Solidified structure, mechanical properties and phase decomposition were investigated on the Al-(0.2 N 3.4) %Zr alloys chill-cast or splat quenched to extend the solid solubility of Zr in Al. Slowly cooled alloys containing 1.1 N 3.4%Zr have a equilibrium A13Zr phase in the shape of a large needle. Chill-cast alloys containing 0.2 to 1.4%Zr have f.c.c. solid solutions highly supersaturated. Chill-cast alloys containing Zr more than 1.7°% have a non-equilibrium Ll2 structure. The metastable A13Zr plays active nuclei for the angular structure and leads to grain refining. Presence of the anglar structure containing more of Zr results in abrupt increase of strength of the alloys. Decomposition of the supersaturated solid solution during tempering occurs by forming a spherical intermediate cubic Al3Zr phase. The spherical precipitate is very slowly coarsened and then preferentially grows along the definite matrix direction. The grain boundary reaction is also observed in the early stage of againg. These precipitates are metastable Al3Zr of Ll2 type structure which is stable during prolonged aging time.
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