Surface-hardened aluminum-rare earth alloys and methods of making the same

Rios, Orlando; Babu, Sudarsanam Suresh; Dehoff, Ryan R.; Ott, Ryan; Plotkowski, Alex J.; Sims, Zachary C.; Sridharan, Niyanth; Weiss, David; Henderson, Hunter B.

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Title: Surface-hardened aluminum-rare earth alloys and methods of making the same

Abstract

Embodiments of surface-hardened aluminum-rare earth alloys and methods of making the alloys are disclosed. In some embodiments, the alloy comprises aluminum and 4 wt % to 60 wt % of a rare earth component X having a maximum solid solubility of ≤0.5 wt % in aluminum. The surface-hardened alloy component has an alloy bulk portion and a hardened alloy surface portion. At least a portion of the hardened alloy surface portion has a Vickers hardness that is at least 30% greater than a Vickers hardness of the alloy bulk portion.

Inventors:: Rios, Orlando; Babu, Sudarsanam Suresh; Dehoff, Ryan R.; Ott, Ryan; Plotkowski, Alex J.; Sims, Zachary C.; Sridharan, Niyanth; Weiss, David; Henderson, Hunter B.

Issue Date:: 2020-03-10

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

Sponsoring Org.:: USDOE

OSTI Identifier:: 1637860

Patent Number(s):: 10584403

Application Number:: 15/650,743

Assignee:: UT-Battelle, LLC (Oak Ridge, TN); University of Tennessee Research Foundation (Knoxville, TN); Iowa State University Research Foundation, Inc. (Ames, IA); Eck Industries Incorporated (Manitowoe, WI)

Patent Classifications (CPCs):: B - PERFORMING OPERATIONS B22 - CASTING B22D - CASTING OF METALS

B - PERFORMING OPERATIONS B23 - MACHINE TOOLS B23K - SOLDERING OR UNSOLDERING

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B - PERFORMING OPERATIONS B22 - CASTING B22D - CASTING OF METALS
B22D21/007 - {with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C}

B - PERFORMING OPERATIONS B23 - MACHINE TOOLS B23K - SOLDERING OR UNSOLDERING
B23K26/354 - by melting

B - PERFORMING OPERATIONS B33 - ADDITIVE MANUFACTURING TECHNOLOGY B33Y - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
B33Y10/00 - Processes of additive manufacturing
B33Y80/00 - Products made by additive manufacturing

C - CHEMISTRY C21 - METALLURGY OF IRON C21D - MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS
C21D1/10 - by electric induction

C - CHEMISTRY C22 - METALLURGY C22C - ALLOYS
C22C1/03 - using master alloys
C22C1/0416 - {Aluminium-based alloys}
C22C21/00 - Alloys based on aluminium
C22C21/06 - with magnesium as the next major constituent
C22C21/08 - with silicon
C22C21/16 - with magnesium
C22C23/06 - with a rare earth metal as the next major constituent
C22C28/00 - Alloys based on a metal not provided for in groups C22C5/00 - C22C27/00
C22C30/06 - containing zinc

C - CHEMISTRY C22 - METALLURGY C22F - CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
C22F1/04 - of aluminium or alloys based thereon

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02P - CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
Y02P10/25 - by increasing the energy efficiency of the process

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DOE Contract Number:: AC05-00OR22725; AC02-07CH11358

Resource Type:: Patent

Resource Relation:: Patent File Date: 07/14/2017

Country of Publication:: United States

Language:: English

Subject:: 36 MATERIALS SCIENCE

Citation Formats


                    Rios, Orlando, Babu, Sudarsanam Suresh, Dehoff, Ryan R., Ott, Ryan, Plotkowski, Alex J., Sims, Zachary C., Sridharan, Niyanth, Weiss, David, and Henderson, Hunter B. Surface-hardened aluminum-rare earth alloys and methods of making the same.  United States: N. p., 2020. 
        Web.

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                    Rios, Orlando, Babu, Sudarsanam Suresh, Dehoff, Ryan R., Ott, Ryan, Plotkowski, Alex J., Sims, Zachary C., Sridharan, Niyanth, Weiss, David, & Henderson, Hunter B. Surface-hardened aluminum-rare earth alloys and methods of making the same.  United States.

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                    Rios, Orlando, Babu, Sudarsanam Suresh, Dehoff, Ryan R., Ott, Ryan, Plotkowski, Alex J., Sims, Zachary C., Sridharan, Niyanth, Weiss, David, and Henderson, Hunter B. Tue .  
        "Surface-hardened aluminum-rare earth alloys and methods of making the same".  United States.  https://www.osti.gov/servlets/purl/1637860.

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@article{osti_1637860,

  title        = {Surface-hardened aluminum-rare earth alloys and methods of making the same},

  author       = {Rios, Orlando and Babu, Sudarsanam Suresh and Dehoff, Ryan R. and Ott, Ryan and Plotkowski, Alex J. and Sims, Zachary C. and Sridharan, Niyanth and Weiss, David and Henderson, Hunter B.},

  abstractNote = {Embodiments of surface-hardened aluminum-rare earth alloys and methods of making the alloys are disclosed. In some embodiments, the alloy comprises aluminum and 4 wt % to 60 wt % of a rare earth component X having a maximum solid solubility of ≤0.5 wt % in aluminum. The surface-hardened alloy component has an alloy bulk portion and a hardened alloy surface portion. At least a portion of the hardened alloy surface portion has a Vickers hardness that is at least 30% greater than a Vickers hardness of the alloy bulk portion.},

  doi          = {},

  journal      = {},
number       = ,

  volume       = ,

  place        = {United States},

  year         = {2020},

  month        = {3}

}

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Works referenced in this record:

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Effect of substituting cerium-rich mischmetal with lanthanum on microstructure and mechanical properties of die-cast Mg–Al–RE alloys
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Materials & Design, Vol. 30, Issue 7, p. 2372-2378
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Process for Isolation and Purification of Astatine-211
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Similar Records

Title: Surface-hardened aluminum-rare earth alloys and methods of making the same

Abstract

Citation Formats

Selected Processing for Non-equilibrium Light Alloys and Products patent-application, October 2003

Evaluation of an Al-Ce alloy for laser additive manufacturing journal, March 2017

Characterization and wear resistance of laser surface melting AZ91D alloy journal, May 2008

Method for making a light metal-rare earth metal alloy patent, August 1991

Multi-element heat-resistant aluminum alloy material with high strength and preparation method thereof patent-application, June 2012

Production of glassy metallic layers by laser surface treatment journal, February 2003

Method and apparatus for shaping semisolid metals patent-application, December 2004

Mechanical Properties of Nanometric Al2O3 Particulate-Reinforced Al-Al11Ce3 Composites Produced by Friction Stir Processing journal, January 2010

The microstructure and mechanical properties of unidirectionally solidified Al−Si alloys journal, June 1989

Effect of substituting cerium-rich mischmetal with lanthanum on microstructure and mechanical properties of die-cast Mg–Al–RE alloys journal, August 2009

Process for Isolation and Purification of Astatine-211 patent-application, February 2016

Cerium-Based, Intermetallic-Strengthened Aluminum Casting Alloy: High-Volume Co-product Development journal, May 2016

High strength aluminum alloy patent, July 1995

Characterization of Near Net-Shape Castable Rare Earth Modified Aluminum Alloys for High Temperature Application book, January 2016

On the Selective Laser Melting (SLM) of the AlSi10Mg Alloy: Process, Microstructure, and Mechanical Properties journal, January 2017

Corrigendum to “Evaluation of an Al-Ce alloy for additive manufacturing” [Acta Mater. 126 (2017) 507–519] journal, October 2018

Effect of high power diode laser surface melting on wear resistance of magnesium alloys journal, January 2006

Aluminum Alloy patent, May 1966

Mixed lanthanum-magnesium aluminates patent, April 1990

Improvement in wear resistance of hyper-eutectic AlSi cast alloy by laser surface remelting journal, June 2003

Method for producing shaped article of aluminum alloy, shaped aluminum alloy article and production system patent-application, November 2014

Selected Processing for Non-equilibrium Light Alloys and Products
patent-application, October 2003

Evaluation of an Al-Ce alloy for laser additive manufacturing
journal, March 2017

Characterization and wear resistance of laser surface melting AZ91D alloy
journal, May 2008

Method for making a light metal-rare earth metal alloy
patent, August 1991

Multi-element heat-resistant aluminum alloy material with high strength and preparation method thereof
patent-application, June 2012

Production of glassy metallic layers by laser surface treatment
journal, February 2003

Method and apparatus for shaping semisolid metals
patent-application, December 2004

Mechanical Properties of Nanometric Al₂O₃ Particulate-Reinforced Al-Al₁₁Ce₃ Composites Produced by Friction Stir Processing
journal, January 2010

The microstructure and mechanical properties of unidirectionally solidified Al−Si alloys
journal, June 1989

Effect of substituting cerium-rich mischmetal with lanthanum on microstructure and mechanical properties of die-cast Mg–Al–RE alloys
journal, August 2009

Process for Isolation and Purification of Astatine-211
patent-application, February 2016

Cerium-Based, Intermetallic-Strengthened Aluminum Casting Alloy: High-Volume Co-product Development
journal, May 2016

High strength aluminum alloy
patent, July 1995

Characterization of Near Net-Shape Castable Rare Earth Modified Aluminum Alloys for High Temperature Application
book, January 2016

On the Selective Laser Melting (SLM) of the AlSi10Mg Alloy: Process, Microstructure, and Mechanical Properties
journal, January 2017

Corrigendum to “Evaluation of an Al-Ce alloy for additive manufacturing” [Acta Mater. 126 (2017) 507–519]
journal, October 2018

Effect of high power diode laser surface melting on wear resistance of magnesium alloys
journal, January 2006

Aluminum Alloy
patent, May 1966

Mixed lanthanum-magnesium aluminates
patent, April 1990

Improvement in wear resistance of hyper-eutectic AlSi cast alloy by laser surface remelting
journal, June 2003

Method for producing shaped article of aluminum alloy, shaped aluminum alloy article and production system
patent-application, November 2014