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Title: Ageless Aluminum-Cerium-Based Alloys in High-Volume Die Casting for Improved Energy Efficiency

Abstract

Strong chemical reactions between Al and Ce lead to the formation of intermetallics with exceptional thermal stability. The rapid formation of intermetallics directly from the liquid phase during solidification of Al-Ce alloys leads to an ultrafine microconstituent structure that effectively strengthens as-cast alloys without further microstructural optimization via thermal processing. Die casting is a high-volume manufacturing technology that accounts for greater than 40% of all cast Al products, whereas Ce is highly overproduced as a waste product of other rare earth element (REE) mining. Reducing heat treatments would stimulate significant improvements in manufacturing energy efficiency, exceeding (megatonnes/year) per large-scale heat-treatment line. In this study, multiple compositions were evaluated with wedge mold castings to test the sensitivity of alloys to the variable solidification rate inherent in high-pressure die casting. Once a suitable composition was determined, it was successfully demonstrated at 800 lbs/h in a 600-ton die caster, after which the as-die cast parts performed similarly to ubiquitous A380 in the same geometry without requiring heat treatment. Furthermore, this work demonstrates the compatibility of Al REE alloys with high-volume die-casting applications with minimal heat treatments.

Authors:
 [1]; ORCiD logo [1]; ORCiD logo [2]; ORCiD logo [1];  [3]; ORCiD logo [4]; ORCiD logo [4];  [5];  [5];  [6]; ORCiD logo [1]
  1. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
  2. Univ. of Tennessee, Knoxville, TN (United States)
  3. Eck Industries, Inc., Manitowoc, WI (United States)
  4. Ames Lab., Ames, IA (United States)
  5. Shiloh Industries, Inc., Plymouth, MI (United States)
  6. Tennessee Tool and Engineering, Inc., Oak Ridge, TN (United States)
Publication Date:
Research Org.:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE)
OSTI Identifier:
1439950
Grant/Contract Number:  
AC05-00OR22725
Resource Type:
Journal Article: Accepted Manuscript
Journal Name:
JOM. Journal of the Minerals, Metals & Materials Society
Additional Journal Information:
Journal Volume: 70; Journal Issue: 6; Journal ID: ISSN 1047-4838
Publisher:
Springer
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE

Citation Formats

Stromme, Eric T., Henderson, Hunter B., Sims, Zachary C., Kesler, Michael S., Weiss, David, Ott, Ryan T., Meng, Fanqiang, Kassoumeh, Sam, Evangelista, James, Begley, Gerald, and Rios, Orlando. Ageless Aluminum-Cerium-Based Alloys in High-Volume Die Casting for Improved Energy Efficiency. United States: N. p., 2018. Web. doi:10.1007/s11837-018-2861-9.
Stromme, Eric T., Henderson, Hunter B., Sims, Zachary C., Kesler, Michael S., Weiss, David, Ott, Ryan T., Meng, Fanqiang, Kassoumeh, Sam, Evangelista, James, Begley, Gerald, & Rios, Orlando. Ageless Aluminum-Cerium-Based Alloys in High-Volume Die Casting for Improved Energy Efficiency. United States. doi:10.1007/s11837-018-2861-9.
Stromme, Eric T., Henderson, Hunter B., Sims, Zachary C., Kesler, Michael S., Weiss, David, Ott, Ryan T., Meng, Fanqiang, Kassoumeh, Sam, Evangelista, James, Begley, Gerald, and Rios, Orlando. Wed . "Ageless Aluminum-Cerium-Based Alloys in High-Volume Die Casting for Improved Energy Efficiency". United States. doi:10.1007/s11837-018-2861-9. https://www.osti.gov/servlets/purl/1439950.
@article{osti_1439950,
title = {Ageless Aluminum-Cerium-Based Alloys in High-Volume Die Casting for Improved Energy Efficiency},
author = {Stromme, Eric T. and Henderson, Hunter B. and Sims, Zachary C. and Kesler, Michael S. and Weiss, David and Ott, Ryan T. and Meng, Fanqiang and Kassoumeh, Sam and Evangelista, James and Begley, Gerald and Rios, Orlando},
abstractNote = {Strong chemical reactions between Al and Ce lead to the formation of intermetallics with exceptional thermal stability. The rapid formation of intermetallics directly from the liquid phase during solidification of Al-Ce alloys leads to an ultrafine microconstituent structure that effectively strengthens as-cast alloys without further microstructural optimization via thermal processing. Die casting is a high-volume manufacturing technology that accounts for greater than 40% of all cast Al products, whereas Ce is highly overproduced as a waste product of other rare earth element (REE) mining. Reducing heat treatments would stimulate significant improvements in manufacturing energy efficiency, exceeding (megatonnes/year) per large-scale heat-treatment line. In this study, multiple compositions were evaluated with wedge mold castings to test the sensitivity of alloys to the variable solidification rate inherent in high-pressure die casting. Once a suitable composition was determined, it was successfully demonstrated at 800 lbs/h in a 600-ton die caster, after which the as-die cast parts performed similarly to ubiquitous A380 in the same geometry without requiring heat treatment. Furthermore, this work demonstrates the compatibility of Al REE alloys with high-volume die-casting applications with minimal heat treatments.},
doi = {10.1007/s11837-018-2861-9},
journal = {JOM. Journal of the Minerals, Metals & Materials Society},
issn = {1047-4838},
number = 6,
volume = 70,
place = {United States},
year = {2018},
month = {4}
}

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