Abstract:Hot working is a crucial method for refining grain structures and enhancing the properties of as-cast Al-Zn-Cu-Mg high-strength alloys. In this study, the microstructures and mechanical properties of Al-8.3Zn-3.3Cu-2.2Mg alloys fabricated via hot extrusion and liquid forging were investigated. Based on the DEFORM simulation analysis, optimal hot extrusion parameters were determined as an ingot initial temperature of 380°C and an extrusion speed of 3 mm/s. The hot-extruded alloy, following T6 heat treatment, demonstrates superior mechanical properties with a yield strength (YS) of 519.6 MPa, ultimate tensile strength (UTS) of 582.1 MPa, and elongation (EL) of 11.0%. Compared to the as-cast and liquid-forged alloy counterparts, the hot-extruded alloy exhibits a 30.8% and 4.9% increase in YS, and a 43.5% and 10.2% increase in UTS, respectively. The significant improvement in tensile strength in the hot-worked alloys is attributed to the elimination of casting defects and refinement of matrix grain and eutectic phases. Furthermore, the hot-extruded alloy demonstrates superior plasticity compared to the liquid-forged alloy. The severe plastic deformation during hot extrusion effectively breaks and disperses eutectic phases, facilitating the dissolution and precipitation of the second phases and inhibiting microcrack initiation.