Recent Progress in High-Temperature Resistant Aluminum-Based Alloys: Microstructural Design and Precipitation Strategy
GAO Yihan, LIU Gang(), SUN Jun()
State Key Laboratory for Mechanical Behavior of Materials, Xi??an Jiaotong University, Xi􀆳 ;an 710049, China
Cite this article:
GAO Yihan, LIU Gang, SUN Jun. Recent Progress in High-Temperature Resistant Aluminum-Based Alloys: Microstructural Design and Precipitation Strategy. Acta Metall Sin, 2021, 57(2): 129-149.
Many load-bearing industrial settings require light-weight structural materials with adequate strength. Although commercial aluminum (Al) alloys are suitable for room-temperature applications, their strength at elevated temperatures (300-500oC) is largely reduced by coarsening of the strengthening precipitates. However, high-temperature alternatives such as titanium alloys are much heavier and more expensive than Al alloys. Creating microstructures that remain stable over 300oC is an important goal of the aluminum-manufacturing community. This article focuses on the recent development of high-temperature resistant Al-based alloys. Especially, it discusses the unique microstructural features, selection criteria of the strengthening phase, alloying effects, and microstructural stabilization of aluminum. The strategies summarized in this review are expected to realize the new microstructural architectures of light-weight alloys, which are currently limited to low-temperature service.
Fig.1 Representative microstructural features of Al-based metal matrix composites (MMCs), including three-dimensional mapping with reinforcement fibers in yellow together with pores in black (a)[20] and cross section of the x-y plane with pores density highlighted by gradient color (b)[20], and high-angle annular dark-field scanning transmission electron microscopy (HAADF-STEM) images showing heterogeneous precipitation (c)[26] and misfit dislocations (d)[26] at the TiB2/α-Al interfaces
Fig.2 Representative nanocrystalline structure (a) and second-phase particles (b) in Al-TM-based alloys[36]
Fig.3 Representative nanoprecipitates in 2xxx (a), 6xxx (b), and 7xxx (c) series ageing-hardenable Al-based alloys[46]
Fig.4 Representative equilibrium binary phase diagram of Al-Cu (a)[62] and Al-Sc (b)[64] systems, and diffusivities of conventional alloying elements in Al matrix at 300 and 400oC (c)[12,65,66]
Fig.5 Solute segregation at θ'-Al2Cu/matrix interfaces (a)[83], grain boundaries (b)[84] and the dislocation core (c)[85] in Al-based and Ni-based alloys (b—Burgers vector)
Fig.6 Nanostructural hierarchy in a rapid solidification (RS) A356 alloy, containing Si nanoprecipitates highly dispersed in α-Al matrix (a, b) as well as nanoscale Al particles embedded in eutectic Si (c)[124]
Fig.7 Eutectic phases (a, c) and high-temperature mechanical properties (b, d) in Al-Ni-bsed (a, b)[42] and Al-Ce-based (c, d)[45] alloys
Fig.8 Representative atom probe tomography (APT) images showing the Al3(Sc,Zr,Er)-based nanoprecipitates with core-shell structure (a~d)[136], and creep resistance of several Al-Sc-Zr-Er-based alloys at 300oC (e)[139] and 400oC (f)[139] (σ—threshold stress)
Fig.9 Representative TEM (a)[152] and APT (b)[153] images showing the morphology and chemical composition of Ω phase in Al-Cu-Mg-Ag-based alloys, and curves indicating this system has great high-temperature resistance within short period while suffers from rapid softening at high temperature (c)[155] and long duration (t—time) (d)[154]
Fig.10 Segregation energies of solutes at each platelet (a)[169] and triple Mn/Zr/Si segregation at the coherent and semi-coherent interfaces between α-Al matrix and θ'-Al2Cu (b~e)[167]
Fig.11 Strong Sc segregation at θ'-Al2Cu/matrix interface (a~d)[82,91] and Si-mediated reassembly of interfacially segregated Sc atoms (e~h)[171] in the Al-Cu-Sc RR (retrogression and re-ageing) alloy
Fig.12 Targeted atomic locations (a~d) and segregation-sandwiched Sc-Fe-Si segregation (e~m) at θ'-Al2Cu/matrix interface, obtained from high-throughput density functional theory (DFT) calculations and experiments, respectively; and curves showing the ultra-stabilized θ'-Al2Cu precipitates (n) and unprecedent creep resistance (o) at 300oC in the studied Al-Cu-Sc-Fe-Si alloy (ΔρSC,Fe and ΔρFe are the changes in bonding charge density; is average half length of θ'-Al2Cu precipitates; is the steady-state creep rates of the studied alloys, σ—tensile creep stress)[172]
Fig.13 Evolution of Ag distribution in G.P. zone, β'' and β' precipitates in an Ag-microalloyed Al-Mg-Si alloy during ageing process (a~d)[57]
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