Effects of Mg, Si, and Cu on the Formation of the Al3Sc/Al3Zr Dispersoids

"6xxx-series Al alloys are the most commonly used alloys in the automotive industry as they have an appropriate balance of strength, corrosion resistance and formability. The main strengthening phase in these alloys is the ß’-Mg2Si precipitates. One opportunity to achieve stronger 6xxx-series Al alloys, without affecting corrosion and formability, is the use of Sc. The main challenge of using Sc in 6xxx-series lies in the heat treatment, which must be designed to allow for a fine precipitation of both Al3Sc and ß’-Mg2Si. In this work, two model alloys are used, an Al-Sc-Zr and an Al-Mg-Si-Cu-Sc-Zr, to explore the impact of the 6xxx-series key elements (Mg, Si and Cu) on the Al3Sc precipitates. Transmission electron microscopy and atom probe tomography are used to investigate the precipitates present in the microstructure after casting. We find that higher Si content results in the formation of dispersoids upon casting. The average composition of these dispersoids is (Al0.8,Si0.2)3 (Sc0.888,Zr0.024,Mg0.08,Cu0.008). A closer look at the solid solution reveals that most of the Sc and Zr is supersaturated after casting even in the presence of Mg, Si and Cu. We discuss the impact of these results on the design of a suitable heat treatment for 6xxx-series alloys with Sc.INTRODUCTION The most common strategy to strengthen aluminum (Al) alloys is by micro-alloying to form a fine distribution of precipitates (Gladman, 1999). Whilst precipitates enhance the strength, this is often done to the detriment of ductility and corrosion performance (Davis, 1999). The 6xxx-series Al alloys are heavily used in the automotive industry as they offer an appropriate balance of strength, ductility and corrosion resistance (W. S. Miller et al., 2000). The strength increment in these alloys comes from the formation of the ß’–Mg2Si and the quaternary Q’ phase (Chakrabarti & Laughlin, 2004; Polmear, St. John, Nie, & Qian, 2017). One opportunity to achieve stronger 6xxx-series alloys, whilst keeping good balance of corrosion resistance and formability, is the use of small additions of scandium (Sc). Sc is one of the most potent strengtheners in Al alloys (Dorin, Ramajayam, Vahid, & Langan, 2018; Røyset & Ryum, 2005). Most of the strengthening benefits from Sc come from the formation of fine Al3Sc dispersoids. The following strengthening mechanisms apply to Sc: 1) Solid solution strengthening, 2) precipitation hardening, 3) inhibiting recrystallization, 4) assisting nucleation of other strengthening phases (Dorin, Ramajayam, Lamb, & Langan, 2017). As compared to other dispersoid phases, Al3Sc dispersoids have good electrochemical compatibility with Al alloys and hence do not affect their corrosion resistance (Cavanaugh, Birbilis, Buchheit, & Bovard, 2007). The coarsening resistance of Al3Sc is often improved by adding zirconium (Zr), as it forms a Zr rich shell around Al3Sc which prevents Sc from moving across the interface."