US 12,305,267 B2
Rapidly solidified aluminum-rare earth element alloy and method of making the same
Orlando Rios, Knoxville, TN (US); Scott McCall, Livermore, CA (US); Ryan Ott, Ames, IA (US); Zachary Cole Sims, Knoxville, TN (US); Michael Kesler, Knoxville, TN (US); Hunter B. Henderson, Knoxville, TN (US); Michael McGuire, Knoxville, TN (US); and David Weiss, Manitowoc, WI (US)
Assigned to UT-Battelle, LLC, Oak Ridge, TN (US); University of Tennessee Research Foundation, Knoxville, TN (US); Iowa State University Research Foundation, Inc., Ames, IA (US); ECK Industries Incorporated, Manitowoc, WI (US); and Lawrence Livermore National Security, LLC, Livermore, CA (US)
Filed by UT-Battelle, LLC, Oak Ridge, TN (US); University of Tennessee Research Foundation, Knoxville, TN (US); Iowa State University Research Foundation, Inc., Ames, IA (US); ECK Industries Incorporated, Manitowoc, WI (US); and Lawrence Livermore National Security, LLC, Livermore, CA (US)
Filed on Feb. 21, 2018, as Appl. No. 15/901,759.
Claims priority of provisional application 62/616,658, filed on Jan. 12, 2018.
Claims priority of provisional application 62/461,899, filed on Feb. 22, 2017.
Prior Publication US 2018/0237893 A1, Aug. 23, 2018
Int. Cl. C22F 1/00 (2006.01); B22D 17/22 (2006.01); B22D 21/00 (2006.01); C22C 1/02 (2006.01); C22C 1/11 (2023.01); C22C 21/00 (2006.01); C22C 21/06 (2006.01); C22C 45/08 (2006.01); C22F 1/04 (2006.01); C22F 1/047 (2006.01)
CPC C22F 1/002 (2013.01) [B22D 17/2218 (2013.01); B22D 21/007 (2013.01); C22C 1/026 (2013.01); C22C 1/11 (2023.01); C22C 21/00 (2013.01); C22C 21/06 (2013.01); C22C 45/08 (2013.01); C22F 1/04 (2013.01); C22F 1/047 (2013.01); C22C 2200/02 (2013.01)] 11 Claims
OG exemplary drawing
 
1. A method, comprising:
combining aluminum with (i) 0.1 wt % to 8 wt % of an additional alloying element selected from magnesium, zinc, titanium, manganese, zirconium, vanadium, scandium, copper, or nickel, or one or more of magnesium, zinc, titanium, manganese, zirconium, vanadium, and scandium in combination with copper or in combination with nickel; (ii) at least one rare earth component selected from lanthanum, cerium, mischmetal, or a combination thereof; and (iii) 0.1 wt % to 2 wt % of an additive component selected from iron, strontium, boron, manganese, titanium, chromium, cobalt, carbon, or a combination thereof to form an aluminum-based alloy composition; wherein the aluminum-based alloy composition does not comprise both copper and nickel in combination; and
performing a cooling step, wherein the mixed aluminum-based alloy composition is cooled at an average cooling rate range from greater than 100 K/s to 108 K/s to provide an aluminum-based alloy comprising an aluminum matrix phase, an Al11X3 intermetallic phase where X is one of lanthanum, cerium, or mischmetal, or a combination thereof, and (i) a semi- to fully-eutectic phase with a maximum spacing between morphologic features of the semi- to fully-eutectic phase being no greater than 8 μm; or (ii) a phase comprising laths and/or rods, wherein the aluminum matrix phase, the Al11X3 intermetallic phase, and the semi- to fully-eutectic phase, or the phase comprising laths and/or rods are obtained without a heat treatment; provided that the cooling step does not comprise continuous cast rolling to cool the mixed aluminum-based alloy composition.