Age‑hardenable aluminium alloys owe their strengthening behaviour to nanoscale precipitates and solute clusters whose structure and distribution remain the focus of extensive research. Recent work from our group combines advanced TEM techniques—HAADF‑STEM, 4D‑STEM and scanning precession electron diffraction (SPED)—to resolve early‑stage clustering, GP‑zones, and metastable precipitates in Al–Mg–Si and Al–Zn–Mg alloys at near‑atomic resolution. These methods enable robust phase mapping and quantification of structural variations across grains, interfaces, deformed regions, and precipitation‑free zones.

Building on our latest studies, we show how solute clustering during natural ageing, quench sensitivity, and the competition between GP‑zones and early precipitate variants influence alloy hardening response. SPED‑based phase mapping further reveals complex precipitation sequences and crystallographic relationships that govern mechanical performance.

The results demonstrate how combining multiple diffraction‑ and imaging‑based TEM modalities provides a comprehensive understanding of precipitation behaviour. This knowledge supports alloy design and optimization efforts carried out in collaboration with SINTEF and the Norwegian aluminium industry and forms a foundation for ongoing developments within the new SFI FAST centre on future aluminium structures.