Hypereutectic Al-Ce-X (X=Mn, Cr, V, Mo, W) alloys fabricated by laser powder-bed fusion

Clement N. Ekaputra; Jovid U. Rakhmonov; Christian Leinenbach; David C. Dunand

doi:10.1016/j.addma.2024.104442

Hypereutectic Al-Ce-X (X=Mn, Cr, V, Mo, W) alloys fabricated by laser powder-bed fusion

Clement N. Ekaputra, Jovid U. Rakhmonov, Christian Leinenbach, David C. Dunand

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

Abstract

We characterize the microstructures and high-temperature mechanical properties of Al-2Ce and ternary Al-2Ce-1X (at.%) alloys fabricated by laser powder-bed fusion (LPBF), where X = Mn, Cr, V, Mo, and W are slow-diffusing transition metals. All ternary alloys show a hypereutectic microstructure in the as-LPBF state, containing an interconnected network of eutectic Al₁₁Ce₃ phases (∼10 vol.%) and an additional population of submicron, equiaxed Al₂₀CeX₂ primary precipitates (∼10 vol.%) which are isomorphous among these five alloys. Similar microstructures are present in arc-melted rods and atomized powders but are coarser due to the slower cooling rates in these processes. The hardness of the as-LPBF ternary Al-Ce-X alloys (1300–1400 MPa) is higher than that of the binary Al-Ce alloy (∼1100 MPa) due to the higher volume fraction of strengthening phases. Furthermore, during exposure at 400 °C for up to three months, greater hardness retention is achieved in the ternary Al-Ce-X alloys (65–75%) than in the binary Al-Ce alloy (∼55%), which is attributed to the extreme coarsening resistance of the Al₂₀CeX₂ precipitates imparted by the very slow-diffusing ternary solute. These coarsening-resistant Al₂₀CeX₂ precipitates also substantially improve alloy creep resistance, increasing the threshold stress for dislocation creep at 300°C from ∼32 MPa for the binary Al-Ce alloy to ∼77–100 MPa for the ternary Al-Ce-X alloys, and at 400°C from <10 MPa for the binary Al-Ce alloy to >40 MPa for the ternary Al-Ce-V alloy.

Original language	English
Article number	104442
Journal	Additive Manufacturing
Volume	93
DOIs	https://doi.org/10.1016/j.addma.2024.104442
State	Published - Aug 5 2024
Externally published	Yes

Funding

This work made use of the MatCI Facility which receives support from the MRSEC Program (NSF DMR-2308691) of the Materials Research Center at Northwestern University. This work made use of the EPIC facility of Northwestern University\u2019s NUANCE Center, which has received support from the SHyNE Resource (NSF ECCS-2025633), the IIN, and Northwestern's MRSEC program (NSF DMR-2308691). Arc-melting and atom-probe tomography was performed at the Northwestern University Center for Atom-Probe Tomography (NUCAPT). The LEAP tomograph at NUCAPT was purchased and upgraded with grants from the NSF-MRI (DMR-0420532) and ONR-DURIP (N00014-0400798, N00014-0610539, N00014-0910781, N00014-1712870) programs. NUCAPT 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 Northwestern University. This work made use of the Jerome B. Cohen X-Ray Diffraction Facility supported by the MRSEC program of the National Science Foundation (DMR-2308691) at the Materials Research Center of Northwestern University and the Soft and Hybrid Nanotechnology Experimental (ShyNE) Resource (NSF ECCS-2025633.) CNE was supported by the DEVCOM Army Research Laboratory (ARL) Research Associateship Program (RAP) and the ThinkSwiss Research Scholarship. The authors thank Dr. Jon-Erik Mogonye (U.S. Army Research Laboratory) for useful discussions, and Dr. David Weiss (Eck Industries) for providing the Al-Ce master alloys used in this work. CNE thanks Mr. Benjamin Minnig, Dr. Marc Leparoux, Mr. Antonios Baganis, Dr. Rafal Wrobel, Dr. Marvin Schuster, Dr. Irene Ferretto, and Ms. Alexandra Lau (Empa-Swiss Federal Laboratories for Materials Research and Technology) for technical support and training. This research was sponsored by the Army Research Laboratory under Cooperative Agreement Number W911NF-20-2-0292 and W911NF-21-2-02199. 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. JUR's visualization, review, and editing contributions were made at Oak Ridge National Laboratory under the sponsorship of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Materials and Manufacturing Technologies Office, and Vehicle Technologies Office's Powertrain Materials Core Program. This work made use of the MatCI Facility which receives support from the MRSEC Program (NSF DMR-2308691) of the Materials Research Center at Northwestern University. This work made use of the EPIC facility of Northwestern University's NUANCE Center, which has received support from the SHyNE Resource (NSF ECCS-2025633), the IIN, and Northwestern's MRSEC program (NSF DMR-2308691). Arc-melting and atom-probe tomography was performed at the Northwestern University Center for Atom-Probe Tomography (NUCAPT). The LEAP tomograph at NUCAPT was purchased and upgraded with grants from the NSF-MRI (DMR-0420532) and ONR-DURIP (N00014\u20130400798, N00014\u20130610539, N00014\u20130910781, N00014\u20131712870) programs. NUCAPT 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 Northwestern University. This work made use of the Jerome B. Cohen X-Ray Diffraction Facility supported by the MRSEC program of the National Science Foundation (DMR-2308691) at the Materials Research Center of Northwestern University and the Soft and Hybrid Nanotechnology Experimental (ShyNE) Resource (NSF ECCS-2025633.) CNE was supported by the DEVCOM Army Research Laboratory (ARL) Research Associateship Program (RAP) and the ThinkSwiss Research Scholarship. The authors thank Dr. Jon-Erik Mogonye (U.S. Army Research Laboratory) for useful discussions, and Dr. David Weiss (Eck Industries) for providing the Al-Ce master alloys used in this work. CNE thanks Mr. Benjamin Minnig, Dr. Marc Leparoux, Mr. Antonios Baganis, Dr. Rafal Wrobel, Dr. Marvin Schuster, Dr. Irene Ferretto, and Ms. Alexandra Lau (Empa-Swiss Federal Laboratories for Materials Research and Technology) for technical support and training. This research was sponsored by the Army Research Laboratory under Cooperative Agreement Number W911NF-20-2-0292 and W911NF-21-2-02199. 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. JUR\u2019s visualization, review, and editing contributions were made at Oak Ridge National Laboratory under the sponsorship of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Materials and Manufacturing Technologies Office, and Vehicle Technologies Office\u2019s Powertrain Materials Core Program.

Funders	Funder number
Northwestern University
Army Research Laboratory of the U.S. Government
Materials Research Science and Engineering Center, Harvard University
Office of Energy Efficiency and Renewable Energy
U.S. Department of Energy
DEVCOM Army Research Laboratory
SHyNE
Advanced Materials and Manufacturing Technologies Office
ONR-DURIP	N00014–0400798, N00014–0610539, N00014–1712870, N00014–0910781
Army Research Laboratory	W911NF-21-2-02199, W911NF-20-2-0292
National Science Foundation	DMR-2308691
Materials Research Science and Engineering Center, Northwestern University	ECCS-1542205
SHyNE Resource	ECCS-2025633, NSF DMR-1720139
NSF-MRI	DMR-0420532

Keywords

Aluminum alloys
Creep
High-temperature
Laser powder-bed fusion
Mechanical properties
Microstructure

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10.1016/j.addma.2024.104442

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@article{a69df98fedbc46edb1b86bdeb0321c97,

title = "Hypereutectic Al-Ce-X (X=Mn, Cr, V, Mo, W) alloys fabricated by laser powder-bed fusion",

abstract = "We characterize the microstructures and high-temperature mechanical properties of Al-2Ce and ternary Al-2Ce-1X (at.%) alloys fabricated by laser powder-bed fusion (LPBF), where X = Mn, Cr, V, Mo, and W are slow-diffusing transition metals. All ternary alloys show a hypereutectic microstructure in the as-LPBF state, containing an interconnected network of eutectic Al11Ce3 phases (∼10 vol.%) and an additional population of submicron, equiaxed Al20CeX2 primary precipitates (∼10 vol.%) which are isomorphous among these five alloys. Similar microstructures are present in arc-melted rods and atomized powders but are coarser due to the slower cooling rates in these processes. The hardness of the as-LPBF ternary Al-Ce-X alloys (1300–1400 MPa) is higher than that of the binary Al-Ce alloy (∼1100 MPa) due to the higher volume fraction of strengthening phases. Furthermore, during exposure at 400 °C for up to three months, greater hardness retention is achieved in the ternary Al-Ce-X alloys (65–75%) than in the binary Al-Ce alloy (∼55%), which is attributed to the extreme coarsening resistance of the Al20CeX2 precipitates imparted by the very slow-diffusing ternary solute. These coarsening-resistant Al20CeX2 precipitates also substantially improve alloy creep resistance, increasing the threshold stress for dislocation creep at 300°C from ∼32 MPa for the binary Al-Ce alloy to ∼77–100 MPa for the ternary Al-Ce-X alloys, and at 400°C from <10 MPa for the binary Al-Ce alloy to >40 MPa for the ternary Al-Ce-V alloy.",

keywords = "Aluminum alloys, Creep, High-temperature, Laser powder-bed fusion, Mechanical properties, Microstructure",

author = "Ekaputra, {Clement N.} and Rakhmonov, {Jovid U.} and Christian Leinenbach and Dunand, {David C.}",

note = "Publisher Copyright: {\textcopyright} 2024 Elsevier B.V.",

year = "2024",

month = aug,

day = "5",

doi = "10.1016/j.addma.2024.104442",

language = "English",

volume = "93",

journal = "Additive Manufacturing",

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TY - JOUR

T1 - Hypereutectic Al-Ce-X (X=Mn, Cr, V, Mo, W) alloys fabricated by laser powder-bed fusion

AU - Ekaputra, Clement N.

AU - Rakhmonov, Jovid U.

AU - Leinenbach, Christian

AU - Dunand, David C.

PY - 2024/8/5

Y1 - 2024/8/5

N2 - We characterize the microstructures and high-temperature mechanical properties of Al-2Ce and ternary Al-2Ce-1X (at.%) alloys fabricated by laser powder-bed fusion (LPBF), where X = Mn, Cr, V, Mo, and W are slow-diffusing transition metals. All ternary alloys show a hypereutectic microstructure in the as-LPBF state, containing an interconnected network of eutectic Al11Ce3 phases (∼10 vol.%) and an additional population of submicron, equiaxed Al20CeX2 primary precipitates (∼10 vol.%) which are isomorphous among these five alloys. Similar microstructures are present in arc-melted rods and atomized powders but are coarser due to the slower cooling rates in these processes. The hardness of the as-LPBF ternary Al-Ce-X alloys (1300–1400 MPa) is higher than that of the binary Al-Ce alloy (∼1100 MPa) due to the higher volume fraction of strengthening phases. Furthermore, during exposure at 400 °C for up to three months, greater hardness retention is achieved in the ternary Al-Ce-X alloys (65–75%) than in the binary Al-Ce alloy (∼55%), which is attributed to the extreme coarsening resistance of the Al20CeX2 precipitates imparted by the very slow-diffusing ternary solute. These coarsening-resistant Al20CeX2 precipitates also substantially improve alloy creep resistance, increasing the threshold stress for dislocation creep at 300°C from ∼32 MPa for the binary Al-Ce alloy to ∼77–100 MPa for the ternary Al-Ce-X alloys, and at 400°C from <10 MPa for the binary Al-Ce alloy to >40 MPa for the ternary Al-Ce-V alloy.

AB - We characterize the microstructures and high-temperature mechanical properties of Al-2Ce and ternary Al-2Ce-1X (at.%) alloys fabricated by laser powder-bed fusion (LPBF), where X = Mn, Cr, V, Mo, and W are slow-diffusing transition metals. All ternary alloys show a hypereutectic microstructure in the as-LPBF state, containing an interconnected network of eutectic Al11Ce3 phases (∼10 vol.%) and an additional population of submicron, equiaxed Al20CeX2 primary precipitates (∼10 vol.%) which are isomorphous among these five alloys. Similar microstructures are present in arc-melted rods and atomized powders but are coarser due to the slower cooling rates in these processes. The hardness of the as-LPBF ternary Al-Ce-X alloys (1300–1400 MPa) is higher than that of the binary Al-Ce alloy (∼1100 MPa) due to the higher volume fraction of strengthening phases. Furthermore, during exposure at 400 °C for up to three months, greater hardness retention is achieved in the ternary Al-Ce-X alloys (65–75%) than in the binary Al-Ce alloy (∼55%), which is attributed to the extreme coarsening resistance of the Al20CeX2 precipitates imparted by the very slow-diffusing ternary solute. These coarsening-resistant Al20CeX2 precipitates also substantially improve alloy creep resistance, increasing the threshold stress for dislocation creep at 300°C from ∼32 MPa for the binary Al-Ce alloy to ∼77–100 MPa for the ternary Al-Ce-X alloys, and at 400°C from <10 MPa for the binary Al-Ce alloy to >40 MPa for the ternary Al-Ce-V alloy.

KW - Aluminum alloys

KW - Creep

KW - High-temperature

KW - Laser powder-bed fusion

KW - Mechanical properties

KW - Microstructure

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DO - 10.1016/j.addma.2024.104442

M3 - Article

AN - SCOPUS:85204501350

SN - 2214-8604

VL - 93

JO - Additive Manufacturing

JF - Additive Manufacturing

M1 - 104442

ER -

Hypereutectic Al-Ce-X (X=Mn, Cr, V, Mo, W) alloys fabricated by laser powder-bed fusion

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