Impact of triaxiality on material behaviour characterization in hot forging processes: focus on near solidus forming

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This study investigates the deformation behaviour of 42CrMo4 steel at high temperatures and varying strain rates, focusing on the impact of different deformation states (compression vs. shear) on material behaviour. Through detailed material characterization, including plane strain compression and traditional compression tests, we reveal that at temperatures between 1300 °C and 1370 °C and strain rates of 1 s −1 –10 s −1 , the material’s behaviour remains largely unaffected by the deformation state. A key finding is that models based solely on compression tests can accurately predict material behaviour under plane strain conditions. Despite this, challenges persist in developing shear test geometries that can reliably capture pure shear deformation states for high-temperature applications. This research provides valuable material parameters for numerical simulations, especially in high temperature forging processes, contributing to the advancement of sustainable manufacturing technologies. These insights are crucial for optimizing processes like NSF forging, directly impacting the digital twin modelling of industrial operations and supporting the transition towards sustainable manufacturing.