Evolution of Al2Cu Secondary Phase and Precipitation Strengthening of 2219 Al Alloy with Ultrasonic Melt Treatment, Hot Rolling, and Solution Aging

This study aims to clarify the combined effect of ultrasonic melt treatment (UST), hot rolling and solution aging (HRSA) on the evolution of the Al2Cu secondary phase in 2219 Al alloy toward the optimization of its mechanical properties for high‐performance structural applications. The results show that UST is beneficial for modifying the morphology and reducing the size of the secondary phase (by an average of 17.9%), and conducive to increasing the Cu content in the Al matrix (by an average of 37.5%) during solidification. The genetic effects of UST on the microstructure generated during HRSA result in denser and finer θ′/θ″ Al2Cu particles precipitating in the α‐Al matrix, with a 62.1% increase in the precipitates volume in the HRSA sample. Theoretical calculations confirm that precipitation strengthening is the predominant mechanism for strength improvement of 2219 Al alloy after UST and HRSA. The ultimate tensile strength (UTS), yield strength (YS), and elongation (EL) of the HRSA alloy without UST are 329, 214 MPa, and 11.9%, respectively, while these parameters are increased by 12.5% (to 370 MPa), 9.8% (to 235 MPa), and 17.6% (to 14.0%) for the UST alloy, respectively. Ultrasonic treatment of a 2219 Al–Cu alloy melt not only modifies the eutectic phase but also increases Cu dissolution in the Al matrix. Besides, genetic effect of as‐cast structure on hot‐rolled/solution‐aged structure is observed. Through theoretical calculations, precipitation strengthening is identified as the main strengthening mechanism of 2219 Al–Cu alloy.