Strain Path Effects in Metal Plastic Forming: Mechanisms, Characterization, and Application

doi:10.11900/0412.1961.2025.00294

Acta Metall Sin

2026, Vol. 62

Issue (5): 975-992 DOI: 10.11900/0412.1961.2025.00294

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Strain Path Effects in Metal Plastic Forming: Mechanisms, Characterization, and Application

FAN Xiaoguang¹^,²^,³, XIAO Yunteng¹^,², ZHAN Mei¹^,²(

), MA Fei¹^,², GAO Pengfei¹^,², ZHENG Zebang¹^,², ZHANG Xin²^,³, SHAO Guangda²^,⁴, WU Yuming¹^,²

1 School of Materials Science and Engineering, Northwestern Polytechnical University, Xi'an 710072, China
2 Shaanxi Key Laboratory of High-Performance Precision Forming Technology and Equipment, Northwestern Polytechnical University, Xi'an 710072, China
3 Key Laboratory of High Performance Manufacturing for Aero Engine, Ministry of Industry and Information Technology, Northwestern Polytechnical University, Xi'an 710072, China
4 Shanghai Key Laboratory of Digital Manufacture for Thin-Walled Structures, Shanghai Jiao Tong University, Shanghai 200240, China

Cite this article:

FAN Xiaoguang, XIAO Yunteng, ZHAN Mei, MA Fei, GAO Pengfei, ZHENG Zebang, ZHANG Xin, SHAO Guangda, WU Yuming. Strain Path Effects in Metal Plastic Forming: Mechanisms, Characterization, and Application. Acta Metall Sin, 2026, 62(5): 975-992.

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Abstract

Strain path is a critical factor governing the forming quality of metallic components, including their geometry, microstructure, and service performance. Achieve high-quality forming often requires the use of nonlinear and complex strain paths, which inevitably give rise to multiscale deformation behaviors. Understanding and characterizing these mechanisms has therefore become a frontier topic in the field of plastic forming. This review synthesizes recent advances in the investigation of macroscopic mechanical responses, damage behavior, and microstructural and textural evolutions under complex strain paths, emphasizing the central role of stress path history in shaping multiscale deformation mechanisms. Finite element modeling strategies that account for strain path effects are discussed, including constitutive models, limit prediction and damage models, as well as microstructure evolution models, with particular attention to their roles in improving predictive accuracy and process simulation capabilities. Engineering-oriented approaches to strain path design are also summarized, highlighting their potential for optimizing formability and service performance. Finally, perspectives on future research directions are presented.

Key words: plastic forming strain path effect multiscale deformation finite element modeling formability service performance

Received: 29 September 2025

ZTFLH:

TG113.25

Fund: National Natural Science Foundation of China(52130507);National Natural Science Foundation of China(U24B2055)

Corresponding Authors: ZHAN Mei, professor, Tel: 13619245419, E-mail: zhanmei@nwpu.edu.cn

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	Articles by authors
	FAN Xiaoguang
	XIAO Yunteng
	ZHAN Mei
	MA Fei
	GAO Pengfei
	ZHENG Zebang
	ZHANG Xin
	SHAO Guangda
	WU Yuming

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https://www.ams.org.cn/EN/10.11900/0412.1961.2025.00294 OR https://www.ams.org.cn/EN/Y2026/V62/I5/975

Fig.1 Comparisons of work hardening behaviors of AA6016-T4 alloy under different strain paths^[21]

Fig.2 Stress-strain curves of commercially pure titanium under different combinations of strain paths (RDC—rolling direction compression, NDC—normal direction compression, TDC—transverse direction compression)^[28]

Fig.3 Stress-strain curves of quenching and partitioning steel (QP980) specimens at various pre-strain levels deformed along RD^[29] (UT-UC—uniaxial tension (UT) followed by compression,UC-UT—uniaxial compression (UC) followed by tension, RD—rolling direction, T—tension, C—compression)
(a) UT-UC (b) UC-UT

Fig.4 Fracture mechanisms of 2219-W aluminum alloy under different strain paths^[35] (MSP—maximum shear plane, ND—normal direction, KAM—kernel average misorientation, IPF—inverse pole figure) (a-c) plane strain tension (PST) specimen (Fig.4b is the RD × ND middle section of PST after fracture; Fig.4c shows the KAM maps and IPF-Z maps of two squared positions in Fig.4b) (d-f) shear (SH) specimen (d), stress components on the shear plane of the fracture element for SH specimen (e), and comparisons of the rigid body and MSP rotation angles of the same element as Fig.4e (f) (σ_xx, σ_yy, and σ_xy are stress com-ponents) (g, h) UC specimen (g) and SEM images of cross cracks on the RD × ND outer surface (h)

Fig.5 Damage index (DUCTCRT) and compressive fractured specimen shape of AA 2024-T3 alloy^[38]
(a) no pre-tensile strain (b) pre-tensile strain of 0.079 (c) pre-tensile strain of 0.093

Fig.6 Schematics of strain accumulation of AZ31 magnesium alloy during constrained groove pressing(CGP)^[40] (TD—transverse direction)
(a) one pass of CGP and two passes of 180° cross-CGP (b) two passes of 90° cross-CGP

Fig.7 Schematic of lamellar globularization behavior under different compression routes^[43] (FD—forging direction, CA—compression axis)

Fig.8 Schematic of twinning behavior in high manganese steel under large pre-deformation tension-compression strain paths^[44] (CG—coarse grain, FG—fine grain, HDI—hetero-deformation-induced)

Fig.9 Phase distribution of 304LN stainless steel under different strain paths^[8] (Insets shows the strain vs time waveforms for different strain paths. OPT—out of phase triangular, OPS—out of phase sinusoidal, OPZ—out of phase trapezoidal, ε—applied axial strain, γ—applied shear strain)

Fig.10 Texture evolutions of Ti65 alloy during rolling process with different strain paths^[49] (UDR—unidirectional rolling, CDR—cross-directional rolling, MSCR—multistep cross-rolling, Bas—basal slip, SF—Schmid factor, GSF—global Schmid factor)

Fig.11 Texture evolution affected by strain path changes during multi axis forging process^[57] (MAF—multi-axial forging; TI—texture intensity; ϕ, φ₁, and φ₂—Euler angles)

Fig.12 Equivalent strain ratio corresponding to different prestrains under nonlinear strain path^[100]

Fig.13 Characteristics of morphology and crystallographic orientation of α phase deformed along different loading paths^[109] (GOS—grain orientation spread) (a1-a3) 0° compression (b1-b3) 45° compression (c1-c3) 90° compression

Fig.14 Comparisons of tensile properties of Al/Mg composite sheets fabricated under single pass (sp) and double passes by direct rolling (dpd), reverse rolling (dpr), and cross rolling (dpc)^[114]

Fig.15 Deformation strain paths under standard equal channel angular pressing (ECAP) routes^[116]
(a) illustration of a cubic element undergoing defor-mation due to shearing after a single pass of ECAP
(b) evolution of deformation in each plane for all 4 ECAP routes after up to 8 passes of ECAP

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