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

Aerospace die forgings are safety-critical structural products whose service performance is governed by coupled microstructural evolution across multiple length scales rather than by any single descriptor. This review critically synthesizes recent progress in multiscale characterization and process–structure–property analysis of aerospace die forgings, with emphasis on forged titanium alloys, wrought nickel-based superalloys, and high-strength aluminum alloys. A practical framework is first established by linking macroscale metal-flow integrity and defect control with mesoscale gradients, microscale grain-boundary and texture evolution, and nanoscale precipitation, segregation, and interface states. The principal characterization routes are then discussed, including X-ray diffraction, EBSD/3D-EBSD, TEM/STEM, atom probe tomography, tomography-based defect evaluation, and correlative workflows. The alloy-specific sections are organized around mechanisms and property consequences rather than isolated micrographs. Finally, the review discusses how multiscale descriptors can support crystal-plasticity, phase-field, cellular-automata, and ICME-oriented modeling, and identifies future priorities in three-dimensional characterization, quantitative descriptor extraction, uncertainty-aware modeling, environmental degradation assessment, and closed-loop process optimization. Overall, the performance of aerospace die forgings is shown to depend on coordinated control of phase stability, grain-boundary network evolution, precipitation state, defect population, and location-dependent heterogeneity across the full manufacturing route.