A Focused Review on Multiscale Characterization and Process-Structure-Property Linkages in Aerospace Die Forgings

Area of Science:

• Materials Science
• Metallurgy
• Aerospace Engineering

Background:

• Aerospace die forgings are safety-critical components.
• Their performance depends on complex microstructural evolution across multiple length scales.

Purpose of the Study:

• To synthesize recent advancements in multiscale characterization and process-structure-property analysis of aerospace die forgings.
• To establish a framework linking macroscale integrity to nanoscale features.
• To review characterization techniques and modeling approaches.

Main Methods:

• Multiscale characterization including X-ray diffraction, EBSD, TEM/STEM, and atom probe tomography.
• Correlative workflows for defect evaluation.
• Analysis of forged titanium alloys, nickel-based superalloys, and aluminum alloys.

Main Results:

• A framework connecting macroscale metal-flow integrity to mesoscale gradients, microscale grain-boundary evolution, and nanoscale precipitation.
• Detailed discussion of alloy-specific mechanisms and property consequences.
• Identification of key microstructural features: phase stability, grain boundaries, precipitation, defects, and heterogeneity.

Conclusions:

• Coordinated control of multiscale features is essential for aerospace die forging performance.
• Multiscale descriptors can enhance predictive modeling (e.g., crystal-plasticity, ICME).
• Future priorities include 3D characterization, quantitative descriptors, and uncertainty-aware modeling.