This study investigates the synergistic effects of Cr–Zr and Mn–Zr additions on the microstructural evolution and mechanical properties of Al–6 wt.%Cu alloys. Alloys were designed with solute concentrations positioned below, near, and above their maximum solubility limits, and were evaluated under as-cast, T4, and T6 heat treatment conditions. Mechanical testing revealed distinct behavioral trends depending on the heat treatment: the T4 heat treatment condition generally exhibited superior hardness and yield strength, whereas the T6 heat treatment condition resulted in a slight reduction in hardness but facilitated a significant recovery in tensile strength and structural stability, particularly in alloys designed near the solubility limit. To elucidate the crystallographic origins of these mechanical variations, X-ray diffraction analysis was conducted to monitor changes in lattice parameters, dislocation density, and micro-strain. The results showed that T4 heat treatment induced lattice contraction and a decrease in dislocation density, suggesting that the high strength under T4 heat treatment conditions arises from lattice distortion caused by supersaturated solute atoms. Conversely, T6 aging led to lattice relaxation approaching that of pure aluminum, yet simultaneously triggered a re-accumulation of dislocation density and micro-strain due to the coherency strain fields surrounding precipitates, which effectively impede dislocation motion. Therefore, rather than proposing a single, definitive optimization condition, this study aims to secure foundational data regarding the correlation between these microstructural descriptors and mechanical behavior, providing a guideline for balancing the strengthening contributions in transition metal-modified Al–Cu alloys.

Porous aluminum alloys are widely used for lightweight structural materials such as marine structures, energy absorbers, and buoyant components. However, the conventional foaming agent TiH₂ presents limitations such as high cost and elevated decomposition temperatures, which increase manufacturing costs and restrict industrial applicability. In addition, the utilization of recycled raw materials such as aluminum machining chips has emerged as an important challenge in material development for resource efficiency and sustainability. To address these issues, porous aluminum alloys were fabricated in this study using recycled A356 aluminum chips by incorporating TiH₂ and a low-cost alternative foaming agent, Na₂B₄O₇·10H₂O (borax), either individually or in combination. The effects of foaming agent content (1, 1.5, and 3 wt.%) on pore characteristics, microstructure, hardness, and corrosion resistance were systematically investigated. TiH₂ induced an increase in porosity due to hydrogen generation and also promoted grain refinement, which contributed to the improvement of hardness and corrosion resistance, while Na₂B₄O₇·10H₂O exhibited effective pore formation and hardness improvement at 1–1.5 wt.% but tended to deteriorate corrosion resistance as its content increased. In particular, combined addition of both agents at 1.5 wt.% showed excellent pore formation and corrosion resistance properties, with a relatively high pore area fraction (2.38%), porosity (27.0%), SDAS (48.1 ± 4.8 µm), hardness (59.35 ± 6.4 HV), corrosion potential (−1.039 V), pitting potential (−0.709 V), and corrosion current density (4.956 μA/cm²). This study demonstrated that Na₂B₄O₇·10H₂O (borax) foaming agent can be an economic alternative to TiH₂, and shows that the performance of porous aluminum alloys can be effectively improved by optimizing the combination of recycled raw materials and foaming agents.