Fcc materials of aluminum, cobalt, iron and nickel, and products made therefrom
The present disclosure relates to new materials comprising Al, Co, Fe, and Ni. The new materials may realize a single phase field of a face-centered cubic (fcc) solid solution structure immediately below the solidus temperature of the material. The new materials may include at least one precipitate phase and have a solvus temperature of at least 1000° C. The new materials may include 4.4-11.4 wt. % Al, 4.9-42.2 wt. % Co, 4.6-28.9 wt. % Fe, and 44.1-86.1 wt. % Ni. In one embodiment, the precipitate is selected from the group consisting of the L1 2 phase, the B2 phase, and combinations thereof. The new alloys may realize improved high temperature properties.
1. A method comprising:
(a) using a feedstock in an additive manufacturing apparatus, wherein the feedstock comprises:
4.4-11.4 wt. % Al;
4.9-42.2 wt. % Co;
4.6-28.9 wt. % Fe; and
44.1-86.1 wt. % Ni;
(b) producing a metal product in the additive manufacturing apparatus using the feedstock.
2. The method of claim 1 , wherein the feedstock comprises a powder feedstock, wherein the method comprises:
(a) dispersing a metal powder of the powder feedstock in a bed and/or spraying a metal powder of the powder feedstock towards or on a substrate;
(b) selectively heating a portion of the metal powder above its liquidus temperature, thereby forming a molten pool;
(c) cooling the molten pool, thereby forming a portion of the metal product, wherein the cooling comprises cooling at a cooling rate of at least 100° C. per second; and
(d) repeating steps (a)-(c) until the metal product is completed, wherein the metal product comprises a metal matrix, wherein the Al, Co, Fe, and Ni make-up the matrix.
3. The method of claim 1 , wherein the feedstock comprises a wire feedstock, wherein the method comprises:
(a) using a radiation source to heat the wire feedstock above its liquidus point, thereby creating a molten pool, wherein the molten pool comprises Al, Co, Fe, and Ni;
(b) cooling the molten pool at a cooling rate of at least 1000° C. per second; and
(c) repeating steps (a)-(b) until the metal product is completed, wherein the metal product comprises a metal matrix, wherein the Al, Co, Fe, and Ni make-up the matrix.
4. The method of claim 1 , comprising: cooling at a rate sufficient to form at least one precipitate phase.
5. The method of claim 4 , wherein the at least one precipitate phase comprises at least one of L1 2 and B2.
6. The method of claim 5 , wherein the metal product comprises at least 0.5 vol. % of the precipitate phase.
7. The method of claim 1 , comprising:
working the metal product.
8. The method of claim 7 , wherein the producing step comprises:
first producing a portion of the metal product using the feedstock;
second producing another portion of the metal product using the feedstock;
wherein the working occurs at least after the first or second producing steps.
9. The method of claim 8 , wherein the working occurs between the first producing step and the second producing step.
10. The method of claim 8 , wherein the working comprises one or more of rolling, forging, extrusion and hot isostatic pressing.