For the development of processing maps to zirconium alloys, a
simple instability condition based on the Ziegler's continuum principles as
applied to large plastic flow is extended for delineating the regions of
unstable metal flow/occurrence of fracture or defects, utilizing the flow
stress data of Zr-2.5Nb-0.5Cu. An attempt is made to fit the measured flow
stress data in a constitutive equation, useful in the finite element process
models. Instability maps at different strain levels were superimposed while
delineating the unstable regions in the processing maps. This phenomenon
takes into account the dependence of strain rate sensitivity and strain
hardening coefficient of the material on the plastic instability during hot
deformation. The applicability of the developed processing map has been
examined by comparing with the reported microstructural observations of the
deformed compression specimens of various zirconium alloys. It is found that
the processing map is practically usable in the real fabrication process for
the zirconium alloys.