Ut-battelle, Inc.

Iowa State University Research Foundation Inc

The University of Tennessee Research Foundation

Eck Industries, Inc.

Lawrence Livermore National Security, LLC

Wisconsin Alumni Research Foundation

Caterpillar Inc.

Trustees of the Colorado School of Mines

Intelligent Composites, LLC

David J Weiss

Orlando Rios

Zachary C Sims

Hunter B Henderson

Ryan T Ott

Scott McCall

Michael S Kesler

Ryan Dehoff

Alex J Plotkowski

Xiaochun Li

Amit Shyam

Scott K Mccall

Hongseok Choi

Sudarsanam Suresh Babu

Ying Yang

Niyanth Sridharan

Kevin D Sisco

Gerard Michael Ludtka

Gerald Albert Gegel

Michael Alan McGuire

Peeyush Nandwana

Aurelien Perron

Alexander J Plotkowski

Sumit Bahl

Michael G Kesler

Noe Gaudencio Alba-Baena

Daniel Earl Hoefert

Woo-hyun Cho

Ben Peter Slater

Kevin M Anderson

William Carter

Bruce A Moyer

Pradeep K Rohatgi

Amelia M Elliott

Craig A Bridges

Edgar Lara-Curzio

Corby G Anderson

Alexander A Baker

Patrice E A Turchi

Hao Cui

Emily E Moore

Benjamin F Schultz

Simon S Beno

Eric Thomas Stromme

Fanqiang Meng

Tian Li

Max Neveau

Alexander H King

Christopher T Jordan

James H Hunter, Iii

Cori Thorne

Richard Michi

Lawrence Allard, Jr

A product includes a material having aluminum and at least one rare earth element (REE). The material includes the following microstructure features: at least 1 volume % particles of a phase of an aluminum-rare earth element alloy, the particles comprise at least 5 weight % of the at least one rare earth element, the particles have an average aspect ratio less than or equal to 5, and an average interparticle spacing between the particles is less than or equal to 1 μm. A method includes forming a base material, the base material having aluminum and at least one rare earth element (REE), and working the base material to form a product.

Thermomechanically processed, nanostructure aluminum-rare earth element alloys

Disclosed herein are embodiments of rapidly solidified alloys that comprise aluminum, a rare earth element, one or more additional alloying elements, such as aluminum, and an optional additive component. The alloy embodiments exhibit a unique microstructure as compared to microstructures obtained from other alloys that are not rapidly cooled. The disclosed aluminum-rare earth element alloys also exhibit improved mechanical properties without the need for post-processing heat treatments and further do not exhibit substantial coarsening.

Rapidly solidified aluminum-rare earth element alloy and method of making the same

Disclosed herein are embodiments of an Al—Ce—Cu alloy for use in additive manufacturing. The disclosed alloy embodiments provide fabricated objects, such as bulk components, comprising a heterogeneous microstructure and having good mechanical properties even when exposed to conditions used during the additive manufacturing process. Methods for making and using alloy embodiments also are disclosed herein.

Aluminum-cerium-copper alloys for metal additive manufacturing

Production of a bulk Al-RE alloy body (product) using cast billets/ingots (cooling rates <100 C/s) or rapidly solidified Al-RE particulates (cooling rates 10-10° C./second) that have beneficial microstructural refinements that are further refined by subsequent consolidation to produce a consolidated bulk alloy product having excellent mechanical properties over a wide temperature range such as up to and above 230° C.

Thermo-mechanical processing of high-performance Al-RE alloys

Disclosed herein are embodiments of an Al—Ce—Ni alloy for use in additive manufacturing. The disclosed alloy embodiments provide fabricated objects, such as bulk components, comprising a heterogeneous microstructure and having good mechanical properties even when exposed to conditions used during the additive manufacturing process. Methods for making and using alloy embodiments also are disclosed herein.

Aluminum-cerium-nickel alloys for additive manufacturing

A product includes a material having: nickel and at least one rare earth element. The at least one rare earth element is present in the material in a weight percentage in a range of about 2% to about 20% relative to a total weight of the material. A method includes forming a material comprising an alloy of nickel and at least one rare earth element. The at least one rare earth element is present in the material in a weight percentage in a range of about 2% to about 20% relative to a total weight of the material.

Castable high temperature nickel-rare earth element alloys

Disclosed herein are embodiments of aluminum-based alloys having improved intergranular corrosion resistance. Methods of making and using the disclosed alloy embodiments also are disclosed herein.

Aluminum alloys with improved intergranular corrosion resistance properties and methods of making and using the same

An alloy includes aluminum, a rare earth element, and an alloying element selected from the following: Si, Cu, Mg, Fe, Ti, Zn, Zr, Mn, Ni, Sr, B, Ca, and a combination thereof. The aluminum (Al), the rare earth element (RE), and the alloying element are characterized by forming at least one form of an intermetallic compound. An amount of the rare earth element in the alloy is in a range of about 1 wt. % to about 12 wt. %, and an amount of the alloying element in the alloy is greater than an amount of the alloying element present in the intermetallic compound.

Rare Earth Element&#x2014;Aluminum Alloys

A solid aluminum-fiber composite comprising: (i) an aluminum-containing matrix comprising elemental aluminum; (ii) coated or uncoated fibers embedded within said aluminum-containing matrix, wherein said fibers have a different composition than said aluminum-containing matrix and impart additional strength to said aluminum-containing matrix as compared to said aluminum-containing matrix in the absence of said fibers embedded therein; and (iii) an intermetallic layer present as an interface between each of said fibers and the aluminum-containing matrix, wherein said intermetallic layer has a composition different from said aluminum-containing matrix and said fibers, and said intermetallic layer contains at least one element that is also present in the aluminum-containing matrix and at least one element present in the fibers, whether from the coated or interior portion of the fibers. Methods of producing the above-described composite are also described.

Aluminum-fiber composites containing intermetallic phase at the matrix-fiber interface

Disclosed herein are embodiments of an Al&#x2014;Ce&#x2014;Mn alloy for use in additive manufacturing. The disclosed alloy embodiments provide fabricated objects, such as bulk components, comprising a heterogeneous microstructure and having good mechanical properties even when exposed to conditions used during the additive manufacturing process. Methods for making and using alloy embodiments also are disclosed herein.

Aluminum-cerium-manganese alloy embodiments for metal additive manufacturing

A reactive matrix infiltration process is described herein, which includes contacting a surface of a preform comprising reinforcement material particles with a molten infiltrant comprising a matrix material, the matrix material comprising an Al&#x2014;Ce alloy, whereby the infiltrant at least partially fills spaces between the reinforcement material particles by capillary action and reacts with the reinforcement material particles to form a composite material form, the composite material comprising the matrix material, at least one intermetallic phase, and, optionally, reinforcement material particles. A composite material form also is described, which includes a plurality of reinforcement material particles comprising a metal alloy or a ceramic, a matrix material at least partially filling spaces between the reinforcement material particles; and at least one intermetallic phase surrounding at least some of the reinforcement material particles. The reinforcement material particles and intermetallic phase together may form a gradient core-shell structure.

Reactive matrix infiltration of powder preforms

An alloy for structural direct-writing additive manufacturing comprising a base element selected from the group consisting of aluminum (Al), nickel (Ni) and a combination thereof, and a rare earth element selected from the group consisting of cerium (Ce), lanthanide (La) and a combination thereof, and a eutectic intermetallic present in said alloy in an amount ranging from about 0.5 wt. % to 7.5 wt. %. The invention is also directed to a method of structural direct-write additive manufacturing using the above-described alloy, as well as 3D objects produced by the method. The invention is also directed to methods of producing the above-described alloy.

Structural direct-write additive manufacturing of molten metals

Described herein are additive manufacturing methods and products made using such methods. The alloy compositions described herein are specifically selected for the additive manufacturing methods and provide products that exhibit superior mechanical properties as compared to their cast counterparts. Using the compositions and methods described herein, products that do not exhibit substantial coarsening, such as at elevated temperatures, can be obtained. The products further exhibit uniform microstructures along the print axis, thus contributing to improved strength and performance. Additives also can be used in the alloys described herein.

Additive manufacturing methods using aluminum-rare earth alloys and products made using such methods

The present invention provides an aluminum hybrid metal matrix composite including cerium and graphite. The aluminum-cerium intermetallic is stable at temperatures up to a melting point of aluminum and graphite provides in situ lubrication. This stability is advantageous in applications such as cylinder liners and other applications where strength and stiffness at elevated temperatures are required.

Aluminum based alloy containing cerium and graphite

The disclosure concerns methods for making a composition comprising a light metal and an intermetallic comprising the light metal and a light rare earth element. The composition also may include a plurality of nanoparticles comprising an oxide of the light metal. The method includes directly reducing a light rare earth element precursor compound in a melt of the light metal, thereby forming the light rare earth element and nanoparticles of the light metal oxide.

Production of castable light rare earth rich light metal compositions from direct reduction processes

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Manitowoc, WI, United States of America

David J Weiss