This paper provides a detailed analysis of the dynamic microstructure evolution of Ti-6Al-2Sn-4Zr-6Mo alloy (Ti6246) through a 4-pass hot rolling process. Additionally, it examines the effect of heat treatment on microstructure evolution during the post-annealing of the hot-rolled alloy. During the rolling process, dynamic recrystallization (DRX) predominantly takes place in the α-phase, leading to grain refinement and spheroidization as a consequence of DRX and lamellae spheroidization. Spheroidization of the lamellar structure is more pronounced in the 2-pass rolling process, while the level of DRX is greater in the 4-pass rolling process. The dislocations present within the α lamellae accumulate and entangle at the sub-grain boundary, leading to the formation of a high-angle grain boundary (HAGB). Meanwhile, the β phase infiltrates the grain boundaries of the α phase, leading to the formation of spheroidized equiaxed α grains. Schmid factors associated with the pyramidal slip systems are relatively high, facilitating the activation of slip systems during hot rolling processes. The evolution of the α-phase morphology during heat treatment processes in various rolling passes is primarily driven by static recrystallization (SRX) and grain boundary terminal migration mechanisms. The deformed microstructure volume fraction diminishes and transforms into substructures and recrystallized grains through post-annealing. Post-annealing facilitates the dissipation of stored deformation energy with increasing temperature, leading to a decrease in dislocation density and an enhancement in the extent of recrystallization. Accumulated deformation during rolling and the temperature of the heat treatment both play a role in affecting the static spheroidization process. Greater accumulated deformation and elevated post-annealing temperatures are advantageous for achieving grain spheroidization. The grain boundary splitting process is more pronounced, and the deformation energy is elevated during the 3,4-pass rolling.
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