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Formation of Metastable Phases in the Zr–Al System by Electron Beam Deposition

Zr–Al binary alloy films with a thickness of about 2 µm prepared by electron beam deposition were found to exist in an amorphous phase in the composition range of 15 to 60 at% Al, although no amorphous phase has been reported in rapidly solidified Zr–Al alloys. The deviation of the Al content from the range causes the formation of mixed hcp-Zr+metastable bcc-Zr phases in the range of 5 to 15 Al at% and L12-type Al3Zr phases in the range of 60 to 85 at% Al. The hardness of the amorphous Zr–Al films increases from 5.98 to 9.18 GPa as the Al content increases from 20 to 58 at%.