Alternating Cu segregation and its stabilization mechanism for coherent η' precipitates in Al–Zn–Mg–Cu alloys

The 7000 series (Al–Zn–Mg) Al-alloys are renowned for their exceptional “lightweight-high strength” properties, primarily owing to nano-sized meta-stable η′ precipitate as the main strengthening phase. However, these η′ precipitates are susceptible to transforming into the stable η2 phase at elevated temperatures, resulting in a decline in strength. To mitigate this, Cu-segregation has been long proposed as a promising method for stabilizing these meta-stable precipitates. However, the mechanisms involved have not been fully understood. In this study, we conducted a thorough investigation on the structural and energetic changes between Cu-free and Cu-segregated η' and η2 precipitates. Utilizing DFT calculations and HAADF-STEM characterizations, we uncovered a distinctive alternating Cu-segregation pattern. This pattern induces significant structural modifications within the bulk of η' precipitates and at the precipitate-matrix interface, markedly enhancing their interfacial and bulk energetics. We believe these modifications are the key factor in improving precipitate stability. Based on our findings, the underlying mechanism of solute segregation was elucidated and a novel strategy for optimal design of Al–Zn–Mg alloys was proposed.