Nano characterization to resolve precipitate free zone formation of an Al alloy

Precipitation-hardenable aluminum alloys in extruded structures can lose ductility due to 'precipitate free zones' (PFZs) along grain boundaries, formed by slow cooling and aging. These nanoscale PFZs, typically tens of nanometers, vary with processing conditions. Current (S)TEM imaging methods face statistical and 2D sectioning challenges, affecting measurement accuracy. To address this, a multi-modal approach combines scanning electron microscopy, plasma focused ion beam (pFIB) for 3D imaging, and synchrotron fluorescence imaging for high-resolution spatial and chemical data. This facilitates quantitative comparisons with simulations to optimize alloy properties for safety applications.