Distortion in a 7xxx Aluminum Alloy during Liquid Phase Sintering

The distortion in a sintered 7xxx aluminum alloy, Al-7Zn-2.5Mg-1Cu (wt. pct), has been investigated by sintering three rectangular bars in each batch at 893 K (620 °C) for 0 to 40 minutes in nitrogen, followed by air or furnace cooling. They were placed parallel to each other, equally spaced apart at 2 mm, with their long axes being perpendicular to the incoming nitrogen flow. Pore evolution in each sample during isothermal sintering was examined metallographically. The compositional changes across sample mid-cross section and surface layers were analyzed using energy dispersive X-ray spectroscopy and X-ray photoelectron spectroscopy depth profiling, respectively. The two outer samples bent toward the middle one, while the middle sample was essentially distortion free after sintering. The distortion in the outer samples was a result of differential shrinkage between their outer and inner surfaces during isothermal sintering. The porous outer surface showed an enrichment of oxygen around the large pores as well as lower magnesium and zinc contents than the interior and inner surface of the same sample, while the inner surface was distinguished by the presence of AlN. The differential shrinkage was caused by different oxygen contents in local sintering atmosphere and unbalanced loss of magnesium and zinc between the outer and inner surfaces.