The Synergistic Role of Mn and Zr/Ti in Producing θ′/L12 Co-precipitates in Al-Cu Alloys

Abstract Microstructural stability is a critical factor to consider when designing new alloys for high-temperature applications. An Al-Cu alloy with Mn and Zr additions has recently been developed to withstand extended exposures of up to 350°C. The addition of Mn in combination with Zr and their segregation to precipitate interfaces play a significant role in stabilizing the metastable θ′ precipitates responsible for the alloy's hardness; however, adding Zr and Mn separately only improves the stability to 200°C and 300°C, respectively. To this end, the effect of the synergistic additions on interfacial structure and chemistry was studied in detail using atom probe tomography (APT) and scanning transmission electron microscopy (STEM) for Al-Cu-Mn-Zr/Ti-containing alloys subjected to long-term annealing (up to 2,100 h) in the critical temperature range, 300°C and 350°C, to investigate the role of Zr/Ti in increasing the θ′-precipitate stability. The APT and STEM results reveal that Mn additions stabilize θ′ long enough for the slower diffusing Zr atoms to segregate to coherent θ′ interfaces that eventually create a θ′/ L12-Al3(Zrx,Ti1-x) co-precipitate structure. The co-precipitate is highly stable, as shown by density functional theory calculations, and is a key factor that governs microstructural stability beyond 300°C. This study reveals how solute additions with different stabilization mechanisms can work in concert to stabilize a desired microstructure, and the results provide insights that can be applied to other high-temperature alloy systems.