The effect of 0.2%Cr addition on the structure, phase composition, and mechanical properties of the novel cast and wrought Al-2.5Zn-2.5Mg-2.5Cu-0.2Zr-Er(Y) alloys were investigated in detail. Chromium is distributed between primary crystals (5.7–6.8%) of the intermetallic phase and the aluminum solid solution (0.2%) (Al). The primary crystals contain for the main part Cr, Ti, Er(Y). The experimental phase composition is in good correlation with the thermodynamic computation data. The micron-sized solidification origin phases (Al₈Cu₄Er(or Y) and Mg₂Si) and supersaturated (Al) with nano-sized Al₃(Zr,Ti) and E (Al₁₈Mg₃Cr₂) precipitates are presented in the microstructure of the novel alloys after solution treatment. The nucleation of η (MgZn₂) (0.5%), S (Al₂CuMg) (0.4%), and T (Al,Zn,Mg,Cu) (8.8%) phase precipitates at 180 °C, providing the achievement of a maximum hardness of 135 HV in the Al2.5Zn2.5Mg2.5CuYCr alloy. The corrosion potential of the novel alloy is similar to the E_cor of the referenced alloy, but the corrosion current density (0.68–0.98 µA/sm²) is still significantly lower due to the formation of E (Al₁₈Mg₃Cr₂) precipitates and S phase precipitates of the aging origin, in addition to the T phase. The formation of E (Al₁₈Mg₃Cr₂) precipitates under the solution treatment provides a lower proportion of recrystallized grains (2.5–5% vs. 22.4–25.1%) and higher hardness (110 HV vs. 85–95 HV) in the Cr-rich alloys compared to the referenced alloys. Solution treated, hot and cold rolled, recrystallized, water quenched and aged at 210 °C alloys demonstrate an excellent microstructure stability and tensile properties: YS = 299–300 MPa, UTS = 406–414 MPa, and El. = 9–12.3%.

The effect of an erbium alloying on the hot deformation behavior of the crossover Al3Zn3Mg3Cu0.2Zr alloy was investigated in detail. First of all, Er increases the solidus temperature of the alloy. This allows hot deformation at a higher temperature. The precipitates resulting from the Er alloying of the Al3Zn3Mg3Cu0.2Zr alloy were analyzed using transmission electron microscopy. Erbium addition to the alloy produces the formation of more stable and fine L1₂-(Al₃(Zr, Er)) precipitates with a size of 20–60 nm. True stress tends to increase with a decline in the temperature and an increase in the deformation rate. The addition of Er leads to decreases in true stress at the strain rates of 0.01–1 s⁻¹ due to particle-stimulated nucleation softening mechanisms. The effective activation energy of the alloy with the Er addition has a lower value, enabling an easier hot deformation process in the alloy with an elevated volume fraction of the intermetallic particles. The addition of Er increases the strain rate sensitivity, which makes the failure during deformation less probable. The investigated alloys have a significant difference in the dependence of the activation volume on the temperature. The flow instability criterion allows better deformability of Er-doped alloys and enables the alloys to be formed more easily. The evenly distributed particles prevent the formation of shear bands with elevated storage energy and decrease the probability of crack initiation during the initial stages of hot deformation when only one softening mechanism (dynamic recovery) is working. The microstructure analysis proves that dynamic recovery is the main softening mechanism.