Publication Date

4-25-2018

Department

Ames Laboratory

Campus Units

Ames Laboratory

OSTI ID+

1439950

Report Number

IS-J 9680

DOI

10.1007/s11837-018-2861-9

Journal Title

JOM Journal of the Minerals, Metals & Materials Society

Volume Number

70

Issue Number

6

First Page

866

Last Page

871

Abstract

Strong chemical reactions between Al and Ce lead to the formation of intermetallics with exceptional thermal stability. The rapid formation of intermetallics directly from the liquid phase during solidification of Al-Ce alloys leads to an ultrafine microconstituent structure that effectively strengthens as-cast alloys without further microstructural optimization via thermal processing. Die casting is a high-volume manufacturing technology that accounts for greater than 40% of all cast Al products, whereas Ce is highly overproduced as a waste product of other rare earth element (REE) mining. Reducing heat treatments would stimulate significant improvements in manufacturing energy efficiency, exceeding (megatonnes/year) per large-scale heat-treatment line. In this study, multiple compositions were evaluated with wedge mold castings to test the sensitivity of alloys to the variable solidification rate inherent in high-pressure die casting. Once a suitable composition was determined, it was successfully demonstrated at 800 lbs/h in a 600-ton die caster, after which the as-die cast parts performed similarly to ubiquitous A380 in the same geometry without requiring heat treatment. This work demonstrates the compatibility of Al REE alloys with high-volume die-casting applications with minimal heat treatments.

DOE Contract Number(s)

AC05-00OR22725

Language

en

Department of Energy Subject Categories

36 MATERIALS SCIENCE

Publisher

Iowa State University Digital Repository, Ames IA (United States)

Included in

Metallurgy Commons

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