February 2026 Volume 8

FORGING RESEARCH

Future Research Directions The framework establishes a foundation for several research extensions: Dynamic Class Adaptation: Development of algorithms for automatic refinement or coarsening of microstructural classes during simulation, addressing current limitations at low Zener Hollomon conditions. Multi-Phase Systems: Extension to handle complex precipitate populations and phase transformations occurring simultaneously with recrystallization. Machine Learning Integration: Incorporation of data-driven models to enhance prediction accuracy while maintaining computational efficiency.

Figure 7: Dynamic recrystallization (DRX) at 980°C, 1050°C, and 1120°C under strain rates of 0.001–1 s ⁻ ¹, without SPP, comparing grain size results from NHM (red curves) and DIGIMU® (green curves). Scientific Research Applications Parameter Identification: The computational efficiency of NHM makes it ideal for inverse analysis to extract constitutive parameters from experimental data. These parameters can then be validated using full-field simulations. Mechanism Investigation: The multi-scale approach allows researchers to investigate competing mechanisms during recrystallization, distinguishing between continuous and discontinuous processes through comparative analysis. Digital Twin Development: Integration with FORGE® enables creation of digital twins for critical components, tracking microstructural evolution throughout manufacturing and predicting in-service performance.

Figure 9: Grain size evolution during dynamic recrystallization (DRX) in Inconel 718 at 1050°C as predicted by NHM (blue) and DIGIMU® (purple). Inset maps show grain cartographies generated with DIGIMU®, highlighting detailed microstructural predictions of the full-field simulation. Conclusion This research successfully demonstrates the development and validation of a comprehensive multi-scale modeling framework for predicting microstructural evolution in nickel-based superalloys. The investigation establishes clear domains of applicability for three distinct modeling approaches, from rapid phenomenological assessments to detailed physics-based simulations.

Figure 8: Comparison of results obtained with DIGIMU® (green curves) and NHM (red curves) during DRX–PDRX at 980°C for an SPP fraction of 0.5%, in terms of average equivalent diameter (a) without SPP and (b) with SPP, and recrystallized fraction (c) without SPP and (d) with SPP.

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