This study aims to explore the influence of distinct forging parameters on microstructure and mechanical properties of TC21 forgings. The trimodal microstructure, which includes equiaxial α (αeq), lath α (αlath), and fine α (αfine) phases, was achieved via quasi-β forging and dual heat treatment. Subsequently, mechanical properties were evaluated through tensile, impact toughness (ak), and fracture toughness (KIC) tests. Results indicate that the content of αeq is higher at lower forging heating temperature, whereas the content of αlath is diminished and the size of αfine remains relatively small. This tendency reverses at higher forging heating temperature due to the increased driving force of the phase transition. The rise in αlath content implies more pronounced interface strengthening and plastic deformation, which significantly contributes to strength compared to αfine and αeq but exerts a weaker influence on plasticity. Moreover, the combined deformation and fracture of αlath and αfine exert a significant influence on the initiation and propagation of cracks in ak and KIC specimens. The limited coordination of deformations exhibited by αlath leads to preferential stacking dislocations and shear fractures at interfaces, which are further influenced by its higher aspect ratio affecting crack propagation paths. This not only increases the required energy for initiating cracks but also raises energy consumption during their propagation. Crucially, the presence of αfine significantly enhances the dislocation accumulation and the plastic deformation zone at the crack tip, thereby playing a pivotal role in determining local deformation capacity and crack deflection frequency.
