The phase equilibria of the Al–Er binary system have been investigated through both experiments and CALPHAD assessment. The phase relationship in the compositional range of 0–50 at. % Er was experimentally redetermined using scanning electron microscopy (SEM) with Energy Dispersive Spectroscopy (EDS), electron probe micro analysis (EPMA) with wavelength dispersive spectrometer (WDS), X-ray diffraction (XRD) and differential scanning calorimetry (DSC). The results confirmed the existence of the Al3Er phase (Al3Ho-type structure) with limited homogeneity range in the Al–Er system. It was formed through the peritectic reaction L + Al2Er ↔ Al3Er at 1105.3 ± 2.4 °C. While the Al17Er2 phase was proved to be metastable in the present work. A full thermodynamic optimization of the Al–Er binary system has been carried out by utilizing the current experimental data as well as all available results in the previous publications. A set of self-consistent thermodynamic parameters for the Al–Er system was established. The calculated phase diagram and thermodynamic properties agree well with the available data. The artificial inverted liquid-liquid miscibility gap at high temperature in the previous evaluation is removed.
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