Al-Cu Alloys Research Articles

Effect of tool rotational speeds on material flow and strain rates during friction stir butt welding of AA2219-T87 plates

ABSTRACT Friction stir welding (FSW) process is widely used for joining Al-Cu alloy (AA2219-T87) plates because of its high joint efficiency and low residual stresses in contrast to fusion-based joining techniques. A two-way coupled, 3D thermal-material flow model has been developed in COMSOL software, and the effect of tool rotational speeds on thermal and material flow fields, strain rates, thermal histories, and size of weld zones are being studied. The non-uniform net heat generation during the FSW process is due to the friction between workpiece and tool materials and the deformation energy of plasticized material flow sheared by the rotating tool. An approximate range of temperatures for the weld zones has been proposed and found to be appropriate because the predicted sizes are in good agreement with the experiments. Furthermore, the authors suggested that a quality FSW joint must have the nugget zone smaller and the heat-affected zone larger than the tool shoulder diameter.

Effect of cooling rates and Fe contents on microstructure evolution of Al-Cu-Mn-Mg-Fe-Si alloys

During the solidification process, the recycled Al-Cu alloys form coarse Fe-rich phases, which seriously deteriorate the mechanical properties of the alloy. The study employed optical microscope (OM), scanning electron microscopy (SEM) with energy dispersive spectroscopy (EDS), and synchrotron X-ray imaging to investigate the impact of cooling rate and Fe contents on the growth of Fe-rich phases, Al2Cu, and pores in recycled Al-Cu-Mn-Mg-Fe-Si alloys under synergistic effect ultrasonic melt processing (USMP) and Al-Ti-B. USMP can homogenize the distribution of TiB2 particles and provides more nucleation sites for the formation of Fe-rich phases. Under the synergistic effect of USMP and Al-Ti-B, increasing the cooling rate,the volume fractions of Fe-rich phases in 0.7FeUB (0.7 wt%Fe + USMP + Al-Ti-B) and 1.2FeUB (1.2 wt%Fe + USMP + Al-Ti-B) alloys decreased from 8.92% and 16.52% to 8.03% and 14.73%, respectively. The volume fraction of Al2Cu increased from 4.06% and 3.13% to 4.37% and 3.54%, respectively. Furthermore, the three-dimensional (3D) morphology of Fe-rich phases and Al2Cu became more compact and uniform. The volume fraction of pores in the 1.2FeUB alloy decreased from 0.412% to 0.072%. In-situ synchrotron X-ray radiography revealed that increasing cooling rates led to increased nucleation undercooling of primary α-Al and Fe-rich phases. These phenomena can be attributed to the combined effects of ultrasonic cavitation, ultrasonic streaming, and an increased cooling rate. These factors serve to homogenize the alloy composition, ensure uniform distribution of TiB2 particles, inhibit element diffusion, reduce solute segregation, and ultimately lead to the refinement of the grain size, α-Al, Fe-rich phases, and Al2Cu, while also inhibiting pore growth.

Study on microstructure and refining effect of deformed Al-4.5Er-1Zr-1.5Ti master alloy

The microstructure and grain refinement of Al-4.5Er-1Zr-1.5Ti master alloy were analyzed by the refinement experiment, OM, SEM and XRD. The results show that the grain size of pure aluminum is reduced from 14,000μm to 202μm by Al-4.5Er-1Zr-1.5Ti master alloy, which is mainly due to the nucleation promoted by Ti2Al20Er, Al3Er and Al3Ti. Plastic deformation further improves the refining effect of the material by improving the primary phase size, and the Al-4.5Er-1Zr-1.5Ti −2ARB can refine the pure aluminum from 202 mμm to 150μm, and the refinement was increased by 25.7 %. The master alloy showed a better refinement effect in Al-5Cu alloy than pure aluminum, with a grain size of 92μm and a refinement improvement of 97.8 %.

Effect of Si Addition on the Weibull Distribution of Tensile Properties of Fe-bearing Al-Cu Alloys

Effect of Si Addition on the Weibull Distribution of Tensile Properties of Fe-bearing Al-Cu Alloys

Atomic-scale investigation on the evolution of T1 precipitates in an aged Al-Cu-Li-Mg-Ag alloy

The T1 (Al2CuLi) phase is one of the most effective strengthening nanoscale-precipitate in Al-Cu alloys with Li. However, its formation and evolution still need to be further clarified during aging due to the complex precipitation sequences. Here, a detailed investigation has been carried out on the atomic structural evolution of T1 precipitate in an aged Al-Cu-Li-Mg-Ag alloy using state-of-the-art Cs-corrected high-angle annular dark field (HAADF)- coupled with integrated differential phase contrast (iDPC)-scanning transmission electron microscopy (STEM) and energy-dispersive X-ray spectroscopy (EDXS) techniques. An intermediate T1’ phase between T1p and T1 phase, with a crystal structure and orientation relationship consistent with T1, but exhibiting different atomic occupancy and chemical composition was found. We observed the atomic structural transformation from T1p to T1’ phase (fcc→hcp), involving only 1/12<112>Al shear component. DFT calculation results validated our proposed structural models and the precipitation sequence. Besides, the distributions of minor solute elements (Ag, Mg, and Zn) in the precipitates exhibited significant differences. These findings may contribute to a further understanding of the nucleation mechanism of T1 precipitate.

Anode-Free Aqueous Aluminum Ion Batteries.

Aqueous aluminum ion batteries (AAIBs) possess the advantages of high safety, cost-effectiveness, eco-friendliness and high theoretical capacity. However, the Al2O3 film on the Al anode surface, a natural physical barrier to the plating of hydrated aluminum ions, is a key factor in the decomposition of the aqueous electrolyte and the severe hydrogen precipitation reaction. To circumvent the obnoxious Al anode, a proof-of-concept of an anode-free AAIB is first proposed, in which Al2TiO5, as a cathode pre-aluminum additive (Al source), can replenish Al loss by over cycling. The Al-Cu alloy layer, formed by plating Al on the Cu foil surface during the charge process, possesses a reversible electrochemical property and is paired with a polyaniline (cathode) to stimulate the battery to exhibit high initial discharge capacity (175 mAh g-1), high power density (≈410Wh L-1) and ultra-long cycle life (4000 cycles) with the capacity retention of ≈60% after 1000 cycles. This work will act as a primer to ignite the enormous prospective researches on the anode-free aqueous Al ion batteries.

Theoretical Insights into Enhancing Catalytic Performance of Al-Cu Alloy for CO2 Electroreduction toward Ethene Production.

The understanding of the reaction mechanism of CO2 electroreduction (CO2RR) is essential for the precise design of catalysts for specific products with high selectivity. In this work, combined with the computational hydrogen electrode model and kinetic energy barrier calculations, CO2RR pathways on Cu(100) and Al1Cu3(100) are intensively investigated. The free energy barrier of the rate-determining step of ethylene formation is reduced from 1.08 eV for *CCOH formation on Cu(100) to 0.51 eV for *CH2OCHOH formation on Al1Cu3(100) and enhances the catalytic activity. The reaction free energy of *CO-*CO coupling is remarkably reduced from 0.86 eV on Cu(100) to -0.43 eV on Al1Cu3(100) and the coupling barrier is reduced from 0.97 to 0.37 eV, suppressing the production of gas phase CO and enhancing the production of C2 products. Furthermore, the selectivity toward C-O breaking of *CH2CHOH on Cu(100) and *CH2CH2OH on Al1Cu3(100) ensures high selectivity toward ethene rather than ethanol.

Evolution of Strengthening Precipitates During Friction Stir Welding of Al-Zn and Al-Cu Alloys

Evolution of Strengthening Precipitates During Friction Stir Welding of Al-Zn and Al-Cu Alloys

Microstructure and mechanical properties of Al-Cu alloy during wire and arc additive manufacturing by adding micron TiB2 particles

ABSTRACT Micron TiB2 particles were added to the 2319 aluminum alloy using a surface coating method during the additive process. The study focused on the formation, microstructure, and properties in order to achieve deposited components with a uniform microstructure and enhancing strength and plasticity. The critical migration velocity (Vcr = 335 μm/s) of with micron-sized TiB2 particles addition was larger than the solidification rate, which caused particles to be pushed by the solid-liquid interface and ultimately reside at the grain boundary position. The micron-sized TiB2 particles reduced the activation energy for nucleation of the precipitation of the θ’ phase, lowered the energy barrier for nucleation, and introduced dislocations to create lattice distortion channels. This enabled rapid diffusion of solute atoms and facilitated the precipitation and growth of the θ’ phase. Finally, the transverse strength and elongation were higher, reaching 339.07 MPa and 21.3%, which increased by 45% and 60% respectively.

Microstructure evolution and multi-reinforcement mechanisms in Al-Cu-Ag alloys

As one of the most commonly used binary alloys, the effect of intermetallic compounds (IMCs) of Al-Cu alloys in powder metallurgy on their structure and properties is instructive for tailoring Al-Cu alloys for different applications. In this investigation, a series of Al-Cu-Ag alloys with varying Cu compositions were fabricated via hot pressing. TEM analysis identified CuAl2 as the primary intermetallic compounds, with Ag existing in forms including Ag2Al, elemental Ag, and an Ag-(Cu) solid solution. The modulation of Cu content influenced the state of Ag and the mechanical behaviors of the Al-Cu-Ag alloy. Particularly, the high Al/Cu alloy, benefiting from a synergistic effect comprising stacking faults, nanoscale precipitates, and solid solutions, exhibited outstanding mechanical properties. Conversely, the Al-50Cu-3Ag alloys displayed significant brittleness, attributed to the adverse impact of large-scale intermetallic compounds and increased grain size due to the formation of CuAl2. The incorporation of nanoparticles effectively mitigated the grain size in high Al/Cu alloys. This study elucidates the correlation between the evolution of intermetallic compounds and composition in Al-Cu alloys, offering novel insights into the reinforcement of both Al-based and Cu-based alloys.

Simultaneous improvement of mechanical and castability properties of Al-Cu-Mn based alloys by Ca/Ni micro-alloying

Currently one major barrier for the design of cast high-strength and high-toughness Al alloys is hot tearing. In this work, a strategy of combination of squeeze casting and microalloying (Ca/Ni eutectic elements) in Al-Cu-Mn based alloys was employed to inherit the excellent mechanical properties of Al-Cu alloys whilst simultaneously reducing their tendency to hot tearing. The developed alloys exhibit comparable castability (fluidity and hot tear resistance) to A356, which is widely available commercially. However, their comprehensive mechanical properties far exceed those of A356. Trace Ca/Ni additions markedly reduce the grain size of the alloy and simultaneously increase the fraction of intergranular low melting point eutectic liquid phases, which is beneficial to the improvement of liquid feeding. The fine equiaxed grains have excellent thermal shrinkage coordination, while the high volume fraction eutectic liquid phase delays the development of grain cohesive skeleton. Accordingly, the localized shrinkage stress/strain at the hot spot is released timely, thus inhibiting the emergence and propagation of hot cracks in the brittle solidification interval. The diminished hot tearing susceptibility is attributed to the reduced load onset temperature and load values in the hot spot region. A new intergranular bridging mechanism is discovered in low-Ca alloys: based on compositional segregation-induced nucleation of an intergranular bridging skeleton, which strengthens the intergranular adhesive force and effectively reduces the hot tearing tendency of the alloys. The alloys with high-Ca/Ni additions, however, reduce the hot tearing tendency by healing cracks through eutectic liquid phase backfill. The results of the hot tearing experiments of the developed alloys are analyzed with the current hot tearing evaluation criteria. The results demonstrate that the predictions of the Kou's criterion provide guidelines for the design of alloys that are resistant to hot tearing.

Porosity suppression and mechanical property improvement of wire-arc directed energy deposited TiCp/Al-Cu alloys joint by oscillating pulsed wave laser beam welding

Hybrid manufacturing technology combining wire-arc directed energy deposition (WA-DED) and laser beam welding (LBW) presents a promising avenue for efficiently manufacturing large-size aluminum alloy components. The high tendency of porosity defects, particle decomposition, and fusion zone softening are outstanding challenges in the LBW welding of additively manufactured particle-reinforced aluminum alloys. Herein, a WA-DED-processed Al-6.3Cu alloy embedded with 0.6 wt% TiC particles was employed as weldment. Four different laser beam modes, including continuous wave (CW), pulsed wave (PW), oscillating continuous wave (OCW), and oscillating pulsed wave (OPW), were used to join TiCp/Al-6.3Cu alloy. The effects of different laser modes on the porosity defects, microstructure evolution, and mechanical properties of WA-DED particle-containing aluminum alloy joints were studied comparatively. Multi-scale characterization results showed that the enhanced molten pool flow via laser beam modulation effectively suppressed porosity defects and facilitated the uniform particle distribution. The OPW mode provides an optimal effect on porosity inhibition and weld microstructure refinement compared to the pulsed or oscillating modulation modes. The heat-treated LBW joint via OPW mode achieved excellent comprehensive mechanical properties, whose elongation and ultimate tensile strength reached 9.5% and 449 MPa, respectively. This enhanced performance can be attributed to the decreased porosity, refined weld microstructure, and high-density nano-precipitation. This study provides fundamental guidance for the welding of high-strength Al-Cu alloy fabricated by additive manufacturing.

Influence of Zr Microalloying on the Microstructure and Room-/High-Temperature Mechanical Properties of an Al-Cu-Mn-Fe Alloy.

Here, 0.3 wt.%Zr was introduced in an Al-4 wt.%Cu-0.5 wt.%Mn-0.1 wt.%Fe alloy to investigate its influence on the microstructure and mechanical properties of the alloy. The microstructures of both as-cast and T6-treated Al-Cu-Mn-Fe (ACMF) and Al-Cu-Mn-Fe-Zr (ACMFZ) alloys were analyzed. The intermetallic compounds formed through the casting procedure include Al2Cu and Al7Cu2Fe, and the Al2Cu phase dissolves into the matrix and re-precipitates as θ' phase during the T6 process. The introduction of Zr results in the precipitation of L12-Al3Zr nanometric precipitates after T6, while the θ' precipitates in ACMFZ alloy are much finer than those in ACMF alloy. The L12-Al3Zr precipitates were found coherently located with θ', which was assumed beneficial for stabilizing the θ' precipitates during the high-temperature tensile process. The tensile properties of ACMF and ACMFZ alloys at room temperature and elevated temperatures (200, 300, and 400 °C) were tested. Especially, the yield strength of ACMFZ alloys can reach 128 MPa and 65 MPa at 300 °C and 400 °C, respectively, which are 31% and 33% higher than those of ACMF alloys. The strengthening mechanisms of grain size, L12-Al3Zr, and θ' precipitates on the tensile properties were discussed. This work may be referred to for designing Al-Cu alloys for application in high-temperature fields.

Influence of Zr element on the atomic structure of Al-Cu alloy liquid

The relationship among chemical composition, structure and glass-forming ability in multicomponent alloys is a long-standing puzzle due to the complexity of compositions. In this work, Al77.8Cu22.2 and Al70Cu20Zr10 amorphous alloy liquids were investigated by combining high-energy X-ray diffraction at a synchrotron facility, ab-initio molecular dynamics and reverse Monte Carlo simulations. The analysis of short- and medium-range order structures of two liquid alloys show that the addition of Zr element increases the number of cluster types and makes the distribution of cluster content more uniform, and enhances the structural heterogeneity and correlation of clusters with high five-fold symmetry. These findings reveal the influence of Zr element on the atomic structure of the Al-Cu liquid alloy and deepen the understanding of Al-based metallic glasses formation.

Strengthening from dislocation restructuring and local climb at platelet linear complexions in Al-Cu alloys

Stress-driven segregation at dislocations can lead to structural transitions between different linear complexion states. In this work, we examine how platelet array linear complexions affect dislocation motion and quantify the associated strengthening effect in Al-Cu alloys using atomistic simulations. The presence of platelet complexions leads to the faceting of the dislocations, with nanoscale segments climbing upwards along the platelet growth direction, resulting in a complex configuration that restricts subsequent dislocation motion. Upon deformation, the leading partial dislocation must climb down from the platelet complexions first, followed by a similar sequence at the trailing partial dislocation, in order to overcome the precipitates and commence plastic slip. The dislocation depinning mechanism of linear complexions is strikingly different from traditional precipitation-strengthened alloys, where dislocations overcome obstacles by either shearing through or looping around obstacles. The critical shear stress required to unpin dislocations from platelet complexions is found to be inversely proportional to precipitate spacing, which includes not just the open space (as observed in Orowan bowing) but also the region along the platelet particle where climb occurs. Thus, linear complexions provide a new way to modify dislocation structure directly and improve the mechanical properties of metal alloys.

Excellent strength-ductility synergy of Cu-Al alloy with a gradient nanograined-nanotwinned surface layer

Gradient nanostructured (GNS) metallic materials have shown significant potential in achieving excellent mechanical properties. However, the underlying strengthening mechanisms resulting from plastically inhomogeneous deformation in GNS materials, particularly those involving nanotwinned structures, remain inadequately understood. In this study, a gradient nanograined-nanotwinned (GNNT) surface layer was generated on a Cu-Al alloy using the severe plastic deformation technique known as single-point diamond turning. Uniaxial tensile and localized micropillar compression tests were conducted to compare the mechanical properties of GNNT samples with conventional gradient nanograined (GNG) and uniform coarse-grained (CG) Cu/Cu-Al counterparts. The results revealed that the GNNT samples exhibit excellent strength-ductility synergy, with a yield strength of approximately 329 MPa, tensile strength of around 477 MPa, and uniform ductility of about 48 %, thereby demonstrating remarkable strain hardening capacity and mechanical stability. These characteristics are further supported by the observed strong back stress effect, well-preserved mobile dislocation density, and effective suppression of grain coarsening in the GNNT surface layer. In contrast to the evident mechanically induced grain coarsening through grain boundary (GB) migration in the GNG surface layer, grain coarsening through twin boundary (TB) migration in GNNT surface layers is effectively inhibited by Lomer-Cottrell (L-C) locks formed by TB-stacking fault and TB-TB intersections, resulting in significantly enhanced structural stability. Furthermore, the L-C locks also extensively contribute to the high density of mobile dislocations observed in the GNNT samples. These findings provide valuable insights into the optimization of GNS structures for achieving excellent strength-ductility synergy in metallic materials.

Mapping elemental solutes at sub-picogram levels during aqueous corrosion of Al alloys using diffusive gradients in thin films (DGT) with LA-ICP-MS

A novel approach using diffusive gradients in thin films (DGT) with laser ablation inductively coupled plasma mass spectrometry (LA-ICP-MS) for two-dimensional mapping of elemental solute release at sub-picogram levels during aqueous corrosion of Al alloys is presented. Evaluation of different DGT gels with mixed micro-sized binding phases (polyacrylamide-Chelex-Metsorb, polyurethane (PU)-Chelex-Metsorb, PU-Chelex-Zr(OH)4) demonstrated the superior performance of PU gels due to their tear-proof handling, low shrinkage, and compliance with green chemistry. DGT devices containing PU-Chelex-Zr(OH)4 gels, which have not been characterized for Al sampling before, showed quantitative uptake of Al, Zn, and Cu solutes over time (t = 4–48 h) with higher Al capacity (ΓDGT = 6.25 µg cm−2) than different gels. Application of PU-Chelex-Zr(OH)4 gels on a high-strength Al-Cu alloy (Al2219) exposed to NaCl (w = 1.5%, pH = 4.5, T = 21 °C) for 15 min in a novel piston-type configuration revealed reproducible patterns of Al and Zn co-solubilization with a spatial expansion ranging between 50 and 1000 µm. This observation, together with complementary solid-state data from secondary electron microscopy with energy-dispersive X-ray spectroscopy, showed the presence of localized pitting corrosion at the material surface. Detection limits for total solute masses of Al, Zn, and Cu were ≤0.72 pg, ≤8.38 pg, and ≤0.12 pg, respectively, for an area of 0.01 mm2, demonstrating the method’s unique capability to localize and quantify corrosion processes at ultra-trace levels and high resolution. Our study advances the assessment of Al alloy degradation in aqueous environments, supporting the design of corrosion-resistant materials for fostering technological safety and sustainability.Graphical

EFFECT OF HIGH-INTENSITY ULTRASONIC TREATMENT ON REFINEMENT OF Al-5Cu ALLOY INGOTS

The effect of high-intensity ultrasonic treatment combined with bottom cooling treatment on the refinement of Al-5Cu alloy ingots was studied. The results show that ultrasonic treatment combined with forced cooling at the bottom of ingots has a good refining effect, and the best refining effect can be obtained at 2000 W and after 120 s. The cross-section of an ingot exhibits almost 100 % refined equiaxed grains and no porosity. The method of combining ultrasonic treatment and forced cooling at the bottom of ingots not only influences the ingot refinement, but also decreases the porosity of the ingots with an increase in the ultrasonic duration. The ultrasonic degassing effect is due to the release of hydrogen in biofilms, which expand and grow gradually; finally, they burst on the melt surface, achieving the effect of degassing.

Orientation distribution and deviation behaviors of dislocation loops in a quenched Al-Cu alloy

Dislocation loops in quenched aluminum alloys are usually seen deviating from their nominal habit planes, while the orientation distribution and deviation mechanism are far from understanding. Based on the method of tomographic crystallography of dislocations and correlative in-situ heating experiments in transmission electron microscopy (TEM), we revisit the three-dimensional (3D) characteristics and deviation behaviors of dislocation loops in a quenched Al-Cu alloy with an aim to fully unravel the relationship between dislocation crystallography and deviation behaviors. The results show that all the dislocation loops exhibit approximately circular shapes and have a/2 < 110>-type Burgers vectors, with loop orientations deviating from their pure edge orientation {110} of 0°-17.8° and distributing mainly close to the [101]-[001] and [101]-[111] edges of the standard stereographic triangle. Three types of deviation behaviors of dislocation loops are then defined, which are characterized by loop rotation around 〈100〉, 〈110〉 and irregular axes, respectively. Theoretical calculations of strain energy variation with increasing deviation angle indicate that the relatively low energy barrier may account for a high frequency of loop deviation in the low angle range. Detailed in-situ TEM heating experiments and correlative tomographic crystallography analyses strongly demonstrate the specific roles of dislocation gliding and climbing at elevated temperatures in the shrinkage, polygonization and deviation processes of dislocation loops, and the competitive and cooperative motion of dislocation segments close to slip planes {111} are the fundamental reasons for the formation of three types of deviated dislocation loops.

Effect of Mn/Ag Ratio on Microstructure and Mechanical Properties of Heat-Resistant Al-Cu Alloys.

This paper mainly investigated the effect of the Mn/Ag ratio on the microstructure and room temperature and high-temperature (350 °C) tensile mechanical properties of the as-cast and heat-treated Al-6Cu-xMn-yAg (x + y = 0.8, wt.%) alloys. The as-cast alloy has α-Al, Al2Cu, and a small amount of Al7Cu2 (Fe, Mn) and Al20Cu2 (Mn, Fe)3 phases. After T6 heat treatment, a massive dispersive and fine θ'-Al2Cu phase (100~400 nm) is precipitated from the matrix. The Mn/Ag ratio influences the quantity and size of the precipitates; when the Mn/Ag ratio is 1:1, the θ'-Al2Cu precipitation quantity reaches the highest and smallest. Compared with the as-cast alloy, the tensile strength of the heat-treated alloy at room temperature and high temperature is greatly improved. The strengthening effect of the alloy is mainly attributed to the nanoparticles precipitated from the matrix. The Mn/Ag ratio also affects the high-temperature tensile mechanical properties of the alloy. The high-temperature tensile strength of the alloy with a 1:1 Mn/Ag ratio is the highest, reaching 135.89 MPa, 42.95% higher than that of the as-cast alloy. The analysis shows that a synergistic effect between Mn and Ag elements can promote the precipitation and refinement of the θ'-Al2Cu phase, and there is an optimal ratio (1:1) that obtains the lowest interfacial energy for co-segregation of Mn and Ag at the θ'/Al interface that makes θ'-Al2Cu have the best resistance to coarsening.