Al-Cu-Ce(-Zr) alloys with an exceptional combination of additive processability and mechanical properties

Sumit Bahl; Kevin Sisco; Ying Yang; Felix Theska; Sophie Primig; Lawrence F. Allard; Richard A. Michi; Christopher Fancher; Benjamin Stump; Ryan Dehoff; Amit Shyam; Alex Plotkowski

doi:10.1016/j.addma.2021.102404

Al-Cu-Ce(-Zr) alloys with an exceptional combination of additive processability and mechanical properties

Sumit Bahl, Kevin Sisco, Ying Yang, Felix Theska, Sophie Primig, Lawrence F. Allard, Richard A. Michi, Christopher Fancher, Benjamin Stump, Ryan Dehoff, Amit Shyam, Alex Plotkowski

Research output: Contribution to journal › Article › peer-review

41 Scopus citations

Abstract

High-temperature Al-9Cu-6Ce and Al-9Cu-6Ce-1Zr (wt%) alloys were designed for fabrication with laser powder bed fusion additive manufacturing (AM). An ultra-fine eutectic structure comprising FCC-Al and particles of a previously unidentified Al₈Cu₃Ce intermetallic phase was obtained with an inter-particle spacing of approximately 280 nm. The inherent hot-tearing resistance of the eutectic alloys resulted in > 99.5% relative density. A thermodynamic model suggested improved hot-tearing resistance of the present alloys relative to the benchmark AM AlSi10Mg alloy. The Al-Cu-Ce alloy exhibited superior thermal stability with approximately 75% of the as-fabricated hardness retained after 200 h exposure at 400 °C, owed to the coarsening resistance of the intermetallic particles. The Al-Cu-Ce-Zr alloy age-hardened through precipitation of nanoscale Al₃Zr precipitates. The aged microstructure was stable at 350 °C with a 13% higher hardness after 200 h exposure compared to the as-fabricated condition. The combined influence of ultra-fine spacing and coarsening resistance of the intermetallic particles resulted in the higher yield strength of the Al-Cu-Ce and Al-Cu-Ce-Zr alloys compared to AM AlSi10Mg and Scalmalloy at temperatures greater than 200 °C. This work essentially demonstrates that thermally stable Al alloys with exceptional mechanical properties can be produced by additive manufacturing.

Original language	English
Article number	102404
Journal	Additive Manufacturing
Volume	48
DOIs	https://doi.org/10.1016/j.addma.2021.102404
State	Published - Dec 2021

Funding

Research was co-sponsored by the U.S. Department of Energy , Office of Energy Efficiency and Renewable Energy , Advanced Manufacturing Office and Vehicle Technologies Office , Propulsion Materials Program . This research used resources of the Advanced Photon Source ; a U.S. Department of Energy (DOE) Office of Science User Facility operated for the DOE Office of Science by Argonne National Laboratory under Contract No. DE-AC02-06CH11357 . The authors acknowledge the facilities, as well as the scientific and technical support of the Microscopy Australia nodes at the University of Sydney (Sydney Microscopy & Microanalysis) and at UNSW Sydney (Mark Wainwright Analytical Centre). S. Primig is supported by the Australian Research Council’s DECRA ( DE180100440 ) and the UNSW Scientia Fellowship schemes. Research was co-sponsored by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office and Vehicle Technologies Office, Propulsion Materials Program. This research used resources of the Advanced Photon Source; a U.S. Department of Energy (DOE) Office of Science User Facility operated for the DOE Office of Science by Argonne National Laboratory under Contract No. DE-AC02-06CH11357. The authors acknowledge the facilities, as well as the scientific and technical support of the Microscopy Australia nodes at the University of Sydney (Sydney Microscopy & Microanalysis) and at UNSW Sydney (Mark Wainwright Analytical Centre). S. Primig is supported by the Australian Research Council's DECRA (DE180100440) and the UNSW Scientia Fellowship schemes. This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan). This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan).

Funders	Funder number
DOE Public Access Plan
United States Government
U.S. Department of Energy
Advanced Manufacturing Office
Office of Science
Office of Energy Efficiency and Renewable Energy
Argonne National Laboratory	DE-AC02-06CH11357
Australian Research Council	DE180100440
University of New South Wales	DE-AC05-00OR22725
University of Sydney

Keywords

Additive manufacturing
Al alloys
Eutectic alloys
High-temperature
Laser powder bed fusion
Tensile properties

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

Access to Document

10.1016/j.addma.2021.102404

Cite this

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title = "Al-Cu-Ce(-Zr) alloys with an exceptional combination of additive processability and mechanical properties",

abstract = "High-temperature Al-9Cu-6Ce and Al-9Cu-6Ce-1Zr (wt%) alloys were designed for fabrication with laser powder bed fusion additive manufacturing (AM). An ultra-fine eutectic structure comprising FCC-Al and particles of a previously unidentified Al8Cu3Ce intermetallic phase was obtained with an inter-particle spacing of approximately 280 nm. The inherent hot-tearing resistance of the eutectic alloys resulted in > 99.5% relative density. A thermodynamic model suggested improved hot-tearing resistance of the present alloys relative to the benchmark AM AlSi10Mg alloy. The Al-Cu-Ce alloy exhibited superior thermal stability with approximately 75% of the as-fabricated hardness retained after 200 h exposure at 400 °C, owed to the coarsening resistance of the intermetallic particles. The Al-Cu-Ce-Zr alloy age-hardened through precipitation of nanoscale Al3Zr precipitates. The aged microstructure was stable at 350 °C with a 13% higher hardness after 200 h exposure compared to the as-fabricated condition. The combined influence of ultra-fine spacing and coarsening resistance of the intermetallic particles resulted in the higher yield strength of the Al-Cu-Ce and Al-Cu-Ce-Zr alloys compared to AM AlSi10Mg and Scalmalloy at temperatures greater than 200 °C. This work essentially demonstrates that thermally stable Al alloys with exceptional mechanical properties can be produced by additive manufacturing.",

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author = "Sumit Bahl and Kevin Sisco and Ying Yang and Felix Theska and Sophie Primig and Allard, {Lawrence F.} and Michi, {Richard A.} and Christopher Fancher and Benjamin Stump and Ryan Dehoff and Amit Shyam and Alex Plotkowski",

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AU - Bahl, Sumit

AU - Sisco, Kevin

AU - Yang, Ying

AU - Theska, Felix

AU - Primig, Sophie

AU - Allard, Lawrence F.

AU - Michi, Richard A.

AU - Fancher, Christopher

AU - Stump, Benjamin

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AU - Shyam, Amit

AU - Plotkowski, Alex

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N2 - High-temperature Al-9Cu-6Ce and Al-9Cu-6Ce-1Zr (wt%) alloys were designed for fabrication with laser powder bed fusion additive manufacturing (AM). An ultra-fine eutectic structure comprising FCC-Al and particles of a previously unidentified Al8Cu3Ce intermetallic phase was obtained with an inter-particle spacing of approximately 280 nm. The inherent hot-tearing resistance of the eutectic alloys resulted in > 99.5% relative density. A thermodynamic model suggested improved hot-tearing resistance of the present alloys relative to the benchmark AM AlSi10Mg alloy. The Al-Cu-Ce alloy exhibited superior thermal stability with approximately 75% of the as-fabricated hardness retained after 200 h exposure at 400 °C, owed to the coarsening resistance of the intermetallic particles. The Al-Cu-Ce-Zr alloy age-hardened through precipitation of nanoscale Al3Zr precipitates. The aged microstructure was stable at 350 °C with a 13% higher hardness after 200 h exposure compared to the as-fabricated condition. The combined influence of ultra-fine spacing and coarsening resistance of the intermetallic particles resulted in the higher yield strength of the Al-Cu-Ce and Al-Cu-Ce-Zr alloys compared to AM AlSi10Mg and Scalmalloy at temperatures greater than 200 °C. This work essentially demonstrates that thermally stable Al alloys with exceptional mechanical properties can be produced by additive manufacturing.

AB - High-temperature Al-9Cu-6Ce and Al-9Cu-6Ce-1Zr (wt%) alloys were designed for fabrication with laser powder bed fusion additive manufacturing (AM). An ultra-fine eutectic structure comprising FCC-Al and particles of a previously unidentified Al8Cu3Ce intermetallic phase was obtained with an inter-particle spacing of approximately 280 nm. The inherent hot-tearing resistance of the eutectic alloys resulted in > 99.5% relative density. A thermodynamic model suggested improved hot-tearing resistance of the present alloys relative to the benchmark AM AlSi10Mg alloy. The Al-Cu-Ce alloy exhibited superior thermal stability with approximately 75% of the as-fabricated hardness retained after 200 h exposure at 400 °C, owed to the coarsening resistance of the intermetallic particles. The Al-Cu-Ce-Zr alloy age-hardened through precipitation of nanoscale Al3Zr precipitates. The aged microstructure was stable at 350 °C with a 13% higher hardness after 200 h exposure compared to the as-fabricated condition. The combined influence of ultra-fine spacing and coarsening resistance of the intermetallic particles resulted in the higher yield strength of the Al-Cu-Ce and Al-Cu-Ce-Zr alloys compared to AM AlSi10Mg and Scalmalloy at temperatures greater than 200 °C. This work essentially demonstrates that thermally stable Al alloys with exceptional mechanical properties can be produced by additive manufacturing.

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Al-Cu-Ce(-Zr) alloys with an exceptional combination of additive processability and mechanical properties

Abstract

Funding

Keywords

UN SDGs

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