Suppress defect-induced plastic instability to achieve superior strength-ductility combination of spray formed 7050 Al alloy

This research aimed to enhance the strength and ductility of spray formed (SFed) 7050 aluminum (Al) alloy through hot extrusion and subsequent heat treatment. Microstructure and mechanical properties evolution during these processes were investigated. It was found that the low densification of the SFed 7050 Al alloy due to various defects such as pores, with an average size of 7.6 μm and an area fraction of 3.7 % could be notably enhanced by hot extrusion, even achieving a level close to theoretical density. This process led to a transformation of grains from equiaxed to elongated shapes along extrusion direction and significant grain refinement, exhibiting a strong fiber texture. While the employed extrusion ratio exceeds 16 with proper heat treatment, the SFed 7050 Al alloys achieves superior strength-ductility combination compared with reported Al alloys. The achieved high performance should be attributed to the grain refinement, strong texture and high densification that suppress defect-induced plastic instability. Furthermore, the combination of hot extrusion and heat treatment, provides an effective way to enhance strength and ductility for SFed 7050 Al alloy.