Hot Deformation Behavior and Hot Workability of Mg/Al Bimetals Prepared by Cold Spray Additive Manufacturing

ZHANG Qixu; LIU Sitong; LONG Jinchuan; LIN Yongcheng; DENG Lei; HAN Xu

doi:10.3969/j.issn.1674-6457.2026.04.007

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (4) : 69-78. DOI: 10.3969/j.issn.1674-6457.2026.04.007

Additive Manufacturing

Hot Deformation Behavior and Hot Workability of Mg/Al Bimetals Prepared by Cold Spray Additive Manufacturing

ZHANG Qixu^1a, LIU Sitong^1b, LONG Jinchuan^1b,*, LIN Yongcheng^1b, DENG Lei², HAN Xu²

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Abstract

The work aims to explore flow behavior and process window during hot deformation of Mg/Al bimetals prepared by cold spray additive manufacturing. Firstly, Mg/Al bimetal specimens were fabricated by cold spray. Subsequently, hot-compression tests were conducted at temperatures from 523 K to 673 K, strain rates from 0.001 s^-1 to 1 s^-1 and a maximum true strain of 50%. By analyzing the flow curve characteristics of the Mg/Al bimetal, an Arrhenius-type high-temperature constitutive model based on the Zener-Hollomon parameter was established and the activation energy for hot deformation under various conditions was calculated and displayed as a 3D activation-energy map. In addition, a 3D processing map was constructed with a modified dynamic material model combined with the Murty instability criterion. Superimposing the activation-energy map and the processing map yielded an activation-energy-processing map that delineated flow-instability regimes and safe deformation domains. The flow curves exhibited pronounced dynamic-recrystallization softening with the increasing strain and were highly sensitive to temperature and strain rate. The flow stress decreased as temperature rose and strain rate dropped. The established high-temperature constitutive model is capable of precisely predicting the flow stress of bimetals under different deformation conditions. The optimal process window obtained based on the activation energy-processing map is a temperature range of T=530 K to 570 K and a strain rate of $\dot{\varepsilon}$=0.001-0.006 s^-1.

Key words

Mg/Al bimetal / cold spray additive manufacturing / hot deformation behavior / hot workability / process window

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ZHANG Qixu, LIU Sitong, LONG Jinchuan, LIN Yongcheng, DENG Lei, HAN Xu. Hot Deformation Behavior and Hot Workability of Mg/Al Bimetals Prepared by Cold Spray Additive Manufacturing[J]. Journal of Netshape Forming Engineering. 2026, 18(4): 69-78 https://doi.org/10.3969/j.issn.1674-6457.2026.04.007

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