Aging behavior and strengthening mechanisms of coarsening resistant metastable θ' precipitates in an Al–Cu alloy

An Al–Cu alloy micro-alloyed with Mn and Zr (ACMZ) was examined to understand the thermal stability and strengthening mechanism of metastable θ'-Al2Cu precipitates with interfacial segregation after prolonged thermal exposure. The microstructure was characterized at multiple scales with techniques including synchrotron x-ray diffraction, scanning electron microscopy, scanning transmission electron microscopy, and atom probe tomography. The θ' precipitates did not exhibit measurable coarsening after thermal exposure at 300°C for 5000 h. Kinetic effects of Mn and Zr interfacial segregation, which dominate over thermodynamic effects under these conditions, were necessary to understand the complete inhibition of precipitate coarsening. The θ' phase fraction was stable during the 5000 h exposure. This stable phase fraction was regarded as the metastable equilibrium value and was smaller than that predicted by the θ' solvus line of the ACMZ alloy. As expected from the observed phase stability, the alloy hardness also remained stable during the 5000 h exposure. An Orowan mechanism alone was inadequate to explain θ' precipitate strengthening. Additional strengthening mechanisms by θ' precipitates specifically related to the transformation strain may explain the observed hardness values. [Display omitted] •Metastable θ'-Al2Cu precipitates are coarsening resistant at 300 °C for 5000 h in an Al-Cu-Mn-Zr alloy.•Metastable equilibrium θ' phase fraction is lower than the prediction using the θ' solvus line.•Hardness remains stable during the 5000 h thermal exposure.•Orowan strengthening from θ' precipitates is inadequate to explain the alloy hardness.