On the high-temperature stability of the Al8Cu3Ce intermetallic in an additively manufactured Al-Cu-Ce-Zr alloy

Theska, Felix; Yang, Ying; Sisco, Kevin D.; Plotkowski, Alex; Primig, Sophie

doi:10.1016/j.matchar.2022.112109

On the high-temperature stability of the Al₈Cu₃Ce intermetallic in an additively manufactured Al-Cu-Ce-Zr alloy

Journal Article · Tue Jul 19 00:00:00 EDT 2022 · Materials Characterization

DOI:https://doi.org/10.1016/j.matchar.2022.112109· OSTI ID:1877487

Theska, Felix ^[1]; ^[2]; Sisco, Kevin D. ^[3]; ^[2]; Primig, Sophie ^[1]

UNSW, Sydney (Australia)
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Univ. of Tennessee, Knoxville, TN (United States)

High-temperature resistant eutectic Al alloys are crucial materials for lightweight and energy efficient design in the automotive and aviation industries. Additive manufacturing offers a pathway to refine eutectic microstructures and develop novel alloys with superior high-temperature strength. High-volume fraction intermetallic Al-Cu-Ce alloys have been developed to deliver high-temperature strength in combination with reduced hot-tearing susceptibility. Zr is added to provide additional strengthening via nanoscale Al₃Zr precipitation, and to stabilize and avoid coarsening of the Al₈Cu₃Ce phase. However, the detailed interaction between Zr and Al₈Cu₃Ce remains unexplored. In this work, we show with synchrotron X-ray diffraction that laser powder bed fusion fabricated Al-Cu-Ce and Al-Cu-Ce-Zr alloys contain predominantly the Al₈Cu₃Ce intermetallic in the as-fabricated condition. Heat treatment of the Al-Cu-Ce alloy results in the Al₈Cu₃Ce → Al₈Cu₄Ce phase transformation. In the Al-Cu-Ce-Zr alloy, minor fractions of (Al,Cu,Si)₄Ce and Al₂Cu-θ are found in the as-fabricated condition, while Al₈Cu₃Ce remains stable during heat treatment. Atom probe microscopy quantifies intermetallic stoichiometries and reveals how Zr is enriched at the Al-matrix/Al₈Cu₃Ce interface acting as a diffusion barrier against solute exchange. Calibrated thermodynamic modeling underpins this as a kinetic effect. Here, a qualitative microstructural model summarizes, how Zr stabilizes Al₈Cu₃Ce against phase transformations and coarsening.

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), Basic Energy Sciences (BES). Scientific User Facilities Division

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

OSTI ID:: 1877487

Alternate ID(s):: OSTI ID: 1961109

Journal Information:: Materials Characterization, Journal Name: Materials Characterization Vol. 191; ISSN 1044-5803

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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On the high-temperature stability of the Al8Cu3Ce intermetallic in an additively manufactured Al-Cu-Ce-Zr alloy

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On the high-temperature stability of the Al₈Cu₃Ce intermetallic in an additively manufactured Al-Cu-Ce-Zr alloy