Effect of Fe additions on microstructure and mechanical properties in near-eutectic Al–Ce alloys

Hyun Sang Park; Clement N. Ekaputra; David C. Dunand

doi:10.1016/j.msea.2023.145409

Effect of Fe additions on microstructure and mechanical properties in near-eutectic Al–Ce alloys

Hyun Sang Park, Clement N. Ekaputra, David C. Dunand

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

15 Scopus citations

Abstract

The effects of adding 1 or 3 wt % Fe to a near-eutectic Al–10Ce alloy are investigated in terms of their as-cast and aged microstructures, thermal stability, and creep resistance. A 1 wt% Fe addition forms fine, Chinese-script Al₁₀CeFe₂ and Al₁₁Ce₃ eutectic phases without loss of microhardness as compared to the Fe-free Al–10Ce alloy, unlike in traditional cast Al-alloys where detrimental coarse phases are observed when adding Fe. Adding 3 wt% Fe increases hardness significantly while forming primary Al₁₀CeFe₂ in a coarse rod morphology. These near-eutectic Al–10Ce–1Fe and hyper-eutectic Al–10Ce–3Fe alloys, after thermal exposure at 400 and 425 °C for up to 384 h, show only a small loss in microhardness, indicating excellent coarsening resistance. Compressive creep measurements performed at 300 °C show similar trends: (i) near-eutectic Al–10Ce–1Fe performs quite similarly to near-eutectic Al–10Ce and (ii) hyper-eutectic Al–10Ce–3Fe exhibits much improved creep resistance, similar to near-eutectic Al–10Ce–5Ni with costly Ni additions, and much better than hyper-eutectic Al–13Ce. After surface laser remelting to simulate laser powder-bed fusion, the near-eutectic Al–10Ce–1 Fe alloy exhibits greatly refined Al₁₀CeFe₂ and Al₁₁Ce₃ eutectic phases with a doubling in microhardness, indicating a strong potential for laser-based additive manufacturing. Cast Al–Ce–Fe-based alloys show great promise as low-cost alloys with high creep- and coarsening-resistance for use at high temperatures, with the high Fe tolerance enabling the use of recycled aluminum with high Fe contamination.

Original language	English
Article number	145409
Journal	Materials Science and Engineering: A
Volume	882
DOIs	https://doi.org/10.1016/j.msea.2023.145409
State	Published - Aug 24 2023
Externally published	Yes

Funding

This research was sponsored by the Army Research Laboratory ( ARL ) under Cooperative Agreement Numbers W911NF-20-2-0292 and W911NF-21-2-02199 . CNE was supported by the ARL DEVCOM Research Associateship Program ( RAP ). The authors thank Dr. Jovid Rakhmonov and Ms. Tiffany Wu (Northwestern University) for experimental assistance and helpful discussions, and Dr. Jon-Erik Mogonye (ARL) for useful discussions. The views and conclusions contained in this document are those of the authors and should not be interpreted as representing the official policies, either expressed or implied, of the Army Research Laboratory of the U.S. Government. The U.S. Government is authorized to reproduce and distribute reprints for Government purposes notwithstanding any copyright notation herein. This work made use of the Materials Characterization and Imaging facility, which has received support from the MRSEC program ( NSF DMR-1720139 ) of the Materials Research Center at Northwestern University. This work made use of the EPIC facility of the NUANCE Center, which has received support from the MRSEC program (NSF DMR-1720139) at the Materials Research Center, SHyNE Resource (NSF ECCS-2025633), the International Institute for Nanotechnology, IIN (NIH-210OD026871), and the State of Illinois, through the INN. Arc-melting was performed at the Northwestern University Center for Atom-Probe Tomography (NUCAPT), which received support from the MRSEC program (NSF DMR-1720139) at the Materials Research Center, the SHyNE Resource (NSF ECCS-1542205), and the Initiative for Sustainability and Energy (ISEN) at NU. This research was sponsored by the Army Research Laboratory (ARL) under Cooperative Agreement Numbers W911NF-20-2-0292 and W911NF-21-2-02199. CNE was supported by the ARL DEVCOM Research Associateship Program (RAP). The authors thank Dr. Jovid Rakhmonov and Ms. Tiffany Wu (Northwestern University) for experimental assistance and helpful discussions, and Dr. Jon-Erik Mogonye (ARL) for useful discussions. The views and conclusions contained in this document are those of the authors and should not be interpreted as representing the official policies, either expressed or implied, of the Army Research Laboratory of the U.S. Government. The U.S. Government is authorized to reproduce and distribute reprints for Government purposes notwithstanding any copyright notation herein. This work made use of the Materials Characterization and Imaging facility, which has received support from the MRSEC program (NSF DMR-1720139) of the Materials Research Center at Northwestern University. This work made use of the EPIC facility of the NUANCE Center, which has received support from the MRSEC program (NSF DMR-1720139) at the Materials Research Center, SHyNE Resource (NSF ECCS-2025633), the International Institute for Nanotechnology, IIN (NIH-210OD026871), and the State of Illinois, through the INN. Arc-melting was performed at the Northwestern University Center for Atom-Probe Tomography (NUCAPT), which received support from the MRSEC program (NSF DMR-1720139) at the Materials Research Center, the SHyNE Resource (NSF ECCS-1542205), and the Initiative for Sustainability and Energy (ISEN) at NU.

Keywords

Additive manufacturing
Al-Ce alloys
Aluminum alloys
Casting
High temperature

UN SDGs

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

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10.1016/j.msea.2023.145409

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title = "Effect of Fe additions on microstructure and mechanical properties in near-eutectic Al–Ce alloys",

abstract = "The effects of adding 1 or 3 wt % Fe to a near-eutectic Al–10Ce alloy are investigated in terms of their as-cast and aged microstructures, thermal stability, and creep resistance. A 1 wt% Fe addition forms fine, Chinese-script Al10CeFe2 and Al11Ce3 eutectic phases without loss of microhardness as compared to the Fe-free Al–10Ce alloy, unlike in traditional cast Al-alloys where detrimental coarse phases are observed when adding Fe. Adding 3 wt% Fe increases hardness significantly while forming primary Al10CeFe2 in a coarse rod morphology. These near-eutectic Al–10Ce–1Fe and hyper-eutectic Al–10Ce–3Fe alloys, after thermal exposure at 400 and 425 °C for up to 384 h, show only a small loss in microhardness, indicating excellent coarsening resistance. Compressive creep measurements performed at 300 °C show similar trends: (i) near-eutectic Al–10Ce–1Fe performs quite similarly to near-eutectic Al–10Ce and (ii) hyper-eutectic Al–10Ce–3Fe exhibits much improved creep resistance, similar to near-eutectic Al–10Ce–5Ni with costly Ni additions, and much better than hyper-eutectic Al–13Ce. After surface laser remelting to simulate laser powder-bed fusion, the near-eutectic Al–10Ce–1 Fe alloy exhibits greatly refined Al10CeFe2 and Al11Ce3 eutectic phases with a doubling in microhardness, indicating a strong potential for laser-based additive manufacturing. Cast Al–Ce–Fe-based alloys show great promise as low-cost alloys with high creep- and coarsening-resistance for use at high temperatures, with the high Fe tolerance enabling the use of recycled aluminum with high Fe contamination.",

keywords = "Additive manufacturing, Al-Ce alloys, Aluminum alloys, Casting, High temperature",

author = "Park, {Hyun Sang} and Ekaputra, {Clement N.} and Dunand, {David C.}",

note = "Publisher Copyright: {\textcopyright} 2023 Elsevier B.V.",

year = "2023",

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doi = "10.1016/j.msea.2023.145409",

language = "English",

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TY - JOUR

T1 - Effect of Fe additions on microstructure and mechanical properties in near-eutectic Al–Ce alloys

AU - Park, Hyun Sang

AU - Ekaputra, Clement N.

AU - Dunand, David C.

PY - 2023/8/24

Y1 - 2023/8/24

N2 - The effects of adding 1 or 3 wt % Fe to a near-eutectic Al–10Ce alloy are investigated in terms of their as-cast and aged microstructures, thermal stability, and creep resistance. A 1 wt% Fe addition forms fine, Chinese-script Al10CeFe2 and Al11Ce3 eutectic phases without loss of microhardness as compared to the Fe-free Al–10Ce alloy, unlike in traditional cast Al-alloys where detrimental coarse phases are observed when adding Fe. Adding 3 wt% Fe increases hardness significantly while forming primary Al10CeFe2 in a coarse rod morphology. These near-eutectic Al–10Ce–1Fe and hyper-eutectic Al–10Ce–3Fe alloys, after thermal exposure at 400 and 425 °C for up to 384 h, show only a small loss in microhardness, indicating excellent coarsening resistance. Compressive creep measurements performed at 300 °C show similar trends: (i) near-eutectic Al–10Ce–1Fe performs quite similarly to near-eutectic Al–10Ce and (ii) hyper-eutectic Al–10Ce–3Fe exhibits much improved creep resistance, similar to near-eutectic Al–10Ce–5Ni with costly Ni additions, and much better than hyper-eutectic Al–13Ce. After surface laser remelting to simulate laser powder-bed fusion, the near-eutectic Al–10Ce–1 Fe alloy exhibits greatly refined Al10CeFe2 and Al11Ce3 eutectic phases with a doubling in microhardness, indicating a strong potential for laser-based additive manufacturing. Cast Al–Ce–Fe-based alloys show great promise as low-cost alloys with high creep- and coarsening-resistance for use at high temperatures, with the high Fe tolerance enabling the use of recycled aluminum with high Fe contamination.

AB - The effects of adding 1 or 3 wt % Fe to a near-eutectic Al–10Ce alloy are investigated in terms of their as-cast and aged microstructures, thermal stability, and creep resistance. A 1 wt% Fe addition forms fine, Chinese-script Al10CeFe2 and Al11Ce3 eutectic phases without loss of microhardness as compared to the Fe-free Al–10Ce alloy, unlike in traditional cast Al-alloys where detrimental coarse phases are observed when adding Fe. Adding 3 wt% Fe increases hardness significantly while forming primary Al10CeFe2 in a coarse rod morphology. These near-eutectic Al–10Ce–1Fe and hyper-eutectic Al–10Ce–3Fe alloys, after thermal exposure at 400 and 425 °C for up to 384 h, show only a small loss in microhardness, indicating excellent coarsening resistance. Compressive creep measurements performed at 300 °C show similar trends: (i) near-eutectic Al–10Ce–1Fe performs quite similarly to near-eutectic Al–10Ce and (ii) hyper-eutectic Al–10Ce–3Fe exhibits much improved creep resistance, similar to near-eutectic Al–10Ce–5Ni with costly Ni additions, and much better than hyper-eutectic Al–13Ce. After surface laser remelting to simulate laser powder-bed fusion, the near-eutectic Al–10Ce–1 Fe alloy exhibits greatly refined Al10CeFe2 and Al11Ce3 eutectic phases with a doubling in microhardness, indicating a strong potential for laser-based additive manufacturing. Cast Al–Ce–Fe-based alloys show great promise as low-cost alloys with high creep- and coarsening-resistance for use at high temperatures, with the high Fe tolerance enabling the use of recycled aluminum with high Fe contamination.

KW - Additive manufacturing

KW - Al-Ce alloys

KW - Aluminum alloys

KW - Casting

KW - High temperature

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U2 - 10.1016/j.msea.2023.145409

DO - 10.1016/j.msea.2023.145409

M3 - Article

AN - SCOPUS:85165227750

SN - 0921-5093

VL - 882

JO - Materials Science and Engineering: A

JF - Materials Science and Engineering: A

M1 - 145409

ER -

Effect of Fe additions on microstructure and mechanical properties in near-eutectic Al–Ce alloys

Abstract

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