Aluminum-cerium-manganese alloy embodiments for metal additive manufacturing

Allard, Lawrence F.; Bahl, Sumit; Dehoff, Ryan R.; Henderson, Hunter B.; Kesler, Michael S.; McCall, Scott K.; Nandwana, Peeyush; Ott, Ryan; Plotkowski, Alex J.; Rios, Orlando; Shyam, Amit; Sims, Zachary C.; Sisco, Kevin; Weiss, David; Yang, Ying

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Title: Aluminum-cerium-manganese alloy embodiments for metal additive manufacturing

Abstract

Disclosed herein are embodiments of an Al—Ce—Mn alloy for use in additive manufacturing. The disclosed alloy embodiments provide fabricated objects, such as bulk components, comprising a heterogeneous microstructure and having good mechanical properties even when exposed to conditions used during the additive manufacturing process. Methods for making and using alloy embodiments also are disclosed herein.

Inventors:: Allard, Lawrence F.; Bahl, Sumit; Dehoff, Ryan R.; Henderson, Hunter B.; Kesler, Michael S.; McCall, Scott K.; Nandwana, Peeyush; Ott, Ryan; Plotkowski, Alex J.; Rios, Orlando; Shyam, Amit; Sims, Zachary C.; Sisco, Kevin; Weiss, David; Yang, Ying

Issue Date:: Tue Mar 21 00:00:00 EDT 2023

Research Org.:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States); Eck Industries Incorporated, Manitowoc, WI (United States); Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States); Ames Laboratory (AMES), Ames, IA (United States); Univ. of Tennessee, Knoxville, TN (United States)

Sponsoring Org.:: USDOE

OSTI Identifier:: 1987234

Patent Number(s):: 11608546

Application Number:: 16/894,551

Assignee:: UT-Battelle LLC (Oak Ridge, TN); Eck Industries Incorporated (Manitowoc, WI); Iowa State University Research Foundation (Ames, IA); Lawrence Livermore National Security, LLC (Livermore, CA); University of Tennessee Research Foundation (Knoxville, TN)

Patent Classifications (CPCs):: B - PERFORMING OPERATIONS B22 - CASTING B22F - WORKING METALLIC POWDER

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

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B - PERFORMING OPERATIONS B22 - CASTING B22F - WORKING METALLIC POWDER
B22F2301/052 - Aluminium

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
B33Y70/00 - Materials specially adapted for additive manufacturing
B33Y80/00 - Products made by additive manufacturing

C - CHEMISTRY C22 - METALLURGY C22C - ALLOYS
C22C1/0416 - {Aluminium-based alloys}
C22C21/00 - Alloys based on aluminium

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:: AC02-07CH11358; AC05-00OR22725; AC52-07NA27344

Resource Type:: Patent

Resource Relation:: Patent File Date: 06/05/2020

Country of Publication:: United States

Language:: English

Citation Formats


                    Allard, Lawrence F., Bahl, Sumit, Dehoff, Ryan R., Henderson, Hunter B., Kesler, Michael S., McCall, Scott K., Nandwana, Peeyush, Ott, Ryan, Plotkowski, Alex J., Rios, Orlando, Shyam, Amit, Sims, Zachary C., Sisco, Kevin, Weiss, David, and Yang, Ying. Aluminum-cerium-manganese alloy embodiments for metal additive manufacturing.  United States: N. p., 2023. 
        Web.

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                    Allard, Lawrence F., Bahl, Sumit, Dehoff, Ryan R., Henderson, Hunter B., Kesler, Michael S., McCall, Scott K., Nandwana, Peeyush, Ott, Ryan, Plotkowski, Alex J., Rios, Orlando, Shyam, Amit, Sims, Zachary C., Sisco, Kevin, Weiss, David, & Yang, Ying. Aluminum-cerium-manganese alloy embodiments for metal additive manufacturing.  United States.

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                    Allard, Lawrence F., Bahl, Sumit, Dehoff, Ryan R., Henderson, Hunter B., Kesler, Michael S., McCall, Scott K., Nandwana, Peeyush, Ott, Ryan, Plotkowski, Alex J., Rios, Orlando, Shyam, Amit, Sims, Zachary C., Sisco, Kevin, Weiss, David, and Yang, Ying. Tue .  
        "Aluminum-cerium-manganese alloy embodiments for metal additive manufacturing".  United States.  https://www.osti.gov/servlets/purl/1987234.

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@article{osti_1987234,

  title        = {Aluminum-cerium-manganese alloy embodiments for metal additive manufacturing},

  author       = {Allard, Lawrence F. and Bahl, Sumit and Dehoff, Ryan R. and Henderson, Hunter B. and Kesler, Michael S. and McCall, Scott K. and Nandwana, Peeyush and Ott, Ryan and Plotkowski, Alex J. and Rios, Orlando and Shyam, Amit and Sims, Zachary C. and Sisco, Kevin and Weiss, David and Yang, Ying},

  abstractNote = {Disclosed herein are embodiments of an Al—Ce—Mn alloy for use in additive manufacturing. The disclosed alloy embodiments provide fabricated objects, such as bulk components, comprising a heterogeneous microstructure and having good mechanical properties even when exposed to conditions used during the additive manufacturing process. Methods for making and using alloy embodiments also are disclosed herein.},

  doi          = {},

  journal      = {},
number       = ,

  volume       = ,

  place        = {United States},

  year         = {Tue Mar 21 00:00:00 EDT 2023},

  month        = {Tue Mar 21 00:00:00 EDT 2023}

}

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URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/3252841

Aluminum powder alloy product for high temperature application
patent, August 1984

Hildeman, Gregory J.; Sanders, Jr., Robert E.
US Patent Document 4,464,199
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/4464199

Aluminum Alloy Containing Mischmetal
patent, October 1953

Russell, James B.
US Patent Document 2656270
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/2656270

Method for producing shaped article of aluminum alloy, shaped aluminum alloy article and production system
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Okamoto, Yasuo
US Patent Application 14/309285; 20140326368
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/20140326368

Structural Direct-Write Additive Manufacturing of Molten Metals
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Rios, Orlando; Weiss, David; Sims, Zachary .
US Patent Application 15/625161; 20170362687
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/20170362687

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Title: Aluminum-cerium-manganese alloy embodiments for metal additive manufacturing

Abstract

Citation Formats

Thermodynamic evaluation and optimization of Al–La, Al–Ce, Al–Pr, Al–Nd and Al–Sm systems using the Modified Quasichemical Model for liquids journal, March 2011

Tough and heat resisting aluminum alloy patent, May 2001

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

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Method to improve the corrosion resistance of aluminum alloys patent, July 2016

Al-Ce-Mg (Aluminum-Cerium-Magnesium) journal, August 2007

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Method of Producing a Castable High Temperature Aluminum Alloy by Controlled Solidification patent-application, November 2009

Intergranular corrosion (IGC) and intergranular stress corrosion cracking (IGSCC) resistance improvement method for metallic alloys patent, July 2015

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Amorphous alloys superior in mechanical strength, corrosion resistance and formability patent, December 1991

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Metal Additive Manufacturing: A Review of Mechanical Properties journal, July 2016

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Rapidly Solidified Aluminum-Rare Earth alloy and method of making Same patent-application, August 2018

Castable Aluminum Alloy patent-application, September 2005

Thermodynamic optimization of the Al–Yb binary system journal, March 2008

Design and production of Al-Mn-Ce alloys with tailored properties journal, November 2016

High strength, heat resistant aluminum-based alloys patent, June 1994

Influence of Magnesium Alloy Degradation on Undifferentiated Human Cells journal, November 2015

Effects of La on the age hardening behavior and precipitation kinetics in the cast Al–Cu alloy journal, November 2012

A new methodology for measurement of semi-solid constitutive behavior and its application to examination of as-cast porosity and hot tearing in aluminum alloys journal, September 2008

Reassessment of the effects of Ce on quasicrystal formation and microstructural evolution in rapidly solidified Al–Mn alloys journal, October 2015

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

Insight into the complex ternary phase behavior in Al-Mn-Ce alloys journal, December 2017

The effect of Mg addition on microstructure and tensile and stress rupture properties of a P/M Al-Fe-Ce alloy journal, September 1998

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Aluminum-Cerium-Nickel Alloys for Additive Manufacturing patent-application, May 2021

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Phase stability in a powder-processed Al–Mn–Ce alloy journal, February 2014

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

Critical evaluation and thermodynamic optimization of the Al–Ce, Al–Y, Al–Sc and Mg–Sc binary systems journal, June 2008

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

High strength aluminum alloy patent, July 1995

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Process for Producing an ALSCCA Alloy and Also an AISCCA Alloy patent-application, November 2013

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

Phase relations in the Cu-poor part of the Ce–Al–Cu system at 503K journal, September 2009

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

Metal Additive Manufacturing: A Review journal, April 2014

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

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Recent development in aluminium alloys for the automotive industry journal, March 2000

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

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Ternary Rare-Earth Aluminum Systems With Copper: A Review and a Contribution to Their Assessment journal, February 2004

Aluminum Alloy patent, May 1966

Thermodynamic evaluation and optimization of Al–La, Al–Ce, Al–Pr, Al–Nd and Al–Sm systems using the Modified Quasichemical Model for liquids
journal, March 2011

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patent, May 2001

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patent, August 1991

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patent-application, June 2012

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journal, March 2016

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journal, May 2007

Methods for Producing Alloy Forms from Alloys Containing One or More Extremely Reactive Elements and for Fabricating a Component Therefrom
patent-application, February 2016

Erbium and ytterbium solubilities and diffusivities in aluminum as determined by nanoscale characterization of precipitates
journal, August 2009

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patent, November 1996

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patent, July 2016

Al-Ce-Mg (Aluminum-Cerium-Magnesium)
journal, August 2007

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patent, November 1988

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patent, April 1990

Method of Producing a Castable High Temperature Aluminum Alloy by Controlled Solidification
patent-application, November 2009

Intergranular corrosion (IGC) and intergranular stress corrosion cracking (IGSCC) resistance improvement method for metallic alloys
patent, July 2015

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patent-application, October 2003

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patent-application, September 2010

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journal, February 1999

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patent, May 2018

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patent, June 2001

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journal, February 2003

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patent-application, May 2021

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patent, December 1991

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patent-application, April 2017

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patent, May 1999

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journal, July 2016

Spray Deposition of L12 Aluminum Alloys
patent-application, November 2010

Additive manufacturing of metallic components – Process, structure and properties
journal, March 2018

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patent-application, August 2018

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patent-application, September 2005

Thermodynamic optimization of the Al–Yb binary system
journal, March 2008

Design and production of Al-Mn-Ce alloys with tailored properties
journal, November 2016

High strength, heat resistant aluminum-based alloys
patent, June 1994

Influence of Magnesium Alloy Degradation on Undifferentiated Human Cells
journal, November 2015

Effects of La on the age hardening behavior and precipitation kinetics in the cast Al–Cu alloy
journal, November 2012

A new methodology for measurement of semi-solid constitutive behavior and its application to examination of as-cast porosity and hot tearing in aluminum alloys
journal, September 2008

Reassessment of the effects of Ce on quasicrystal formation and microstructural evolution in rapidly solidified Al–Mn alloys
journal, October 2015

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

Insight into the complex ternary phase behavior in Al-Mn-Ce alloys
journal, December 2017

The effect of Mg addition on microstructure and tensile and stress rupture properties of a P/M Al-Fe-Ce alloy
journal, September 1998

Castable High Temperature Aluminum Alloy
patent-application, August 2004

Aluminum-Cerium-Nickel Alloys for Additive Manufacturing
patent-application, May 2021

Criteria for developing castable, creep-resistant aluminum-based alloys – A review
journal, March 2006

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

Phase stability in a powder-processed Al–Mn–Ce alloy
journal, February 2014

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

Critical evaluation and thermodynamic optimization of the Al–Ce, Al–Y, Al–Sc and Mg–Sc binary systems
journal, June 2008

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

High strength aluminum alloy
patent, July 1995

Aluminum-Based Alloy and Method of Fabrication of Semiproducts Thereof
patent-application, December 2005

Process for Producing an ALSCCA Alloy and Also an AISCCA Alloy
patent-application, November 2013

High performance aluminum–cerium alloys for high-temperature applications
journal, January 2017

Microstructure and Properties of Novel Heat Resistant Al–Ce–Cu Alloy for Additive Manufacturing
journal, November 2018

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book, January 2016

High-strength rolled sheet of aluminum alloy and process for producing the same
patent, June 1994

Manufacture of Metal Articles
patent-application, May 2015

Additive manufacturing methods using aluminum-rare earth alloys and products made using such methods
patent-application, March 2018

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patent, July 1997

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

Phase relations in the Cu-poor part of the Ce–Al–Cu system at 503K
journal, September 2009

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

Metal Additive Manufacturing: A Review
journal, April 2014

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

Aluminum Fluxes and Fluxing Practice
book, December 2008

L12 Strengthened Amorphous Aluminum Alloys
patent-application, October 2009

A Quest for a New Hot Tearing Criterion
journal, May 2007

Method for Producing a Wear-Resistant Aluminum Alloy, an Aluminum Alloy Obtained According to the Method, and Ues Thereof
patent-application, September 2008

Improving the strength and ductility of magnesium die-casting alloys via rare-earth addition
journal, November 2003

A criterion for cracking during solidification
journal, April 2015

Recent development in aluminium alloys for the automotive industry
journal, March 2000

Dual characteristic of trace rare earth elements in a commercial casting Al–Cu–X alloy
journal, September 2014

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

Ternary Rare-Earth Aluminum Systems With Copper: A Review and a Contribution to Their Assessment
journal, February 2004

Aluminum Alloy
patent, May 1966

Aluminum powder alloy product for high temperature application
patent, August 1984

Aluminum Alloy Containing Mischmetal
patent, October 1953

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