Microstructure and strengthening of Al-6Ce-3Ni-0.7Fe (wt%) alloy manufactured by laser powder-bed fusion

Wu, Tiffany; Poplawsky, Jonathan D.; Allard, Lawrence F.; Plotkowski, Alex; Shyam, Amit; Dunand, David C.

doi:10.1016/j.addma.2023.103858

Title: Microstructure and strengthening of Al-6Ce-3Ni-0.7Fe (wt%) alloy manufactured by laser powder-bed fusion

Journal Article · 09 November 2023 · Additive Manufacturing

DOI: https://doi.org/10.1016/j.addma.2023.103858 · OSTI ID:2333818

Wu, Tiffany ^[1]; Poplawsky, Jonathan D. ^[2]; Allard, Lawrence F. ^[2]; Plotkowski, Alex ^[2];

^[2]; Dunand, David C. ^[1]

Northwestern Univ., Evanston, IL (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

In this study, an Al-6Ce-3Ni-0.7Fe (wt%) alloy was fabricated via laser powder-bed fusion and its microstructure, thermal stability, tensile properties, and creep properties are investigated for two rapid-solidification rates with different eutectic spacings. For both faster- and slower-cooled states, the as-fabricated alloy mostly shows elongated grains with very fine eutectic networks (~40 nm lamellar width) comprising a high-volume fraction (~18 %) of intermetallic phases. Faster-cooled samples, however, display a less continuous eutectic network with finer spacing (~100 nm), leading to higher Orowan strengthening and therefore superior microhardness and yield stress up to ~350 °C. Upon aging (300 - 450 °C), micron-size Al₉(Ni,Fe)₂ needle-like precipitates form within grains, and the Al₁₁Ce₃ eutectic network spheroidizes, while retaining a submicron width and spacing, resulting in 33–37 % drop in microhardness after 144 h aging at 400 °C. Limited tensile ductility (~6 %) and creep ductility (~1-2 %) are measured for both faster- and slower-cooled alloys due to an inhomogeneous microstructure, where cavitation preferentially initiates at melt-pool boundaries, precipitate-free zones, and/or denuded zones, eventually leading to local fracture. Denuded zones, induced by stress, form due to diffusional flow with stress-dependent orientations, and are identified as microstructurally weak regions leading to strain localization. The present alloy does not show a significant difference in 300 °C creep resistance between: (i) tensile and compressive loading, (ii) faster- and slower-cooled samples, and (iii) continuous and spheroidized eutectics. Creep resistance at 300 °C is comparable to that of a Ce-richer Al-10.5Ce-3.1Ni-1.2Mn (wt%) alloy, despite the formation of denuded zones and needle-like Al₉(Ni,Fe)₂ precipitates.

View Accepted Manuscript (DOE)

Cite

Export

Save

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

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Materials & Manufacturing Technologies Office (AMMTO); USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Vehicle Technologies Office (VTO); USDOE Office of Science (SC), Basic Energy Sciences (BES). Scientific User Facilities (SUF)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 2333818

Alternate ID(s):: OSTI ID: 2212801

Journal Information:: Additive Manufacturing, Journal Name: Additive Manufacturing Journal Issue: 1 Vol. 78; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

References (38)

Towards high-temperature applications of aluminium alloys enabled by additive manufacturing Michi, Richard A.; Plotkowski, Alex; Shyam, Amit International Materials Reviews https://doi.org/10.1080/09506608.2021.1951580	journal	July 2021
Effect of Mn on eutectic phase equilibria in Al-rich Al-Ce-Ni alloys Perrin, Alice E.; Michi, Richard A.; Leonard, Donovan N. Journal of Alloys and Compounds, Vol. 965 https://doi.org/10.1016/j.jallcom.2023.171455	journal	November 2023
Microstructure and creep properties of cast near-eutectic Al–Ce–Ni alloys Wu, Tiffany; Plotkowski, A.; Shyam, A. Materials Science and Engineering: A, Vol. 833 https://doi.org/10.1016/j.msea.2021.142551	journal	January 2022
Strengthening of an Al–Cu–Sn alloy by deformation-resistant precipitate plates Nie, J. F.; Muddle, B. C. Acta Materialia, Vol. 56, Issue 14 https://doi.org/10.1016/j.actamat.2008.03.028	journal	August 2008
Influence of Si precipitates on fracture mechanisms of AlSi10Mg parts processed by Selective Laser Melting Delahaye, J.; Tchuindjang, J. Tchoufang; Lecomte-Beckers, J. Acta Materialia, Vol. 175 https://doi.org/10.1016/j.actamat.2019.06.013	journal	August 2019
New Aluminum Alloys Specifically Designed for Laser Powder Bed Fusion: A Review Aversa, Alberta; Marchese, Giulio; Saboori, Abdollah Materials, Vol. 12, Issue 7 https://doi.org/10.3390/ma12071007	journal	March 2019
Elevated temperature microstructural stability in cast AlCuMnZr alloys through solute segregation Shyam, A.; Roy, S.; Shin, D. Materials Science and Engineering: A, Vol. 765 https://doi.org/10.1016/j.msea.2019.138279	journal	September 2019
Identifiying creep mechanisms at low stresses Langdon, Terence G. Materials Science and Engineering: A, Vol. 283, Issue 1-2 https://doi.org/10.1016/S0921-5093(00)00624-9	journal	May 2000
Six decades of the Hall–Petch effect – a survey of grain-size strengthening studies on pure metals Cordero, Z. C.; Knight, B. E.; Schuh, C. A. International Materials Reviews, Vol. 61, Issue 8 https://doi.org/10.1080/09506608.2016.1191808	journal	June 2016
Composition-dependent solidification cracking of aluminum-silicon alloys during laser powder bed fusion Hyer, Holden; Zhou, Le; Mehta, Abhishek Acta Materialia, Vol. 208 https://doi.org/10.1016/j.actamat.2021.116698	journal	April 2021
Ambient- and elevated-temperature strengthening by Al3Zr-Nanoprecipitates and Al3Ni-Microfibers in a cast Al-2.9Ni-0.11Zr-0.02Si-0.005Er (at.%) alloy Michi, Richard A.; Toinin, Jacques Perrin; Seidman, David N. Materials Science and Engineering: A, Vol. 759 https://doi.org/10.1016/j.msea.2019.05.018	journal	June 2019
Effect of Initial Fe Content on Microstructure and Mechanical Properties of Recycled Al-7.0Si-Fe-Mn Alloys with Constant Mn/Fe Ratio Song, Dongfu; Jia, Yiwang; Li, Qing Materials, Vol. 15, Issue 4 https://doi.org/10.3390/ma15041618	journal	February 2022
Preparation of high quality Al TEM specimens via a double-jet electropolishing technique Ünlü, Necip Materials Characterization, Vol. 59, Issue 5 https://doi.org/10.1016/j.matchar.2007.04.003	journal	May 2008
Evaluation of an Al-Ce alloy for laser additive manufacturing Plotkowski, A.; Rios, O.; Sridharan, N. Acta Materialia, Vol. 126 https://doi.org/10.1016/j.actamat.2016.12.065	journal	March 2017
On the strength of discontinuous silicon carbide reinforced aluminum composites Nardone, V. C.; Prewo, K. M. Scripta Metallurgica, Vol. 20, Issue 1 https://doi.org/10.1016/0036-9748(86)90210-3	journal	January 1986
Beneficial effects of Sc/Zr addition on hypereutectic Al–Ce alloys: Modification of primary phases and precipitation hardening Ye, Jieyun; Dai, Kun; Wang, Zhigang Materials Science and Engineering: A, Vol. 835 https://doi.org/10.1016/j.msea.2022.142611	journal	February 2022
Laser powder bed fusion of Al–10 wt% Ce alloys: microstructure and tensile property Zhou, Le; Huynh, Thinh; Park, Sharon Journal of Materials Science, Vol. 55, Issue 29 https://doi.org/10.1007/s10853-020-05037-z	journal	July 2020
An additively manufactured heat-resistant Al-Ce-Sc-Zr alloy: Microstructure, mechanical properties and thermal stability Yang, Ziwei; Chen, Chao; Li, Dan Materials Science and Engineering: A, Vol. 872 https://doi.org/10.1016/j.msea.2023.144965	journal	May 2023
Diffusion of iron, nickel and cobalt in aluminum Hirano, Ken-ichi; Agarwala, R. P.; Cohen, Morris Acta Metallurgica, Vol. 10, Issue 9 https://doi.org/10.1016/0001-6160(62)90100-1	journal	September 1962
Comparing evolution of precipitates and strength upon aging of cast and laser-remelted Al–8Ce-0.2Sc-0.1Zr (wt.%) Rakhmonov, Jovid U.; Weiss, David; Dunand, David C. Materials Science and Engineering: A, Vol. 840 https://doi.org/10.1016/j.msea.2022.142990	journal	April 2022
Microstructure diversity dominated by the interplay between primary intermetallics and eutectics for Al-Ce heat-resistant alloys Guo, Yueling; Hu, Jinlong; Han, Qifei Journal of Alloys and Compounds, Vol. 899 https://doi.org/10.1016/j.jallcom.2021.162914	journal	April 2022
A creep-resistant additively manufactured Al-Ce-Ni-Mn alloy Michi, Richard A.; Sisco, Kevin; Bahl, Sumit Acta Materialia, Vol. 227 https://doi.org/10.1016/j.actamat.2022.117699	journal	April 2022
The effects of scandium heterogeneous distribution on the precipitation behavior of Al3(Sc, Zr) in aluminum alloys Sun, Yuqiao; Pan, Qinglin; Luo, Yuhong Materials Characterization, Vol. 174 https://doi.org/10.1016/j.matchar.2021.110971	journal	April 2021
Microstructure and mechanical property evolution of additive manufactured eutectic Al-2Fe alloy during solidification and aging Wu, Yiyou; Zhang, Taomei; Chen, Chao Journal of Alloys and Compounds, Vol. 897 https://doi.org/10.1016/j.jallcom.2021.163243	journal	March 2022
Elevated temperature ductility dip in an additively manufactured Al-Cu-Ce alloy Bahl, Sumit; Plotkowski, Alex; Sisco, Kevin Acta Materialia, Vol. 220 https://doi.org/10.1016/j.actamat.2021.117285	journal	November 2021
High temperature deformation of oxide dispersion strengthened al and AlMg solid solutions Oliver, W. C.; Nix, W. D. Acta Metallurgica, Vol. 30, Issue 7 https://doi.org/10.1016/0001-6160(82)90153-5	journal	July 1982
Ambient- and high-temperature mechanical properties of isochronally aged Al–0.06Sc, Al–0.06Zr and Al–0.06Sc–0.06Zr (at.%) alloys Knipling, Keith E.; Seidman, David N.; Dunand, David C. Acta Materialia, Vol. 59, Issue 3 https://doi.org/10.1016/j.actamat.2010.10.017	journal	February 2011
On the threshold stress for dislocation creep in particle strengthened alloys McLean, M. Acta Metallurgica, Vol. 33, Issue 4 https://doi.org/10.1016/0001-6160(85)90018-5	journal	April 1985
In situ site-specific specimen preparation for atom probe tomography Thompson, K.; Lawrence, D.; Larson, D. J. Ultramicroscopy, Vol. 107, Issue 2-3 https://doi.org/10.1016/j.ultramic.2006.06.008	journal	February 2007
Back pressure equal channel angular consolidation of pure Al particles Xia, K.; Wu, X. Scripta Materialia, Vol. 53, Issue 11 https://doi.org/10.1016/j.scriptamat.2005.08.012	journal	December 2005
Design, microstructure and thermal stability of a novel heat-resistant Al-Fe-Ni alloy manufactured by selective laser melting Ding, Han; Xiao, Yakai; Bian, Zeyu Journal of Alloys and Compounds, Vol. 885 https://doi.org/10.1016/j.jallcom.2021.160949	journal	December 2021
Effect of grain-boundary θ-Al2Cu precipitates on tensile and compressive creep properties of cast Al–Cu–Mn–Zr alloys Bahl, Sumit; Rakhmonov, Jovid U.; Kenel, Christoph Materials Science and Engineering: A, Vol. 840 https://doi.org/10.1016/j.msea.2022.142946	journal	April 2022
Review of high-strength aluminium alloys for additive manufacturing by laser powder bed fusion Rometsch, Paul A.; Zhu, Yuman; Wu, Xinhua Materials & Design, Vol. 219 https://doi.org/10.1016/j.matdes.2022.110779	journal	July 2022
Analysis of Three-dimensional Atom-probe Data by the Proximity Histogram Hellman, Olof C.; Vandenbroucke, Justin A.; Rüsing, Järg Microscopy and Microanalysis, Vol. 6, Issue 05 https://doi.org/10.1007/S100050010051	journal	September 2000
Microstructure and mechanical properties of cast Al-Ce-Sc-Zr-(Er) alloys strengthened by Al11Ce3 micro-platelets and L12 Al3(Sc,Zr,Er) nano-precipitates Ekaputra, Clement N.; Rakhmonov, Jovid U.; Weiss, David Acta Materialia, Vol. 240 https://doi.org/10.1016/j.actamat.2022.118354	journal	November 2022
Cast near-eutectic Al-12.5 wt.% Ce alloy with high coarsening and creep resistance Liu, Yang; Michi, Richard A.; Dunand, David C. Materials Science and Engineering: A, Vol. 767 https://doi.org/10.1016/j.msea.2019.138440	journal	November 2019
Improving creep resistance of Al-12 wt.% Ce alloy by microalloying with Sc Yi, Meng; Zhang, Peng; Yang, Chong Scripta Materialia, Vol. 198 https://doi.org/10.1016/j.scriptamat.2021.113838	journal	June 2021
The kinetics of dislocation climb over hard particles—II. Effects of an attractive particle-dislocation interaction Arzt, E.; Rösler, J. Acta Metallurgica, Vol. 36, Issue 4 https://doi.org/10.1016/0001-6160(88)90159-9	journal	April 1988

Similar Records

Microstructure and mechanical properties of hypoeutectic Al–6Ce–3Ni-0.7Fe (wt.%) alloy

Journal Article · 2023 · Materials Science and Engineering. A, Structural Materials: Properties, Microstructure and Processing · OSTI ID:1973330

Wu, Tiffany; Plotkowski, Alex; Shyam, Amit; +1 more

Microstructure and creep properties of cast near-eutectic Al–Ce–Ni alloys

Journal Article · 2021 · Materials Science and Engineering. A, Structural Materials: Properties, Microstructure and Processing · OSTI ID:1841484

Wu, Tiffany; Plotkowski, Alex; Shyam, Amit; +1 more

A creep-resistant additively manufactured Al-Ce-Ni-Mn alloy

Journal Article · 2022 · Acta Materialia · OSTI ID:1847532

Michi, Richard A.; Sisco, Kevin; Bahl, Sumit; +6 more

Related Subjects

36 MATERIALS SCIENCE
Additive manufacturing
Creep
Al alloys
Alloy design

Title: Microstructure and strengthening of Al-6Ce-3Ni-0.7Fe (wt%) alloy manufactured by laser powder-bed fusion

Citation Formats

References (38)

Similar Records

Related Subjects