Low density aluminum alloys and method

A method for producing a low-density, aluminum alloy, consolidated articles, comprising the steps of:

• compacting particles composed of a low density aluminum-base alloy, consisting essentially of the formula Al.sub.bal Zr.sub.a Li.sub.b Mg.sub.c T.sub.d, wherein T is at least one element selected from the group consisting of Cu, Si, Sc, Ti, V, Hf, Be, Cr, Mn, Fe, Co and Ni, "a" ranges from about 0.25-2 wt %, "b" ranges from about 2.7-5 wt %, "c" ranges from about 0.5-8 wt %, "d" ranges from about 0.5-5% and the balance is aluminum, said alloy having a primary, cellular dendritic, fine-grain, supersaturated aluminum alloy solid solution phase with filamentary, intermetallic phases of the constituent elements dispersed therein, and said intermetallic phases having width dimensions of not more than about 100 nm;
• heating said alloy during said compacting step to a temperature of not more than about 400.degree. C. to minimize coarsening of said intermetallic phases;
• solutionizing said compacted alloy by heat treatment at a temperature ranging from about 500.degree. to 550.degree. C. for a period of approximately 0.5 to 5 hrs to convert elements from micro-segregated and precipitated phases into said aluminum solid solution phase;
• and
• quenching said compacted alloy in a fluid bath.