Based on end-quenching experiments combined with conductivity, hardness testing, and microstructural characterization, the quenching sensitivity of the mechanical and corrosion properties of 7475 aluminum alloy was investigated. The study revealed that as the quenching rate decreased, both the mechanical properties and exfoliation corrosion resistance exhibited increased quenching sensitivity. With the quenching rate decreasing from 31.9 °C/s to 2.5 °C/s, the conductivity increased by 4.1%IACS, the hardness decreased by 31%, the exfoliation corrosion grade transitioned from EC to ED, and the maximum exfoliation corrosion depth increased from 237 μm to 508 μm. As the quenching rate decreased, the η phase sequentially precipitated at recrystallized grain boundaries (RGBs), E phase particles, and subgrain boundaries (SGBs), while the T phase primarily precipitated on E phase particles. Furthermore, the significant precipitation of η and T phases led to a notable reduction in the quantity of age-precipitated phases, an increase in their size, and poor coherency with the matrix, resulting in decreased mechanical properties and a higher quenching sensitivity of the mechanical performance. Meanwhile, with the reduction in quenching rate, the size and spacing of grain boundary precipitated phases increased, the Zn and Mg contents of grain boundary precipitated phases increased, and the Precipitation Free Zone (PFZ) widened, leading to decreased exfoliation corrosion resistance and higher quenching sensitivity of the exfoliation corrosion performance.

The influence of grain structure and quenching rates on the exfoliation corrosion (EXCO) susceptibility of 7085 alloy was studied using immersion tests, optical microscopy (OM), scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and scanning transmission electron microscopy (STEM). The results show that as the cooling rate decreases from 1048 °C/min to 129 °C/min; the size of grain boundary precipitates (GBPs); the width of precipitate-free zones (PFZ); and the content of Zn, Mg, and Cu in GBPs rise, leading to an increase in EXCO depth and consequently higher EXCO susceptibility. Meanwhile, there is a linear relationship between the average corrosion depth and the logarithm of the cooling rate. Corrosion cracks initiate at the grain boundaries (GBs) and primarily propagate along the HAGBs. In the bar grain (BG) sample at lower cooling rates, crack propagation along the sub-grain boundaries (SGBs) was observed. Compared to equiaxed grain (EG) samples, the elongated grain samples exhibit larger GBPs, a wider PFZ, and minor compositional differences in the GBPs, resulting in higher EXCO susceptibility.

Based on end-quenching and step-quenching experiments combined with scanning electron microscopy (SEM) and transmission electron microscopy (TEM), the quench sensitivity of a novel high-strength aluminum alloy was investigated and compared with that of GB/T 7075 and 7175 alloys; quench factor analysis (QFA) was employed to predict the hardness values of the alloy and investigate the effect of quenching rate on its mechanical properties. The experimental results indicate that when the cooling rate decreases from 402.5 °C/s to 3.6 °C/s, the hardness reduction rate of the novel high-strength aluminum alloy is 15%. Furthermore, the nose temperature of the time–temperature–property (TTP) curve for this alloy is 325 °C, with a critical transformation time of 0.4 s. The quench-sensitive temperature range is 219 °C to 427 °C, which is lower than the quenching sensitivity of 7075 and 7175 alloys. The new alloy reduces its quenching sensitivity by optimizing the composition of alloying elements. Furthermore, the QFA demonstrates high predictive accuracy, with a maximum error of 5%. The smaller the quenching factor τ, the greater the hardness of the alloy after aging. Combined with the TTP curve, the alloy properties are optimized by modulating the quenching rate. This study provides a theoretical basis for selecting hot forming–quenching integrated process parameters in automotive high-strength aluminum alloys.