An additively manufactured near-eutectic Al-Ce-Ni-Mn-Zr alloy with high creep resistance

Bahl, Sumit; Wu, Tiffany; Michi, Richard A.; An, Ke; Yu, Dunji; Allard, Lawrence F.; Rakhmonov, Jovid U.; Poplawsky, Jonathan D.; Fancher, Christopher M.; Dunand, David C.; Plotkowski, Alex; Shyam, Amit

doi:10.1016/j.actamat.2024.119787

Title: An additively manufactured near-eutectic Al-Ce-Ni-Mn-Zr alloy with high creep resistance

Journal Article · 22 February 2024 · Acta Materialia

DOI: https://doi.org/10.1016/j.actamat.2024.119787 · OSTI ID:2317777

^[1]; Wu, Tiffany ^[2];

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^[1]; Rakhmonov, Jovid U. ^[1];

^[3];

^[1]; Dunand, David C. ^[4];

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Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States); Northwestern Univ., Evanston, IL (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States). Center for Nanophase Materials Sciences (CNMS)
Northwestern Univ., Evanston, IL (United States)

A new additively manufactured (AM) Al-7.5Ce-4.5Ni-0.4Mn-0.7Zr (wt.%) near-eutectic alloy is reported, which shows unprecedented creep resistance up to 400 °C (a homologous temperature of 0.72). The eutectic solidification microstructure comprises ~ 27 vol% of coarsening-resistant second phase network with an ultrafine (<100 nm) inter-phase spacing. Both Mn and Zr contribute to creep resistance of the alloy. Small amount of Mn addition promotes selection of coarsening resistant phases without compromising the alloy processability. Zr not only improves hot-tearing resistance, but further enhances the second phase coarsening resistance resulting in improved creep resistance. Neutron diffraction performed during creep deformation reveals that the underlying mechanism for creep resistance in this alloy is impedance to dislocation motion stemming from the ultrafine eutectic solidification microstructure, whereas load transfer strengthening becomes less effective as the creep temperature increases. The second phase forms a continuous network in the as-fabricated condition, which is maintained during long-term creep at 300 °C. However, this network is fragmented into fine dispersoids at higher temperatures. It is proposed that the rate-limiting deformation mechanism at 300–400 °C is (i) dislocation climb for the alloy with fragmented second phase dispersoids and (ii) Orowan looping for the alloy with a continuous second phase network. In conclusion, the present design of an AM-processable multicomponent eutectic alloy with high creep resistance can be applied to other metallic systems exhibiting eutectic reactions, with expected extreme creep resistance.

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Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States). Center for Nanophase Materials Sciences (CNMS)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Materials & Manufacturing Technologies Office (AMMTO); USDOE

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 2317777

Alternate ID(s):: OSTI ID: 2369937

Journal Information:: Acta Materialia, Vol. 268, Issue 1; ISSN 1359-6454

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Title: An additively manufactured near-eutectic Al-Ce-Ni-Mn-Zr alloy with high creep resistance

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