Homogeneous Age-hardening of Large-sized Al-Sc Foams via Micro-alloying with Zr and Ti

Al-based foams have drawn increasing attention from industry due to their integration of structure and functional properties. However, large-sized Al-based foams still cannot be homogeneously strengthened by long-time aging due to their low thermal conductivity. In this study, we proposed an age-hardening approach that was applied in large-sized Al-0.16Sc-0.17Zr (wt.%) foams via micro-alloying with Zr and Ti compared with Al-0.21Sc foams; it not only achieved homogeneous strength by long-term aging but also reduced the cost of the alloy by substituting Zr and Ti for the more expensive Sc content. The results show that the Al₃(Sc, Zr, Ti) phase with a core-shell structure as a crucial precipitation strengthening phase by micro-alloying with Zr and Ti was less prone to coarsening after a prolonged aging heat treatment. Therefore, the yielding strength of Al-Sc foam micro-alloying with Zr and Ti remained almost unchanged after a maximum aging time of 1440 h due to less coarsening precipitate, which is consistent with the results of mechanical experiments. These findings provide a new way for the heat treatment strengthening of large-sized Al-based foams, thus promoting their industrial applications.