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All sources NASA NTRS DOE OSTI

DOE OSTI2025

Attempting to Develop the World’s Most Cost-Effective Metal 3D Printing Technology Through Industrial Adoption of a High-Temperature Electro-Magnetic Nozzle for 3D Printing and Computer Numerical Control Integration

This project aimed to make a practical system capable of sustained metal deposition in air engineered with industrial integration and controls. The Al-Ce wire feedstock was tailored with appropriate deposition and solidification properties for direct reactive interface printing (DRIP), and the goal was to integrate onto a Hybrid Manufacturing Technologies system for producing test parts without a controlled environment.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Phase Selection During Solidification and Solid-State Phase Transformations in an Al-10Ce-8Mn (wt pct) Alloy

In multicomponent Al-Ce alloys, and especially after additive manufacturing (AM), complex and metastable solidification microstructures are frequently observed. Here, in this research, the relationship between solidification conditions and phase selection are explored for an Al-10Ce-8Mn (wt pct) alloy using a systematic study of laser melting conditions. Three solidification modes were observed: primary Al 10 Mn 2 Ce; primary Al 20 Mn 2 Ce; and eutectic FCC Al + Al 20 Mn 2 Ce. These solidification modes were correlated to specific liquid-solid interface velocities using a simple thermal model, showing the change in primary solidification phase for low (< 6.8 × 10 −4 m/s), moderate (between 8.2 × 10 −4 and 5.9 × 10 −2 m/s) and high solidification velocities (> 6.2 x 10 −2 m/s) for the above three solidification microstructures, respectively. These results were rationalized by using interface response function (IRF) theory to describe the solidification undercooling for the possible primary intermetallic phases. The implication of the local phase selection from differing solidification conditions is summarized by a comparison of hardness which demonstrates the potential variance of Vickers hardness from 101 to 242 (VHV) by changing the laser velocity from 1 to 83 mm/s. Interestingly, on heat treatment at 400°C, the decomposition pathways of the solidification microstructure and hardness were also found to be different, thereby opening multiple pathways for spatial microstructure and property control within AM components.

Sisco, Kevin↗

DOE OSTI2024

Combining solution-, precipitation- and load-transfer strengthening in a cast Al-Ce-Mn- Sc -Zr alloy

Here, a cast Al-9Ce-0.75Mn-0.18Sc-0.12Zr (wt%) alloy is designed to combine three strengthening phases: (i) micron-scale Al 11 Ce 3 platelets formed during eutectic solidification, (ii) nano-scale L1 2 -Al 3 (Sc,Zr) precipitates formed during aging, and (iii) Mn in solid solution in the α-Al matrix. Microstructural analyses by SEM, TEM, and atom-probe tomography reveal that Mn remains in solid solution in the as-cast alloy, providing solution strengthening with no influence on the eutectic Al-Al 11 Ce 3 microstructure, which provides precipitation- and load-transfer strengthening. During long-term over-aging at 400 °C, Mn-rich precipitates grow at the Al-Al 11 Ce 3 interface, with no effect on the microhardness. However, after short aging at 350 °C, a high number density of fine L1 2 -Al 3 (Sc,Zr) nanoprecipitates form in the Al matrix (with a coarser size at the Al-Al 11 Ce 3 interface), providing precipitation strengthening. The synergistic combination of the three strengthening mechanisms (solution, precipitation, and load transfer) in our Al-Ce-Mn-Sc-Zr alloy results in higher microhardness after aging at 350 and 400 °C, and higher creep resistance at 300 °C, as compared to alloys with two strengthening mechanisms: an Al-10Ce-0.93Mn control alloy (without precipitation strengthening from Sc and Zr), Al-Ce-Sc-Zr (without solution strengthening from Mn), and Al-Mn-Zr-Er (without load-transfer strengthening from Ce). Furthermore, these dual-strengthened alloys are more creep resistant than alloys with a single strengthening mechanism (Al-Ce, Al-Mn, and Al-Sc-Zr), confirming that the three mechanisms can be combined in pairs or all together.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Heterogeneous phase transformation pathways in additively manufactured Al-Ce-Mn alloys

Heat treatment of additively manufactured Al-Ce based multicomponent alloys leads to complex microstructure evolution. In this research, the ability to extend the phase transformation theories involving nucleation of a product phase from a heterogeneous multi-phase microstructure typical to that of additively manufactured samples is explored. The Al-10Ce-8Mn (wt%) was used as a model alloy system. Under additive manufacturing conditions different solidification microstructures were obtained due to spatial and temporal variations of thermal gradients (G) and liquid-solid interface velocities (R) within a given melt pool. Near the melt pool boundary (high G and low R, referred as MPB region), initially, Al 20 Mn 2 Ce forms from the liquid followed by a eutectic of FCC Al and Al 11 Ce 3 . In the melt pool interiors (low G and high R referred as ES region) a eutectic structure between FCC Al and Al 20 Mn 2 Ce is observed. During subsequent heat treatments, the MPB and ES regions transform into different sets of microstructures. In the MPB region, a fine globular microstructure containing FCC Al, Al 11 Ce 3 , Al 6 Mn, and Al 12 Mn results from the decomposition of Al 20 Mn 2 Ce. In the ES region a faceted Al 51 Mn 7 Ce 4 plate phase results from the decomposition of Al 20 Mn 2 Ce. The formation of the Al 51 Mn 7 Ce 4 phase within the eutectic microstructure at the boundaries of FCC Al and Al 20 Mn 2 Ce has not been reported in the literature. Further, these two distinct phase transformation pathways are rationalized based on the role of driving force on the nucleation of (Al 6 Mn) and/or metastable intermetallic (Al 51 Mn 7 Ce 4 ) phases at the interface of aluminum (FCC) and the non-equilibrium intermetallic (Al 20 Mn 2 Ce) phases.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Attempting to Develop the World’s Most Cost-Effective Metal 3D Printing Technology Through Industrial Adoption of a High-Temperature Electro-Magnetic Nozzle for 3D Printing and Computer Numerical Control Integration

36 MATERIALS SCIENCE↗

DOE OSTI2023

First-principles study of interfaces in Al/SiC metal-matrix composite system

In this work, first-principles calculations were performed on the interfaces between Al and SiC, which is a widely used strengthening agent in aluminum metal-matrix-composites (Al/MMC). C-terminated interfaces have much larger work of adhesion than Si-terminated interfaces, indicating that the former has much stronger interfacial bonding. The electron localization function shows that the chemical bonding between Al and C has a strong covalent character, while the bonding between Al and Si is largely metallic. As a result of the vastly different chemical bonding, the work of adhesion for C-terminated interfaces increases with the number of dangling bonds at the interface, while the opposite trend was observed for Si-terminated interfaces. Additionally, the interface energy for Si-terminated interfaces is comparable to that for C-terminated interfaces, suggesting both types of terminations can coexist in the Al/SiC system.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Strength mechanisms and tunability in Al-Ce-Mg ternary alloys enabled by additive manufacturing

Al-Ce-based alloys are promising candidates for additive manufacturing (AM) due to their hot-cracking resistance and because they do not require heat treatment to obtain precipitation strengthening. Rapid solidification rates enabled by AM methods can lead to enhanced mechanical properties; however, the strengthening mechanisms over large composition ranges were unclear. Here, combinatorial synthesis by directed-energy deposition (DED) and hardness measurements were used to rapidly map the composition-dependent strength of the ternary Al-Ce-Mg system. Tensile testing and microstructure characterization of selected compositions were performed to elucidate the compositional dependence of the strengthening mechanisms. Al 11 Ce 3 precipitates were present in all cases, and the maximum hardness (1.25 GPa) was measured for the Al-8Ce-10Mg composition. A combination of (i) Hall-Petch strengthening, based on the FCC-matrix-phase cell size; (ii) particle strengthening, based on Al 11 Ce 3 volume fraction and size; and (iii) solid-solution strengthening, based on Mg composition of the matrix phase, were used to account for the measured strengths. Vickers hardness is shown to correlate well with ultimate tensile strength in these alloys, highlighting the value of surface-based techniques for rapid screening.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Developing an experimental-computational framework to investigate the deformation mechanisms and mechanical properties of Al-8Ce-10Mg alloys at micro and macroscales

There is a promising future for the use of aluminum-cerium-magnesium alloys in a broad range of applications, including devices that operate at high temperatures. With cerium currently considered a waste product of rare earth mining validation studies of possible applications are essential to reduce the environmental waste. Here, a computational-experimental framework is developed to investigate the role both the intermetallic and matrix have on the mechanical properties of these alloys. A set of experiments, including SEM/EBSD imaging, nanoindentation, in-situ SEM tensile testing, and in-situ SEM-DIC tests are performed to characterize the microstructure and mechanical properties of these alloys. Furthermore, the elastic, plastic, and failure deformation mechanisms of the microstructure, and their correlation with the bulk scale mechanical properties are investigated. Experimental results are also used to calibrate parameters for a crystal plasticity finite element model, by performing a computational framework that minimizes the error between the computational and experimental results. This model is then utilized to investigate how the area percentage of intermetallics and the crystallographic texture control the mechanical properties of the alloy. Simulation results show that an increase in the percentage of intermetallics increase the strength but decrease the ductility of the alloy. Also, a change in material texture improves strength and reduces damage that leads to material failure. The development of the crystal plasticity model, as discussed in this work, opens opportunities for future investigations of similar aluminum-cerium-magnesium alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Corrosion analysis of Al-Ce-Ni and Al-Cu-Ce cast alloys in dilute boric acid at room and elevated temperatures

Two Al-Ce-Ni cast alloys, and an Al-Cu-Ce cast alloy, as candidate wet storage materials for spent nuclear fuels, were tested in 0.23 wt% H 3 BO 3 solution to assess the alloy corrosion resistance. Electrochemical and gravimetric corrosion data suggest that the three Al alloys are unlikely to undergo any severe corrosion in dilute H 3 BO 3 at or below 50 °C. Post-exposure characterization of the three Al alloys, including scanning and transmission electron microscopy and electron dispersive spectroscopy, revealed a corrosion product layer, mostly Al 2 O 3 , on the exposed surface and local penetration of oxygen into the alloy matrix. The degree of oxide layer growth and oxygen penetration is greater at 80 °C than the temperature at/below 50 °C. The Al-Cu-Ce alloy is considered less corrosion resistant than the other two alloys studied.

Al-Ce alloy↗

DOE OSTI2020

Materials Data on CeAl by Materials Project

CeAl is Tetraauricupride structured and crystallizes in the cubic Pm-3m space group. The structure is three-dimensional. Ce is bonded in a body-centered cubic geometry to eight equivalent Al atoms. All Ce–Al bond lengths are 3.18 Å. Al is bonded in a body-centered cubic geometry to eight equivalent Ce atoms.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Materials Data on CeAl by Materials Project

CeAl crystallizes in the orthorhombic Cmcm space group. The structure is three-dimensional. Ce is bonded in a 10-coordinate geometry to two equivalent Ce and eight Al atoms. Both Ce–Ce bond lengths are 3.10 Å. There are a spread of Ce–Al bond distances ranging from 3.10–3.45 Å. There are two inequivalent Al sites. In the first Al site, Al is bonded in a 10-coordinate geometry to eight equivalent Ce and two equivalent Al atoms. Both Al–Al bond lengths are 2.79 Å. In the second Al site, Al is bonded to eight equivalent Ce and four Al atoms to form a mixture of face, edge, and corner-sharing AlCe8Al4 cuboctahedra. Both Al–Al bond lengths are 2.69 Å.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Materials Data on CeAl2 by Materials Project

CeAl2 is Cubic Laves structured and crystallizes in the cubic Fd-3m space group. The structure is three-dimensional. Ce is bonded in a 12-coordinate geometry to four equivalent Ce and twelve equivalent Al atoms. All Ce–Ce bond lengths are 3.44 Å. All Ce–Al bond lengths are 3.30 Å. Al is bonded to six equivalent Ce and six equivalent Al atoms to form a mixture of edge, corner, and face-sharing AlCe6Al6 cuboctahedra. All Al–Al bond lengths are 2.81 Å.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Materials Data on Ce3Al by Materials Project

Ce3Al crystallizes in the hexagonal P6_3/mmc space group. The structure is three-dimensional. Ce is bonded in a 12-coordinate geometry to eight equivalent Ce and four equivalent Al atoms. There are a spread of Ce–Ce bond distances ranging from 3.01–3.70 Å. There are two shorter (3.16 Å) and two longer (3.36 Å) Ce–Al bond lengths. Al is bonded to twelve equivalent Ce atoms to form a mixture of face and corner-sharing AlCe12 cuboctahedra.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Materials Data on CeAl4 by Materials Project

CeAl4 crystallizes in the tetragonal I4/mmm space group. The structure is three-dimensional. Ce is bonded in a 8-coordinate geometry to sixteen Al atoms. There are eight shorter (3.25 Å) and eight longer (3.54 Å) Ce–Al bond lengths. There are two inequivalent Al sites. In the first Al site, Al is bonded to four equivalent Ce and eight Al atoms to form a mixture of edge, face, and corner-sharing AlCe4Al8 cuboctahedra. There are four shorter (2.64 Å) and four longer (3.00 Å) Al–Al bond lengths. In the second Al site, Al is bonded in a 9-coordinate geometry to four equivalent Ce and five Al atoms. The Al–Al bond length is 2.51 Å.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Materials Data on Ce3Al by Materials Project

Ce3Al is Uranium Silicide structured and crystallizes in the cubic Pm-3m space group. The structure is three-dimensional. Ce is bonded to eight equivalent Ce and four equivalent Al atoms to form distorted CeCe8Al4 cuboctahedra that share corners with twelve equivalent CeCe8Al4 cuboctahedra, edges with eight equivalent AlCe12 cuboctahedra, edges with sixteen equivalent CeCe8Al4 cuboctahedra, faces with four equivalent AlCe12 cuboctahedra, and faces with fourteen equivalent CeCe8Al4 cuboctahedra. All Ce–Ce bond lengths are 3.32 Å. All Ce–Al bond lengths are 3.32 Å. Al is bonded to twelve equivalent Ce atoms to form AlCe12 cuboctahedra that share corners with twelve equivalent AlCe12 cuboctahedra, edges with twenty-four equivalent CeCe8Al4 cuboctahedra, faces with six equivalent AlCe12 cuboctahedra, and faces with twelve equivalent CeCe8Al4 cuboctahedra.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Materials Data on CeAl3 by Materials Project

CeAl3 crystallizes in the hexagonal P6_3/mmc space group. The structure is three-dimensional. Ce is bonded to twelve equivalent Al atoms to form a mixture of distorted corner and face-sharing CeAl12 cuboctahedra. There are six shorter (3.12 Å) and six longer (3.22 Å) Ce–Al bond lengths. Al is bonded in a 10-coordinate geometry to four equivalent Ce and six equivalent Al atoms. There are two shorter (2.79 Å) and four longer (2.82 Å) Al–Al bond lengths.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Materials Data on Ce3Al by Materials Project

Ce3Al crystallizes in the monoclinic P2_1/m space group. The structure is three-dimensional. there are six inequivalent Ce sites. In the first Ce site, Ce is bonded in a 12-coordinate geometry to eight Ce and four Al atoms. There are a spread of Ce–Ce bond distances ranging from 3.16–3.72 Å. There are a spread of Ce–Al bond distances ranging from 3.20–3.41 Å. In the second Ce site, Ce is bonded in a 12-coordinate geometry to eight Ce and four Al atoms. There are a spread of Ce–Ce bond distances ranging from 2.81–3.56 Å. There are a spread of Ce–Al bond distances ranging from 3.17–3.63 Å. In the third Ce site, Ce is bonded in a 12-coordinate geometry to eight Ce and four Al atoms. There are a spread of Ce–Ce bond distances ranging from 2.94–3.74 Å. There are a spread of Ce–Al bond distances ranging from 3.19–3.65 Å. In the fourth Ce site, Ce is bonded in a 12-coordinate geometry to eight Ce and four Al atoms. There are a spread of Ce–Ce bond distances ranging from 2.88–3.76 Å. There are a spread of Ce–Al bond distances ranging from 3.08–3.38 Å. In the fifth Ce site, Ce is bonded in a 12-coordinate geometry to eight Ce and four Al atoms. There are a spread of Ce–Al bond distances ranging from 3.20–3.70 Å. In the sixth Ce site, Ce is bonded in a 12-coordinate geometry to eight Ce and four Al atoms. There are a spread of Ce–Al bond distances ranging from 3.10–3.37 Å. There are two inequivalent Al sites. In the first Al site, Al is bonded to twelve Ce atoms to form a mixture of distorted corner and face-sharing AlCe12 cuboctahedra. In the second Al site, Al is bonded to twelve Ce atoms to form a mixture of corner and face-sharing AlCe12 cuboctahedra.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Materials Data on Ce3Al11 by Materials Project

Al11Ce3 crystallizes in the orthorhombic Immm space group. The structure is three-dimensional. there are two inequivalent Ce sites. In the first Ce site, Ce is bonded in a 12-coordinate geometry to fourteen Al atoms. There are a spread of Ce–Al bond distances ranging from 3.19–3.60 Å. In the second Ce site, Ce is bonded to sixteen Al atoms to form distorted CeAl16 cuboctahedra that share corners with four equivalent AlCe4Al8 cuboctahedra, faces with two equivalent CeAl16 cuboctahedra, and faces with six AlCe4Al8 cuboctahedra. There are a spread of Ce–Al bond distances ranging from 3.26–3.59 Å. There are four inequivalent Al sites. In the first Al site, Al is bonded in a 9-coordinate geometry to four Ce and five Al atoms. There are a spread of Al–Al bond distances ranging from 2.60–2.73 Å. In the second Al site, Al is bonded to four Ce and eight Al atoms to form distorted AlCe4Al8 cuboctahedra that share corners with four equivalent AlCe4Al8 cuboctahedra, an edgeedge with one AlCe4Al8 cuboctahedra, faces with two equivalent CeAl16 cuboctahedra, and faces with five AlCe4Al8 cuboctahedra. There are four shorter (2.81 Å) and two longer (3.05 Å) Al–Al bond lengths. In the third Al site, Al is bonded in a 10-coordinate geometry to four Ce and six Al atoms. The Al–Al bond length is 2.87 Å. In the fourth Al site, Al is bonded to four equivalent Ce and eight Al atoms to form distorted AlCe4Al8 cuboctahedra that share corners with four equivalent CeAl16 cuboctahedra, faces with two equivalent CeAl16 cuboctahedra, and faces with six AlCe4Al8 cuboctahedra.

36 MATERIALS SCIENCE↗