Al-Cu-Ce(-Zr) alloys with an exceptional combination of additive processability and mechanical properties

Bahl, Sumit; Sisco, Kevin; Yang, Ying; Theska, Felix; Primig, Sophie; Allard Jr., Lawrence F.; Michi, Richard A.; Fancher, Christopher; Stump, Benjamin; Dehoff, Ryan; Shyam, Amit; Plotkowski, Alex

doi:10.1016/j.addma.2021.102404

Al-Cu-Ce(-Zr) alloys with an exceptional combination of additive processability and mechanical properties

Journal Article · Sat Oct 16 04:00:00 EDT 2021 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2021.102404· OSTI ID:1838985

Bahl, Sumit ^[1]; Sisco, Kevin ^[2]; ^[1]; Theska, Felix ^[3]; Primig, Sophie ^[3]; ^[1]; Michi, Richard A. ^[1]; ^[1]; Stump, Benjamin ^[1]; ^[4]; ^[1]; ^[1]

Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Materials Science & Technology Division
Univ. of Tennessee, Knoxville, TN (United States)
Univ. of New South Wales, Sydney, NSW (Australia)
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Science Division

In this study, high-temperature Al-9Cu-6Ce and Al-9Cu-6Ce-1Zr (wt%) alloys were designed for fabrication with laser powder bed fusion additive manufacturing (AM). An ultra-fine eutectic structure comprising FCC-Al and particles of a previously unidentified Al₈Cu₃Ce intermetallic phase was obtained with an inter-particle spacing of approximately 280 nm. The inherent hot-tearing resistance of the eutectic alloys resulted in > 99.5% relative density. A thermodynamic model suggested improved hot-tearing resistance of the present alloys relative to the benchmark AM AlSi10Mg alloy. The Al-Cu-Ce alloy exhibited superior thermal stability with approximately 75% of the as-fabricated hardness retained after 200 h exposure at 400 °C, owed to the coarsening resistance of the intermetallic particles. The Al-Cu-Ce-Zr alloy age-hardened through precipitation of nanoscale Al₃Zr precipitates. The aged microstructure was stable at 350 °C with a 13% higher hardness after 200 h exposure compared to the as-fabricated condition. The combined influence of ultra-fine spacing and coarsening resistance of the intermetallic particles resulted in the higher yield strength of the Al-Cu-Ce and Al-Cu-Ce-Zr alloys compared to AM AlSi10Mg and Scalmalloy at temperatures greater than 200 °C. This work essentially demonstrates that thermally stable Al alloys with exceptional mechanical properties can be produced by additive manufacturing.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE); USDOE Office of Science (SC); Australian Research Council (ARC)

Grant/Contract Number:: AC05-00OR22725; AC02-06CH11357

OSTI ID:: 1838985

Alternate ID(s):: OSTI ID: 1827230
OSTI ID: 1828053
OSTI ID: 1828943

Journal Information:: Additive Manufacturing, Journal Name: Additive Manufacturing Journal Issue: Part B Vol. 48; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Al-Cu-Ce(-Zr) alloys with an exceptional combination of additive processability and mechanical properties

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