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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 T 1 + 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. • The DH and doubling the strain of MDF both promoted the dissolution of non-equilibrium phases. • Combine DH treatment with MDF enhanced the precipitation kinetics of the T 1 phase, increasing the strength by 20–30 MPa. • The coarse phase was the main transgranular cracking sources, which was diminished gradually by the improved process. [ABSTRACT FROM AUTHOR]

The 2195 Al-Cu-Li alloy is widely utilized for the fabrication of key aerospace vehicle components; hence, an in-depth understanding of its hot deformation behavior is essential for consistently achieving high-performance products. In this study, isothermal compression tests were performed on 2195 Al-Cu-Li alloy ingots in the temperature and strain rate ranges of 250–500 °C and 10−3-1 s−1, respectively. A processing map was established to predict the workability under different conditions. The corresponding microstructures were examined to reveal their hot deformation mechanism. Results demonstrated that the processing map was divided into four distinct domains. The unstable zone was located in the 250–375 °C/10−1.5-1 s−1 and 250–275 °C/10−2.5–10−1.5 s−1, temperature/strain rate regimes, in which deformation bands and flow localization were observed. The deformation bands blocked dislocations and compromised the dynamic recrystallization (DRX) behavior, hence damaging the microstructure. Further, large coarse T 1 phases precipitated in the 325–410 °C/10−2.5–10−3 s−1 regime, which led to the formation of heterogeneities in the microstructure, corresponding to a minimum workability in the processing map. The optimal hot-working domain for the 2195 alloy was determined to be 460–500 °C/10−3–10−2 s−1, and the dominating hot deformation mechanisms were DRX and dynamic recovery (DRV). Specifically, continuous and discontinuous DRX behaviors dominated in the 300–400 °C/10−3 s−1 and 450–500 °C/10−3 s−1 regimes, respectively. DRX gradually weakened as the strain rate increased at 500 °C. Further, the weakening of DRX was only minimally affected by temperature at 400–500 °C during high-speed deformation (1 s−1). The results reported herein can provide valuable insights into the hot working of Al-Cu–Li alloys. • A processing map (PM) was established to accurately predict the hot deformation behavior of the 2195 alloy. • Deformation bands and flow localization were the main microstructure response in the unstable domain. • Large coarse T 1 phases precipitated in the precipitation sensitive domain, leading to heterogeneity deformation. • The optimal hot working domain was 460–500 °C/10−3–10−2 s−1, which was dominated by DRX and DRV. • Within the 300–400 °C/10−3 s−1 regime, CDRX was the main DRX mechanism, whereas DDRX predominant at 450–500 °C/10−3 s−1. [ABSTRACT FROM AUTHOR]