Aluminium steel clad materials have high potential for industrial applications. Their mechanical properties are governed by an intermetallic layer, which forms upon heat treatment at the Al-Fe interface. Transmission electron microscopy was employed to identify the phases present at the interface by selective area electron diffraction and energy dispersive spectroscopy. Three phases were identified: orthorhombic Al₅Fe₂, monoclinic Al₁₃Fe₄ and cubic Al₁₉Fe₄MnSi₂. An effective interdiffusion coefficient dependent on concentration was determined according to the Boltzmann–Matano method. The highest value of the interdiffusion coefficient was reached at the composition of the intermetallic phases. Afterwards, the process of diffusion considering the evaluated interdiffusion coefficient was simulated using the finite element method. Results of the simulations revealed that growth of the intermetallic phases proceeds preferentially in the direction of aluminium.

A homogenization of billets from Al-Cu-Li-Mg-Sc-Zr alloys should be accomplished at high annealing temperatures exceeding 500 °C. This type of aluminum alloy is susceptible to the depletion of surface layers from Li. Therefore, choosing a suitable homogenization temperature and duration is a crucial step in assuring a homogeneous distribution of alloying elements and optimal exploitation of the potential of the alloy. In situ heating in an electron microscope was performed on a twin-roll-cast Al-Cu-Li-Mg-Sc-Zr alloy to understand the peculiarities of the homogenization process. Four types of primary phase particles rich in Cu, Li, Mg, and Fe were identified in the as-cast material. They appear as coarse particles at the boundaries of eutectic cells. Their partial dissolution occurs at temperatures above 450 °C. They are almost fully dissolved at 550 °C, except for complex phases containing Fe and Cu. Small dimensions of eutectic cells in the range of 10 µm assure a homogeneous distribution of the main alloying elements within the matrix after 20 min of annealing at 530 °C. Direct comparison with the same material prepared by mold casting indicates that such short annealing times result in the dissolution of the main primary phase particles but do not assure a homogeneous distribution of the alloying elements in the whole volume of the specimen.

Thin twin-roll cast strips from a model Al-Cu-Mg-Li-Zr alloy with a small addition of Sc were prepared. A combination of a fast solidification rate and a favorable effect of Sc microalloying refines the grain size and the size of primary phase particles and reduces eutectic cell dimensions to 10–15 $\mathsf{\mu }$m. Long-term homogenization annealings used in conventionally cast materials lasting several tens of hours followed by a necessary dimension reduction through rolling/extruding could be substituted by energy and material-saving procedure. It consists of two-step short annealings at 300 °C/30 min and 450 °C/30 min, followed by the refinement and hardening of the structure using constrained groove pressing. A dense dispersion of 10–20 nm spherical ${\mathrm{Al}}_3(\mathrm{Sc},\mathrm{Zr})$ precipitates intensively forms during this treatment and effectively stabilizes the structure and inhibits the grain growth during subsequent solution treatment at 530 °C/30 min. Small (3%) pre-straining after quenching assures more uniform precipitation of strengthening ${\mathrm{Al}}_2\mathrm{Cu}$ (${\theta }^{\prime }$), ${\mathrm{Al}}_2\mathrm{CuMg}$ ($S\prime$), and Al₂CuLi ($T_1$) particles during subsequent age-hardening annealing at 180 °C/14 h. The material does not contain a directional and anisotropic structure unavoidable in rolled or extruded sheets. The proposed procedure thus represents a model near net shape processing strategy for manufacturing lightweight high-strength sheets for cryogenic applications in aeronautics.

The influence of the casting method on the microstructures of Al-Cu-Li-Mg-Zr-Sc was examined. The techniques include mold casting, twin-roll casting, and melt spinning. Estimated solidification rates of up to 10 7 K•s-1 produce dendritic solidification with eutectic cells ranging from 500 nm to 50 μm, decorated by primary phase particles with thicknesses from 200 nm to 3 μm. Exceeding this solidification rate results in near-diffusionless solidification, which traps more solutes in the matrix. This type of solidification yields a more supersaturated material, with nearly 90% of the total Cu content in the matrix and a fine dispersion of nanoscale spherical precipitates, each with a diameter of less than 100 nm. The small addition of Sc during casting primarily affects the material at low cooling rates, where primary Sccontaining particles modify the grain boundary shape. Al-Cu-Li-Mg-Zr-Sc Mold casting Twin-roll casting Melt-spinning Diffusionless solidification

Thin twin-roll cast strips from a model Al-Cu-Mg-Li-Zr alloy with a small addition of Sc were prepared. A combination of a fast solidification rate and a favorable effect of Sc microalloying impacts the size and distribution of primary phase particles and the dimension of eutectic cells. Small interdendritic spacing in the range of 10-15 um enables substitution of the initial long-term homogenization annealing by a two-step annealing at 300 and 450 °C and a short solution treatment at 530 °C before quenching and the final age-hardening procedure. A dense dispersion of small Al3(Sc,Zr) precipitates intensively inhibiting recrystallization forms during this treatment. Further refining and fragmentation of the structure were performed using constrained groove pressing before the solution treatment. Small pre-straining of quenched specimens and subsequent age-hardening simulating T8 temper were used to promote the formation of a homogeneous distribution of strengthening particles and to suppress preferential heterogeneous precipitation on subgrain and grain boundaries. Microstructural features and microhardness evolution during annealing were critically examined and confronted with microstructural characteristics observed on reference mold cast alloy or alloys without Sc alloying. The proposed treatment represents a model near net shape procedure for manufacturing thicker sheets for the aerospace industry.