Enhancing elevated temperature strength of copper containing aluminium alloys by forming L12 Al3Zr precipitates and nucleating θ″ precipitates on them

Strengthening by precipitation of second phase is the guiding principle for the development of a host of high strength structural alloys, in particular, aluminium alloys for transportation sector. Higher efficiency and lower emission demands use of alloys at higher operating temperatures (200 °C–250 °C) and stresses, especially in applications for engine parts. Unfortunately, most of the precipitation hardened aluminium alloys that are currently available can withstand maximum temperatures ranging from 150–200 °C. This limit is set by the onset of the rapid coarsening of the precipitates and consequent loss of mechanical properties. In this communication, we present a new approach in designing an Al-based alloy through solid state precipitation route that provides a synergistic coupling of two different types of precipitates that has enabled us to develop coarsening resistant high-temperature alloys that are stable in the temperature range of 250–300 °C with strength in excess of 260 MPa at 250 °C.