The electrochemistry of Zr͑IV͒ and Zr͑II͒ and the electrodeposition of Al-Zr alloys were examined in the Lewis acidic 66.7-33.3 mol % aluminum chloride-1-ethyl-3-methylimidazolium chloride molten salt at 353 K. The electrochemical reduction of Zr͑IV͒ to Zr͑II͒ is complicated by the precipitation of ZrCl 3 ; however, solutions of Zr͑II͒ can be prepared by reducing Zr͑IV͒ with Al wire. Al-Zr alloys can be electrodeposited from plating baths containing either Zr͑IV͒ or Zr͑II͒, but for a given concentration and current density, baths containing Zr͑IV͒ lead to Al-Zr alloys with the higher Zr content. This result was traced to the diminutive concentration-dependent diffusion coefficient for Zr͑II͒. It was possible to prepare Al-Zr alloys containing up to ϳ17% atomic fraction ͑atom %͒ Zr. The structure of these deposits depended on the Zr content. Alloys containing less than 5 atom % Zr could be indexed to a disordered face-centered cubic structure similar to pure Al, whereas alloys containing ϳ17 atom % Zr were completely amorphous ͑metallic glass͒. The chloride pitting potentials of alloys with more than 8 atom % Zr were approximately ϩ0.3 V relative to pure Al.The maximum solubility of zirconium in face-centered cubic ͑fcc͒ aluminum is 0.08% atomic fraction ͑atom %͒. This occurs at the peritectic transformation point at 660.5°C. At room temperature, zirconium has negligible solubility in aluminum. 1 However like most aluminum-transition metal alloys, supersaturated solid solutions greatly exceeding the equilibrium solubility can be obtained by nonequilibrium processing methods. For example, solid solutions containing up to 3.0 atom % zirconium have been produced by rapid solidification 2-6 and vapor deposition. 7 The Al-Zr solid solution, although metastable, shows good thermal stability up to ϳ400-450°C. This observation is consistent with the general trend that the thermal stability of the solid solution is related to the melting point of the alloying addition; i.e., the higher the melting point, the more stable the solid solution. 8 The thermal decomposition of the supersaturated solid solution results in the nucleation of a metastable Al 3 Zr phase having an ordered cubic L1 2 structure (Cu 3 Au-type͒ 5,6,9-13 and eventually the equilibrium Al 3 Zr phase having a tetragonal structure. These two phases, cubic Al 3 Zr and tetragonal Al 3 Zr, have also been observed in supersaturated Al-Zr solid solutions produced by rapid quenching. 14 The properties of aluminum and its alloys are significantly altered by the addition of zirconium. The rapid solidification of binary Al-Zr alloys with more than 0.15 atom % zirconium produces considerable grain refinement, 15,16 resulting in aluminum grain sizes typically less than 10 m. The general explanation for this phenomenon is that L1 2 Al 3 Zr acts as a low-energy nucleation site for fcc Al due to the similar crystal structures. Rapid quenching is required to ensure that the Al 3 Zr solidifies with the metastable L1 2 structure rather than the equilibrium tetragonal structure...