Experimental Characterization and Finite Element Simulation of the Microstructure and Mechanical Properties in 0.2% Sc-Modified A242 Aluminum Alloy

Scandium (Sc) is well recognized as a potent grain refiner, yet optimizing its addition amount in the Al-Cu-Mg-Ni-Fe (A242) system remains a longstanding challenge, critically important for material performance in high-temperature automotive and aerospace applications. The present work, therefore, presents a study of low-Sc modified A242 alloys, demonstrating that 0.2 wt.% Sc microalloying of the system has a pronounced effect on its solidification-driven microstructural evolution, improving the high-temperature formability of the alloy over a 20–200 °C temperature range. The study demonstrates that this addition triggers a dramatic columnar-to-equiaxed grain transition, reducing the average grain size by 90.8% (from 400 ± 100 μm to 37 ± 10 μm) and fragmenting the brittle, continuous intermetallic network into a highly uniform architecture. Uniaxial compression testing revealed that, while the as-cast solid-solution alloy slightly reduces room-temperature strength due to solute trapping, it delivers an exceptional 142% increase in strain-to-failure at 200 °C (exceeding 0.8 mm) compared to the base alloy. This significant enhancement in ductility is driven by thermally stable Al3Sc dispersoids that exert Zener pinning pressure, halting thermal grain coarsening and activating superplastic deformation mechanisms. These findings support the development of advanced thermoforming applications, with the finite element (FE) model predicting process improvements that enhance manufacturing efficiency. This work presents a validation and simulation-ready material framework that substantiates the viability of low-Sc-modified A242 alloys for such operations.