This study investigates the influence of increased build rates on the high-cycle fatigue (HCF) life of PBF-LB manufactured 316L stainless steel by detailed analysis of pore characteristics using X-ray Computed Tomography (XCT) and surface roughness. Furthermore, the effects of post-processing surface treatments by chemical mechanical processing (CMP) and Hirtisation (R) on surface improvement and fatigue life were studied as well. Although increased build rates led to reduced fatigue life compared to the reference condition, this was related to distinct pore morphologies revealed by XCT. Specifically, the impact of porosity generated by increased hatch distance (PA) exhibited more uniform lack of fusion (LoF) pores, while porosity generated by higher scan speed (PB), displayed larger, more randomly distributed defects, leading to larger scatter in fatigue life. Examination of the fracture surfaces confirmed that crack initiation sites were associated with surface defects in the reference samples, LoF along the hatch lines in the PA samples, and larger, randomly distributed LoF pores in the PB samples. Both CMP and Hirtisation (R) surface treatments approximately doubled the fatigue life of the reference condition. However, limited material removal in CMP exposed subsurface porosity, acting as initiation sites. In contrast, the material removal during Hirtisation (R) effectively mitigated surface and near-surface defects. These findings highlight the critical role of build strategy in controlling defect morphology and the effectiveness of surface treatments in enhancing the fatigue performance of additively manufactured stainless steel, crucial for expanding their industrial applications.

Hot isostatic pressing (HIP) is commonly applied to additively manufactured Ti-6Al-4V to eliminate lack-of-fusion (LoF) defects; however, significant differences in fatigue performance are often observed even when residual porosity is comparable. This study investigates whether fatigue behaviour in PBF-LB Ti-6Al-4V material with varying defect content is controlled by process defects or by microstructure-dependent crack initiation mechanisms. Specimens were produced using two process themes, a minimal porosity (MP) and a high productivity (HP) condition with reduced volumetric energy input, and subsequently HIP treated below or above the fl-transus temperature. X-ray computed tomography confirmed that HIP effectively healed LoF defects in the HP material, reducing residual porosity to levels comparable to MP builds. Fatigue testing revealed that, once defects were eliminated, fatigue life depended strongly on the HIP microstructure: sub-fl HIP consistently produced longer lives than super-fl HIP across all stress levels. EBSD analysis showed that sub-fl HIP generated a fine a structure that distributed cyclic plasticity across many grains, whereas super-fl HIP formed large prior-fl grains containing coarse a colonies with very fine lamellar structure within each colony. These colonies acted as microstructural units, concentrating cyclic slip into long bands and promoting early crack initiation. The results show that HIP reduces defect density and the remaining fatigue failures are predominantly governed by microstructural mechanisms. After excluding a few samples with defect initiated failures, fatigue life was controlled by colony slip localisation, identifying the a colony size as the dominant microstructural fatigue length scale. Tailoring HIP temperature provides a route to achieving wrought-comparable fatigue performance in high-productivity PBF-LB Ti-6Al-4V.

Additive manufacturing (AM) is an innovative production approach that has gained significant attention due to its ability to overcome many limitations associated with traditional manufacturing techniques. As a consequence of efforts to optimize various AM processes, especially across different methods, a vast amount of data is either utilized (e.g., material properties, printer specifications, and process settings) or generated (e.g., monitoring data during printing, slicing strategies, and parameter configurations). Effectively managing, understanding, and retrieving information from this data remains a major challenge. The data often exhibits complex interrelationships and is distributed across heterogeneous sources, making it difficult for researchers and industry professionals to extract meaningful insights or make informed decisions. To address these challenges, we propose a knowledge-based approach designed to support the structured management of AM data. The core of this approach is a modular ontology (PBF-AMP-Onto), which serves as a semantic foundation for integrating diverse data sources, enabling semantic querying, and supporting decision-making systems. This ontology facilitates semantics-aware data management, enhances the interpretability of AM processes, and contributes to the optimization of manufacturing outcomes. In this paper, we focus on one of the most advanced AM techniques, powder bed fusion (PBF), with a particular emphasis on electron beam (EB-PBF). To validate the feasibility and practical utility of our approach, we constructed a knowledge graph using a workbench (PBF-AMP-KG Workbench) and based on our ontology using data from real-world EB-PBF use cases. We then demonstrate how domain-relevant queries, such as those concerning process parameters, material behavior, and machine settings, can be answered efficiently using this knowledge graph, showcasing its potential to support researchers in navigating and leveraging AM data more effectively.

This study investigates the corrosion behavior of AA5182 Al-Mg alloy produced by thin-strip (TS) and direct-chill (DC) casting. Through immersion tests, polarization measurements, and electrochemical impedance spectroscopy (EIS), the impact of as-cast microstructure on corrosion resistance in HNO3 solution was examined. The results show that TS samples with reduced formation of intergranular Mg-rich eutectics, particularly (3-Al3Mg2, exhibit a lower degree of sensitization (DOS), attributed to Mg supersaturation in the matrix due to rapid solidification, and demonstrate superior corrosion resistance.

Tailoring the mechanical properties of a part is a very desirable feature which could be realised using additive manufacturing (AM). In electron beam powder bed fusion (EB-PBF) the option of using point melt strategies opens the possibility of creating advanced thermal conditions during printing, which could control the solidification process. This paper aims at using a new point melt strategy developed by Colibrium Additive to investigate its impact on microstructure and mechanical properties. In this strategy, the main parameters for different process conditions are the inhibition time and inhibition radius where the main change would be the background temperature. A total of 45 Ti6Al4V samples with 15 different melt conditions obtained by changing these two parameters were printed. The results show a clear relationship between the parameters in the point melt algorithm and the mechanical properties, with yield strength among the highest found for EB-PBF printed Ti6Al4V in present literature. High background temperature decreased the strength but increased the ductility, while low background temperature increased the strength. Larger alpha grains and colonies could be seen for samples printed with high background temperature and as the background temperature decreased, these grains decreased in size. The increase in strength is attributed to the decrease in alpha lath size in combination with more columnar primary beta grains.Samples printed with lower background temperature also exhibited defects which could be due to the decrease in melt pool overlap or placement on the build plate. This work demonstrates the possibilities of using advanced melt strategies, showing that significant differences in mechanical properties can be achieved simply by changing the order in which single points are melted.

The present study investigates the role of process-induced defects on the fatigue performance of high-strength Al2139 alloy fabricated by laser-based powder bed fusion of metals (PBF-LB/M). Specimens of two surface conditions: as-built and machined, underwent high-cycle uniaxial fatigue testing to evaluate the combined influence of surface state and defect characteristics. Fractographic examination using scanning electron microscopy identified gas pores and lack-of-fusion (LoF) defects as the dominant crack initiation sites. The LoF defects were further classified into regular LoF defects with relatively compact morphology and shallow, irregularly shaped LoF defects exhibiting larger projected areas.Despite the removal of surface roughness effects, machined specimens exhibited greater scatter in the S–N response and, in several cases, shorter fatigue lives than as-built counterparts tested at identical stress levels. Premature failures in the machined group were consistently associated with shallow, irregular LoF defects with a larger effective size that were exposed at the surface by the machining operation. This concludes that defect morphology and projected area govern fatigue performance more critically than nominal surface finish.Defect severity was quantified using Murakami’s √area parameter. An equivalent defect radius was calculated by idealising defects as semicircular surface cracks on a cylindrical specimen to determine the corresponding stress intensity factor (SIF). A clear correlation between SIF and fatigue life was established, enabling a defect-based life prediction method. The proposed framework provides a quantitative basis for defining allowable defect sizes at given stress levels and contributes to defect-tolerant design strategies for PBF-LB/M Al2139 components.

Metal additive manufacturing (MAM) enables cost-effective, sustainable production of complex components. Among its techniques, metal material extrusion (MEX) is attractive due to its simplicity, safety, and lower cost than laser-based or vacuum-assisted methods. However, sintering MEX-fabricated aluminum is challenging because rapid alumina formation hinders particle bonding and densification. This study investigates how heating rate, thermal-debinding soaking time, sintering temperature, and sintering time affect microstructure, EDS oxygen signal, porosity, apparent (Archimedes) density, and hardness of pure aluminum parts processed in air. A design of experiments (DOE) framework was used as a screening study to evaluate main effects; interaction effects are not fully decoupled and results are interpreted within this limitation. Heating rate and sintering temperature showed the strongest contributions to the EDS oxygen signal, while sintering time mainly affected hardness and densification. Soaking time had the highest contribution to porosity, though only slightly higher than the other factors. A moderate heating rate (5 degrees C/min) and intermediate sintering temperature (930 degrees C) yielded the lowest mean porosity (similar to 38%) and a more uniform microstructure. A higher sintering temperature (1030 degrees C) increased the temperature-level mean hardness (24.6 HV) along with a higher EDS oxygen signal. Overall, the results suggest that thermal management can partially mitigate oxide pinning via diffusion-controlled neck growth and Kirkendall-type pore evolution, enabling controllable porosity and improved bonding even in air. These findings clarify process-structure-property relationships in MEX aluminum and support practical, low-cost sintering protocols for sustainable metal AM.

The microstructure and corrosion properties of electron beam powder bed fusion (EB-PBF)-fabricated 316L stainless steel are evaluated in the as-fabricated condition with and without the deposition of IN 625 coating. Different surface profiles were achieved by introducing layer thickness and a contour scan strategy as process variables. A potentiodynamic polarization test was used for corrosion testing, while state-of-the-art microstructural investigation techniques were employed to elucidate a possible link between the microstructure and corrosion properties of the samples. Results from this pilot study showed that the corrosion response was dictated by the combined effects of surface roughness, coating depth, coating morphology, and passive film characteristics. For specimens for which a contour scan strategy was not used, the coating hinted to an improved corrosion potential while it increased the corrosion rate for both layer thicknesses. On the contrary, for specimens where a contour scan was applied, as-fabricated samples trended towards better corrosion resistance than the coated samples. It is shown that the dross particles that are formed during EB-PBF processing influence the flattening mechanism of the coating, ultimately resulting in a coating deposit that is characterized by surface defects, microcracks, cavities, and incoherent splat boundaries.

This study reports the effects of build orientation and precipitates on the hydrogen embrittlement susceptibility of powder bed fusion – laser beam (PBF-LB) alloy 718 for aerospace applications. The material is subjected to hot isostatic pressing (HIP) then to a modified aerospace heat treatment to minimize delta (δ) phase. The horizontal and vertical specimens are tensile tested at room temperature in air and in a 150 bar gaseous hydrogen environment. In air, horizontal and vertical specimens show similar mechanical properties. In hydrogen, anisotropy was apparent with elongation at fracture of about 6% for horizontal and 17% for vertical specimens. The specimens tested in hydrogen also show a lower reduction of area than those tested in air. The microstructure shows a localized plasticity along grain boundaries, leading to preferential decohesion at precipitates. These findings are consistent with hydrogen embrittlement (HE) mechanisms, like hydrogen-enhanced localized plasticity (HELP) and hydrogen-enhanced decohesion (HEDE).

Previous studies have shown that metastable phase transformation under cyclic loading can enhance the fatigue performance of AISI 316L. However, the underlying mechanisms and the potential for further improvement remain unclear. This study aims to investigate the cyclic deformation mechanisms in cold-drawn AISI 316L and the effect of stress relieving heat treatment. Cold-drawn and stress-relieved specimens were subjected to tensile and stress-controlled fatigue testing. The stress relieving heat treatment significantly improved fatigue performance while resulting in a slight increase in yield strength. Microstructural characterization revealed that this improvement can be attributed to the combined effects of increased yield strength and a greater extent of martensitic transformation in dislocation-free regions under cyclic loading, which delays fatigue crack initiation. The stress relieving heat treatment promotes the development of a low-energy dislocation configuration, which facilitates the formation of dislocation-free regions under cyclic loading and subsequently promotes martensite nucleation. Furthermore, the distribution of martensitic transformation under cyclic loading was found to differ from that under monotonic loading, primarily due to differences in dislocation arrangements under the two loading modes. This study clarifies the role of stress relieving heat treatment in fatigue resistance enhancement through metastable phase transformation and provides insights into the development of more fatigue-resistant steels.

Additive Manufacturing (AM), specifically Powder Bed Fusion - Laser Beam (PBF-LB), offers unique capabilities for manufacturing of components with Ni-base superalloys like CM247LC, yet often introduces microstructuredependent mechanical anisotropy. This study investigates the profound influence of build direction on the high-temperature tensile creep performance and deformation mechanisms of a PBF-LB CM247LC superalloy with test conditions of 871 degrees C and 380 MPa, correlating macroscopic performance with detailed post-mortem electron backscattered diffraction and controlled electron channeling contrast imaging. Significant creep anisotropy was revealed with vertically built (VB) specimens exhibiting markedly higher creep rupture lives (100-200 h) and ductility (up to 6 %) compared to horizontally built (HB) counterparts (15 h, 0.8 %). Microstructural analysis of heat-treated specimen prior to creep confirmed the persistence of an inherent columnar grain structure, directly linking this anisotropy to the relative alignment of grains with the applied load. Post-creep microstructural analysis of ruptured vertically built specimens showed widespread plastic deformation identified through the presence of dislocations, deformation twins (microtwins) and stacking faults. In contrast, horizontal specimens show localized plastic deformation at grain boundaries, leading to premature, brittle intergranular fracture with minimal overall ductility. While the creep performance of vertically built PBF-LB CM247LC specimens approaches that of conventionally cast CM247LC, horizontally built specimens remain significantly inferior. These insights into anisotropic deformation mechanisms are crucial for optimizing design, processing, and reliable deployment of additively manufactured superalloys in high-temperature applications.

In-situ inoculation of grain-refining elements can effectively mitigate columnar grain growth and alleviate mechanical anisotropy in additively manufactured metals, while enhancing strength via the Hall-Petch effect. However, the refinement mechanism of Ti in austenitic stainless steel remains unclear. This study investigates Mn-assisted Ti inoculation in 316L stainless steel (SS316L), followed by annealing. Despite near-full densification, localized Ti enrichment formed coarse, brittle FeTi and C14 Laves intermetallic clusters, encapsulated by ultrafine ferritic grains within an austenitic matrix. Elevated annealing temperatures dissolved Laves phases and promoted Ti diffusion, resulting in dispersed TiO particles and ferritic domains. Refined Laves phases were redistributed to grain boundaries and triple junctions. Mechanical testing showed improved ductility with increasing annealing temperature: ultimate tensile strength decreased from 650 MPa to 610 MPa, while elongation rose from 13 % to 38 %. Hardness mapping revealed a more uniform distribution, though the maximum hardness dropped from 370 HV to 210 HV. Electrochemical corrosion tests in saline solution indicated that phase transformations induced by Ti-Mn co-inoculation undermined the corrosion resistance of SS316L, rendering it more susceptible to degradation in aggressive environments.

This study examines the effects of minor Ce microalloying (∼0.15 wt%) and strain rate (10−3-10−1 s−1) on the microstructure, solidification microtexture, plastic anisotropy, and deformation behavior of rapidly solidified thin-strip (TS) cast AA5182 Al-Mg alloy. Microstructural characterization reveals that Ce microalloying modifies the solidification pathway by suppressing the formation of Mg/Si-rich eutectic intermetallics (e.g., β-Al3Mg2) and promoting the emergence of Ce-rich compounds, consistent with enhanced non-equilibrium solute redistribution. Although the TS casting produces fine semi-equiaxed grains in both alloys, Ce subtly intensifies preferred crystallographic orientations by strengthening the S, Cu, and Q texture components while reducing the fraction of random orientations. Tensile testing at 0°, 45°, and 90° relative to the casting direction shows that Ce microalloying decreases the yield strength through an effectively negative strain-rate sensitivity; however, it enhances the ultimate tensile strength and elongation at 0° and 90°, primarily due to improved strain-hardening capacity and more slip activity. Anisotropy increases with strain rate in both alloys, with Ce microalloying further elevating planar anisotropy (Δr: 0.09 → 0.16 vs. 0.12 → 0.19) and in-plane anisotropy (IPA: 2.65%→6.99% vs. 3.29%→7.38%), indicating stronger texture-induced directional dependence. Both alloys exhibit strain-rate-dependent Portevin-Le Chatelier (PLC) behavior, transitioning from mixed Type-A + B serrations to predominantly Type-A at higher strain rates. Ce microalloying reduces the stress-drop amplitudes by up to 50% and increases the critical strain (εc) for serration onset by 7-22%, reflecting enhanced flow stability. Fractography confirms fully ductile fracture in all samples, with Ce microalloying inducing finer and more uniformly distributed dimples. Hence, while Ce microalloying improves ductility and stabilizes plastic flow, it concurrently amplifies texture-driven plastic anisotropy in TS cast AA5182.

Strain-age cracking (SAC) remains a critical barrier in post-processing of gamma '-strengthened nickel-based superalloys manufactured by laser powder bed fusion (PBF-LB). In this work, the SAC susceptibility of PBF-LB IN738LC was systematically investigated using V-notch samples under different heating conditions. Residual strain evolution during build plate removal was tracked by strain gauges, and residual stress at different notch depths was measured using synchrotron X-ray diffraction. SAC onset was determined by direct current potential drop (DCPD) and in situ optical imaging, while crack propagation kinetics were quantified under controlled heating rates and isothermal exposures. Post-mortem characterization of SAC morphologies was performed using X-ray photoelectron spectroscopy, scanning and transmission electron microscopy, energy-dispersive X-ray spectroscopy, and electron backscatter diffraction. SAC initiation is governed by gamma ' precipitation kinetics, with onset temperatures following the gamma ' precipitation behavior. Faster heating delays SAC onset, while isothermal holds trigger cracking after sufficient incubation, with longer times at lower isothermal temperatures. Shallow notches concentrate tensile stresses and develop extensive SAC, whereas deeper notches remain largely crack-free due to stress relaxation, sometimes aided by pre-existing solidification cracks. SAC propagates mainly along grain boundaries, assisted by wedge-shaped oxide intrusions. Fast-heating cross-sections reveal that most stored energy is released prior to SAC initiation, indicating that SAC results from instability of local ductility deficit rather than stress relief. Early-stage nanoscale gamma ' formation drives rapid strengthening and localized ductility loss, leading to SAC. These findings provide mechanistic insights and processing guidelines for mitigating SAC in PBF-LB superalloys.

We propose a fracture mechanics based method for determination of equivalent initial damage size (EIDS) distribution in as-built additively manufactured (AM) Ti-6Al-4V notched geometries. The crack growth model is shown to correctly capture the effect of the stress raisers and load ratio on the fatigue life of notched specimens. Results of constant amplitude fatigue tests on notched round bar specimens, with two different stress concentration factors and at multiple load ratios, are fitted to a three-parameter Weibull distribution. Based on the surface roughness measurements performed in this study and in the literature, maximum surface valley depth is found to be a reasonable estimation of the median EIDS.

This study systematically examined the effects of inert (pure argon) and active (argon + 2 wt% oxygen) shielding gases on the corrosion behavior of wire arc additively manufactured (WAAM) duplex stainless steel (DSS), named Ar-P and Ar-O. Active shielding gases are commonly used in arc welding to enhance arc stability and efficiency, which prompted their selection in this study. Adding 2 % oxygen introduced similar to 0.1 % oxygen into Ar-O, with thermodynamic simulations suggesting potential spinel phase formation but microstructural analyses revealed more complex oxide inclusions in Ar-O, reducing surface homogeneity and increasing intragranular and secondary austenite formation. Kernel Average Misorientation (KAM) analysis indicated higher residual strain in these areas. Electrochemical tests, including Open Circuit Potential (OCP), Electrochemical Impedance Spectroscopy (EIS), and Potentiodynamic Polarization, demonstrated superior corrosion resistance in Ar-P, with higher OCP (+73 mV), corrosion potential (+39 mV), and significantly lower corrosion current density (13 mu A/cm(2) vs. 49 mu A/cm(2)), leading to similar to 3 times greater corrosion resistance. This improvement is attributed to Ar-P's thicker, less defective passive layer (87.3 nm vs. 14.0 nm). Corroded surface morphology indicated selective dissolution of delta-ferrite phase and likely pitting around inclusions. These findings highlight that active shielding gas in WAAM deteriorates the corrosion resistance of DSS.

The anisotropic microstructure and strengthening mechanisms of laser powder bed fused (L-PBF) Inconel 718 (IN718) superalloy were comprehensively investigated using experimental and theoretical analyses. Due to the complex thermal gradient and history, the cell structure evolved heterogeneously along the building direction (BD), exhibiting coarser dimensions with increasing distance from the baseplate. This unique microstructural feature played a dominant role in the anisotropic tensile properties (i.e. yield strength and strain hardening behavior) between the loading direction (LD) parallel and normal to BD. To deeply explore the correlation between the directional flow behavior and the various cellular configurations, in-situ high-energy X-ray diffraction (HEXRD) during tensile loading together with multiscale microstructural characterization was performed. It was revealed that the different yield strengths were primarily induced by the heterogeneous cell structures that experienced distinct thermomechanical histories, rather than by crystallographic texture. Furthermore, the more pronounced strain hardening capability observed in the horizontal specimen (loading normal to BD) was attributed to the strong dislocation-boundary interactions, inhibited microvoid formation and growth in the < 200 > //LD grains, and enhanced micro stress responses in the < 111 > //LD and < 200 > //LD grains. These findings offer new insights into the fundamental mechanisms governing the anisotropic mechanical behavior of L-PBF alloys.

This study investigates the microstructure evolution and texture development of friction stir processed (FSP) AA6061-T6 Al-Mg-Si matrix composites reinforced with graphene nanoplatelets. Using electron backscatter diffraction (EBSD), we studied changes in grain boundary characteristics and texture components. As heat input increases, the Zener-Hollomon parameter decreases, causing grain size to grow. Particles, including those of Fe-rich and Mg2Si nature, also coarsen from average sizes of 0.9-1.4 mu m, and 0.2-0.5 mu m, respectively. Higher heat input and plastic strain lead to a reduction of the fraction of low-Sigma boundaries, while increasing high-Sigma boundaries suggest activation of other deformation mechanisms, i.e., from dislocation slip to twinning, respectively, as a function of dislocation generation and recovery kinetics. Grain orientation spread (GOS) and kernel average misorientation (KAM) values also decrease, indicating a higher homogeneity and smaller local disorientations under the excess heat. The higher texture indices observed in the composite samples suggest that frictional heat and graphene addition collectively enhance preferred orientations, potentially leading to higher anisotropy. Principal texture components shift from {101}<121>, {123}<634>, {111}<110>, {332}<113>, {013}<231>, and {214}<121> in the base metal to {011}<122>, {011}<011>, and {112}<110> in composites. Components such as {101}<010> remains unaffected.

Insufficient time-dependent properties at elevated temperatures, particularly creep resistance and ductility, are currently crucial factors impeding the use of additively manufactured Hastelloy X (HX). To address this limitation, a micro-nano olive-shaped carbide network was purposely introduced into HX via laser powder bed fusion (L-PBF) and following optimized heat treatment. The inherent chemical heterogeneity combined with the sufficient stored energy of boundaries, induced by the ultrafast cooling rate of the L-PBF process, creates favorable conditions for the formation of micro-nano precipitate networks. Compared to its untreated counterpart, the optimized HX exhibited considerably improved creep resistance, with an 85 % increase in creep life and a 122 % improvement in fracture ductility. Furthermore, through multiscale characterization techniques and theoretical calculations, the preferential precipitation behavior of the micro-nano carbide networks was systematically investigated from both kinetic and thermodynamic perspectives. The superior creep resistance of the L-PBF HX, decorated with carbide networks, stems from the synergistic effects of the high cavity surface energy, effective pinning for grain boundary sliding, and reduced plasticity-assisted diffusion rate, which markedly inhibit the nucleation and growth of microvoids during high-temperature deformations. This work provides a comprehensive understanding of the strengthening mechanisms associated with non-equilibrium solidification-facilitated carbide networks, providing new insights into the targeted design and optimization of L-PBF alloys.

This study investigates the evolution of ultimate crystallographic texture in AA5182 Al-Mg alloy under uniaxial tensile deformation at quasi-static strain rates (10(-3) and 10(-1) s(-1)), focusing on two casting routes of thin-strip (TS) and direct-chill (DC) casting. The TS sample, solidified at similar to 10(3) K/s, exhibited an initial average grain size of 49.7 mu m, significantly finer than the 114.5 mu m observed in the DC counterpart solidified at a cooling rate of similar to 10(1)-10(2) K/s. The fraction of intermetallic particles in the TS sample (similar to 2.74 %) was markedly lower than in the DC sample (similar to 6.07 %), contributing to enhanced solute supersaturation and reduced strain localization, which is linked to a lower frequency of low-angle misorientations within the matrix. Texture analysis revealed that TS samples experienced an approximately 28 % increase in texture index (from 1.32 to 1.69) with increasing strain rate, compared to a 15 % rise in DC samples (from 1.75 to 2.01), indicating more pronounced strain-induced texture development in the TS sample. Taylor factor (M) analysis showed a greater fraction of favorably oriented grains (M <= 2.5) in as-cast TS samples, increasing from 11.5 % to 14.0 % after deformation, compared to an increase from 7.5 % to 14.6 % in the DC samples. However, the DC sample exhibited greater strain localization and a higher kernel average misorientation (KAM, 0.83 vs. 0.67), consistent with its higher density of intergranular/interdendritic intermetallic particles and coarser structure. It was demonstrated that in the TS sample, strain accommodation primarily occurred through grain rotation and dislocation annihilation, facilitated by lower particle density and higher solute supersaturation. By contrast, the DC sample accommodated strain mainly through dislocation pile-ups and boundary-mediated mechanisms, resulting in more constrained deformation behavior. The unique microstructure in the TS sample enabled a broader range of grain rotation trajectories, resulting in a higher number of distinct texture evolution pathways. These findings underscore the critical role of casting routes in governing texture development and highlight the superior potential of the TS sample for enhanced ductility and formability under dynamic loading conditions.