US 11,986,904 B2
Aluminum-cerium-nickel alloys for additive manufacturing
Ryan R. Dehoff, Knoxville, TN (US); Hunter B. Henderson, Livermore, CA (US); Scott McCall, Livermore, CA (US); Richard Michi, Knoxville, TN (US); Peeyush Nandwana, Oak Ridge, TN (US); Ryan Ott, Ames, IA (US); Alexander J. Plotkowski, Knoxville, TN (US); Orlando Rios, Knoxville, TN (US); Amit Shyam, Knoxville, TN (US); Zachary C. Sims, Knoxville, TN (US); Kevin D. Sisco, Knoxville, TN (US); David Weiss, Manitowoc, WI (US); and Ying Yang, Knoxville, TN (US)
Assigned to UT-Battelle, LLC, Oak Ridge, TN (US); University of Tennessee Research Foundation, Knoxville, TN (US); and Iowa State University Research Foundation, Inc., Ames, IA (US)
Filed by Ryan R. Dehoff, Knoxville, TN (US); Hunter B. Henderson, Livermore, CA (US); Scott McCall, Livermore, CA (US); Richard Michi, Knoxville, TN (US); Peeyush Nandwana, Oak Ridge, TN (US); Ryan Ott, Ames, IA (US); Alexander J. Plotkowski, Knoxville, TN (US); Orlando Rios, Knoxville, TN (US); Amit Shyam, Knoxville, TN (US); Zachary C. Sims, Knoxville, TN (US); Kevin D. Sisco, Knoxville, TN (US); David Weiss, Manitowoc, WI (US); and Ying Yang, Knoxville, TN (US)
Filed on Oct. 29, 2020, as Appl. No. 17/084,582.
Claims priority of provisional application 62/927,884, filed on Oct. 30, 2019.
Prior Publication US 2021/0129270 A1, May 6, 2021
Int. Cl. C22C 21/00 (2006.01); B23K 26/342 (2014.01); B33Y 10/00 (2015.01); B33Y 70/00 (2020.01); B33Y 70/10 (2020.01); B22F 9/08 (2006.01); B23K 103/10 (2006.01)
CPC B23K 26/342 (2015.10) [B33Y 10/00 (2014.12); B33Y 70/00 (2014.12); B33Y 70/10 (2020.01); C22C 21/00 (2013.01); B22F 2009/0824 (2013.01); B22F 2301/052 (2013.01); B22F 2304/10 (2013.01); B23K 2103/10 (2018.08)] 15 Claims
OG exemplary drawing
 
1. An alloy composition, comprising:
greater than 0 wt % to 35 wt % cerium;
greater than 1 wt % to 35 wt % nickel;
a minor alloying element that is manganese, wherein the manganese is present in an amount ranging from greater than 0 wt % to 3 wt %; and
a balance of aluminum;
wherein, when the alloy composition is additively manufactured, the amount of cerium and amount of nickel present in the alloy composition are sufficient to cause the formation of an aluminum-based matrix phase comprising isolated features having an average length of 50 nm to 50 μm and one or more intermetallic phases selected from Al23Ni6Ce4, Al11Ce3, Al7Ni2Ce, Al20Mn2Ce or Al3Ni, wherein at least one of the one or more intermetallic phases forms lattice-like structures between the aluminum-based matrix, with a thickness ranging from 10 nm to 100 nm; and
wherein more than half of the manganese amount in the alloy is in solid solution in the aluminum-based matrix phase and provides solid solution strengthening to the aluminum-based matrix phase when the alloy is additively manufactured.