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WO2020106764A1 - Produits d'alliage d'aluminium améliorés et leurs procédés de fabrication - Google Patents

Produits d'alliage d'aluminium améliorés et leurs procédés de fabrication

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Publication number
WO2020106764A1
WO2020106764A1 PCT/US2019/062278 US2019062278W WO2020106764A1 WO 2020106764 A1 WO2020106764 A1 WO 2020106764A1 US 2019062278 W US2019062278 W US 2019062278W WO 2020106764 A1 WO2020106764 A1 WO 2020106764A1
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WO
WIPO (PCT)
Prior art keywords
aluminum alloy
product
elements
class
mol
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2019/062278
Other languages
English (en)
Inventor
Lynette M. Karabin
Cagatay Yanar
Andreas Kulovits
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Howmet Aerospace Inc
Original Assignee
Arconic Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Arconic Inc filed Critical Arconic Inc
Publication of WO2020106764A1 publication Critical patent/WO2020106764A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/17—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by forging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/18—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by using pressure rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/20—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by extruding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/009—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of turbine components other than turbine blades
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • Aluminum alloys are useful in a variety of applications. However, improving one property of an aluminum alloy without degrading another property often proves elusive. For example, it is difficult to increase the strength of an alloy without decreasing the toughness of an alloy.
  • Other properties of interest for aluminum alloys include thermal stability, corrosion resistance and fatigue crack growth rate resistance, to name two.
  • the field of the invention relates to aluminum alloy products and methods for making the same.
  • the present patent application relates to new aluminum alloys.
  • the new aluminum alloys comprise (and some instances consist essentially of or consist of) from 1.2 to 4.1 at. % Fe, from 0.2 to 1.1 at. % of Class X elements, where the at. % Fe plus at. % Class X elements (i.e., (at. % Fe) + (at. % Class X elements)) is from 2.3 to 4.3 at. %, and from 0.9 to 2.5 at. % Si.
  • the Class X elements generally comprise at least one of vanadium (V), molybdenum (Mo), niobium (Nb), tantalum (Ta), and tungsten (W).
  • the new aluminum alloys generally include an amount of the Fe, the Class X elements, and the Si falling within an area on a graph having (at. % Fe plus at. % Class X) content on one axis and having (at. % Si) on another axis, the area being defined by the following comers in Table 1, below.
  • FIG. 1 is a graph of at. % Si versus at. % (Fe + X) that illustrates the aluminum alloy composition space for the new aluminum alloys described herein.
  • the use of iron (or its transition metal substitutes, noted below) the Class X elements, and the silicon may facilitate, for instance, the formation of a-AlFeSi phase while restricting the formation of Ak,(Fe,Mn) phases in the alloy.
  • the a-AlFeSi phase may facilitate, for instance, improved thermal stability. Restriction of Ak,(Fe,Mn) phases may facilitate, for instance, production of crack- free products.
  • the balance of the new aluminum alloys is aluminum, optional incidental elements, and impurities. Products incorporating such alloy compositions may achieve an improved combination of, for instance, printability in additive manufacturing, strength, and/or ductility, among others.
  • FIG. 1 is a graph showing the boundaries of (Fe + X) and Silicon for the new aluminum alloys described herein.
  • the new aluminum alloys generally include from 0.9 to 2.5 at. % Si.
  • a new aluminum alloy includes at least 1.0 at. % Si.
  • a new aluminum alloy includes at least 1.1 at. % Si.
  • a new aluminum alloy includes at least 1.2 at. % Si.
  • a new aluminum alloy includes at least 1.3 at. % Si.
  • a new aluminum alloy includes not greater than 2.4 at. % Si.
  • a new aluminum alloy includes not greater than 2.4 at. % Si.
  • a new aluminum alloy includes not greater than 2.3 at. % Si.
  • a new aluminum alloy includes not greater than 2.1 at. % Si.
  • a new aluminum alloy includes not greater than 2.0 at. % Si.
  • the new aluminum alloys generally include an amount of Fe plus Class X elements (i.e., (at. % Fe) + (at. % Class X elements)) of from 2.3 to 4.3 at. %.
  • the amount of at. % Fe plus at. % Class X elements in a new aluminum alloy is not greater than 4.2 at. %.
  • the amount of at. % Fe plus at. % Class X elements in a new aluminum alloy is not greater than 4.1 at. %.
  • the amount of at. % Fe plus at. % Class X elements in a new aluminum alloy is not greater than 4.0 at. %.
  • % Class X elements in a new aluminum alloy is not greater than 3.95 at. %. In another embodiment, the amount of at. % Fe plus at. % Class X elements in a new aluminum alloy is not greater than 3.9 at. %. In yet another embodiment, the amount of at. % Fe plus at. % Class X elements in a new aluminum alloy is not greater than 3.85 at. %. In another embodiment, the amount of at. % Fe plus at. % Class X elements in a new aluminum alloy is not greater than 3.8 at. %. In yet another embodiment, the amount of at. % Fe plus at. % Class X elements in a new aluminum alloy is not greater than 3.75 at. %.
  • the new aluminum alloys comprise up to 4.0 at. % of Class Z elements.
  • the Class Z elements are generally comprised of at least one of copper (Cu), magnesium (Mg), zinc (Zn), lithium (Li), and silver (Ag).
  • a new aluminum alloy includes from 0.01 to 4.0 at. % of Class Z elements.
  • a new aluminum alloy includes up to 3.0 at. % of Class Z elements.
  • a new aluminum alloy includes up to 2.0 at. % of Class Z elements.
  • a new aluminum alloy includes up to 1.0 at. % of Class Z elements.
  • a new aluminum alloy includes up to 0.5 at. % of Class Z elements.
  • a new aluminum alloy includes up to 0.25 at. % of Class Z elements. In another embodiment, a new aluminum alloy includes up to 0.1 at. % of Class Z elements. In yet another embodiment, a new aluminum alloy includes up to 0.05 at. % of Class Z elements. In another embodiment, a new aluminum alloy includes not greater than 0.01 at. % of Class Z elements. In yet another embodiment, a new aluminum alloy includes not greater than 0.005 at. % of Class Z elements.
  • the new aluminum alloys comprise up to 3.0 at. % of Class H elements.
  • the Class H elements are generally comprised of at least one of titanium (Ti), zirconium (Zr), and hafnium (Hf).
  • the Class H metals be used for grain refining / grain structure control, for instance.
  • a new aluminum alloy may include titanium, and the titanium may form the intermetallic AhTi phase during solidification (e.g., before the formation of other solid phases). The AhTi that forms during solidification may facilitate alloy crystal formation (i.e., may grain refine).
  • a new aluminum alloy includes from 0.01 to 3.0 at. % of Class H elements.
  • a new aluminum alloy includes up to 2.0 at. % of Class H elements. In another embodiment, a new aluminum alloy includes up to 1.0 at. % of Class H elements. In yet another embodiment, a new aluminum alloy includes up to 0.5 at. % of Class H elements. [009] In some embodiments, the new aluminum alloys comprise up to 1.0 at. % of Class
  • a new aluminum alloy includes from 0.01 to 1.0 at. % Class E metals. In one embodiment, a new aluminum alloy includes up to 0.75 at. % Class E metals. In another embodiment, a new aluminum alloy includes up to 0.50 at. % Class E metals. In yet another embodiment, a new aluminum alloy includes up to 0.25 at. % Class E metals. In another embodiment, a new aluminum alloy includes up to 0.10 at. % Class E metals. In yet another embodiment, a new aluminum alloy includes up to 0.05 at. % Class E metals. In another embodiment, a new aluminum alloy includes not greater than 0.01 at. % Class E metals. In yet another embodiment, a new aluminum alloy includes not greater than 0.005 at. % Class E metals.
  • the new aluminum alloys include up to 2.0 at. % of rare earth elements. In one embodiment, a new aluminum alloy includes up to 1.5 at. % of rare earth elements. In another embodiment, a new aluminum alloy includes up to 1.0 at. % of rare earth elements. In yet another embodiment, a new aluminum alloy includes up to 0.75 at. % of rare earth elements. In another embodiment, a new aluminum alloy includes up to 0.5 at. % of rare earth elements. In yet another embodiment, a new aluminum alloy includes up to 0.25 at. % of rare earth elements. In another embodiment, a new aluminum alloy includes up to 0.1 at. % of rare earth elements. In yet another embodiment, a new aluminum alloy includes up to 0.05 at. % of rare earth elements. In another embodiment, a new aluminum alloy includes not greater than 0.01 at. % of rare earth elements. In yet another embodiment, a new aluminum alloy includes not greater than 0.005 at. % of rare earth elements.
  • rare earth elements includes one or more of, for instance, scandium, yttrium, and any of the fifteen lanthanides elements.
  • the lanthanides are the fifteen metallic chemical elements with atomic numbers 57 through 71, from lanthanum through lutetium.
  • the balance of the new aluminum alloys may be aluminum and any optional incidental elements and impurities.
  • incidental elements means those elements or materials, other than the above listed elements, that may optionally be added to the alloy to assist in the production of the alloy.
  • incidental elements include casting aids, such as grain refiners and deoxidizers.
  • Optional incidental elements may be included in the alloy in a cumulative amount of up to 1.0 at. %. Some incidental elements may be added to the alloy to reduce or restrict (and is some instances eliminate) cracking in the additively manufactured part due to, for example, folds (e.g., oxide folds), pits and patches (e.g., oxide patches).
  • deoxidizers These types of incidental elements are generally referred to herein as deoxidizers.
  • deoxidizers include Ca, Sr, P and Be.
  • calcium (Ca) When calcium (Ca) is included in the alloy, it is generally present in an amount of up to 0.3 wt. %, or up to 0.2 wt. %, or up to 0.1 wt. %.
  • Ca is included in the alloy in an amount of 0.001-0.1 wt. % or 0.001- 0.2 wt. % or 0.001-0.3 wt. %, such as 0.001-0.25 wt. % (or 10 to 2500 ppm).
  • Strontium may be included in the alloy as a substitute for Ca (in whole or in part), and thus may be included in the alloy in the same or similar amounts as Ca.
  • Phosphorus (P) may be included in the alloy as a substitute for Ca or Sr (in whole or in part), and thus may be included in the alloy in the same or similar amounts as Ca or Sr.
  • Be beryllium
  • incidental elements include carbon and boron, which may be used, for instance, with titanium, to facilitate grain refining, among other things (e.g., when in the form of T1B2 or TiC, for instance).
  • Carbon and/or boron may be included, for instance, in an amount of up to 3.0 wt. %.
  • carbon and/or boron are included in an aluminum alloy in an amount up to 2.0 wt. %.
  • carbon and/or boron are included in an aluminum alloy in an amount up to 1.0 wt. %.
  • Other elements, such as oxygen and nitrogen, may also find use in the alloy (e.g., when in the form of oxides or nitrides).
  • Incidental elements may be present in minor amounts, or may be present in significant amounts, and may add desirable or other characteristics on their own without departing from the alloy described herein, so long as the alloy retains the desirable characteristics described herein. It is to be understood, however, that the scope of this disclosure should not/cannot be avoided through the mere addition of an element or elements in quantities that would not otherwise impact on the combinations of properties desired and attained herein. Some of the above ranges of incidental elements that may be included are given in weight percent. Those skilled in the art can readily convert the weight percentages to atomic percentages as necessary.
  • grain refiner means a nucleant or nucleants that facilitates alloy crystal formation. As it relates to the present alloying systems, a grain refiner may facilitate, for instance, formation of eutectic structures and/or primary phase solidification. In one embodiment, a grain refiner comprises an intermetallic material.
  • chromium fully replaces iron, and thus a new aluminum alloy may include from 1.2 to 4.1 at. % Cr, with iron being present as an impurity.
  • chromium is partially substituted for iron, and thus a new aluminum alloy may include from 1.2 to 4.1 at. % at. % (Cr+Fe).
  • manganese fully replaces iron, and thus a new aluminum alloy may include from 1.2 to 4.1 at. % Mn, with iron being present as an impurity.
  • manganese is partially substituted for iron, and thus a new aluminum alloy may include from 1.2 to 4.1 at. % (Mn+Fe).
  • cobalt fully replaces iron, and thus a new aluminum alloy may include from 1.2 to 4.1 at. % Co, with iron being present as an impurity.
  • cobalt is partially substituted for iron, and thus a new aluminum alloy may include from 1.2 to 4.1 at. % (Co+Fe).
  • nickel fully replaces iron, and thus a new aluminum alloy may include from 1.2 to 4.1 at. % Ni, with iron being present as an impurity.
  • nickel is partially substituted for iron, and thus a new aluminum alloy may include from 1.2 to 4.1 at. % (Ni+Fe).
  • transition metals While only combinations of two transition metals are shown above, three or more transition metals may be used in the new aluminum alloys, and the ranges and amounts described above apply to aluminum alloys having three or more transition metals.
  • a-AlFeSi phase and “Ale(Fe, Mn) phase” also includes chromium- containing, manganese-containing, cobalt-containing and nickel-containing intermetallic compounds, and irrespective of whether iron is contained in those compounds or not.
  • the recitation of any ranges or compositions relating to iron also specifically apply to aluminum alloys having chromium, manganese, cobalt and/or nickel, and irrespective of whether iron is included in such aluminum alloys.
  • a new aluminum alloy comprises from 12 mol. % to 24 mol. % of a-AlFeSi phase. In another embodiment, a new aluminum alloy comprises not greater than 22 mol. % of a-AlFeSi phase. In yet another embodiment, a new aluminum alloy comprises not greater than 20 mol. % of a-AlFeSi phase. In another embodiment, a new aluminum alloy comprises not greater than 18 mol. % of a-AlFeSi phase.
  • the“a -AlFeSi phase” means the Alo . 66Feo.i9Sio . o5(Al,Si)o .i phase in a Scheil solidification model.
  • the PANDAT® computer software employing the“PanA12018b_all” database is used to produce the Scheil solidification models described herein.
  • a new aluminum alloy comprises not greater than 5 mol. % of Ale(Fe, Mn) phases. In another embodiment, a new aluminum alloy comprises not greater than 4 mol. % of Ak,(Fe, Mn) phases. In yet another embodiment, a new aluminum alloy comprises not greater than 3 mol. % of Ak,(Fe, Mn) phases. In another embodiment, a new aluminum alloy comprises not greater than 2 mol. % phases. In yet another embodiment, a new aluminum alloy comprises not greater than 1 mol. % of Ak,(Fe, Mn) phases. In one embodiment, a new aluminum alloy comprises 0% Ah,(Fe, Mn) phases.
  • the“A (Fe, Mn) phase” means the“A (Fe, Mn) phase” phase in a Scheil solidification model.
  • the PANDAT® computer software employing the“PanA12018b_all” database is used to produce the Scheil solidification models described herein.
  • The“mol. % of a-AlFeSi phase” and“mol. % of Ale(Fe, Mn) phase” are determined by inputting a specific aluminum alloy composition into the PANDAT® computer software (version 2018.1, dated May 24, 2018) employing the“PanA12018b_all” database (dated May 24, 2018), where the computer software parameters are the following:
  • o f_tot(@Diamond) i.e., the Si (diamond) phase
  • o f_tot(@A16_FeMn) i.e., the Ah,(Fe, Mn) phase
  • the Class X elements i.e., V, Mo, Nb, Ta, and W
  • the transition metal substitutes for iron i.e., Cr, Mn, Co and Ni
  • the amounts of these elements are added to the total amount of iron.
  • the amounts of these elements shall be added to the amount of iron, even if the total amount of iron exceeds the amount of iron indicated in a disclosed or claimed embodiment in the present application.”
  • an aluminum alloy having 3.0 at. % Fe, 0.5 at. % V, 1.5 at. % Si, and a balance of aluminum is input into the PANDAT® computer software as an aluminum alloy having 3.5 at. % Fe, 1.5 at. % Si, and a balance of aluminum.
  • the output from the PANDAT® computer software for this hypothetical alloy is given in Table 2:
  • f_tot(@Alpha_AlFeSi) is the mole fraction of a-AlFeSi phase
  • f_tot(@Fcc) is the mole fraction of fee aluminum phase
  • f_tot(@Diamond) is the mole fraction of Si (diamond) phase
  • f_tot(@A16_FeMn) is the mole fraction of Ah,(Fe, Mn) phase.
  • the new aluminum alloys comprise a fine eutectic-type structure.
  • a“fine eutectic-type structure” means an alloy microstructure having regularly dispersed iron-bearing phases, such as regularly dispersed Ak,(Fe, Mn) and/or a-AlFeSi phases, which phases may at least partially make-up one or more of the following types of structures: spheroidal, cellular, lamellar, and wavy eutectic, for instance.
  • a fine eutectic-type structure comprises at least two of the following strucutres: spheroidal, cellular, lamellar, wavy eutectic, or other.
  • an aluminum alloy product includes, as a non-limiting example, from 12 to 24 mol.% of a- AlFeSi phases and up to 0.05 mol. % of Ale(Fe, Mn) phases.
  • a new aluminum alloy product comprises a fine eutectic-type structure having an average spacing between eutectic structures (“average eutectic spacing”) of not greater than 10 micrometers.
  • the average eutectic spacing is not greater than 8 micrometers.
  • the average eutectic spacing is not greater than 6 micrometers.
  • the average eutectic spacing is not greater than 5 micrometers.
  • the average eutectic spacing is not greater than 4 micrometers.
  • the average eutectic spacing is not greater than 3 micrometers.
  • the average eutectic spacing is not greater than 2 micrometers.
  • the average eutectic spacing is not greater than 1 micrometers.
  • the average eutectic spacing is not greater than 0.5 micrometers.
  • “average eutectic spacing” means the average spacing between the eutectic structures of the product as determined by the“Heyn Lineal Intercept Procedure” method described in ASTM standard El 12-13, entitled, “Standard Test Methods for Determining Average Grain Size”, wherein the distance between eutectic structures is/are measured as opposed to the grains.
  • an additively manufactured aluminum alloy comprises equiaxed grains.
  • Additively manufactured products that comprise equiaxed grains may realize, for instance, improved ductility and/or strength, among others.
  • equiaxed grains may facilitate the realization of improved ductility and/or strength, among others.
  • an additively manufactured aluminum alloy product comprises equiaxed grains, wherein the average grain size is of from 0.05 to 50 microns.
  • “equiaxed grains” means grains having an average aspect ratio of less than 4: 1 as measured in the XY, YZ, and XZ planes.
  • The“aspect ratio” is determined using commercial software Edax OIM version 8.0 or equivalent. The commercial software fits an ellipse to the perimeter points of the grain.
  • “aspect ratio” is the inverse of: the length of the minor axis of the ellipse divided by the length of the major axis of the ellipse as determined using commercial software.
  • an additively manufactured aluminum alloy product comprises equiaxed grains having an average aspect ratio of less than 4: 1.
  • an additively manufactured aluminum alloy product comprises equiaxed grains having an average aspect ratio of not greater than 3: 1. In one described embodiment, an additively manufactured aluminum alloy product comprises equiaxed grains having an average aspect ratio of not greater than 2: 1. In one embodiment, an additively manufactured aluminum alloy product comprises equiaxed grains having an average aspect ratio of not greater than 1.5: 1. In one embodiment, an additively manufactured aluminum alloy product comprises equiaxed grains having an average aspect ratio of not greater than 1.1 : 1.
  • the amount (volume percent) of equiaxed grains in the additively manufactured product in the as-built condition may be determined by EBSD (electron backscatter diffraction) analysis of a suitable number of SEM micrographs of the additively manufactured- product in the as-built condition. Generally, at least 5 micrographs should be analyzed.
  • EBSD electron backscatter diffraction
  • the average size of equiaxed grains of the additively manufactured aluminum alloy product may be not greater than 50 microns. In one embodiment, the average size of the equiaxed grains of the additively manufactured aluminum alloy product is not greater than 40 microns. In another embodiment, the average size of the equiaxed grains of the additively manufactured aluminum alloy product is not greater than 30 microns. In yet another embodiment, the average size of the equiaxed grains of the additively manufactured aluminum alloy product is not greater than 20 microns. In another embodiment, the average size of the equiaxed grains of the additively manufactured aluminum alloy product is not greater than 10 microns.
  • the average size of the equiaxed grains of the additively manufactured aluminum alloy product is not greater than 5 microns. In another embodiment, the average size of the equiaxed grains of the additively manufactured aluminum alloy product is not greater than 4 microns. In yet another embodiment, the average size of the equiaxed grains of the additively manufactured aluminum alloy product is not greater than 3 microns. In another embodiment, the average size of the equiaxed grains of the additively manufactured aluminum alloy product is not greater than 2 microns, or less. In any of these embodiments, the equiaxed grains may be realized in the as-built condition.
  • an additively manufactured aluminum alloy product comprises grains and at least 50 vol. % of the grains are equiaxed grains. In another embodiment, an additively manufactured aluminum alloy product comprises at least 60 vol. % of equiaxed grains. In yet another embodiment, an additively manufactured aluminum alloy product comprises at least 70 vol. % of equiaxed grains. In another embodiment, an additively manufactured aluminum alloy product comprises at least 80 vol. % of equiaxed grains. In yet another embodiment, an additively manufactured aluminum alloy product comprises at least 90 vol. % of equiaxed grains. In another embodiment, an additively manufactured aluminum alloy product comprises at least 95 vol. % of equiaxed grains. In yet another embodiment, an additively manufactured aluminum alloy product comprises at least 99 vol. % of equiaxed grains, or more. In any of these embodiments, the equiaxed grains may be realized in the as-built condition.
  • the“as-built condition” means the condition of the additively manufactured aluminum alloy product after production and absent of any subsequent mechanical, thermal or thermomechanical treatments.
  • the“grain size” is calculated by the following equation:
  • a i is the area of the individual grain as measured using commercial software Edax OIM version 8.0 or equivalent;
  • Grain size is determined based on a two-dimensional plane that includes the build direction of the additively manufactured product.
  • the“area weighted average grain size” is calculated by the following equation: v-bar - C ⁇ /UvO/ffi ⁇ Ai)
  • Ai is the area of each individual grain as measured using commercial software Edax OIM version 8.0 or equivalent;
  • vi is the calculated individual grain size assuming the grain is a circle
  • v-bar is the area weighted average grain size.
  • the aluminum alloy products comprise columnar grains (defined below).
  • columnar grains means grains having an average aspect ratio of at least 4: 1 as measured in the YZ and/or XZ planes, wherein the Z plane is the build direction.
  • The“aspect ratio” is determined using commercial software Edax OIM version 8.0 or equivalent. The commercial software fits an ellipse to the perimeter points of the grain.
  • columnar grains have an average aspect ratio of at least 5: 1.
  • columnar grains have an average aspect ratio of at least 6: 1.
  • columnar grains have an average aspect ratio of at least 7: 1.
  • columnar grains have an average aspect ratio of at least 8: 1.
  • columnar grains have an average aspect ratio of at least 9: 1.
  • columnar grains have an average aspect ratio of at least 10: 1.
  • the new aluminum alloys may be made via any suitable processing route.
  • the new aluminum alloys are in a cast form such as in the form of an ingot or billet (e.g., for using in making atomized powders).
  • the new aluminum alloys are in the form of a wrought product, such as in the form of a sheet product, a plate product, a foil product, a forged product, or an extruded product.
  • the new aluminum alloys are in the form of a powder metallurgy product.
  • the new aluminum alloys are shape cast.
  • the processing route involves rapid solidification (e.g., to facilitate production of fine eutectic-type microstructures), such as high-pressure die casting and some continuous castings techniques.
  • the new aluminum alloys are additively manufactured, as described below.
  • the new aluminum alloys are in the form of powders or wires (e.g., for use in an additive manufacturing process).
  • the new aluminum alloys are in the form of sheets (e.g., foils) for use in additive manufacturing processes such as sheet lamination, per ASTM F2792-12a.
  • the new aluminum alloys described herein may be used to produce aluminum alloy products via powder metallurgy methods.
  • a powder comprising any of the aluminum alloy compositions described above may be used to produce a powder metallurgy product.
  • the powder may be produced by suitable methods, such as by mechanical, chemical, and physical methods (e.g., atomization).
  • mechanical methods for producing powders may include machining, milling, and/or mechanical alloying.
  • Chemical methods for producing powders may include electrolytic deposition, thermal decomposition, precipitation from a liquid, precipitation from a gas, and/or solid-solid reactive synthesis.
  • the powder may comprise alloyed particles (i.e., a chemical mixture of elements) and/or non-alloyed particles (i.e., particles essentially consisting of one element).
  • alloyed particles i.e., a chemical mixture of elements
  • non-alloyed particles i.e., particles essentially consisting of one element.
  • any combination of alloyed and non- alloyed powders may be blended to realize an aluminum alloy powder having a composition described herein.
  • Aluminum alloy powders may be compacted into final or near-final product form using powder metallurgy methods.
  • the powder may be compacted via low pressure methods such as, loose powder sintering, slip casting, slurry casting, tape casting, or vibratory compaction.
  • pressure may be used to realize the compaction by methods such as, for instance, die compaction, cold/hot isostatic pressing, and/or sintering. Such methods may facilitate production of crack-free final or near-final aluminum alloy products.
  • the crack-free powder metallurgy product may be further processed to obtain a wrought final product.
  • This further processing may include any combination of thermal treating (e.g., solution heat treating, annealing) and working steps, described above, as appropriate to achieve the final aluminum alloy product form.
  • thermal treating e.g., solution heat treating, annealing
  • working steps described above, as appropriate to achieve the final aluminum alloy product form.
  • the material may be precipitation hardened (e.g., naturally aged, artificially aged) to develop strengthening precipitates.
  • the final product form may be a rolled product, an extruded product or a forged product, for instance.
  • the new aluminum alloys may be thermally treated.
  • Thermally treating may include one or more of solution heat treating and quenching, precipitation hardening (aging), and annealing.
  • solution heat treating means heating an alloy body to a suitable temperature, generally above a solvus temperature, and holding at that temperature long enough to allow at least some soluble constituents to enter solid solution. Quenching may optionally be employed after a solution heat treatment. The quenching may comprise cooling rapidly enough to hold at least some dissolved element(s) in solid solution. The quenching may facilitate production of a supersaturated solid solution. A subsequent precipitation hardening step may facilitate the production of precipitate phases from a supersaturated solid solution, as discussed in greater detail below.
  • thermally treating an aluminum alloy comprises precipitation hardening.
  • a precipitation hardening step may be employed after production of an aluminum alloy product and/or after solution heat treating and quenching of an aluminum alloy product.
  • an additively manufactured aluminum alloy product may realize a supersaturated solid solution in the as-built condition (e.g., due to high cooling rates of at least 1000°C/s).
  • Precipitation hardening of the new aluminum alloys may occur at room temperature (sometimes referred to as a“natural age”) and/or at one or more elevated temperatures (sometimes referred to as an“artificial age”).
  • the precipitation hardening may be performed for a time sufficient and at a temperature sufficient to facilitate the production of one or more precipitates.
  • a precipitation hardening step comprises producing precipitates comprising one or more Class Z elements.
  • additive manufacturing means,“a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies”, as defined in ASTM F2792-12a entitled “Standard Terminology for Additively Manufacturing Technologies”.
  • Additively manufactured aluminum alloy bodies may be manufactured via any appropriate additive manufacturing technique described in this ASTM standard, such as binder jetting, directed energy deposition, material extrusion, material jetting, powder bed fusion, or sheet lamination, among others. Any suitable feedstocks may be used, including one or more powders, one or more wires, one or more sheets, and combinations thereof.
  • an additive manufacturing process includes depositing successive layers of one or more powders and then selectively melting and/or sintering the powders to create, layer-by-layer, an additively manufactured aluminum alloy body (product).
  • an additive manufacturing processes uses one or more of Selective Laser Sintering (SLS), Selective Laser Melting (SLM), and Electron Beam Melting (EBM), among others.
  • SLS Selective Laser Sintering
  • SLM Selective Laser Melting
  • EBM Electron Beam Melting
  • an additive manufacturing process uses an EOSINT M 280 Direct Metal Laser Sintering (DMLS) additive manufacturing system, or comparable system, available from EOS GmbH (Robert-Stirling-Ring 1, 82152 Krailling/Munich, Germany).
  • additive manufacturing process uses a LENS additive manufacturing system, or comparable system, available from OPTOMEC, 3911 Singer N.E., Albuquerque, NM 87109.
  • a feedstock such as a powder or wire, comprising (or consisting essentially of) any of the aluminum alloy compositions described above may be used in an additive manufacturing apparatus to produce an additively manufactured aluminum alloy body.
  • the additively manufactured aluminum alloy body is a crack- free preform.
  • the feedstock may be selectively heated above the liquidus temperature of the material, thereby forming a molten pool having any of the aluminum alloy compositions described above, followed by rapid solidification of the molten pool thereby forming an additively manufactured aluminum alloy product.
  • the additively manufactured aluminum alloy product may realize a fine eutectic-type microstructure.
  • additive manufacturing may be used to create, layer-by-layer, the aluminum alloy product.
  • a metal powder bed is used to create a tailored aluminum alloy product.
  • a“metal powder bed” means a bed comprising a metal powder.
  • One embodiment of a method of making an additively manufactured aluminum alloy body may include (a) dispersing a powder comprising any of the aluminum alloy compositions described above, (b) selectively heating a portion of the powder (e.g., via a laser) to a temperature above the liquidus temperature of the particular body to be formed, (c) forming a molten pool having any of the aluminum alloy compositions described above, and (d) cooling the molten pool at a cooling rate of at least 1000°C per second.
  • the cooling rate is at least 10,000°C per second.
  • the cooling rate is at least 100,000°C per second.
  • the cooling rate is at least 1,000,000°C per second.
  • Steps (a)-(d) may be repeated as necessary until the aluminum alloy body is completed, i.e., until the final additively manufactured aluminum alloy body is formed / completed.
  • the final additively manufactured aluminum alloy body may be of a complex geometry, or may be of a simple geometry (e.g., in the form of a sheet or plate), and may realize a fine eutectic-type microstructure.
  • an additively manufactured aluminum alloy product may be deformed (e.g., by one or more of rolling, extruding, forging, stretching, compressing).
  • the powders used to additively manufacture an aluminum alloy body may be produced by atomizing a material (e.g., an ingot or melt) of the new alloy aluminum alloys into powders of the appropriate dimensions relative to the additive manufacturing process to be used.
  • “powder” means a material comprising a plurality of particles. Powders may be used in a powder bed to produce a tailored alloy product via additive manufacturing. In one embodiment, the same general powder is used throughout the additive manufacturing process to produce an aluminum alloy product.
  • the final tailored aluminum alloy product may comprise a single region / matrix produced by using generally the same metal powder during the additive manufacturing process.
  • the final tailored aluminum alloy product may alternatively comprise at least two separately produced distinct regions.
  • a first metal powder bed may comprise a first metal powder and a second metal powder bed may comprise a second metal powder, different than the first metal powder.
  • the first metal powder bed may be used to produce a first layer or portion of the alloy product, and the second metal powder bed may be used to produce a second layer or portion of the alloy product.
  • a“particle” means a minute fragment of matter having a size suitable for use in the powder of the powder bed (e.g., a size of from 5 microns to 100 microns). Particles may be produced, for example, via atomization.
  • the additively manufactured aluminum alloy body may be subject to any appropriate working steps. If employed, the working steps may be conducted on an intermediate form of the additively manufactured body and/or may be conducted on a final form of the additively manufactured body. In one embodiment, an additively manufactured body consists essentially of any of the aluminum alloy compositions described above.
  • an aluminum alloy body is a preform for subsequent working.
  • a preform may be an additively manufactured product.
  • a preform is of a near net shape product that is close to the final desired shape of the final product, but the preform is designed to allow for subsequent working to achieve the final product shape.
  • the preform may be worked such as by forging, rolling, extrusion, or hipping (hot isostatic pressing) to produce an intermediate product or a final product, which intermediate or final product may be subject to any further appropriate working or thermal steps (e.g., stress relief), as described above, to achieve the final product.
  • the working comprises hipping to compress the part.
  • an aluminum alloy preform may be compressed and porosity may be reduced.
  • the hipping temperature is maintained below the incipient melting point of the aluminum alloy preform.
  • the preform may be a near net shape product.
  • a method comprises feeding a wire (e.g., ⁇ 5 mm in diameter) of the new aluminum alloys described herein to the wire feeder portion of an electron beam gun.
  • the wire may be of the compositions, described above.
  • the electron beam (EB) heats the wire above the liquidus point of the body to be formed, followed by rapid solidification (e.g., at least 100°C per second) of the molten pool to form the deposited material.
  • the wire could be fabricated by a conventional ingot process or by a powder consolidation process.
  • Plasma arc wire feed may similarly be used with the aluminum alloys disclosed herein.
  • an electron beam (EB) or plasma arc additive manufacturing apparatus may employ multiple different wires with corresponding multiple different radiation sources, each of the wires and sources being fed and activated, as appropriate to provide the aluminum alloy product.
  • a method may comprise (a) selectively spraying one or more metal powders of the new aluminum alloys described herein towards a building substrate, (b) heating, via a radiation source, the metal powders, and optionally the building substrate, above the liquidus temperature of the product to be formed, thereby forming a molten pool, (c) cooling the molten pool, thereby forming a solid portion of the product, wherein the cooling comprises cooling at a cooling rate of at least 100°C per second. In one embodiment, the cooling rate is at least 1000°C per second. In another embodiment, the cooling rate is at least 10,000°C per second.
  • the cooling step (c) may be accomplished by moving the radiation source away from the molten pool and/or by moving the building substrate having the molten pool away from the radiation source. Steps (a)-(c) may be repeated as necessary until the product is completed.
  • the spraying step (a) may be accomplished via one or more nozzles, and the composition of the metal powders can be varied, as appropriate, to provide a tailored final aluminum alloy product.
  • the composition of the metal powder being heated at any one time can be varied in real-time by using different powders in different nozzles and/or by varying the powder composition(s) provided to any one nozzle in real-time.
  • the work piece can be any suitable substrate.
  • the building substrate is, itself, a metal product (e.g., an alloy product, such as any of the aluminum alloy products described herein.)
  • the new aluminum alloys described above may be suitable for elevated temperature applications.
  • the new aluminum alloy bodies of the new aluminum alloys described herein may be suitable in aerospace and/or automotive applications.
  • a new aluminum alloy is used in a ground transportation application.
  • aerospace applications may include heat exchangers and turbines (e.g., turbocharger impeller wheels).
  • automotive applications may include interior or exterior trim/appliques, pistons, valves, and/or turbochargers.
  • Other examples include any components close to a hot area of the vehicle, such as engine components and/or exhaust components, such as the manifold.
  • the new aluminum alloy bodies of the present disclosure may also be utilized in a variety of consumer products, such as any consumer electronic products, including laptops, cell phones, cameras, mobile music players, handheld devices, computers, televisions, microwave, cookware, washer/dryer, refrigerator, sporting goods, or any other consumer electronic product requiring durability and selective visual appearance.
  • the visual appearance of the consumer electronic product meets consumer acceptance standards.
  • the new aluminum alloy bodies of the present disclosure may be utilized in a variety of products including non-consumer products including the likes of medical devices, transportation systems and security systems, to name a few.
  • the new aluminum alloy bodies may be incorporated in goods including the likes of car panels, media players, bottles and cans, office supplies, packages and containers, among others.
  • the new aluminum alloys may be used in a variety of product applications.
  • at least a portion of a product e.g., an additively manufactured product
  • an aluminum alloy product may comprise one of the new aluminum alloy compositions, and at least one other portion may be comprised of a different material (e.g., a different aluminum alloy).
  • the new aluminum alloy compositions may be present in a product comprising a compositional gradient (i.e., a graded product). At least a portion of a graded product may comprise any of the new aluminum alloy compositions described above.
  • the term “or” is an inclusive “or” operator, and is equivalent to the term “and/or,” unless the context clearly dictates otherwise.
  • the term “based on” is not exclusive and allows for being based on additional factors not described, unless the context clearly dictates otherwise.
  • the meaning of “a,” “an,” and “the” include plural references, unless the context clearly dictates otherwise.
  • the meaning of “in” includes “in” and “on”, unless the context clearly dictates otherwise.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Powder Metallurgy (AREA)

Abstract

La présente invention concerne de nouveaux alliages à base d'aluminium. D'une manière générale, les nouveaux alliages à base d'aluminium comprennent généralement de 1,2 à 4,1. % atomique, de 0.2 à 1,1 % atomique d'éléments de classe X, où le % atomique du Fe plus le % atomique des éléments de classe X est compris entre 2,3 et 4,3 % atomique et entre 0,9 et 2,5 % % atomique de Si. Les éléments de classe X comprennent généralement au moins un des éléments parmi le vanadium (V), le molybdène (Mo), le niobium (Nb), le tantale (Ta) et le tungstène (W). Les nouveaux alliages d'aluminium comprennent généralement une quantité de Fe, les éléments de classe X, et le Si se situe dans une plage présentée dans la FIG. 1.
PCT/US2019/062278 2018-11-20 2019-11-19 Produits d'alliage d'aluminium améliorés et leurs procédés de fabrication Ceased WO2020106764A1 (fr)

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CN112775436A (zh) * 2020-12-22 2021-05-11 西安交通大学 一种促进钛合金增材制造过程生成等轴晶的制造方法
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CN119979980A (zh) * 2025-02-17 2025-05-13 南京鸿发有色金属制造股份有限公司 一种6005c光伏边框用高强轻质铝合金型材及其制备方法

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