近年來，多種結合多步驟時效與溫成形參數之 AA7075 鋁合金板材溫成形製程路徑被提出，以兼顧成形性、製程效率與近似 T6 之強度需求。然而，儘管不同製程可達成相近強度目標，其成形性仍因材料基地析出物特徵差異而存在顯著差異，相關成形機制尚未釐清。本論文針對此一問題，系統性探討不同溫成形製程路徑對 AA7075 變形行為與成形性的影響，並建立析出物特徵與宏觀成形性之定量關聯。
為此，本論文探討三種 AA7075 鋁合金板材之溫成形製程路徑，分別為回歸再時效溫成形(RRAWF)、預時效溫成形(PAWF)，以及本論文新提出之時效溫成形(AWF），並於各製程條件下進行成形試驗與微觀結構分析。針對 AWF 製程，首先透過溫成形極限高度試驗與烤漆後機械性質評估，系統性建立並驗證其製程可行性與適用參數。隨後，透過等溫中島試驗與單軸拉伸試驗，評估各製程路徑下 AA7075 板材之溫變形行為與成形性，並進行基地析出物之鑑定與定量分析。研究結果顯示，在本論文所探討之溫成形製程路徑範圍內，材料對變形的抵抗能力為主導 AA7075 板材變形行為與成形性的主要因素；同時，於各製程條件下形成之析出物皆屬可剪切型。基於此前提，進一步確認支配材料變形阻抗之關鍵基體顯微結構參數為析出物體積分率與平均半徑之乘積(fvRavg)，可有效表徵不同溫成形製程路徑下之成形性差異。
隨後，基於已建立的微觀結構特徵與宏觀成形性之間的定量相關性，將代表AA7075鋁合金板材溫成形性的fvRavg參數納入修正的Cockcroft & Latham破裂準則，修正並得到一「基於微觀組織特性整合之破壞能量準則」，利用此微觀結構整合準則，系統地計算了AA7075鋁合金板材在不同溫成形條件下的成形極限對應的斷裂能值，從而將微觀結構效應定量地傳遞到成形極限預測中。
在與試驗結果比較並驗證所提出之破壞準則於各溫成形條件下對破裂成形極限曲線及其導入之有限元素模型具備良好預測準確性後，本論文進一步建立一套適用於溫成形條件下之 Lankford 係數快速評估方法。該方法透過設計具等效應變路徑之 Nakajima 試片，使其變形行為與單軸拉伸試驗一致，並於恆溫條件下進行驗證。由最終破裂試片之主、次應變所計算之 Lankford 係數，與傳統單軸拉伸試驗結果之差異低於 5%，有效克服高溫條件下 Lankford 係數不易量測之限制，並提供一項具工業應用潛力之材料各向異性快速評估方法。
綜上所述，本論文建構一套整合顯微組織特徵、變形行為與成形性的研究架構，並透過系統化實驗、模型建立與數值模擬，將微觀組織效應定量導入成形性能評估，為溫成形製程設計與工程應用提供具體且可行之理論基礎與分析方法。此外，亦提出一項適用於 AA7075 鋁合金板材之時效溫成形(AWF)製程路徑，使其於高強度輕量化結構件之開發中，提供一項具可行性之替代成形路徑。

In recent years, several warm-forming process routes combining multi-step ageing treatments with tailored forming parameters have been proposed for AA7075 aluminium alloy sheets to achieve a balance between formability, process efficiency, and near-T6 strength levels. However, although different process routes can deliver comparable post formed strength, their formability often differs significantly due to variations in matrix precipitate (MPts) characteristics, and the underlying deformation mechanisms remain insufficiently understood. To address this issue, this dissertation systematically investigates the influence of different warm-forming process routes on the deformation behaviour and formability of AA7075 sheets and establishes a quantitative correlation between precipitate characteristics and macroscopic formability.
In pursuit of this objective, three distinct warm forming process routes are examined, namely retrogression–reageing warm forming (RRAWF), pre-aged warm forming (PAWF), and a newly developed ageing warm forming (AWF). Forming experiments and comprehensive microstructural characterisation were conducted under each condition. For the AWF route, its process feasibility and applicable parameter range were first established through warm limit dome height tests and post–paint-bake mechanical property evaluations. Subsequently, isothermal Nakajima and uniaxial tensile tests were employed to assess the warm deformation behaviour and formability of AA7075 sheets, accompanied by detailed identification and quantitative analysis of matrix precipitates. The results show that, within the investigated warm forming routes, deformation resistance is the primary factor governing the deformation behaviour and formability of AA7075 sheets, while the precipitates formed under all conditions remain shearable. Accordingly, the product of precipitate volume fraction and average precipitate radius (fvRavg) is identified as the key microstructural parameter controlling deformation resistance and effectively characterising formability differences among the process routes.
Based on this established microstructure–formability correlation, the fvRavg parameter was incorporated into a modified Cockcroft–Latham fracture criterion, leading to the development of a microstructure-integrated fracture energy criterion. This criterion enables systematic determination of the fracture energy corresponding to forming limits under different warm forming conditions and provides a quantitative linkage between microstructural characteristics and macroscopic formability.
After validating the proposed fracture criterion and the associated finite element framework against experimental fracture forming limit curves, a rapid evaluation method for the Lankford coefficient under warm-forming conditions was further developed using specially designed isothermal Nakajima tests with equivalent strain paths to uniaxial tension. The resulting R-values deviate by less than 5% from conventional uniaxial tensile measurements, providing a practical solution to the experimental challenges of anisotropy evaluation at elevated temperatures.
Overall, this dissertation establishes an integrated framework linking microstructural characteristics, deformation behaviour, and formability of AA7075 aluminium alloy sheets. Through systematic experiments, model development, and numerical simulations, microstructural effects are quantitatively incorporated into forming performance evaluation, offering a physically informed basis for warm-forming process design. In addition, the proposed ageing warm forming (AWF) process route provides a feasible alternative processing pathway for high-strength lightweight structural components manufactured from AA7075 aluminium alloy.

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