Rapidly solidified high-temperature aluminum iron silicon alloys

{
  "publication_number": "US10294552B2",
  "country": "US",
  "kind": "B2",
  "title": "Rapidly solidified high-temperature aluminum iron silicon alloys",
  "abstract": "Methods of making high-strength, lightweight alloy components capable of high temperature performance comprising aluminum, silicon, and iron and/or nickel are provided. A high-energy stream, such as a laser or electron beam, may be selectively directed towards a precursor material to melt a portion of the precursor material in a localized region. The molten precursor material is cooled at a rate of greater than or equal to about 1.0×10 5 K/second to form a solid high-strength, lightweight alloy component comprising a stable ternary cubic phase having high heat resistance and high strength. The stable ternary phase may be Al x Fe y Si z, where x ranges from about 4 to about 5 or about 7.2 to about 7.6, y is about 1.5 to about 2.2, and z is about 1. The stable ternary phase may also be Al 6 Ni 3 Si. Materials and components, such as automotive components, made from such methods are also provided.",
  "claims": [
    "1. A method of making a high-strength, lightweight alloy component comprising: directing an energy stream towards a precursor material in a localized region to melt a portion of the precursor material in the localized region, wherein the precursor material comprises aluminum, silicon, and iron; and cooling the molten precursor material at a rate of greater than or equal to about 1.0×10 5 K/second to form a solid high strength, lightweight alloy component comprising a stable Al x Fe y Si z phase, wherein x ranges from about 4 to about 5 or about 7.2 to about 7.6, y is about 1.5 to about 2.2, and z is about 1.",
    "2. The method of claim 1, wherein the solid high-strength lightweight alloy component comprises greater than or equal to about 50% by volume of the stable Al x Fe y Si z phase.",
    "3. The method of claim 1, wherein the stable Al x Fe y Si z phase has a formula represented by Al 4 Fe 1.7 Si or Al 5 Fe 2 Si, with a composition comprising aluminum at greater than or equal to about 64.5 to less than or equal to about 66 atomic weight %; iron at about 24.5 atomic weight %; and silicon at greater than or equal to about 9.5 to less than or equal to about 11 atomic weight %.",
    "4. The method of claim 1, wherein the stable Al x Fe y Si z phase has an (a) lattice parameter of about 0.7509 nm and a (c) lattice parameter of about 0.7594 nm and a space group of P6 3 /mmc.",
    "5. The method of claim 1, wherein the solid high-strength lightweight alloy component comprises greater than or equal to about 80% by volume of the stable Al x Fe y Si z phase.",
    "6. The method of claim 1, wherein the precursor material further comprises less than or equal to about 0.5 mass % of an alloying element selected from the group consisting of: manganese, copper, and combinations thereof, wherein the stable Al x Fe y Si z phase is formed by converting an intermediate phase having a formula represented by Al 7.4 Fe 2 Si to a hexagonal crystal structure by incorporation of the alloying element.",
    "7. The method of claim 1, wherein the cooling of the molten precursor material is at a rate of greater than or equal to about 1.0×10 7 K/second.",
    "8. The method of claim 1, wherein the precursor material is a powder material.",
    "9. The method of claim 8, wherein the powder material is a combination of elemental powders or a pre-alloyed powder.",
    "10. The method of claim 1, wherein the localized region has a volumetric size of less than or equal to about 100 μm 3.",
    "11. A method of making a high-strength, lightweight alloy component comprising: directing an energy stream towards a precursor material in a localized region to melt a portion of the precursor material in the localized region, wherein the precursor material comprises aluminum, silicon, and at least one of iron or nickel; and cooling the molten precursor material at a rate of greater than or equal to about 1.0×10 5 K/second to form a solid high-strength, lightweight alloy component comprising a stable ternary phase comprising aluminum, silicon, and at least one of iron or nickel having high heat resistance and high strength.",
    "12. The method of claim 11, wherein the solid high-strength lightweight alloy component comprises greater than or equal to about 80% by volume of the stable ternary phase and the stable ternary phase is Al x Fe y Si z, wherein x ranges from about 4 to about 5 or about 7.2 to about 7.6, y is about 1.5 to about 2.2, and z is about 1.",
    "13. The method of claim 11, wherein the solid high-strength lightweight alloy component comprises greater than or equal to about 80% by volume of the stable ternary phase and the stable ternary phase is Al 6 Ni 3 Si, comprising aluminum at greater than or equal to about 58.6 to less than or equal to about 61 atomic weight %; nickel at about 30 atomic weight %; and silicon at greater than or equal to about 9 to less than or equal to about 11.4 atomic weight %.",
    "14. A method of making a high-strength, lightweight alloy component comprising: directing a high-energy stream selected from the group consisting of: direct metal laser sintering, electron beam direct metal melting systems, and combinations thereof towards a precursor material in a localized region to melt a portion of the precursor material in the localized region, wherein the precursor material comprises aluminum, silicon, and iron and a temperature within the localized region is raised to greater than or equal to about 997° C.; and cooling the molten precursor material at a rate of greater than or equal to about 1.0×10 5 K/second to form a solid high strength, lightweight alloy component comprising a stable Al x Fe y Si z phase, wherein x ranges from about 4 to about 5 or about 7.2 to about 7.6, y is about 1.5 to about 2.2, and z is about 1."
  ],
  "description_excerpt": "The present disclosure relates to methods for forming high-temperature alloys comprising aluminum, iron, and silicon.\n\nThis section provides background information related to the present disclosure which is not necessarily prior art.\n\nLightweight metal components have become an important focus for manufacturing vehicles, especially automobiles, where continual improvement in performance and fuel efficiency is desirable. Other lightweight metal components for automotive applications are often made of aluminum and/or magnesium alloys. Such lightweight metals can form load bearing components that need to be strong and stiff, while having good strength and ductility (e.g., elongation). High strength and ductility are particularly important for safety requirements and durability in vehicles like automobiles. While conventional steel and titanium alloys provide high temperature strength these alloys are, respectively, either heavy or expensive.\n\nAn exemplary lightweight metal alloy for forming structural components in a vehicle is an aluminum-containing alloy. Conventionally, aluminum-containing alloys can be formed by bulk formation processes, like wrought processes such as extrusion, rolling, forging, stamping, or casting techniques, such as die-casting, sand casting, investment casting, permanent-mold casting, and the like.\n\nWhen casting or working lightweight alloys, industry standards and limitations during the formation process typically determine which alloy materials and alloying constituents are selected.",
  "cpc": [
    "C22C 45/08",
    "B22F 10/00",
    "B22F 10/28",
    "B33Y 10/00",
    "B33Y 70/00",
    "B33Y 80/00",
    "C22C 1/002",
    "C22C 1/026",
    "C22C 1/11",
    "C22C 21/00",
    "Y02P 10/25"
  ],
  "ipc": [
    "C22C 1/00",
    "C22C 45/08"
  ],
  "assignees": [
    "GM Global Technology Operations LLC"
  ],
  "inventors": [
    "Zhongyi Liu",
    "Anil K. Sachdev"
  ],
  "filing_date": "2016-12-20",
  "publication_date": "2019-05-21",
  "grant_date": "2019-05-21",
  "priority_date": "2016-01-27",
  "application_number": "US-201615384889-A",
  "family_id": "59358954",
  "cited_by_count": 115,
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