The present investigation demonstrated the manufacturing of Al – x wt.% Zn (x = 0, 10, 20, & 30) die-casting alloys through liquid metallurgy route followed by squeezing and hot-extrusion processes. The phase analyses and microstructural evolutions were investigated by x-ray diffractometer and electron microscopes (FESEM with EDAX, EBSD, and HRTEM) respectively. The mechanical behaviour was examined by the Vickers micro-hardness and tensile tests. The results revealed that the solid solution formation of the Al-Zn phase (α+η) along with an individual α-Al phase was obtained. The distribution of (α+η) nanocrystallites nucleates in the α-Al and (α+η) major phases was observed with the formation of spider-leg like dislocations due to thermal misfit. Hot-extruded alloys exhibited different structural changes, namely, grains flow pattern, cracking/fragmentation, redistribution, shrinkages, porosities, and micron-sized voids. Al-20Zn alloy exhibited improved microstructural observation whereas Al-30Zn alloy displayed more shrinkages and porosities. The EBSD analyses illustrated the variation in grain flow patterns (coloured maps) and deformation mean uniform density (pole figures) values with the solid solution of Zn addition. The Al – 20Zn alloy exhibited improved mechanical properties (strength and ductility) owing to the effective solid solution of α-Al with the precipitated coherent α+η phases in addition to the absence of defects which can be recommended for die-casting products.

目前的研究表明，通过液态冶金工艺，然后进行挤压和热挤压工艺，可以制造出Al-x wt。％Zn（x = 0、10、20和30）的压铸合金。分别通过X射线衍射仪和电子显微镜（带有EDAX的FESEM，EBSD和HRTEM）研究了相分析和微观结构演变。通过维氏显微硬度和拉伸试验检查了机械性能。结果表明，获得了Al-Zn相（α+η）与单独的α-Al相的固溶体形成。观察到（α+η）纳米微晶在α-Al和（α+η）主相中的分布，并且由于热失配而形成了蜘蛛腿状的位错。热挤压合金表现出不同的结构变化，即晶粒流态，裂纹/碎片，重新分布，收缩，孔隙和微米级空隙。Al-20Zn合金表现出改善的显微组织观察，而Al-30Zn合金表现出更多的收缩率和孔隙率。EBSD分析说明了固溶添加Zn时晶粒流型（彩色图）和变形平均均匀密度（极图）值的变化。Al – 20Zn合金由于具有沉淀的相干α+η相的有效固溶的α-Al固溶体，而且不存在缺陷（建议用于压铸产品），因此具有改进的机械性能（强度和延展性）。EBSD分析说明了固溶添加Zn时晶粒流型（彩色图）和变形平均均匀密度（极图）值的变化。Al – 20Zn合金由于具有沉淀的相干α+η相的有效固溶的α-Al固溶体，而且不存在缺陷（建议用于压铸产品），因此具有更好的机械性能（强度和延展性）。EBSD分析说明了固溶添加Zn时晶粒流型（彩色图）和变形平均均匀密度（极图）值的变化。Al – 20Zn合金由于具有沉淀的相干α+η相的有效固溶的α-Al固溶体，而且不存在缺陷（建议用于压铸产品），因此具有改进的机械性能（强度和延展性）。