Effect of upset forging on microstructure and tensile properties in a devitrified Al–Ni–Co–Y Alloy

Devitrified Al—transition metal—rare earth alloys offer routes to obtain higher volume fractions of dispersed strengthening phases than conventional precipitation routes. Here, we report a study of the microstructure–property relationships of an Al–Ni–Co–Y alloy processed by gas atomization and consolidated/devitrified by warm extrusion. Microstructural characterization by electron microscopy and serial section FIB tomography show that the alloy comprises an FCC Al matrix and 44 % by volume of elongated Al 19 (Ni,Co) 5 Y 3 plates with the Al 19 Ni 5 Gd 3 structure. The plates are aligned with the extrusion direction in the as-extruded alloy, and tensile data show a distinct anisotropy in yield strength and strain to failure. These data are consistent with the alloy acting more like a unidirectional short-fiber-reinforced metal–matrix composite than a conventional precipitation-hardened alloy. During axial upset forging, the ternary plates do not break up, but instead they rotate, until at large upset strains they lie perpendicular to their original orientation with corresponding changes in the tensile properties. The materials exhibit yield strengths of up to 713 MPa and tensile elongations of up to 5 %. Thus, such systems could form the basis for truly deformable high-strength low-density metal–matrix composites.