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12 Chapter 1: Introduction  14 1.1 Research Goals  14 1.2 Motivations for Research  15 1.3 Organization of the Dissertation  15 Chapter 2: Background  17 2.1 General Overview of Sc and Zr Usage in Al Alloys  17 2.2 Precipitate Strengthening Mechanisms in Aluminum  19 2.2.1 Mismatch and Coherency Strengthening  21 2.2.2 Order Strengthening  23 2.2.3 Orowan Strengthening  25 2.2.4 Determining Dominance in Strengthening Mechanisms  26 2.3 Effect of Solidification Rate on Achievable Supersaturation  28 2.4 Consolidation of Rapidly Solidified Materials  30 Chapter 3: Experimental Techniques 31 3.1 Rapid Solidification 31 3.1.1 Melt Spinning Crucibles  31 4 3.1.2 Setting up the Melt Spinner  34 3.1.3 Melt Spinner Operation  36 3.2 Consolidation of Ribbon  39 3.3 Additive Friction Stir Processing  41 3.4 Heat Treating  42 3.4.1 Box Furnaces  42 3.4.2 Vacuum Furnace  44 3.5 Inductively Coupled Plasma Optical Emission Spectroscopy  46 3.6 XRD Analysis of Solute Concentration  47 3.7 Vicker's Hardness Testing  48 3.8 Electrical Conductivity Testing  50 3.9 Scanning Electron Microscopy Analysis  51 3.9.1 Sample Preparation  51 3.9.2 Backscatter Electron Imaging  52 3.9.3 Wavelength Dispersive Spectrometry  53 3.10 Transmission Electron Microscopy Analysis  54 3.10.1 TEM Sample Preparation  54 3.10.2 TEM Operation  58 3.11 Cutting Samples  58 3.11.1 Wire EDM  58 5 3.11.2 Saws and Shears  60 3.11.3 Abrasive Cutoff Discs  62 3.12 Grinding and Polishing Samples  62 3.12.1 Mounting Samples  63 3.12.2 Grinding Operations 66 3.12.3 Polishing Operations  67 3.13 Melting Charge Preparation 68 3.13.1 Calculations of Charge Materials  68 3.13.2 Preparation of Charge Materials  69 3.13.3 Special Considerations for Charge Materials  70 3.14 Vacuum Induction Melting  73 3.14.1 Vacuum Induction Melter Overview  74 3.14.2 Computer Assisted Pouring Program 74 3.14.3 Design of the Permanent Mold  75 3.14.4 General Operation of the VIM  77 Chapter 4: Precipitate Evolution and Strengthening in Rapidly Solidified Supersaturated Al-Sc and Al-Zr Alloys  79 4.1 Abstract and Background  79 4.1.1 Abstract  79 4.1.2 Introduction  80 6 4.2 Structure of Experiments  82 4.2.1 Determination of Achievable Supersaturation Levels  83 4.2.2 Melt Spinning Overview  83 4.2.3 Heat Treatment and Testing of Melt Spun Ribbon  84 4.3 Results and Discussion  85 4.3.2 Extent of Initial Supersaturation  85 4.3.3 Lattice Parameter Change with Heat Treatment  87 4.3.4 Transmission Electron Microscopy  93 4.3.5 Prediction of Precipitate Contribution to Strength  98 4.4 Conclusions  100 Chapter 5: Effect of Additive Friction Stir Processing on Supersaturated Al-Sc  103 5.1 Abstract  103 5.2 Background  104 5.3 Experimental Design  106 5.4 Results and Discussion  109 5.6 Conclusion  117 Chapter 6: Designing Heat Treatments for Al-Sc Alloys with the Kampmann and Wagner Numerical Model  119 6.1 Abstract  119 6.2 Predictive Model Design and Function  120 7 6.2.1 Purpose of this Modeling  120 6.2.2 Basic Structure and Theory of this Modeling  120 6.2.3 Special Considerations  128 6.2.4 Future KWN Modeling Work  129 6.3 Experimental Verification Setup  132 6.4 Results and Discussion  134 6.5 Conclusions  150 Chapter 7: Effect of Zr Additions on Thermal Stability of Al-Cu precipitates in AsCast and Cold Worked Samples  153 7.1 Abstract  153 7.2 Experimental Design  154 7.3 Results and Discussion  159 7.4 Conclusions  168 Chapter 8: Summary

INVESTIGATION AND MODELING OF Al3(Sc, Zr) PRECIPITATION STRENGTHENING IN THE PRESENCE OF ENHANCED SUPERSATURATION AND WITHIN Al-Cu BINARY ALLOYS