High Strength Aluminum Additive Manufacturing
- Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
- Boeing Research and Technology, Ladson, SC (United States)
High-strength aluminum alloys for elevated temperature applications are desirable to replace heavier and more expensive titanium alloys. However, most aluminum alloys lose a large fraction of their strength at temperatures above approximately 200°C. ORNL has designed DuAlumin-3D, an alloy with nominal composition Al-9Ce-4Ni-0.5Mn-1Zr (wt.%), which utilizes the high cooling rates in additive manufacturing (AM) to achieve a refined microstructure, and thermally stable mechanical properties. DuAlumin-3D was fabricated by laser powder bed fusion and tested for its tensile mechanical properties across a range of temperature, and for its room temperature high-cycle fatigue resistance. The alloy was tested in both the as-printed and heat treated conditions, and both parallel and perpendicular to the AM build direction. The alloy was found to have anisotropic mechanical behavior in the as-printed state, but the anisotropy significantly decreased (both for tensile and fatigue properties) following heat treatment. The tensile properties significantly out-performed benchmark wrought 2219-T61 across a wide temperature range. The room temperature fatigue performance was approximately similar to 2219-T61.
- Research Organization:
- Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States); Boeing Research and Technology, Ladson, SC (United States)
- Sponsoring Organization:
- USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Materials & Manufacturing Technologies Office (AMMTO)
- DOE Contract Number:
- AC05-00OR22725
- OSTI ID:
- 2301648
- Report Number(s):
- ORNL/TM--2024/3244; CRADA/NFE-20-08161; CRADA/NFE-20-08161
- Country of Publication:
- United States
- Language:
- English
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