Effect of Zr Additions on the Microstructure and Elevated-Temperature Mechanical Properties of Al–Cu–Mg–Ag–Zn–Mn–Zr Alloys

This study systematically investigates the influence of Zr additions (0–0.24 wt.%) on the microstructure evolution and mechanical properties of Al–4.0Cu–0.5Mg–0.5Zn–0.5Mn–0.4Ag alloys under peak-aged conditions. Alloys were subjected to homogenization (420 °C/8 h + 510 °C/16 h), solution treatment (510 °C/1.5 h), and aging (190 °C/3 h). Microstructural characterization via OM, SEM, EBSD, and TEM revealed that Zr refines grains and enhances recrystallization resistance through coherent Al₃Zr precipitates, which pin grain boundaries and dislocations. However, excessive Zr (0.24 wt.%) induces heterogeneous grain size distribution and significant Schmid factor variations, promoting stress concentration and premature intergranular cracking. Crucially, Al₃Zr particles act as heterogeneous nucleation sites for Ω-phase precipitates, accelerating their nucleation near grain boundaries, refining precipitates, and narrowing precipitate-free zones (PFZs). Mechanical testing demonstrated that the Al–4.0Cu–0.5Mg–0.5Zn–0.5Mn–0.4Ag alloy exhibits optimal properties: peak tensile strength of 368.8 MPa and 79.8% tensile strength retention at 200 °C. These improvements are attributed to synergistic microstructural modifications driven by controlled Zr addition, establishing Al–4.0Cu–0.5Mg–0.5Zn–0.5Mn–0.4Ag–0.16Zr as a promising candidate for high-temperature aerospace applications.