Solid State Phenomena Vol 197 (2013) pp 238-243 Online: 2013-02-27

© (2013) Trans Tech Publications, Switzerland

doi:10.4028/www.scientific.net/SSP.197.238

Analysis of intermetallic phases in 2024 aluminium alloy

Grażyna Mrówka – Nowotnik1, a, Jan Sieniawski2,b
1,2
Department of Materials Science, Rzeszow University of Technology, W. Pola 2, 35-959 Poland
a
mrowka@prz.edu.pl, b jansien@prz.edu.pl

Keywords: 2xxx aluminium alloys, microstructure, intermetallic phase.

Abstract. The main objective of this study was to analyze the evolution of the microstructure
(morphology, composition and distribution of intermetallic phases) in the 2024 aluminium alloy
cooled with different cooling rates after solidification process. A few techniques: optical light
microscopy (LM), scanning (SEM) electron microscopy combined with an energy dispersive X-ray
microanalysis (EDS), X-ray diffraction (XRD) were used to identify intermetallics in the examined
alloy. The results show that the microstructure of 2024 aluminium alloys in as-cast condition
consisted following intermetallic phases: Al2Cu, Al2CuMg, Al7Cu2Fe, Al4Cu2Mg8Si7, AlCuFeMnSi
and Mg2Si.

Introduction
Aluminium alloys of the 2xxx series are the most widely used in aircraft and aerospace structures
owing to their good specific strength and lightweight [1-6]. These multiphase alloys belong to the
group of commercial, in which relative volume, chemical composition and morphology of structural
constituents exert significant influence on their useful properties [1,2]. The microstructure of 2xxx
aluminium alloys are usually complex because of the many additives used for strength, corrosion
resistance or grain structure control [4]. The particles of intermetallic phases form either on
solidification or whilst the alloy is at a relatively high temperature in the solid state, e.g. during
homogenization, solution treatment or recrystallization [3,5]. The exact composition of the alloy
and casting conditions will directly influence the type and volume fraction of intermetallic
phases [7].

Experimental
The material used in this investigation was AA2024 aluminium alloy (composition: 1.63%Mg,
0.50%Si, 4.5%Cu, 0.50%Fe, 0.59%Mn). The alloy was prepared using high pure aluminium
(99.99%), high pure magnesium (99.99%) and preliminary alloys: Al-Si, Al-Cu, Al-Fe and Al-Mn.
These raw materials were weighed precisely and melted in an electric resistance crucible furnace.
The alloy casting was gradually refined with crucible preheating temperature which was within the
range of 690-710oC. After refining the alloy was cast into an ingots and then cooling in the air and
with furnace. The microstructure of the examined alloy after different cooling rate was observed
using optical microscope - Nikon 300 on the polished sections etched in Keller solution (0.5 % HF
in 50ml H2O). The observation of specimens morphology was performed on the scanning electron
microscope (SEM) HITACHI S-3400. The chemical composition of the intermetallics was made by
energy dispersive spectroscopy (EDS) manufactured by Thermo Noran attached to the SEM.
Quantitative analysis of the microstructure components of the cast alloy was performed by X-ray
diffraction (ARL XTR’A Thermo diffractometer).

Results and discussion

The microstructure of 2024 alloy in as-cast state (Fig.1 and 2) contains of primary aluminium
dendrites and substantial amount of different intermetallic phases constituents varied in shape, size
and distribution. They are located at the grain boundaries of α-Al and they form dendritic network
structure. Large, irregular eutectic phases and intermetallic particles had a determinal effect on the

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 Solid State Phenomena Vol. 197 239

mechanical properties of the alloy. Figure 1 presents the microstructure of 2024 aluminium alloy
cooling in furnace after solidification process. This alloy besides the eutectic phases and primary
intermetallics contains a large amount of the fine particles of hardening phases (Fig. 1). Large
number of the fine needle shaped strengthening phase are located in the boundary zone of the
dendritic network structure.
a) b)

Fig. 1. Microstructure of 2024 aluminium alloy after cooling with the furnace
Figure 2 presents the microstructure of the 2024 aluminium alloy cooled in the air after
solidification process. The microstructure of this alloy contains large, irregular eutectic phases and
intermetallic particles located mainly at the grain boundaries of α-Al.

a) b)

Fig. 2. Microstructure of 2024 aluminium alloy cooled in the air after solidification process
In order to identify the intermetallic phases in the examined alloy, series of SEM observation and
EDS analysis were performed. Figure 3 shows the SEM micrographs with corresponding EDS-
spectra of intermetallics observed in 2024 alloy cooled with the furnace. However, Fig. 4 shows the
SEM micrographs with corresponding EDS-spectra of intermetallics observed in 2024 alloy cooled
in the air. The EDS analysis indicate that the light gray oval or block particles are Al2Cu (Fig.3 and
4). Besides Al2Cu phase, other Cu containing phases were observed, namely: S-Al2CuMg,
Al4Cu2Mg8Si7 and AlCuFeMnSi. In addition to the Cu-containing intermetallics nucleating as a
black in color phases, primary eutectic β-Mg2Si particles have been also identified (Fig.3a and 4b).
Fe has a very low solid solubility in Al alloy (maximum 0.05% at equilibrium) [5], and most of
Fe in aluminium alloys form a wide variety of Fe-containing intermetallics depending on the alloy
composition and its solidification conditions [6]. In the investigated 2024 alloy Fe-containing
intermetallics such as light grey needle like Al7Cu2Fe (Fig. 4) and blocky or “Chinese script” phase
consisting of Al, Cu, Si, Mn and Fe (Fig. 4a,b) were observed.
240 Stereology and Image Analysis in Materials Science

a) b)

c) d)

e) f)

g) h)

Fig. 3. SEM microstructure of 2024 alloy after cooling in the air with particles of the phases (a,b)
and EDS spectra of the revealed particles: c) Al2CuMg, d) Al2Cu, e) Al4Cu2Mg8Si7, f) AlCuFeMnSi
g) Al7Cu2Fe,and h) Mg2Si
 Solid State Phenomena Vol. 197 241

a) b)

c) d)

e) f)

g)

Fig. 4. SEM microstructure of 2024 alloy after cooling with the furnace with particles of phases
(a,b) and EDS spectra of particles: c) Al2Cu, d) Al2CuMg, e) Al4Cu2Mg8Si7, f) AlCuMnFeSi and g)
Mg2Si
The results of SEM observation and EDS-analysis of the intermetallics particles observed in
the as-cast condition are summarized in Tab. 1.
Table 1. The chemical composition of the intermetallic phases in 2024 alloy in the as-cast state
No. of Chemical composition of determined intermetallic phases, (%wt)
Suggested type
analyzed
of phases Al Cu Si Mg Fe Mn
particles
25 S-Al2CuMg 46.2 42.0 11.8
25 Θ-Al2Cu 46.2-48.5 49.5 - 54.5
20 Al4Cu2Mg8Si7 17.2-18.5 20.3 31.40 31.0
15 Al7Cu2Fe 53.65 36.51 10.74
20 β-Mg2Si 39.1 60.9
20 AlFeCuMnSi 53.8-56.4 6.8-13.5 3.8-5.7 12.6-17.2 6.8-11.5
242 Stereology and Image Analysis in Materials Science

Since it is rather difficult to produce detailed identification of intermetallics using only one
method therefore XRD technique was utilized to provide confidence in the results of phase
classification based on metallographic study. The X-ray diffraction pattern from the examined alloy
is shown in Figure 5 and 6. The observed peaks confirmed SEM results. The majority of the peaks
in both alloy were coming from S-Al2CuMg, θ-Al2Cu, Al7Cu2Fe, β-Mg2Si and Al3Cu2Mg8Si7
phases.

Fig. 5. The X-ray diffraction pattern of the 2024 alloy after cooling with the furnace

Fig. 6. The X-ray diffraction pattern from the 2024 alloy cooled in the air
 Solid State Phenomena Vol. 197 243

Summary
The microstructure of the 2024 aluminium alloys in the as-cast state cooled in the air solidification
process contains exactly the same eutectic phases and intermetallic particles as it was reaveled in
the alloy cooled with the furnace. In both cases, at least six distinct eutectic phases and intermetallic
particles were observed, namely: S-Al2CuMg, θ-Al2Cu, Al7Cu2Fe, β-Mg2Si, AlCuFeMnSi and
Al3Cu2Mg8Si7. SEM analysis and XRD scan exhibit good conformity in the evaluation of phase
particles in the examined 2024 aluminium alloy. It has been proved that both technique are able to
carry out successfully simple and fast determination of the phases precipitates during solidification
and cooling process.

Acknowledgment
This work was carried out with the financial support of the Ministry of Science and Higher
Education under grant No. N N507 247940

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Stereology and Image Analysis in Materials Science
10.4028/www.scientific.net/SSP.197

Analysis of Intermetallic Phases in 2024 Aluminium Alloy

10.4028/www.scientific.net/SSP.197.238

DOI References
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the microstructure of AA2024-T3?, Corr. Sci. 51 (2009) 1565-1568.
http://dx.doi.org/10.1016/j.corsci.2009.05.001
[2] G. Wang, B. Xiong, Y. Zhang, Z. Li, P. Li, Microstructural characterization of as-cast and homogenized
2D70 aluminium alloy, Int. J. Min. Met. Mater. 16 (2009) 427-431.
http://dx.doi.org/10.1016/S1674-4799(09)60075-3
[6] Y. Ji, F. Guo, Y. Pan, Microstructural characteristics and paint-bake response of Al-Mg-Si-Cu alloy, T.
Nonferr. Metal. Soc. 18 (2008) 126-129.
http://dx.doi.org/10.1016/S1003-6326(08)60023-0