ALUMINUM ALLOYS HAVING IRON, SILICON, VANADIUM AND COPPER, AND WITH A HIGH VOLUME OF CERAMIC PHASE THEREIN
New aluminum alloys having iron, vanadium, silicon, and copper, and with a high volume of ceramic phase therein are disclosed. The new products may include from 3 to 12 wt. % Fe, from 0.1 to 3 wt. % V, from 0.1 to 3 wt. % Si, from 1.0 to 6 wt. % Cu, from 1 to 30 vol. % ceramic phase, the balance being aluminum and impurities. The ceramic phase may be homogenously distributed within the alloy matrix.
1 . An aluminum alloy consisting essentially of:
from 3 to 12 wt. % Fe;
from 0.1 to 3 wt. % V;
from 0.1 to 3 wt. % Si;
from 1.0 to 6 wt. % Cu; and
from 1.0 to 30 vol. % ceramic phase;
the balance being aluminum and impurities.
2 . An aluminum alloy body made from the aluminum alloy of claim 1 , the aluminum alloy body having an alloy matrix and a ceramic phase, wherein the aluminum alloy body comprises a homogenous distribution of the ceramic phase within the alloy matrix.
3 . The aluminum alloy body of claim 2 , wherein the aluminum alloy body is in the form of an engine component for an aerospace vehicle.
4 . The aluminum alloy body of claim 2 , comprising from 5 to 35 vol. % AlFeVSi dispersoids.
5 . The aluminum alloy body of claim 4 , wherein the AlFeVSi dispersoids comprise at least some copper.
6 . The aluminum alloy body of claim 2 , comprising a cellular structure comprising iron and copper.
7 . The aluminum alloy of claim 1 , wherein the ceramic phase is selected from the group consisting of TiB 2 , TiC, and combinations thereof.
8 . The aluminum alloy of claim 1 , wherein the ceramic phase is TiB 2 .
9 . A method of making an aluminum alloy body, comprising:
(a) dispersing a powder comprising in a bed, wherein the powder consists essentially of:
from 3 to 12 wt. % Fe;
from 0.1 to 3 wt. % V;
from 0.1 to 3 wt. % Si;
from 1.0 to 6 wt. % Cu;
from 1.0 to 30 vol. % ceramic phase; and
the balance being aluminum (Al) and impurities;
(b) selectively heating a portion of the powder to a temperature above the liquidus temperature of the particular aluminum alloy body to be formed;
(c) forming a molten pool having the Fe, V, Si, Cu, Al, and ceramic phase;
(d) cooling the molten pool at a cooling rate of at least 1000° C. per second; and
(e) repeating steps (a)-(d) to form an additively manufactured aluminum alloy body.
10 . The method of claim 9 , comprising:
completing the additively manufactured aluminum alloy body, thereby realizing a final aluminum alloy product;
naturally aging the final aluminum alloy product; and
after the natural aging, artificially aging the final aluminum alloy product.
11 . The method of claim 10 , comprising:
after the naturally aging step, deforming the final aluminum alloy product by from 1 to 10%.
12 . The method of claim 10 , wherein the artificial aging comprises:
heating the final aluminum alloy product at a temperature of from 125° C. to 300° C. and for a period of from 2 to 48 hours.
13 . The method of claim 12 , wherein the final aluminum alloy product is in the form of an engine component for an aerospace or automotive vehicle, wherein the method comprises:
incorporating the engine component into the aerospace or automotive vehicle.
14 . The method of claim 13 , comprising:
operating the aerospace or automotive vehicle.
15 . The method of claim 13 , wherein the final aluminum alloy product is a compressor wheel for a turbo charger.
16 . The method of claim 13 , wherein the final aluminum alloy product is a blade for a turbine.
17 . The method of claim 13 , wherein the final aluminum alloy product is a heat exchanger.