This study focused on the microstructural analysis, superplasticity, modeling of superplastic deformation behavior, and superplastic forming tests of the Al-Mg-Si-Cu-based alloy modified with Fe, Ni, Sc, and Zr. The effect of the thermomechanical treatment with various proportions of hot/cold rolling degrees on the secondary particle distribution and deformation behavior was studied. The increase in hot rolling degree increased the homogeneity of the particle distribution in the aluminum-based solid solution that improved superplastic properties, providing an elongation of ~470–500% at increased strain rates of (0.5–1) × 10⁻² s⁻¹. A constitutive model based on Arrhenius and Beckofen equations was used to describe and predict the superplastic flow behavior of the alloy studied. Model complex-shaped parts were processed by superplastic forming at two strain rates. The proposed strain rate of 1 × 10⁻² s⁻¹ provided a low thickness variation and a high quality of the experimental parts. The residual cavitation after superplastic forming was also large at the low strain rate of 2 × 10⁻³ s⁻¹ and significantly smaller at 1 × 10⁻² s⁻¹. Coarse Al₉FeNi particles did not stimulate the cavitation process and were effective to provide the superplasticity of alloys studied at high strain rates, whereas cavities were predominately observed near coarse Mg₂Si particles, which act as nucleation places for cavities during superplastic deformation and forming.

The study aims to investigate the influence of fraction of coarse undeformed particles on the microstructure evolution and mechanical properties of alloys processed by isothermal multidirectional forging (MDF). For this purpose, Al-Mg-Ni-Sc-Zr-based alloys with different Ni concentrations and a fraction of Al₃Ni particles of solidification origin phase were subjected to MDF at 350 °C. Precipitates of the L1₂-structured Al₃(Sc,Zr) phase retained their structure, morphology, and size after MDF and were coherent with the aluminum matrix. The Al₃Ni phase particles stimulated the nucleation of recrystallized grains and contributed significantly to the formation of an ultrafine-grained structure. The uniformity of the grain structure increased, and the average grain size decreased with an increase in the fraction of Al₃Ni particles. A fine-grained structure with a mean grain size of 2.4–3.4 µm was observed after MDF with a cumulative strain of 12. The results demonstrate that a bimodal particles size distribution with a volume fraction of nanoscale f~0.1% and microscale f~8% particles provided for the formation of a homogenous fine-grained structure after MDF and improved the mechanical properties.

The effect of zirconium on the microstructure, phase composition, and mechanical properties of AlCuYb and AlCuGd alloys was studied. The microstructure of the as-cast alloys did not consist of new intermetallic phases of zirconium with other elements, so the zirconium was fully dissolved in the aluminum matrix. The AlCuYbZr/AlCuGdZr alloys demonstrated higher hardness values compared to the AlCuYb/AlCuGd alloys due to the precipitation of the Al₃(Zr,Yb) and Al₃(Zr,Gd) phases, which were formed during the homogenization treatment. The AlCuYbZr alloy had a 10–20 MPa higher yield and tensile strength than the AlCuGdZr alloy at the same annealing temperature and time. The AlCuYbZr alloy exhibited good mechanical tensile properties at an annealing temperature of 100 °C for 1 h, with a yield strength of 276 MPa, ultimate tensile strength of 312 MPa, and elongation of 3.1%, while the as-rolled AlCuGdZr alloy had similar mechanical tensile properties, with a yield strength of 279 MPa, ultimate tensile strength of 307 MPa, and elongation of 4.8%. At an annealing temperature of 300 °C for 10 min, The AlCuYbZr and AlCuGdZr alloys showed a good ductility of 10.5% and 8%, respectively, with 207 MPa yield strength for both alloys. AlCuYbZr and AlCuGdZr alloys are a prospective base composition for developing novel high technology heat resistant aluminum alloys.

In the present research an Al–7.7%Mn–4.9%Zr–3.2%Cu (wt%) alloy was processed by mechanical alloying (MA) followed by hot press sintering. The microstructure, phase composition, and mechanical properties of the MA granules and sintered samples were investigated. The dissolution of Mn, Zr, and Cu with further precipitation of the Al₆Mn phase were observed during high-energy ball milling. In the alloy processed without stearic acid after milling for ~10 h, an Al-based solid solution with ~4.9 wt%Zr, ~3.2 wt%Cu and a ~5 wt%Mn with a grain size of ~16 nm and a microhardness of ~530 HV were observed. The addition of stearic acid facilitated Mn dissolution and precipitation of the Al₆Mn phase during milling but led to the formation of the ZrH₂ phase that decreased the Zr solute and the microhardness. Precipitation of the Al₆Mn, L1₂–Al₃Zr, and Al₂Cu phases during annealing and sintering of the MA granules in the temperate range of 350–375 °C was observed, and an additional Al₂₀Cu₂Mn₃ phase was precipitated at 400–450 °C. Hot-press sintering at 450 °C provided a low fraction of cavities of ~1.5%, the yield strength of 1100 MPa, ultimate compressive strength of 1200 MPa, strain at fracture of 0.5% at room temperature, the yield strength of 380 MPa, ultimate compressive strength of 440 MPa, and strain at fracture of 3.5% at 350 °C. The microstructural evolution during high-temperature deformation on the sample surface was studied and the differences in deformation behavior for the alloys sintered at different temperatures were discussed.

The current study analyzed the effect of Ni content on the microstructure and superplastic deformation behavior of the Al-Mg-Si-Cu-based alloy doped with small additions of Sc and Zr. The superplasticity was observed in the studied alloys due to a bimodal particle size distribution. The coarse particles of eutectic origin Al₃Ni and Mg₂Si phases with a total volume fraction of 4.0–8.0% and a mean size of 1.4–1.6 µm provided the particles with a stimulated nucleation effect. The L1₂– structured nanoscale dispersoids of Sc- and Zr-bearing phase inhibited recrystallization and grain growth due to a strong Zener pinning effect. The positive effect of Ni on the superplasticity was revealed and confirmed by a high-temperature tensile test in a wide strain rate and temperature limits. In the alloy with 4 wt.% Ni, the elongation-to-failure of 350–520% was observed at 460 °C, in a strain rate range of 2 × 10⁻³–5 × 10⁻² s⁻¹.

Increasing the strength of Al-based alloys is an important issue of physical metallurgy and industrial processing. Severe plastic deformation and related extension of solid solubility during mechanical alloying provide an opportunity for significant strengthening due to grain refinement, solid solution, and precipitation strengthening mechanisms. During mechanical alloying, an anomalous increase in the solid-state solubility of alloying elements occurs. The present study focuses on the investigation of the pre-milling treatment to the microstructure, phase composition, and solubility in Al-7.7 Mn-3.5 Cu (wt%) alloy processed by a high-energy ball milling of Al-14.3 Mn-6.5 Cu (wt%) master alloy diluted with Al powder. During milling, the mean granular size decreased to ~5 µm, and a strong grain refinement occurred. According to our TEM and XRD data, ball milling provided a mean grain size of 13–14 nm and a microhardness of 490–540 HV. The lattice parameter of the Al-based solid solution decreased with an increase in the milling time to 7.5–10 h, which suggested the dissolution of the alloying elements, and the lattice parameter increased at a higher milling time of 12.5–40 h, which suggested the decomposition of the solid solution. The XRD data revealed the dissolution of the Al₆Mn and Al₂₀Cu₂Mn₃ solidification-originated phases with a further precipitation of the Al₆Mn dispersoids. Pre-milling of the master alloy entailed a significant decrease in the minimal lattice parameter value from 0.4029 nm to 0.4023 nm due to an increase in the Mn solute content from 6.2 wt% (3.3 at%) to 7.5 wt % (4.0 at%) in the studied alloy during high-energy ball milling.