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•Cu precipitation was promoted by the addition of Al.•The dislocation density after tempering was higher in Al-added steel.•The increase in Cu particles and dislocation density caused an increase in hardness.•The composition of Cu clusters deviated considerably from the equilibrium value.
The effect of Al addition on the evolution of Cu precipitates in an Fe-2Cu-1.5Mn-1.5Ni alloy during tempering at 500 °C was investigated. The atomic-scale characterization revealed that the Al addition enhanced Cu nucleation in the matrix and on dislocations (or PAGB). Furthermore, the dislocation density was greater in steel with Al, probably because a larger number of Cu particles delayed the recovery and annihilation of dislocations in the martensite matrix, which resulted in a significant increase of hardness after tempering. The concentrations of Cu and Mn in Cu clusters were lower and those of Al and Ni were higher than the values of both metastable equilibrium bcc-Cu and equilibrium fcc-Cu phases.