This study investigates the role of Ni addition on the precipitation behavior of Al-Mg-Si alloys, with particular emphasis on the solubility of trace elements during artificial aging. Comparative experiments were performed on a Base alloy (Al-0.73Mg-0.42Si, wt.%) and a Ni-added alloy (Al-0.73Mg-0.42Si-0.11Ni, wt.%) subjected to aging at 200 °C and 260 °C. The results reveal that Ni addition significantly enhances the age-hardening response by refining βʺ precipitates, which is primarily attributed to heterogeneous nucleation of Si clusters at Ni-rich clusters, regardless of aging temperature. Whereas at 260 °C, Ni segregation at the βʺ and βʹ precipitate interfaces becomes more pronounced, contributing to improved thermal stability during over-aging. Ni exhibits solute partitioning behavior similar to Cu forming sub-unit structure at the low-density cylinder structure of βʺ and or habit planes of βʹ. However, unlike Cu, Ni is ultimately expelled as a pure phase during prolonged over-aging, which is presumed to be because Ni cannot be stabilized by forming quaternary precipitates such as C or Qʹ phases. Atom probe tomography demonstrates that the ratio between two different solute states of Ni is dependent on solubility at the aging temperature, and this mainly determines how many Ni solutes contributes to solute segregation at the matrix/precipitate boundary of βʺ and βʹ. These results emphasize the importance of solubility at the aging temperature in governing the role of low-solubility trace elements and suggest that Ni provides a unique alternative to Cu for tailoring precipitation pathways in Al-Mg-Si alloys.
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