li alloy

The 2195 Al-Cu-Li alloy is widely utilized in the aerospace industry due to its lightweight nature and high strength. Consequently, gaining a comprehensive understanding of techniques to enhance its microstructural and mechanical properties is crucial for the consistent production of reliable and high-strength aerospace components. In this investigation, a pristine 2195 industrial ingot was subject to three distinct forging pretreatments: PT1, which involved a direct three upsetting and three stretching (3U3S) process; PT2, which combined double stage homogenization (DH) with 3U3S; and PT3, which involved DH along with six upsetting and six stretching (6U6S). Subsequent warm deformation and T8 aging treatment were applied to the pretreated forgings. The microstructure evolution during the processes and the final mechanical properties in three orthogonal dimensions were examined. The findings revealed that the combination of DH and multi-dimensional forging (MDF) facilitated the dissolution of non-equilibrium phases to a greater extent. Consequently, the main strengthening phase transformed from the T1 + δ` phase observed in PT1 to the denser T1 + little θ` phase observed in PT2 and PT3 after T8 aging treatment. Notably, the tensile strength and yield strength of PT2 and PT3 specimens increased by 20–30 MPa in all three directions. Moreover, the MDF process accelerated the recrystallization behavior from PT1 to PT3, resulting in a gradual reduction in the average grain size of the pretreated samples from 356 µm to 186 µm. Following warm forging and T8 aging, the grains exhibited a finer and equiaxed structure. Additionally, the coarse phase was identified as the primary source of transgranular cracking. The coarse phases within the matrix became more homogeneous and finer from PT1 to PT3, with a gradual decrease in their area fraction. On the fracture surfaces, the aggregation of coarse phases diminished. Consequently, the elongation in the z-direction improved, and the elongation anisotropy and standard deviation decreased in all three directions for PT3 specimens. The findings presented in this study provide valuable insights into the high-performance manufacturing of Al-Cu-Li alloys.