Effect of Post-Fabricated Aging on Microstructure and Mechanical Properties in Underwater Friction Stir Additive Manufacturing of Al–Zn–Mg–Cu Alloy

The fabricated Al–Zn–Mg–Cu alloy build has low mechanical properties due to the dissolution of strengthening precipitates back into the matrix during friction stir additive manufacturing (FSAM). Post-fabricated aging was considered an effective approach to improve the mechanical performance of the build. In this study, various post-fabricated aging treatments were applied in the underwater FSAM of Al–7.5 Zn–1.85 Mg–1.3 Cu–0.135 Zr alloy. The effect of the post-fabricated aging on the microstructure, microhardness, and local tensile properties of the build was investigated. The results indicated that over-aging occurred in the low hardness zone (LHZ) of the build after artificial aging at 120 °C for 24 h as the high density of grain boundaries, subgrain boundaries, dislocations, and Al(3)Zr particles facilitated the precipitation. Low-temperature aging treatment can effectively avoid the over-aging problem. After aging at 100 °C for 48 h, the average microhardness value of the build reached 178 HV; the yield strength of the LHZ and high hardness zone (HHZ) was 453 MPa and 463 MPa, respectively; and the ultimate tensile strength of the LHZ and HHZ increased to 504 MPa and 523 MPa, respectively.