Gm Global Technolgoy Operations, Inc.

Tengjiao Qi

Zhongyi Liu

Michael P Balogh

Fang Dai

James R Salvador

Frederick E Pinkerton

Hongliang Wang

Ratandeep S Kukreja

Daad B Haddad

A method of manufacturing a crystalline aluminum-iron-silicon alloy and a crystalline aluminum-iron-silicon alloy part. An aluminum-, iron-, and silicon-containing composite powder is provided that includes an amorphous phase and a first crystalline phase having a hexagonal crystal structure at ambient temperature. The composite powder is heated at a temperature in the range of 850&#xb0; C. to 950&#xb0; C. to transform at least a portion of the amorphous phase into the first crystalline phase and to transform the composite powder into a crystalline aluminum-iron-silicon (Al&#x2014;Fe&#x2014;Si) alloy. The first crystalline phase is a predominant phase in the crystalline Al&#x2014;Fe&#x2014;Si alloy.

Method of manufacturing a crystalline aluminum-iron-silicon alloy

Provided is a method of manufacturing a crystalline aluminum-iron-silicon alloy, and optionally an automotive component comprising the same, comprising forming a composite ingot including a plurality of crystalline phases by melting aluminum, iron, and silicon raw materials in an inert environment to form a substantially homogenous melt, subsequently solidifying the melt, and annealing the ingot under vacuum by heating at a temperature in the range of 850&#xb0; C. to 1000&#xb0; C. yield an annealed crystalline ingot wherein the predominant crystalline phase is FCC AlFeSi. The raw materials can further include one or more additives such as zinc, zirconium, tin, and chromium. Melting can occur above the FCC AlFeSi crystalline phase melting point, or at a temperature of about 1100&#xb0; C. to about 1400&#xb0; C. Annealing can occur under vacuum conditions.

A lithium-based electrode assembly and methods of formation relating thereto are provided. The lithium-based electrode assembly comprises a metal current collector, an electrode comprising lithium metal, and an intermediate layer disposed therebetween. The intermediate layer comprising an intermetallic compound comprising the lithium metal of the electrode and a metal selected from the group consisting of: aluminum, silver, gold, barium, bismuth, boron, calcium, cadmium, carbon, gallium, germanium, mercury, indium, iridium, lead, palladium, platinum, rhodium, antimony, selenium, silicon, tin, strontium, sulfur, tellurium, zinc, and combinations thereof. The method of forming the lithium assembly includes coating a surface of the metal current collector with the intermediate layer; disposing the electrode onto an exposed surface of the intermediate layer; and heating the electrode, the intermediate layer, and the metal current collector to form the lithium intermetallic compound, which joins the metal current collector and the electrode together.

Methods of preparing lithium metal anodes

In an example of a method for forming a high-strength, lightweight alloy, starting materials are provided. The starting materials include aluminum, iron, and silicon. The starting materials are ball milled to generate the high-strength, lightweight alloy of a stable AlFeSiphase, wherein x ranges from about 3 to about 5, y ranges from about 1.5 to about 2.2, and z is about 1.

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Clinton Township, MI, United States of America

Tengjiao Qi