Effects of heat treatment on the microstructure and mechanical properties of AA2618 DC cast alloy

Direct chill (DC) cast ingot plates of AA2618 alloy have been increasingly used for large-mold applications in the plastics and automotive industries. The effects of different heat treatments on the microstructure and mechanical properties of AA2618 DC cast alloy were investigated using scanning electron microscopy (SEM), transmission electron microscopy (TEM) and hardness and tensile testing. The as-cast microstructure contained a considerable amount of coarse intermetallic phases, including Al₂CuMg, Al₂Cu, Al₇Cu₄Ni, Al₇Cu₂(Fe,Ni) and Al₉FeNi, resulting in poor mechanical properties. Solution treatment at 530 °C for 5 h dissolved the first three phases into the solid solution and consequently improved the mechanical properties of the alloy. By utilizing the appropriate aging temperature and time, different combinations of strength and ductility could be obtained to fulfill the design requirements of large-mold applications. The strengthening of AA2618 DC cast alloy under the aging conditions studied was caused by GPB zones and S′ precipitates. The evolution of both precipitates in terms of their size and density was observed to have a significant effect on the mechanical properties of the alloy.     

Microstructural evolution of Al–Zn–Mg–Cu alloy during homogenization

In this study, the microstructural evolution of an as-cast Al–Zn–Mg–Cu alloy (AA7085) during various homogenization schemes is investigated. It is found that in a single-stage homogenization scheme, some of the primary eutectic gets transformed into the Al₂CuMg phase at 400 °C, and the primary eutectic and Al₂Cu phase gradually dissolve into the alloy matrix at 450 °C. The Al₃Zr particles are mainly precipitated at the center of the grain because Zr is peritectic. However, the homogeneous distribution of the Al₃Zr particles improves and the fraction of Al₃Zr particles increases in two-stage homogenization scheme. At the first low-temperature (e.g., 400 °C) stage, the Al₃Zr particles are homogeneously precipitated at the center of the grain by homogeneous nucleation and may be heterogeneously nucleated on the residual second-phase particles at the grain boundary regions. At the second elevated-temperature (e.g., 470 °C) stage, the Al₃Zr nuclei become larger. A suitable two-stage homogenization scheme for the present 7085-type Al alloy is 400 °C/12 h + 470 °C/12 h.     

Effect of Homogenization Process on Microstructure of Al–Zn–Mg–Cu Aluminum Alloys

Herein, the best homogenization process of 466.5 °C × 36 h + 490 °C × (14–26.4 h) that can completely eliminate the coarse phases σ[Mg(Zn, Al, Cu)₂] and S(Al₂CuMg) in the Al–Zn–Mg–Cu aluminum alloy is developed. The homogenization process is determined by the method of calculation phase diagram, and the experimental verification. It is shown in the results that, first, in the microstructure of the as-cast alloys, the crystal structure of the σ[Mg(Zn, Al, Cu)₂], Al₇Cu₂Fe, and Mg₂Si phases is determined. Second, during the homogenization process, the σ[Mg(Zn, Al, Cu)₂] phase dissolves and also transforms into the S(Al₂CuMg) phase. Most importantly, the dissolution temperature range of the σ[Mg(Zn, Al, Cu)₂], S(Al₂CuMg), and Al₇Cu₂Fe phases is determined from 472.56 to 476.36 °C, from 484.09 to 485.39 °C, and from 540.18 to 547.23 °C, respectively. At best homogenization process, the residual Al₇Cu₂Fe phase area fraction ranges from 1.28 ± 0.16% to 1.60 ± 0.18%. In addition, dispersed η(MgZn₂) phase precipitates in supersaturated Al-matrix during differential scanning calorimeter heating. And, the concentration differences between the grain center and the eutectic of structure of Zn, Mg and Cu regression equations are established, which can provide some reference for the design of experimental parameters, thus reducing the experimental workload.     

Characterisation of AA2618 containing alumina particles

Abstract

The microstructure of cast aluminium based alloy AA2618 and its composites containing 10 and 15 vol.-% alumina particles was characterised by means of transmission electron microscopy, electron probe microanalysis, and microhardness testing. The AA2618 and composite specimens were solution heat treated for 2 h at 530°C, quenched in water, and aged accordingly to produce phases of interest. The Al₂ CuMg, Al₂ Cu, and X phases were identified as the principal precipitates. It was also found that the reinforcing particles influenced the development and distribution of precipitate phases.     

Effect of solid solution state of zirconium and Al3Zr (L12) precipitates on the recrystallization behavior of Al-0.2 wt.%Zr alloy

Effect of homogenization annealing on the existence form of zirconium in Al-0.2wt.%Zr alloy and effect of various existence form of zirconium on the recrystallization behavior of Al-0.2wt.%Zr cold-rolled (total deformation is 92.8 %) sheet are studied. The results show that large numbers of nearly spherical Al₃Zr (L1₂) nanoparticles precipitated from aluminum matrix after homogenizing at 475 °C for 24 h. Moreover, due to the precipitation of Al₃Zr particles, the hardness and electrical conductivity of the as-cast Al-0.2wt.%Zr alloy is increased from 25.1±0.5 HV 3 and 54.0±0.2 %IACS to 28.6±0.7 HV 3 and 56.2±0.1 %IACS, respectively. Hence, zirconium exists as solid solution state in the as-cast Al-0.2wt.%Zr alloy and metastable Al₃Zr phase in the homogenized alloy. Moreover, the recrystallization temperature of the pure aluminum without addition of zirconium is 300 °C, while the recrystallization temperature of the Al-0.2wt.%Zr alloy without and with homogenization is about 350 °C and 400 °C, respectively. Obviously, the solid solution state of zirconium has certain effect on retarding the recrystallization of aluminum alloy, while the nanometer Al₃Zr particles can inhibit the recrystallization of aluminum alloy effectively and increase the recrystallization temperature remarkably.     

A study on the re-solution heat treatment of AA 2618 aluminum alloy

In the present study, the effects of re-solution treatment of AA2618 aluminum alloy has been investigated. Solution heat treatments of 520–640 °C for 14–24 h were applied followed by artificial aging. Characterization studies that were carried out by optical microscopy, scanning electron microscopy and energy dispersive X-ray spectroscopy techniques showed that recrystallisation was not observed by solution treatment at 530 °C whereas it did occur as the solution treatment and the duration time were increased above 530 °C. Increasing the solution treatment temperature further coarsened both the grains and the precipitates, resulting in significant reduction in hardness. Al₉FeNi-type intermetallics are not completely dissolved by these solution treatments.     

Aluminium based composites strengthened with metallic amorphous phase or ceramic (Al2O3) particles

Two methods were used to obtain amorphous aluminium alloy powder: gas atomization and melt spinning. The sprayed powder contained only a small amount of the amorphous phase and therefore bulk composites were prepared by hot pressing of aluminium powder with the 10% addition of ball milled melt spun ribbons of the Al₈₄Ni₆V₅Zr₅ alloy (numbers indicate at.%). The properties were compared with those of a composite containing a 10% addition of Al₂O₃ ceramic particles. Additionally, a composite based on 2618A Al alloy was prepared with the addition of the Al₈₄Ni₆V₅Zr₅ powder from the ribbons used as the strengthening phase. X-ray studies confirmed the presence of the amorphous phase with a small amount of aluminium solid solution in the melt spun ribbons. Differential Scanning Calorimetry (DSC) studies showed the start of the crystallization process of the amorphous ribbons at 437 °C. The composite samples were obtained in the process of uniaxial hot pressing in a vacuum at 380 °C, below the crystallization temperature of the amorphous phase. A uniform distribution of both metallic and ceramic strengthening phases was observed in the composites. The hardness of all the prepared composites was comparable and amounted to approximately 50 HV for those with the Al matrix and 120 HV for the ones with the 2618A alloy matrix. The composites showed a higher yield stress than the hot pressed aluminium or 2618A alloy. Scanning Electron Microscopy (SEM) studies after compression tests revealed that the propagation of cracks in the composites strengthened with the amorphous phase shows a different character than these with ceramic particles. In the composite strengthened with the Al₂O₃ particles cracks have the tendency to propagate at the interfaces of Al/ceramic particles more often than at the amorphous/Al interfaces.     

Effects of d.c. current on the phase transformation in 7050 alloy during homogenization

Evolutions of properties and morphologies of secondary phases in 7050 alloy homogenized with direct electric current were studied in detail by conductivity measurement, tensile test and energy dispersive X-ray microanalysis. With increasing temperature, the conductivity decreases, and while the ultimate tensile strength, yield strength and elongation of 7050 alloy increase in alloy homogenized with direct electric current, and reaches the saturation values at 440 °C/2 h. During homogenization, the brighter white AlZnMgCu phase having (weight ratio %) 12.1–15.2Mg, 27.2–32.1Al, 20.9–26.2Cu and 31.4–34.4Zn gradually transforms to the gray phase having (weight ratio %) 10.3–15.1Mg, 41.4–53.7Al, 22.9–35.2Cu and 5.8–13.1Zn and then to the dark gray phase having (weight ratio %) 10.6–14.2 Mg, 38.2–54.9Al, 23.3–44Cu, and 3.6–9.2Zn. With the application of direct electric current, the elemental diffusion network becomes profuse, the amount of gray phase increases, the diffusion of Zn accelerates, the apparent activation of the transformation from AlZnMgCu to Al₂MgCu decreases from 125.52 kJ/mol for the alloy homogenized without direct electric current to 118.82 kJ/mol, and the area fraction of secondary phase decreases by 38% at 450 °C.     

Optimizing the tensile properties of Al–Si–Cu–Mg 319-type alloys: Role of solution heat treatment

The work presented in this study was carried out on Al–Si–Cu–Mg 319-type alloys to investigate the role of solution heat treatment on the dissolution of copper-containing phases (CuAl₂ and Al₅Mg₈Cu₂Si₆) in 319-type alloys containing different Mg levels, to determine the optimum solution heat treatment with respect to the occurrence of incipient melting, in relation to the alloy properties. Two series of alloys were investigated: a series of experimental Al–7 wt% Si–3.5 wt% Cu alloys containing 0, 0.3, and 0.6 wt% Mg levels. The second series was based on industrial B319 alloy. The present results show that optimum combination of Mg and Sr in this study is 0.3 wt% Mg with 150 ppm Sr, viz. for the Y4S alloy. The corresponding tensile properties in the as-cast condition are 260 MPa (YS), 326 MPa (UTS), and 1.50% (%El), compared to 145 MPa (YS), 232 MPa (UTS), and 2.4% (%El) for the base alloy with no Mg. At 520 °C solution temperature, incipient melting of Al₅Mg₈Cu₂Si₆ phase and undissolved block-like Al₂Cu takes place. At the same time, the Si particles become rounder. Therefore, the tensile properties of Mg-containing alloys are controlled by the combined effects of dissolution of Al₂Cu, incipient melting of Al₅Mg₈Cu₂Si₆ phase and Al₂Cu phase, as well as the Si particle characteristics.     

Microstructural stability and creep properties of die casting Mg–4Al–4RE magnesium alloy

The AE44 (Mg–4Al–4RE) alloy was prepared by a hot-chamber die casting method. The microstructure, microstructural stability and creep properties at 175 °C were investigated. The microstructure was analyzed by scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray diffraction (XRD) and the Rietveld method. The results show that die cast AE44 magnesium alloy consists of α-Mg, Al₁₁RE₃, Al₂RE and Al_2.12RE_0.88 phases. The Al₁₁RE₃ phase is thermally stable at 175 °C whereas the metastable Al_2.12RE_0.88 phase undergoes a transition into the equilibrium Al₂RE phase. The alloy investigated is characterized by good creep properties at temperatures of 175 °C and 200 °C.     

Contact angles by the solid-phase grain boundary wetting (coverage) in the Co–Cu system

The microstructure of binary Co–13.6 wt% Cu and Cu–4.9 wt% Co alloys after long anneals (930–2,100 h) was studied between 880 and 1,085 °C. The contact angles between (Co) particles and (Cu)/(Cu) grain boundaries (GBs) in the Cu–4.9 wt% Co alloy are between 50° and 70°. In the Co–13.6 wt% Cu alloy, the transition from incomplete to complete wetting (coverage) of (Co)/(Co) GBs by the second solid phase (Cu) has been observed. The portion of completely wetted (Co)/(Co) GBs increases with increasing temperature beginning from T _wss = 970 ± 10 °C and reaches a maximum of 15% at 1,040 °C. This temperature is very close to the Curie point in the Co–Cu alloys (1,050 °C). Above 1,040 °C, the amount of completely wetted (Co)/(Co) GBs decreases with increasing temperature and reaches zero at T _wsf = 1,075 ± 5 °C. Such reversible transition from incomplete to complete wetting (coverage) of a GB by a second solid phase is observed for the first time.     

Wetting of grain boundaries in Al by the solid Al<Subscript>3</Subscript>Mg<Subscript>2</Subscript> phase

The microstructure of binary Al_100−x –Mg _x (x = 10, 15, 18 and 25 wt%) alloys after long anneals (600–4000 h) was studied between 210 and 440 °C. The transition from incomplete to complete wetting of Al/Al grain boundaries (GBs) by the second solid phase Al₃Mg₂ has been observed. The portion of completely wetted GBs increases with increasing temperature beginning from T _wsmin = 220 °C. Above T _wsmax = 410 °C all Al/Al GBs are completely wetted by the Al₃Mg₂ phase.     

Microstructure of MgAl5Ca3Sr alloy after creep deformation and high‐temperature heat treatment

The paper presents results of microstructural investigations of MgAl5Ca3Sr magnesium alloys in the as‐cast condition, after creep tests at 180 °C, and after heat treatment at 450 °C for 4.5 hours. The microstructure of MgAl5Ca3Sr alloy is composed of α‐Mg solid solution, irregular shaped (Mg,Al)₂Ca phase with C36 crystal structure, bulky (Mg,Al)₁₇(Sr,Ca)₂ phase, fine lamellar Mg₂Ca phase with C14 structure, needle‐shaped Al₂Ca precipitates with the C15 crystal structure. The precipitation of the needle‐shaped Al₂Ca phase in the α‐Mg grains and spheroidization of the C14 phase were found after heat treatment at 450 °C in argon atmosphere. The (Mg,Al)₂Ca (C36) and (Mg,Al)₁₇(Sr,Ca)₂ phases seems to be stable at 450 °C, however, the increasing of aluminum content in C36 compound was observed suggesting the initial stage of C36 → C15 transformation. After creep deformation at 180 °C precipitates of the Al₂Ca phase were found in α‐Mg phase. The intermetallic compounds are stable at 180 °C. The MgAl5Ca3Sr alloy exhibits good creep resistance up to 75 MPa. Tensile properties are comparable to those of Mg‐RE‐Zn–Zr alloys.     

Non-isothermal aging of a high-Zn-containing Al–Zn–Mg–Cu alloy: microstructure and mechanical properties

The non-isothermal aging behaviour of a newly developed Al–Zn–Mg–Cu alloy containing 17?wt-% Zn was investigated. Hardness and shear punch tests demonstrated that during non-isothermal aging, the mechanical properties of the alloy first increased and then decreased. The best properties were obtained in a sample which was non-isothermally aged upto 250°C with heating rate of 20°C?min^?1, due to the presence of η′/η (MgZn₂) phases. This was confirmed by differential scanning calorimetery. After homogenisation, residual eutectic phases remained at triple junctions or in a spherical form. During aging, these phases transformed into rodlike S (Al₂CuMg)-phase at 400°C, with sizes ranging from 50 to 250?nm. The precipitation sequence in this high-Zn alloy was similar to that for conventional Al–Zn–Mg–Cu alloys.     

Effects of rare earth La on microstructure and properties of Ag–21Cu–25Sn alloy ribbon prepared by melt spinning

Ag–21Cu–25Sn alloy ribbon as a promising intermediate temperature alloy solder (400–600 °C) was prepared by melt spinning technique in this paper. Rare earth La was added into Ag–21Cu–25Sn alloy to refine the microstructures and improve the wettabilities of as-prepared alloy solders. The phase constitutions, microstructures, melting temperatures and wettabilities of selected specimens were respectively tested. The results showed that the dominant phase constitutions of Ag–21Cu–25Sn–xLa alloy ribbons were Ag₃Sn and Cu₃Sn. The grain size of Ag–21Cu–25Sn–xLa alloy decreased with the addition of La increasing. La addition reduced the melting temperatures of Ag–21Cu–25Sn–xLa alloy ribbons, and effectively improved the wettabilities of the alloy ribbons. When the addition of La was 0.5 wt%, the wettability of as-prepared alloy solder achieved the optimal value of 158 cm² g⁻¹ under brazing temperature 600 °C and dwell time 15 min. In addition, raising brazing temperature and prolonging dwell time could improve the wettability of Ag–21Cu–25Sn–xLa alloy ribbon.     

Transient liquid phase (TLP) bonding of Al7075 to Ti–6Al–4V alloy

TLP diffusion bonding of two dissimilar aerospace alloys, Ti–6Al–4V and Al7075, was carried out at 500 °C using 22 μm thick Cu interlayers for various bonding times. Joint formation was attributed to the solid-state diffusion of Cu into the Ti alloy and Al7075 alloy followed by eutectic formation and isothermal solidification along the Cu/Al7075 interface. Examination of the joint region using SEM, EDS and XPS showed the formation of eutectic phases such as, ?(Al₂Cu), T(Al₂Mg₃Zn₃) and Al₁₃Fe along grain boundaries within the Al7075 matrix. At the Cu/Ti alloy bond interface a solid-state bond formed resulting in a Cu₃Ti₂ phase formation along this interface. The joint region homogenized with increasing bonding time and gave the highest bond strength of 19.5 MPa after a bonding time of 30 min.     

Microstructural evolution after creep in aluminum alloy 2618

The microstructural evolution of Al–2.24 Cu–1.42 Mg–0.9 Fe–0.9 Ni (AA2618) alloy after 195 °C/18 h aging, as well as after 180 and 240 °C/100 h creep, has been studied by transmission electron microscopy and high resolution electron microscopy (HREM). The Guinier–Preston–Bagaryatsky (GPB) zones/co-clusters, S″, S, and Al₉FeNi phases co-exist in the alloys after the 195 °C/18 h aging. After creep, precipitates become coarser and the transformation of GPB zones/co-clusters and S″ to S phase take place. A large number of GPB zones/co-clusters as those in aging state exist after 180 °C/100 h creep which possibly dynamically precipitates during the creep process. After the 240 °C/100 h creep, most of the precipitates are S variants with a few GPB zones and S″ phase. More dislocations appear upon which precipitate colonies form after creep. HREM images show that most of the early precipitates less than about 5 nm cannot exhibit perfect lattice image for the existence of stress. However, certain GPB/co-clusters possessing coherent relationship with the matrix can also be observed. HREM demonstrates that certain S particles viewed along [100]_S and [013]_S have classic orientation relationship with the matrix, and that those upon the dislocations depart from the standard orientation.     

Study on the evolution of the microstructure,phase composition,three-dimensional morphology,and hardness in the solution treatment of Mg−7.80Gd−2.43Y−0.38Zr alloy

The evolution of the microstructure, phase composition, three-dimensional morphology, and hardness of Mg−7.80Gd−2.43Y−0.38Zr (wt.%) alloys during solution treatment at 480 °C is investigated using scanning electron microscopy (SEM), electron probe micro-analyzer, nanoindentation, and x-ray tomography. The as-cast alloy consists of an α-Mg matrix phase and divorced eutectics, including the secondary and the supersaturated magnesium phases. The chemical composition of the secondary phase is similar to that of Mg_7.22(Gd, Y), and the nanoindentation hardness of the secondary phase is significantly higher than that of the α-Mg matrix phase, according to the energy-dispersive spectroscopic and nanoindentation analyses. The three-dimensional morphology and quantitative information, such as the number and volume fraction of the secondary phases during the solution treatment, are discussed in detail. A large number of small acicular secondary phases are found near the large secondary phase after solution treatment at 480 °C for 1 h, while the acicular phase disappears completely after 2 h. The secondary phase dissolves into the α-Mg matrix after solution treatment for 8 h, and the solution-treated alloy primarily consists of an α-Mg matrix phase and a cuboid-shaped phase, which was identified as (Gd,Y)H₂.     

Effect of Cu addition on microstructures and tensile properties of high-pressure die-casting Al-5.5Mg-0.7Mn alloy

In this study, Cu was added into the high-pressure die-casting Al-5.5Mg-0.7Mn (wt%) alloy to improve the tensile properties. The effects of Cu addition on the microstructures, mechanical properties of the Al-5.5Mg-0.7Mn alloys under both as-cast and T5 treatment conditions have been investigated. Additions of 0.5 wt%, 0.8 wt% and 1.5 wt% Cu can lead to the formation of irregular-shaped Al₂CuMg particles distributed along the grain boundaries in the as-cast alloys. Furthermore, the rest of Cu can dissolve into the matrixes. The lath-shaped Al₂CuMg precipitates with a size of 15–20 nm × 2–4 nm were generated in the T5-treated Al-5.5Mg-0.7Mn-xCu (x = 0.5, 0.8, 1.5 wt%) alloys. The room temperature tensile and yield strengths of alloys increase with increasing the content of Cu. Increasing Cu content results in more Al₂CuMg phase formation along the grain boundaries, which causes more cracks during tensile deformation and lower ductility. Al-5.5Mg-0.7Mn-0.8Cu alloy exhibits excellent comprehensive tensile properties under both as-cast and T5-treated conditions. The yield strength of 179 MPa, the ultimate tensile strength of 303 MPa and the elongation of 8.7% were achieved in the as-cast Al-5.5Mg-0.7Mn-0.8Cu alloy, while the yield strength significantly was improved to 198 MPa after T5 treatment.     

Reinterpretation of precipitation behavior in an aged AlMgCu alloy

Precipitation behavior of AlMgCu alloy during S phase aging sequence was studied with high resolution transmission electron microscope (HRTEM) and selected area diffraction (SAED) to determine the existence of S″ phase and GPBII zone in the alloy. Fast Fourier transform (FFT) patterns corresponding to GPB zones at different aging stages were observed, and it is revealed that S phase forms instantly after the GPB zone dissolves during aging. Both simulated HRTEM and SAED images illustrate that the S″ phase shows exactly the same characteristics as the S phase does, which is consistent with the experimental observations. A unique phase was also observed, which produced extra diffraction dots near the {012}_Al positions in FFT pattern. This phase was once considered to be either S″ phase or GPBII zone, but none of them has been affirmed so far. In this work, it is found that the unique phase is a distorted and rotated S phase and that S″ phase or GPBII zone does not form during the aging. We further show that the S precipitation sequence of the aged AlMgCu alloy should be SSS → Cu–Mg clusters/GPB zone → S′/S(Al₂CuMg).