The Beneficial Effect of Iron in Aluminum-Cerium-Based Cast Alloys

Journal Article · Fri Mar 08 00:00:00 UTC 2024 · Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science

DOI: https://doi.org/10.1007/s11661-024-07333-8 · OSTI ID:2438347

Moodispaw, Michael P. ^[1]; Cinkilic, Emre ^[2]; Miao, Jiashi ^[2]; Luo, Alan A. ^[2]

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1. The Ohio State University, Columbus, OH (United States); The Ohio State University
2. The Ohio State University, Columbus, OH (United States)

Iron (Fe) has been considered a major impurity since it is detrimental to the mechanical properties of many cast aluminum alloys due to the formation of Fe-containing brittle intermetallic phases. Fe is found naturally as an impurity in bauxite ore, resulting in Fe contamination of aluminum alloys with increasing contamination from current recycling practices. The Al–Ce–Fe system was investigated using CALPHAD (CALculation of PHAse Diagrams) modeling and experimental casting techniques. It was found that additions of Fe to the Al–Ce system are beneficial to the strength (slightly) and ductility (significantly) of the ternary alloys, which is attributed to the formation of fine metastable Al₈CeFe₂ phase with aggregate morphology and equilibrium Al₁₀CeFe₂ phase, suppressing coarse proeutectic Al₁₁Ce₃ phase in near-eutectic Al–Ce alloys. Heat treatment study showed that the metastable Al₈CeFe₂ phase transforms to predicted equilibrium Al₁₀CeFe₂ phase at 500 °C, with essentially no intermetallic or grain coarsening; thus, the alloy displayed excellent property retention. The Al–Ce–Fe alloy system offers opportunities for sustainable, recyclable alloy development using low-cost Fe and low-cost cerium (a byproduct of rare-earth extraction).

• Research Organization: The Ohio State University, Columbus, OH (United States)
• Sponsoring Organization: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Materials & Manufacturing Technologies Office (AMMTO)
• Grant/Contract Number: EE0007897
• OSTI ID: 2438347
• Journal Information: Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science, Journal Name: Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science Journal Issue: 5 Vol. 55; ISSN 1073-5623
• Publisher: SpringerCopyright Statement
• Country of Publication: United States
• Language: English