Al-Cu Alloys Research Articles

Anodic Oxide Layers on Aluminum-Lithium Alloy

Al-Cu-Li alloys regained attention with Cu as the major addition and Li around 2 %wt. However, oxide blistering of is frequently found by the sulfuric acid anodizing of these alloys, which has been sometimes attributed to Li-rich precipitate dissolution or to thermomechanical stresses in the anodic oxide layer. In this work, anodic layer properties (composition, morphology, pitting resistance) were studied in dependence of anodizing process parameters. Blisters form by higher anodizing charges, independent of the applied current density and its density increases at lower temperatures, at which the anodizing efficiency is higher. Blistering cannot be associated to second phase precipitates, as their diameters (100-200 µm) are much larger than the precipitates size. The 45º-cracks at the mid section of the porous film are typical of compressive stresses perpendicular to the growth direction, indicating that blistering is possibly caused by a higher molar volume compared to other Al-Cu alloys.

Microstructure, Mechanical and Corrosion Properties of Copper-Nickel 90/10 Alloy Produced by CMT-WAAM Method.

In the case of copper and its alloys, Wire Arc Additive Manufacturing (WAAM) 3D printing technology is mainly used to produce elements for the maritime industry and research has focused on the use of Cu-Al alloys. There is little information devoted to the use of Cu-Ni alloys in this technology, which are also widely used in the maritime industry. In this work, tests were carried out on the microstructure, mechanical properties, and corrosion properties in a 1M NaCl solution of Cu-Ni 90/10 alloy 3D walls printed using the WAAM method. The obtained objects are characterized by a microstructure with elongated column grains and particles of the Ni-Ti phase, hardness in the range of 138-160 HV10, ultimate tensile strength of 495-520 MPa, yield strength of 342-358 MPa, elongation of 16.6-17.9%, and a low average corrosion rate of 7.4 × 10-5 mm/year. The work shows that it is possible to obtain higher mechanical properties of Cu-Ni 90/10 alloy 3D objects produced using the WAAM method compared to cast materials, which opens up the possibility of using this alloy to produce objects with more complex shapes and for use in corrosive working conditions.

Multi-regional microstructure control using ultrasonic-assisted directed energy deposition for Al-Cu alloy

The uneven microstructure and element distribution between the inner-layer zone (INZ) and the inter-layer zone (ITZ) resulting from the thermal cycling effect during the directed energy deposition process with the electric arc energy source (DED-Arc) can lead to inferior mechanical properties. In order to address this problem, the ultrasonic treatment of the 2319 Al-Cu alloy during the DED-Arc process is investigated to control the multi-regional microstructure quantitatively. Therefore, the effect of ultrasonic vibration during the DED-Arc process on grain morphology, distribution of precipitates and mechanical properties in different regions are explored in detail. The formation mechanism of differential microstructure is elucidated by using an ultrasonic-heat-flow coupling simulation model for the DED-Arc process. The results indicate that ultrasonic vibration refines the average grain size, leading to 16% and 40% reductions at the molten pool center (MPC) and boundary (MPB), respectively. However, the grains in the semi-melting zone (SMZ) experience coarsening due to the reduced temperature gradient after ultrasonic treatment. The enhanced melt flow rate is considered responsible for both the homogenization of Cu and the fragmentation of the θ-Al2Cu phase. The higher subgrain boundary density in the ITZ leads to an average microhardness of approximately 60 HV, which is lower than that found in the INZ (72.3 HV). Meanwhile, ultrasonic treatment increases the average strength and elongation by 38.1% and 17.5%, respectively, mainly through precipitation strengthening, which results in a strength increment of 91.6 MPa. The slip directions tend to be consistent after ultrasonic vibration, which is conducive to crystal sliding and displays excellent ductility.

Enhancement of mechanical properties of Al-Cu alloy composite reinforced by Ni element: A combination of mixture design of experiment and artificial neural network approach

The high practicality of Al-Cu alloy is the key reason it is highly used across most industries. In this research, the primary objective was to optimize the mechanical properties of the aluminum-copper alloy by incorporating Ni nanoparticles. The study employed a combination of Ni nanoparticles with the alloy and utilized a mixture design of experiments to determine the most effective Al-Cu-Ni alloy composition. This composition was validated through molecular dynamics simulation. Mechanical tests were carried out on the Al-6 %Cu-1 %Ni alloy at different strain rates and temperatures. The findings indicated that an increase in temperature led to a reduction in tensile properties. Moreover, the strength of the Al-6 %Cu-1 %Ni alloy increased with higher strain rates while the stiffness remained relatively constant. Additionally, a specialized deep neural network with two hidden layers was employed to predict the mechanical properties of the Al-Cu-Ni alloy. The optimal parameters for this deep neural network were determined using the Taguchi method.

Estimation of Activity and Molar Excess Gibbs Energy of Binary Liquid Alloys Al-Cu, Al-Ni, and Al-Fe from the Partial Radial Distribution Function Simulated by Ab Initio Molecular Dynamics

To accurately and conveniently obtain the thermodynamic data of binary liquid alloys, a new method is proposed in this study. It combines ab initio molecular dynamics (AIMD) simulation with a thermodynamic model to estimate the activity and molar excess Gibbs energy of binary liquid alloys. Additionally, two methods of grouping the partial radial distribution function (PRDF) of 5000 steps obtained by simulation are proposed for the first time. The PRDF of Al50Cu50, Al50Ni50, and Al50Fe50 is obtained by AIMD simulation. These PRDF are combined with four thermodynamic models to estimate the activity and molar excess Gibbs energy. Furthermore, the estimation results of the four models are compared with those of the Miedema model. The results show that when the first peak of the PRDF is obtained by the symmetric method, the average relative deviation (ARD) of the activity and molar excess Gibbs energy of the four models are, respectively: 28% and 32% for Molecular Interaction Volume Model (MIVM); 162% and 38% for Regular Solution Model (RSM); 508% and 65% for Wilson model; 562% and 67% for Non-Random Two-Liquid (NRTL). When the first peak of PRDF is obtained by non-symmetric method, the average ARD of the activity and molar excess Gibbs energy of the four models are, respectively: 64% and 20% for MIVM; 115% and 26% for RSM; 661% and 70% for Wilson; 727% and 72% for NRTL. In addition, the average ARD of the activity and molar excess Gibbs energy of the Miedema model are 113% and 33%. These data indicate that the estimation performance of the MIVM model is superior to the other four models, and the symmetric method performs better than the non-symmetric method. The grouping treatment of PRDF data effectively improves estimation performance.

Enhanced strength-plasticity of 2319 Al-Cu alloy formed by hybrid interlayer friction stir processing and wire-arc additive manufacturing

Enhanced strength-plasticity of 2319 Al-Cu alloy formed by hybrid interlayer friction stir processing and wire-arc additive manufacturing

Corrosion behavior assessment of an Al-Cu alloy manufactured via laser powder bed fusion

Additively manufactured Aluminum-Copper alloys are attracting interest because of their high tensile strength. Nevertheless, the presence of Cu strongly affects the corrosion performances. In this work, the corrosion behavior of an innovative laser powder bed fusion-processed 2139 alloy was investigated, and its corrosion performances were compared to the well-consolidated AlSi10Mg alloy, as well as the parent wrought alloy. Electrochemical, Kelvin probe microscopy and intergranular corrosion tests were performed. The unique corrosion morphology at melt pool boundaries are presented and discussed alongside with the effect of surface finishing and heat treatments.

Contribution of the Fe-rich phase particles to the high temperature mechanical behaviour of an Al-Cu-Fe alloy

The high temperature strengthening mechanisms in Al-Cu-Fe aluminium alloy was analysed basis on a comprehensive microstructural study of the as-cast alloy and mechanical testing results. An approach which extracts the specific contribution of solid solution atoms, precipitates, and Fe-rich particles to the creep strengthening was utilized. Additionally, the Shear Lag model, was employed to account for the contribution to strengthening of the Fe-rich intermetallic particles through a load transfer mechanism. For this study, an as-cast Al-Cu alloy, which does not contain Fe impurities, has been also used for comparative purposes. The findings suggest that the large and 3D interconnected Fe-rich phase particles (Al6(MnFe) and α-Fe) generate the main strengthening effect at high temperature through a load transfer mechanism, whereas the contribution of the nanometric Al2CuMg precipitates were very limited.

Integrated control mechanism of ultrasound and ZrO2 particles on differential microstructures for the wire arc additive manufacturing

ABSTRACT Inhibiting unhomogenised microstructure during the directed energy deposition process with the electric arc energy source (DED-Arc) has become a significant challenge. Ultrasonic vibration leads to the severe stirring of liquid metal and break down dendrites in the inner-layer zone, which promotes the formation of fine grains after rapid solidification. In contrast, the grain refinement effect is not obvious in the semi-melting zone. The addition of ZrO2 particles in the 2319 Al-Cu alloy during the DED-Arc process can drag and pin the grain boundary to prevent grain coarsening in the semi-melting zone. Under the integrated effect of ultrasound and particles, ZrO2 particles can be evenly distributed in different regions, which is beneficial to enhance the microstructure uniformity of the deposition layer and ultimately achieving significant improvement in mechanical properties. The intergrated effect of ultrasonic vibration and particles on strength and elongation reach 13.8% and 92.4%, respectively.

Transmission electron microscopy of the rapid solidification microstructure evolution and solidification interface velocity determination in hypereutectic Al-20at.%Cu after laser melting

The evolution of rapid solidification (RS) microstructure and solidification interface velocity has been studied experimentally by in-situ transmission electron microscopy and postmortem characterization for hypereutectic Al-20at.%Cu (37 wt.%Cu) after laser melting. Four morphologically distinct regions formed via growth modes changing from θ-Al2Cu phase dendrites to eutectic cell growth, possibly α-Al dendrite growth (α-cell), banded growth, and α-Al plane front growth. Tendency for faceting and low capacity for solute trapping limited the θ-phase dendrite growth to solidification interface velocity v < 0.07 m/s. Consequently, formation of pro-eutectic micro-constituent was suppressed, and RS microstructure formation was dominated by eutectic, α-cell, and banded morphology grains for the Al-20at.%Cu alloy. Eutectic growth operated for interface velocity of 0.1 m/s ≤ v < 0.3 m/s, with a transition from regular lamellar, 2-λ and 1-λ mode to a dense irregular morphology dominated by α-phase at v = 0.3 m/s. Interface temperature calculations indicated feasibility of α-cell growth mode for 0.3 m/s ≤ v < 0.7 m/s. Banded growth occurred for 0.7 m/s ≤ v < 1.3 m/s. Plane front α-phase growth was evident for interface velocities v ≥ 1.3 m/s. Previous work on rapid solidification microstructure development in hypereutectic Al-Cu alloys reported a regime of α-cell growth subsequently to eutectic and prior to transition to banded growth for Al-19at.%Cu (36 wt.%Cu), while for Al-22at.%Cu (40 wt.%Cu) eutectic growth transitioned directly to α-plane front growth without emergence of a banded regime. Based on the current study the disappearance of the banded growth regime occurs for a composition larger than 20at.%Cu.

Effect of laser oscillation and beam incident angle on porosity in double-sided filler welding of 2219 aluminum alloy T joint

In the current research, the double-sided laser beam oscillation filler welding (DLBOW) with beam incident angle from 20° to 40° were carried out for 2219 Al-Cu alloy T joint welding. Double-sided laser beam filler welding (DLBW) was conducted as a reference group. 3D computed tomography (CT) scanning analysis method was performed to investigate the precise three-dimensional locations of the porosity defects in the T joints. High-speed photography was conducted to evaluate the keyhole stability. The dynamic behavior of keyhole of DLBW and DLBOW was simulated by Flow-3D to study the formation process of pores. The effects of beam oscillation and beam incident angle on the macrostructure, microstructure, porosity, and mechanical property of T joints were discussed. It was found that beam oscillation and smaller beam incident angle promoted porosity suppression. The mechanical properties of T joints were improved by laser oscillation. With the beam incident angle of 20°, the porosity of T joint welded by DLBOW was lowest (0.26 %). The hoop tensile strength and T-pull tensile strength of the T joint were 403 MPa and 302 MPa, approximately 89.5 % and 71.6 %, in contrast with that of the base metal.

Experimental determination of solid-liquid interface energy for para- and diamagnetic solid solution in equilibrium with eutectic liquid under a high magnetic field

The solid-liquid interface energy (SLIE) of the Al-Cu and Bi-Cd systems under a high magnetic field (HMF) has been experimentally determined by a Bridgeman-type directional solidification furnace. The equilibrated grain boundary groove shapes for the paramagnetic solid α-Al solution and the diamagnetic solid Bi solution in equilibrium with the eutectic liquid under various HMFs were observed in Al-15.3at%Cu alloy and Bi-50at%Cd alloy. It can be found that the profiles of grain boundary grooves changed significantly under the action of the HMF. The Gibbs-Thomson coefficient and the SLIE for the solid α-Al and solid Bi solution in equilibrium with the eutectic liquid under various HMFs were obtained from obtained grain boundary groove shapes. The results show that the SLIE of the Al-Cu and Bi-Cd alloys increase and decrease under an HMF, respectively. The interaction theory of magnetic dipoles induced by an HMF can be responsible for the above experimental phenomena. Additionally, the results of the differential thermal analysis (DTA) and theoretical analysis indicate that the undercooling of the Al-15.3at%Cu and Bi-50at%Cd alloys increase and decrease under the influence of an HMF, respectively, which is ascribed to the existence of HMF-induced interface energy.

Atomistic insight into dendrite growth orientation transition in Al-Cu alloy

In this study, we investigate the impact of solid-melt interfacial energy anisotropy on the microstructure of components. Our focus is on the Al-Cu system's Al-rich side, where we compute the solid-melt interfacial free energy and its anisotropy using Molecular Dynamics (MD) simulations. Our findings reveal that, as the Cu concentration in the melt increases, the preferred dendrite growth orientation shifts from <100> to <110>. Furthermore, atomic density profile analysis shows an improvement in ordering in the (110) plane at higher Cu concentrations. Our results suggest that the transition in dendrite growth orientation is a consequence of the weakened anisotropy between (100) and (110) interfacial energies at higher Cu concentrations and undercooling temperatures. We also observe displaced atomic density profiles between Al and Cu atoms in proximity to the interface. We propose that a displaced atomic density profile between solute and solvent atoms could be a characteristic feature of systems undergoing a dendrite orientation transition.

Ultrahigh grain boundary strengthening ability of VCoNi medium entropy alloy

Tensile tests of VCoNi medium-entropy alloy with different grain sizes were conducted at 77 K, 194 K and 293 K. The results show that the grain boundary strengthening ability characterized by the Hall-Petch slope of the alloy increases with decreasing temperature and is evidently higher than that of FCC pure metals, CuAl alloys, and some common FCC high-entropy alloys/medium-entropy alloys at room temperature. A new model correlated to intrinsic stacking fault energy and lattice friction stress is derived to describe the high grain boundary strengthening ability. The high grain boundary strengthening ability and its temperature dependence of the VCoNi medium-entropy alloy are mainly attributed to the high lattice friction stress of the VCoNi alloy. The findings provide a possibility for designing the single-phase FCC medium-entropy alloy with ultra-high yield strength and considerable plasticity.

Numerical/Experimental Study of Process Optimization Conducted on an Al-Cu Alloy Produced by Combined Fields of Applied Pressure and Ultrasonic Vibration

Single-pressure and ultrasonic action have their own unique advantages in the treatment of metal melts. When the two are combined into a composite field, the advantages of a single physical field can be fully utilized. So, the cavitation and acoustic streaming effects characteristics of an Al-5.0Cu alloy treated under different coupling process parameters, related to applied extrusion pressure and ultrasonic vibration, were analyzed by combining numerical simulation and experimental verification. The simulation results were experimentally verified by quantitative analysis of the microstructure, the melt, and its macro characteristics. The results show that the closing time t decreases with an increase in the extrusion pressure. In addition, when the ultrasonic power and extrusion force are increased simultaneously (100 MPa and 1 kW), the average grain size and the proportion of columnar grains reach the ideal effect. The influence of pressure parameters is greater, which will also lead to an increase in the proportion of columnar crystals. By optimizing the parameters, the grain size can be further reduced, the proportion of columnar crystal structure can be reduced, and fine and uniform equiaxed crystal structures can be easily obtained.

Mirrored symbols, opposite effects: Impact of Ga and Ag additions on the martensite decomposition of the Cu81Al19 alloy

Although the presence of martensite is desirable in several applications of increasingly complex Cu-rich Cu-Al alloys, there is a lack of understanding about the effects of alloying in its stability. Martensite decomposition was investigated in as-quenched Cu81Al19, Cu79Al19Ga2, and Cu79Al19Ag2 alloys (compositions in atomic percentage) by optical microscopy, scanning electron microscopy, energy-dispersive X-ray spectroscopy, X-ray diffraction, differential scanning calorimetry, and Vickers microhardness measurements. It was found that the similarity of crystalline structure between alloying element and host phase, as well as the interactions between ternary addition atoms and Al interfere with the stages of the martensite decomposition during heating. The Ga addition refined the microstructure, resulted in the precipitation of other phases, and favored the eutectoid reaction in the Cu81Al19 alloy. The Ag addition increased the tendency for martensite ordering, stabilized the β1 phase, and induced the precipitation of Ag particles from martensite on heating. Possible technological consequences arising from these results were also discussed.

Dendrite operating state in directional solidification of AlCu binary system: numerical benchmark test with the OpenPhase software

A scientific benchmark test is carried out for a multi-phase-field model with double-obstacle potential by performing three-dimensional simulations of dendritic growth under directional solidification. The effects of key numerical parameters of the multi-phase-field model such as numerical resolution and interface width on the dendrite tip operating state are studied, optimal parameter values are set, and where the operating state becomes independent of varying these parameters is elaborated. Some uncertainties in the proper choice of effective interface mobility in the thin-interface limit are discussed and a pragmatic solution is adopted. The binary alloy Al-Cu with 4 at.% Cu is chosen as the material system because it has been used in many previous experimental and numerical studies to investigate dendrite morphology under directional solidification. The recently developed sharp phase-field model by Finel and colleagues is adapted to the double-obstacle potential function and included in the benchmark test. It is shown how the sharp phase-field model helps in achieving agreeable convergence with larger discretization, thereby reducing the computational cost significantly. The benchmarks are performed using the OpenPhase software.

Influence of the iron additive on the microstructural behavior of an aluminum-copper foundry alloy B206

Although used and studied since the beginning of the century, the mechanical properties of aluminum-based structural hardening alloys still conceal some secrets that metallurgists are trying to uncover. In this work we are interested in aluminum alloys and more particularly in an Al-Cu alloy. The main objective of this work was to study the influence of structural hardening heat treatments on the evolution of the mechanical and structural properties of B206 alloys. For that, we used several experimental methods adapted to this kind of scientific work. We quote essentially: the thermal treatments of setting in hardening, as well as measurements of the hardness. The analysis of the experimental results obtained by these methods allowed us to explain and to affirm that Al-Cu alloys do not give appreciable structural hardening; because of the difficulty of diffusion of iron and silicon which influences the treatment and brought in a general way to the precipitation of the phase β; plays an important role in the evolution of the mechanical characteristics of Al-Cu alloys.

Aluminum alloy W-temper cryogenic forming with enhanced formability and strength

Simultaneously obtaining excellent formability and post-form strength in the traditional sheet metal forming of heat-treatable aluminum alloy is challenging, owing to the coexistence of wrinkling and splitting defects during forming and the control problem of microstructure. To solve these problems, W-temper cryogenic forming was proposed based on the cryogenic ‘dual-enhancement effect’ of an as-quenched (W-temper) aluminum alloy. The effects of the cryogenic temperature gradient and blank-holder force on the drawing behaviors were studied by analyzing the forming defects and thickness distribution. Strength distributions were reflected through Vickers hardness measurements under different aging conditions. The related strengthening mechanism was revealed through microstructure characterization. The drawability can be significantly improved at small or large cryogenic temperature gradients. An Al-Cu alloy semispherical shell component was fabricated via W-temper cryogenic forming. The depth of the formed hemispherical specimens increased by more than 106.4%. Uniform thickness can be also obtained at the temperature gradient of 216 °C, with an average thickness deviation rate of 6.5%, benefiting from the cryogenic dual enhancement effect and enlargement of the stress gradient. The hardness in all regions was higher than 146.5 HV of traditional T8-temper because of the enough accelerating precipitation of θʺ and θʹ phases by prior cryogenic deformation. Strain and precipitation strengthening were the main strengthening mechanisms under post-forming and post-aging conditions, respectively. The peak-aging time can be shortened to 6 h, which is one-third that of the traditional process. Enhanced formability and post-form strength can be simultaneously obtained by W-temper cryogenic forming, which has great potential for the fabrication of thin shells made from heat-treatable aluminum alloys.

Sn-induced phase transformation mechanism from θ’ to θ in Al-4Cu alloy and its influence on high temperature strength

The effects of 0.02 wt.% Sn addition to Al-4Cu alloy on the phase transformation mechanism from θ’ to θ phase during a long-time heat exposure at 573 K for 100 h and on high temperature strength were studied through microstructure observation and tensile test. It is found that Sn micro-alloying in Al-4Cu alloy completely changes the mechanism of θ’ → θ phase transformation during the long-time heat exposure. In the alloy without Sn addition, rod-like θ phase nucleates and grows on the surface of coarsened disc-like θ' phase. However, with Sn-micro-alloying, θ phase firstly heterogeneously nucleates on β-Sn particles, and then grows into much coarser needle-like phase. Trace addition of Sn significantly increases the yield strength of T5-samples at both room temperature and 573 K, because addition of Sn increases the number density of θ’ particles and reduces its size. But, after the long-time heat exposure, the high temperature (573 K) strength of Al-4Cu alloy is severely degraded because Sn accelerates the phase transformation from θ’ to θ phase.