Characterization of hot extrusion and heat treatment on mechanical properties in a spray formed ultra-high strength Al-Zn-Mg-Cu alloy

Highlights: • The spray forming technology was used to fabricate ultra-high strength aluminum alloy. • The alloy under RRA state obtained the highest ultimate tensile strength of 732 MPa. • The effects of dislocations, solutes and precipitates etc., on yield strength were calculated. • Precipitation was characterized as the main strengthening mechanism for aging states. - Abstract: To obtain the optimal mechanical properties, several processes including spray forming technology, two passes hot extrusion and substantial heating treatments were operated on an Al-Zn-Mg-Cu-Zr alloy. The characterization methods used in this study include tensile tests, X-ray diffraction, differential scanning calorimetry and microstructure observations by optical microscope, scanning and transmission electron microscopy. The typical characteristics were the refined grain, homogeneous precipitates and porosity in the as-deposited pre-forms. The ultimate tensile strength, yield strength, hardness and elongation improved significantly after two passes hot extrusion. A good combination of ultimate tensile strength at 704 MPa and elongation at 9.7% were achieved under peak-aged treatment. The best ultimate tensile strength was obtained at 732 MPa after re-aging and regression. It was main dimple fracture in the extruded and aging treated specimens while brittle fracture for the as-deposited. The secondary phases were main MgZn₂ and Al₃Zr dispersoids throughout all the states. The contributions of grain boundaries, dislocations, solid-solution and precipitates on the yield strength were analyzed using a quantitative equation.