Title
Ageless Aluminum-Cerium-Based Alloys in High-Volume Die Casting for Improved Energy Efficiency
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)