In the present research, a general model for the description of the microstructural evolution of metallic systems is presented, which can examine the process without direct measurements and without requiring complex sample preparations. An existing challenge in the field of microstructural studies is to determine the strain dependence of the coefficient in the Taylor and Tabor theories used for the calculation of stress from dislocation densities and hardness values. The parameter describing the geometrical factor in the Taylor equation is analysed as a function of the mean free path. From the measured hardness values, the dislocation densities and characteristic structural size are determined by existing models, in which the general dependence is described by the Sahoo stress model. The dislocation density values are compared with Kocks–Mecking–Estrin and Kubin–Estrin models, and a correlation is found between the coefficients of the various models. The model also calculates the deformation energy.

The structural model is validated by Vickers hardness indentations made on plates with three different chemical compositions from alloy series of Al-1xxx, 5xxx and 6xxx. Based on the results, the applicability can be extended to a wide range of different alloys. The model can be supported by numerical results from the literature on pure aluminum, copper, nickel, iron, chromium, niobium, and aluminum alloys.

This research is supported by the EKÖP-25 University Excellence Scholarship Program of the Ministry for Culture and Innovation from the source of the National Research, Development, and Innovation Fund.

Project no. TKP2021-NVA-29 has been implemented with the support provided by the Ministry of Culture and Innovation of Hungary from the National Research, Development and Innovation Fund, financed under the TKP2021-NVA funding scheme.