Microstructure and Properties of Spark Plasma Sintered Al-Zn-Mg-Cu Alloy

The microstructure of an aluminum alloy containing 53 wt% Zn, 2.1 wt% Mg and 1.3 wt% Cu as main alloying elements has been studied with the focus on the precipitation behavior during the spark plasma sintering process. The starting material was an atomized Al-Zn-Mg-Cu powder with the particle size below 50 μm. The particles showed a solidification microstructure from cellular to columnar or equiaxed dendritic morphology with a large fraction of the alloying elements segregated in form of intermetallic phases, mainly (Zn,Al,Cu)₄₉Mg₃₂ and Mg₂(Zn,Al,Cu)₁₁, at the cell and dendrite boundaries. The microstructure of the sintered specimens followed the microstructure of the initial powder. However, Mg(Zn,Al,Cu)₂ precipitates evolve at the expense of the initial precipitate phases. The precipitates which were initially continuously distributed along the intercellular and interdendritic boundaries form discrete chain-like structures in the sintered samples. Additionally, fine precipitates created during the sintering process evolve at the new low-angle boundaries. The large fraction of precipitates at the grain boundaries and especially at the former particle boundaries could not be solved into the matrix applying a usual solid solution heat treatment. A bending test reveals low ductility and strength. The mechanical properties suffer from the precipitates at former particle boundaries leading to fracture after an outer fiber tensile strain of 3.8%.