Phase stability in cast and additively manufactured Al-rich Al-Cu-Ce alloys

Alice Perrin; Sumit Bahl; Donovan N. Leonard; Richard Michi; Kevin Sisco; Alex Plotkowski; Amit Shyam; Ryan Dehoff; Dongwon Shin; Ying Yang

doi:10.1016/j.jallcom.2022.166984

Phase stability in cast and additively manufactured Al-rich Al-Cu-Ce alloys

Alice Perrin, Sumit Bahl, Donovan N. Leonard, Richard Michi, Kevin Sisco, Alex Plotkowski, Amit Shyam, Ryan Dehoff, Dongwon Shin, Ying Yang

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

12 Scopus citations

Abstract

Additively manufactured (AM) eutectic Al alloy systems have been studied extensively for advantageous thermal stability and mechanical properties due to their refined microstructures. Al-Cu-Ce alloys are one subset of these AM eutectic alloys. Here we studied phase stability in AM Al-Cu-Ce alloys and compared it to that of conventionally cast ones. A new phase, Al₈Cu₃Ce, was identified in the microstructures of both AM and cast Al-Cu-Ce alloys. This Al₈Cu₃Ce phase was not previously included on experimental or thermodynamically calculated phase diagrams of the Al-Cu-Ce system. Therefore, we performed additional thermodynamic modeling of the system. These models were experimentally validated with cast and subsequently heat-treated Al-Cu-Ce alloys. We found that despite the refined microstructure of the AM alloys, the phases formed were consistent with the cast alloys, suggesting that AM processing did not significantly alter the formation and stability of phases from that in the conventional alloys. This work has resolved inconsistent previous descriptions of the Al-Cu-Ce ternary phase diagram in the Al-rich region and resulted in the addition of the Al₈Cu₃Ce as an equilibrium phase above 500 ℃.

Original language	English
Article number	166984
Journal	Journal of Alloys and Compounds
Volume	926
DOIs	https://doi.org/10.1016/j.jallcom.2022.166984
State	Published - Dec 10 2022

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 manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. Use of the Advanced Photon Source at Argonne National Laboratory was supported by the U. S. Department of Energy, Office of Science, Office of Basic Energy Sciences, under Contract No. DE-AC02–06CH11357. We acknowledge Larry Allard for his help obtaining the TEM micrograph in Fig. 7a. 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). 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 manuscript has been authored by UT-Battelle , LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. Use of the Advanced Photon Source at Argonne National Laboratory was supported by the U. S. Department of Energy, Office of Science, Office of Basic Energy Sciences , under Contract No. DE-AC02–06CH11357 . We acknowledge Larry Allard for his help obtaining the TEM micrograph in Fig. 7 a.

Funders	Funder number
DOE Public Access Plan
United States Government
U.S. Department of Energy
Advanced Manufacturing Office	DE-AC05-00OR22725
Office of Science
Office of Energy Efficiency and Renewable Energy
Basic Energy Sciences	DE-AC02–06CH11357

Keywords

Additive manufacturing
Intermetallics
Metals and alloys
Microstructure
Phase diagrams
Thermodynamic modelling

UN SDGs

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

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10.1016/j.jallcom.2022.166984

Cite this

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title = "Phase stability in cast and additively manufactured Al-rich Al-Cu-Ce alloys",

abstract = "Additively manufactured (AM) eutectic Al alloy systems have been studied extensively for advantageous thermal stability and mechanical properties due to their refined microstructures. Al-Cu-Ce alloys are one subset of these AM eutectic alloys. Here we studied phase stability in AM Al-Cu-Ce alloys and compared it to that of conventionally cast ones. A new phase, Al8Cu3Ce, was identified in the microstructures of both AM and cast Al-Cu-Ce alloys. This Al8Cu3Ce phase was not previously included on experimental or thermodynamically calculated phase diagrams of the Al-Cu-Ce system. Therefore, we performed additional thermodynamic modeling of the system. These models were experimentally validated with cast and subsequently heat-treated Al-Cu-Ce alloys. We found that despite the refined microstructure of the AM alloys, the phases formed were consistent with the cast alloys, suggesting that AM processing did not significantly alter the formation and stability of phases from that in the conventional alloys. This work has resolved inconsistent previous descriptions of the Al-Cu-Ce ternary phase diagram in the Al-rich region and resulted in the addition of the Al8Cu3Ce as an equilibrium phase above 500 ℃.",

keywords = "Additive manufacturing, Intermetallics, Metals and alloys, Microstructure, Phase diagrams, Thermodynamic modelling",

author = "Alice Perrin and Sumit Bahl and Leonard, {Donovan N.} and Richard Michi and Kevin Sisco and Alex Plotkowski and Amit Shyam and Ryan Dehoff and Dongwon Shin and Ying Yang",

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doi = "10.1016/j.jallcom.2022.166984",

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AU - Perrin, Alice

AU - Bahl, Sumit

AU - Leonard, Donovan N.

AU - Michi, Richard

AU - Sisco, Kevin

AU - Plotkowski, Alex

AU - Shyam, Amit

AU - Dehoff, Ryan

AU - Shin, Dongwon

AU - Yang, Ying

PY - 2022/12/10

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N2 - Additively manufactured (AM) eutectic Al alloy systems have been studied extensively for advantageous thermal stability and mechanical properties due to their refined microstructures. Al-Cu-Ce alloys are one subset of these AM eutectic alloys. Here we studied phase stability in AM Al-Cu-Ce alloys and compared it to that of conventionally cast ones. A new phase, Al8Cu3Ce, was identified in the microstructures of both AM and cast Al-Cu-Ce alloys. This Al8Cu3Ce phase was not previously included on experimental or thermodynamically calculated phase diagrams of the Al-Cu-Ce system. Therefore, we performed additional thermodynamic modeling of the system. These models were experimentally validated with cast and subsequently heat-treated Al-Cu-Ce alloys. We found that despite the refined microstructure of the AM alloys, the phases formed were consistent with the cast alloys, suggesting that AM processing did not significantly alter the formation and stability of phases from that in the conventional alloys. This work has resolved inconsistent previous descriptions of the Al-Cu-Ce ternary phase diagram in the Al-rich region and resulted in the addition of the Al8Cu3Ce as an equilibrium phase above 500 ℃.

AB - Additively manufactured (AM) eutectic Al alloy systems have been studied extensively for advantageous thermal stability and mechanical properties due to their refined microstructures. Al-Cu-Ce alloys are one subset of these AM eutectic alloys. Here we studied phase stability in AM Al-Cu-Ce alloys and compared it to that of conventionally cast ones. A new phase, Al8Cu3Ce, was identified in the microstructures of both AM and cast Al-Cu-Ce alloys. This Al8Cu3Ce phase was not previously included on experimental or thermodynamically calculated phase diagrams of the Al-Cu-Ce system. Therefore, we performed additional thermodynamic modeling of the system. These models were experimentally validated with cast and subsequently heat-treated Al-Cu-Ce alloys. We found that despite the refined microstructure of the AM alloys, the phases formed were consistent with the cast alloys, suggesting that AM processing did not significantly alter the formation and stability of phases from that in the conventional alloys. This work has resolved inconsistent previous descriptions of the Al-Cu-Ce ternary phase diagram in the Al-rich region and resulted in the addition of the Al8Cu3Ce as an equilibrium phase above 500 ℃.

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KW - Intermetallics

KW - Metals and alloys

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KW - Phase diagrams

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Phase stability in cast and additively manufactured Al-rich Al-Cu-Ce alloys

Abstract

Funding

Keywords

UN SDGs

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