Characterization of hot deformation of FeCoCrNiAl0.1 high entropy alloy: 3D processing maps, FEM numerical simulation and microstructure evolution

To investigate the hot deformation and dynamic recrystallization (DRX) behavior of FeCoCrNiAl_0.1 high-entropy alloy (HEA), hot compression tests were conducted under varying temperatures range of 950–1100 °C with strain rates range of 0.001 and 1 s⁻¹. FeCoCrNiAl_0.1 HEA exhibit distinct DRX characteristics, synergistically controlled by dynamic recovery (DRV) and DRX. The hot processing map indicates that the studied alloy exhibits an optimal hot processing window of 1000–1100 °C/0.001–0.02 s⁻¹. According to finite element model (FEM), DRX distribution is temperature and strain-rate-dependent. The DRX region expands radially from core to peripheral with increasing temperature or decreasing strain rate. Microstructural evolution analysis reveals that the studied alloy exhibits pronounced DRV and DRX characteristics during hot deformation. DRX primarily proceeds through Continuous Dynamic Recrystallization (CDRX) driven by subgrain rotation and Discontinuous Dynamic Recrystallization (DDRX) through grain boundary bulging nucleation. As strain rate decreases or temperature increases, the studied alloy exhibits a grain coarsening and substantial dislocation density reduction. The grain orientation evolves from the typical R texture {134}<211> to the Cube texture {001}<100>, and this texture transition facilitates the progression of DRX.