US20220205067A1 - Aluminum Alloy for Additive Technologies - Google Patents
Aluminum Alloy for Additive Technologies Download PDFInfo
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- US20220205067A1 US20220205067A1 US17/695,808 US202217695808A US2022205067A1 US 20220205067 A1 US20220205067 A1 US 20220205067A1 US 202217695808 A US202217695808 A US 202217695808A US 2022205067 A1 US2022205067 A1 US 2022205067A1
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- aluminum
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- scandium
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- 239000000654 additive Substances 0.000 title claims abstract description 17
- 230000000996 additive effect Effects 0.000 title claims abstract description 14
- 238000005516 engineering process Methods 0.000 title claims abstract description 14
- 229910000838 Al alloy Inorganic materials 0.000 title claims description 34
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 63
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 60
- 239000000956 alloy Substances 0.000 claims abstract description 60
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 52
- 229910052706 scandium Inorganic materials 0.000 claims abstract description 44
- SIXSYDAISGFNSX-UHFFFAOYSA-N scandium atom Chemical compound [Sc] SIXSYDAISGFNSX-UHFFFAOYSA-N 0.000 claims abstract description 40
- 229910052726 zirconium Inorganic materials 0.000 claims abstract description 29
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims abstract description 28
- 239000011777 magnesium Substances 0.000 claims abstract description 26
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims abstract description 25
- 239000001301 oxygen Substances 0.000 claims abstract description 25
- 229910052760 oxygen Inorganic materials 0.000 claims abstract description 25
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims abstract description 24
- 229910052749 magnesium Inorganic materials 0.000 claims abstract description 24
- 239000011575 calcium Substances 0.000 claims abstract description 23
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 claims abstract description 22
- 229910052791 calcium Inorganic materials 0.000 claims abstract description 22
- 238000000889 atomisation Methods 0.000 claims abstract description 5
- 238000010309 melting process Methods 0.000 claims abstract description 4
- 239000000843 powder Substances 0.000 claims description 61
- 239000002245 particle Substances 0.000 claims description 13
- 238000000137 annealing Methods 0.000 claims description 8
- 239000012535 impurity Substances 0.000 claims description 7
- 238000002844 melting Methods 0.000 claims description 6
- 230000008018 melting Effects 0.000 claims description 6
- 238000010894 electron beam technology Methods 0.000 claims description 5
- 239000000203 mixture Substances 0.000 abstract description 15
- 238000000034 method Methods 0.000 abstract description 14
- 238000005272 metallurgy Methods 0.000 abstract description 2
- 238000005275 alloying Methods 0.000 description 14
- 239000000463 material Substances 0.000 description 12
- 239000000155 melt Substances 0.000 description 8
- 230000000694 effects Effects 0.000 description 6
- 239000000126 substance Substances 0.000 description 6
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 238000010438 heat treatment Methods 0.000 description 4
- 238000007639 printing Methods 0.000 description 4
- 239000006104 solid solution Substances 0.000 description 4
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 3
- 230000007797 corrosion Effects 0.000 description 3
- 238000005260 corrosion Methods 0.000 description 3
- 238000004090 dissolution Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 229910052719 titanium Inorganic materials 0.000 description 3
- 239000010936 titanium Substances 0.000 description 3
- 229910052723 transition metal Inorganic materials 0.000 description 3
- 150000003624 transition metals Chemical class 0.000 description 3
- 239000011701 zinc Substances 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 2
- VVTSZOCINPYFDP-UHFFFAOYSA-N [O].[Ar] Chemical compound [O].[Ar] VVTSZOCINPYFDP-UHFFFAOYSA-N 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 239000011572 manganese Substances 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- DOTMOQHOJINYBL-UHFFFAOYSA-N molecular nitrogen;molecular oxygen Chemical compound N#N.O=O DOTMOQHOJINYBL-UHFFFAOYSA-N 0.000 description 2
- 229910052758 niobium Inorganic materials 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 238000004781 supercooling Methods 0.000 description 2
- 238000009864 tensile test Methods 0.000 description 2
- 229910052727 yttrium Inorganic materials 0.000 description 2
- 229910052725 zinc Inorganic materials 0.000 description 2
- 229910018125 Al-Si Inorganic materials 0.000 description 1
- 229910003407 AlSi10Mg Inorganic materials 0.000 description 1
- 229910018520 Al—Si Inorganic materials 0.000 description 1
- 229910052684 Cerium Inorganic materials 0.000 description 1
- 229910052688 Gadolinium Inorganic materials 0.000 description 1
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 229910052776 Thorium Inorganic materials 0.000 description 1
- QRSFFHRCBYCWBS-UHFFFAOYSA-N [O].[O] Chemical compound [O].[O] QRSFFHRCBYCWBS-UHFFFAOYSA-N 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- RGKMZNDDOBAZGW-UHFFFAOYSA-N aluminum calcium Chemical compound [Al].[Ca] RGKMZNDDOBAZGW-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000002425 crystallisation Methods 0.000 description 1
- 230000008025 crystallization Effects 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000007405 data analysis Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 229910052733 gallium Inorganic materials 0.000 description 1
- 229910052735 hafnium Inorganic materials 0.000 description 1
- 229910000765 intermetallic Inorganic materials 0.000 description 1
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical group [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 230000000051 modifying effect Effects 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 230000009257 reactivity Effects 0.000 description 1
- 238000004626 scanning electron microscopy Methods 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 238000002791 soaking Methods 0.000 description 1
- 230000035882 stress Effects 0.000 description 1
- 229910052715 tantalum Inorganic materials 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
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- 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
- C22C21/06—Alloys based on aluminium with magnesium 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
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- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/14—Treatment of metallic powder
- B22F1/145—Chemical treatment, e.g. passivation or decarburisation
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
- B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
- B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
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- 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
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- 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
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/02—Making non-ferrous alloys by melting
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/02—Making non-ferrous alloys by melting
- C22C1/026—Alloys based on aluminium
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/0408—Light metal alloys
- C22C1/0416—Aluminium-based alloys
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- 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
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
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- B22F10/36—Process control of energy beam parameters
- B22F10/366—Scanning parameters, e.g. hatch distance or scanning strategy
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- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/40—Structures for supporting workpieces or articles during manufacture and removed afterwards
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- 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
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
- B22F2009/065—Melting inside a liquid, e.g. making spherical balls
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- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
- B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
- B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
- B22F2009/0824—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid with a specific atomising fluid
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
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- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
- B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
- B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
- B22F2009/0848—Melting process before atomisation
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- 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
- B22F2202/00—Treatment under specific physical conditions
- B22F2202/11—Use of irradiation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
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- B22F2301/00—Metallic composition of the powder or its coating
- B22F2301/05—Light metals
- B22F2301/052—Aluminium
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- 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
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
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- 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
- the present disclosure relates to the field of aluminum metallurgy and can be used for producing part blanks and finished parts from aluminum based alloys, including but not limited to using selective laser melting (SLM) processes.
- SLM selective laser melting
- AlSi 10 Mg aluminum alloy used in a powder form to produce finished parts with additive technologies. Although said alloy has good processability and allows to achieve mechanical properties at the level of cast alloys. But this level of characteristics is insufficient to compete with high-strength wrought alloys.
- Scandium-containing materials allow the strength of up to 500-550 MPa to be achieved so that such materials may find a wider range of applications.
- a high cost of scandium at present results in a low interest of designers and process engineers in the use of these materials.
- a drawback of the known aluminum alloy is a high content (4 to 10 wt. %) of zinc which is evaporated during the process of producing finished parts by additive technologies.
- quenching is required for achieving high level of tensile properties, which may cause various distortions during heat treatment and result in a longer time for producing finished parts.
- the content of zirconium or the aggregate content of zirconium and titanium is less than 50% of the content of scandium.
- a drawback of this alloy is a high silicon content (1 to 4 wt. %) which substantially improves the casting properties but results in forming coarse excess phases lowering the material plasticity characteristics due to a poor coherency to the aluminum matrix.
- At least one element which is selected from the group consisting of the lanthanum group except for Ce, Y, Ga, Nb, Ta, W, V, Ni, Co, Mo, Li, Th, Ag, wherein the proportion of these elements is at most 0.5; and
- a drawback of the claimed aluminum alloy is a high material cost due to a high content of scandium (up to 30 wt. %) and other rare elements; in addition, over alloying of the material results in lower plasticity and fatigue characteristics.
- a technical problem to be solved by the proposed disclosure is to develop an aluminum powder for producing high-strength and reasonably priced part blanks and finished parts by additive technologies.
- the present disclosure relates to a method for producing an aluminum powder from an aluminum-based alloy, the method including (a) adding a scandium and a zirconium batch-wise as alloying elements to an aluminum melt at a temperature from 850-950° C. to avoid super cooling of the aluminum melt to a temperature below 750° C.; (b) adding calcium as master alloy after dissolution of scandium; (c) adding magnesium; and (d) atomizing the melt using a nitrogen-oxygen or argon-oxygen mixture to obtain an aluminum powder while maintaining the following ratio of the melt composition components before atomization (wt. %):
- a disclosed method includes spraying the melt with an oxygen content of 0.2-1.0% at a temperature 160-250° C. above an alloy liquidus point.
- a spherical powder includes a particle size of 20 to 150 ⁇ m, preferably 20-63 ⁇ m.
- a method may include at least one of producing a finished part produced from the spherical powder by selective laser alloying; and producing a finished part produced from the spherical powder by electron-beam alloying.
- the present disclosure relates to an aluminum-based alloy comprising magnesium, zirconium and scandium for atomization an aluminum powder therefrom and subsequent producing finished parts by additive technologies, characterized in that the aluminum-based alloy has a reduced scandium content and further includes oxygen and calcium at the following ratio of components (wt. %):
- An aluminum-based alloy may include a spherical powder having a particle size of 20 to 150 ⁇ m.
- a spherical powder may have a particle size of 20-63 ⁇ m.
- a spherical powder may contain a finished part formed by a selective laser alloying or electron-beam alloying processes.
- An aluminum-based alloy may be a spherical powder.
- An aluminum-based alloy may have an ultimate tensile strength of at least 450 MPa after annealing.
- An aluminum-based alloy may a magnesium content of 6.5 wt. %, the zirconium content of 1.0 wt. %, the scandium content of 0.2 wt. %, the calcium content of 0.01 wt.
- An aluminum-based alloy may be formed from a feedstock of aluminum having a purity of at least 99.5%.
- An aluminum-based alloy may have a magnesium content of 4.0 wt. %, the zirconium content of 0.5 wt. %, the scandium content of 0.6 wt. %, the calcium content of 0.2 wt. %, and the oxygen content of 0.005 wt. %.
- the present disclosure relates to an aluminum-alloy-based powder comprising magnesium, zirconium and scandium for producing part blanks and finished parts by additive technologies, characterized in that the aluminum-based alloy has a reduced scandium content and further comprises oxygen and calcium at the following ratio of components (wt.%):
- An aluminum-alloy-based powder may have a spherical shape.
- An aluminum-alloy-based powder may have an average particle size ranging from 20 ⁇ m to 150 ⁇ m.
- An aluminum-alloy-based powder may have a particle size ranging from 20 ⁇ m to 63 ⁇ m.
- An aluminum-alloy-based powder may include a finished part formed by a selective laser melting or electron-beam melting processes.
- a final part made from an aluminum-alloy based powder may have an ultimate tensile strength of at least 450 MPa after annealing.
- An aluminum-alloy-based powder may have a magnesium content of 6.5 wt. %, a zirconium content of 1.0 wt.
- An aluminum-alloy-based powder may be formed from a feedstock of aluminum having a purity of at least 99.5%.
- An aluminum-alloy-based powder may have a magnesium content of 4.0 wt. %, a zirconium content of 0.5 wt. %, a scandium content of 0.6 wt. %, a calcium content of 0.2 wt. %, and an oxygen content of 0.005 wt. %.
- FIG. 1 is a photograph illustrating aluminum powder particles, according to a specific example embodiment of the disclosure.
- FIG. 2 is a digital 3D model of the arrangement of specimens at the platform for selective laser alloying, according to a specific example embodiment of the disclosure
- FIG. 3 is a photograph illustrating metallographic specimens produced from a powder according to the proposed alloy for determining porosity
- FIG. 4 is a graph illustrating a relationship between the hardness of specimens produced from the powder according to the proposed alloy and the annealing time and temperature in case of single-step annealing.
- the present disclosure relates to producing an aluminum alloy with high-strength properties (ultimate tensile strength of at least 470 MPa) and an increased elongation level of at least of 11% and its powder for producing part blanks and finished parts by additive technologies.
- a distinctive feature is a low powder cost due to its optimized composition and a lower concentration of expensive elements compared to the closest prior art so that the production costs of finished parts may be substantially reduced due to the use of less expensive feed stock.
- the powder may be used for producing high-loaded finished parts for use, among other things, under exposure to an impact load requiring improved strength and plastic characteristics.
- the content of magnesium in the alloy is limited because a narrow crystallization range has to be provided to improve processability as articles and parts are produced by selective laser melting. A content of magnesium higher than 6.5 wt. % of the alloy will result in an undesirable effect of reduced corrosion resistance because the Al 3 Mg 2 phase tends to nucleate at the grain boundary leading to a fraction due to stress corrosion cracking.
- the content of scandium is limited because its maximum solubility at a room temperature is 0.02 wt. % and its maximum solubility does not exceed 0.8 wt. %, which makes it possible to avoid for sure formation of primary intermetalics both in the powder as such and in the produced finished parts. Alloying both with scandium and zirconium allows scandium to be partly replaced to form the Al 3 (Sc, Zr) phase which has an increased heat resistance and efficiently hardens the material in case of correctly selected heat treatment parameters.
- Oxygen is necessary to provide the required sphericity and reduced reactivity of the powder.
- An increased oxygen content of above 0.2 wt. % will result in a lower quality of the particle surface and disturbed spherical shape.
- Addition of calcium prevents aluminum oxide from being formed along the boundaries of the synthesized material in the process of repeated remelting.
- Al 4 Ca-type phase is formed to enable the grain retirement effect so that the micro grain size becomes smaller and the strength characteristics improve.
- aluminum of a purity grade not lower than A5 according to GOST 11069 (with the content of aluminum not lower than 99.5%) is generally used.
- the impurities present in the metal are below the limit of their maximum solubility and have no significant effect on the characteristics of the final specimens because of being found in a solid solution or as inter-metallides at a volume ratio of less than 0.1%.
- the proposed alloy contains no additives of manganese and titanium because the hardening achievable due to the ageing of an aluminum solid solution with these transition metals (TM) is manifested far less than due to the disintegration of a zirconium and scandium solid solution in aluminum.
- the modifying effect of these additives is manifested less than in case of introducing zirconium, making unpractical introducing these additives.
- An increased content of intermetallics in the alloy may also decrease their resistance to pitting corrosion.
- An aluminum powder was obtained as follows: scandium and zirconium were added batch-wise as alloying elements to an aluminum melt of a grade not lower than A7 according to GOST 11069 at a temperature of 850-950° C. to avoid super cooling of the melt to a temperature below 740° C. Calcium was added as alloying element after dissolution of scandium and zirconium.
- magnesium was added at a temperature not above 820° C., melt specimens were selected and the chemical composition was adjusted.
- the melt was atomized using a nitrogen-oxygen or argon-oxygen mixture containing 0.2-1.0% of oxygen at a cooling rate not lower than 5.10 4 K/s to produce an oversaturated solid solution.
- the melt was sprayed at a temperature 160-250° C. above a liquidus point to avoid the presence of fine primary intermetallides of zirconium and scandium in the melt.
- the powder was separated to sift out the fraction of below 20 ⁇ m and above 63 ⁇ m or above 130 ⁇ m depending on the requirements.
- the powder morphology was studied by scanning electron microscopy. Photographs illustrating the particles of the produced aluminum powder are shown in FIG. 1 .
- the oxygen content in the powder was studied using Leco gas analyzer depending on the oxygen content in the gas carrying mixture.
- the oxygen content varied from 0.2% to 2%.
- Part blanks were produced from the above powder according to Example 1 by selective laser melting.
- a digital 3D model of an article (for example of specimens for tensile testing as shown in FIG. 2 ) was generated using CAD (SolidWorks, Catia, Creo, NX, Compas 3D), and then stored as a STL. The resulting file was then loaded to the machine. The 3D model was divided into layers (each of 30 ⁇ m in thickness) using special software packages. An article from the metal powder was produced based on these layers.
- the platform comprises a removable metal plate.
- the plate is made of a material having a base similar to that of the powder for printing. Parts to be produced are attached to the plate by means of special supporting structures (emphasized in red in FIG. 2 ). The supporting structures are removed after printing.
- the powder was flatly spread throughout the platform by means of a special doctor blade which may comprise a cylinder, a metal or ceramic blade.
- the powder particles were melted along a predetermined contour by exposure to 180 Watt laser radiation. Printing process was then performed by repeatedly applying the powder layers and alloying the same along a predetermined contour.
- the parts were cut from the platform mechanically or by electric discharge cutting.
- FIG. 3 shows a photograph illustrating a metallographic specimen grown according to the above process.
- the level of porosity does not exceed 0.35%.
- FIG. 4 shows a relationship between the hardness of specimens produced from the inventive aluminum-based alloy powder and the soaking time at different annealing temperatures. Based on the curve data analysis, heat treatment modes were determined for carrying out tensile tests of cylindrical specimens in accordance with the requirements of GOST 1497.
- Table 1 shows the chemical composition of the powders under study.
- Table 2 shows the tensile properties as determined after single-step annealing at 400° C.
- the powder cost was calculated based on the 35% yield of the required fraction and the use of the following feed stock:
- Composition 1 Composition 2
- Composition 3 Reduction in the 7 kg 5.5 kg 3 kg amount of scandium used per 1 ton of the alloy compared to the prototype Reduction in the 350 kg 275 kg 150 kg amount of the Al-2% Sc preliminary alloy used per 1 ton of the alloy compared to the prototype Cost savings per $17,500 $13,750 $7,500 1 ton of the alloy due to reduced alloying with scandium compared to the prototype
- the proposed alloy is similar in terms of the tensile strength to its high-scandium content prototype while having an elongation value higher by 20-30% so that it may be used to manufacture structural elements able to withstand severe strains.
- the engineering and economic performance according to the claimed disclosure is far higher than that of the prototype.
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Abstract
Description
- This application is a continuation of U.S. patent application No. 17/100,578, filed Nov. 20, 2020, which claims priority to PCT Application No. PCT/RU2018/000313 filed May 21, 2018. The contents from the above are hereby incorporated in their entirety by reference.
- The present disclosure relates to the field of aluminum metallurgy and can be used for producing part blanks and finished parts from aluminum based alloys, including but not limited to using selective laser melting (SLM) processes.
- At present, aluminum alloys based on Al—Si and Al—Mg—Sc systems are widely used to produce various parts using additive technologies.
- Known is AlSi10Mg aluminum alloy used in a powder form to produce finished parts with additive technologies. Although said alloy has good processability and allows to achieve mechanical properties at the level of cast alloys. But this level of characteristics is insufficient to compete with high-strength wrought alloys.
- Scandium-containing materials allow the strength of up to 500-550 MPa to be achieved so that such materials may find a wider range of applications. However a high cost of scandium at present results in a low interest of designers and process engineers in the use of these materials.
- Accordingly, there exists an actual problem of developing high-strength and reasonably priced new materials for additive technologies.
- Known is an aluminum alloy for producing parts by additive technologies, comprising (in wt. %):
- Zn-4-10;
- Mg-1-3.5;
- Zr-0-0.5;
- Cu-0-2.5;
- Sc-0-1.25;
- Aluminum—base (see US patent application No. 20170233857, published on Aug. 17, 2017, C22F1/053; B33Y10/00; B33Y70/00; B33Y80/00; C22C21/10).
- A drawback of the known aluminum alloy is a high content (4 to 10 wt. %) of zinc which is evaporated during the process of producing finished parts by additive technologies. In addition, quenching is required for achieving high level of tensile properties, which may cause various distortions during heat treatment and result in a longer time for producing finished parts.
- Known is an aluminum alloy for producing part blanks by additive technologies (see U.S. patent application No. 2017121794, published on May 4, 2017, C22C21/08; B22F1/00; C22F1/05; C23C4/08), comprising (in wt. %):
- Mg-3-6;
- Si-1-4;
- Ti-0.005-0.2;
- Sc-0.1-0.75;
- Zr-0.01-0.375;
- Hf, Mo, Tb, Nb, Gd, Er, V-0-0.5;
- Be-0-0.004;
- Aluminum-base;
- wherein the content of zirconium or the aggregate content of zirconium and titanium is less than 50% of the content of scandium.
- A drawback of this alloy is a high silicon content (1 to 4 wt. %) which substantially improves the casting properties but results in forming coarse excess phases lowering the material plasticity characteristics due to a poor coherency to the aluminum matrix.
- Known is an alloy according to U.S. patent application No. 20170165795, published on Jun. 15, 2017, B23K35/28; C22C21/08, disclosing an aluminum powder alloy comprising (in wt. %):
- Mg-0.5-10;
- Sc-0.1-30;
- Zr-0.05-1.5;
- Mn-0.01-1.5;
- Zn-0-2.0;
- Ti-0.01-0.2;
- Ce≤0.25;
- Be-0-0.004;
- B-0-0.008;
- Si≤0.25;
- Fe≤0.25;
- Hf≤0.5;
- at least one element which is selected from the group consisting of the lanthanum group except for Ce, Y, Ga, Nb, Ta, W, V, Ni, Co, Mo, Li, Th, Ag, wherein the proportion of these elements is at most 0.5; and
- aluminum as the remainder.
- A drawback of the claimed aluminum alloy is a high material cost due to a high content of scandium (up to 30 wt. %) and other rare elements; in addition, over alloying of the material results in lower plasticity and fatigue characteristics.
- A technical problem to be solved by the proposed disclosure is to develop an aluminum powder for producing high-strength and reasonably priced part blanks and finished parts by additive technologies.
- According to some embodiments, the present disclosure relates to a method for producing an aluminum powder from an aluminum-based alloy, the method including (a) adding a scandium and a zirconium batch-wise as alloying elements to an aluminum melt at a temperature from 850-950° C. to avoid super cooling of the aluminum melt to a temperature below 750° C.; (b) adding calcium as master alloy after dissolution of scandium; (c) adding magnesium; and (d) atomizing the melt using a nitrogen-oxygen or argon-oxygen mixture to obtain an aluminum powder while maintaining the following ratio of the melt composition components before atomization (wt. %):
-
magnesium 4.0-6.5; zirconium 0.5-1.0; scandium 0.2-0.6; calcium 0.005-0.2; and aluminum and inevitable impurities remainder. - In some embodiments, a disclosed method includes spraying the melt with an oxygen content of 0.2-1.0% at a temperature 160-250° C. above an alloy liquidus point. A spherical powder includes a particle size of 20 to 150 μm, preferably 20-63 μm. A method may include at least one of producing a finished part produced from the spherical powder by selective laser alloying; and producing a finished part produced from the spherical powder by electron-beam alloying.
- In some embodiments, the present disclosure relates to an aluminum-based alloy comprising magnesium, zirconium and scandium for atomization an aluminum powder therefrom and subsequent producing finished parts by additive technologies, characterized in that the aluminum-based alloy has a reduced scandium content and further includes oxygen and calcium at the following ratio of components (wt. %):
-
magnesium 4.0-6.5; zirconium 0.5-1.0; scandium 0.2-0.6; oxygen 0.001-0.2; calcium 0.005-0.2; and aluminum and inevitable impurities remainder. - An aluminum-based alloy may include a spherical powder having a particle size of 20 to 150 μm. A spherical powder may have a particle size of 20-63 μm. In some embodiments, a spherical powder may contain a finished part formed by a selective laser alloying or electron-beam alloying processes. An aluminum-based alloy may be a spherical powder. An aluminum-based alloy may have an ultimate tensile strength of at least 450 MPa after annealing. An aluminum-based alloy may a magnesium content of 6.5 wt. %, the zirconium content of 1.0 wt. %, the scandium content of 0.2 wt. %, the calcium content of 0.01 wt. %, and the oxygen content of 0.01 wt. %. An aluminum-based alloy may be formed from a feedstock of aluminum having a purity of at least 99.5%. An aluminum-based alloy may have a magnesium content of 4.0 wt. %, the zirconium content of 0.5 wt. %, the scandium content of 0.6 wt. %, the calcium content of 0.2 wt. %, and the oxygen content of 0.005 wt. %.
- In some embodiments, the present disclosure relates to an aluminum-alloy-based powder comprising magnesium, zirconium and scandium for producing part blanks and finished parts by additive technologies, characterized in that the aluminum-based alloy has a reduced scandium content and further comprises oxygen and calcium at the following ratio of components (wt.%):
-
magnesium 4.0-6.5; zirconium 0.5-1.0; scandium 0.2-0.6; oxygen 0.001-0.2; calcium 0.005-0.15; - aluminum and inevitable impurities being remainder components. An aluminum-alloy-based powder may have a spherical shape. An aluminum-alloy-based powder may have an average particle size ranging from 20 μm to 150 μm. An aluminum-alloy-based powder may have a particle size ranging from 20 μm to 63 μm. An aluminum-alloy-based powder may include a finished part formed by a selective laser melting or electron-beam melting processes. A final part made from an aluminum-alloy based powder may have an ultimate tensile strength of at least 450 MPa after annealing. An aluminum-alloy-based powder may have a magnesium content of 6.5 wt. %, a zirconium content of 1.0 wt. %, a scandium content of 0.2 wt. %, a calcium content of 0.01 wt. %, and an oxygen content of 0.01 wt. %. An aluminum-alloy-based powder may be formed from a feedstock of aluminum having a purity of at least 99.5%. An aluminum-alloy-based powder may have a magnesium content of 4.0 wt. %, a zirconium content of 0.5 wt. %, a scandium content of 0.6 wt. %, a calcium content of 0.2 wt. %, and an oxygen content of 0.005 wt. %.
- Some embodiments of the disclosure may be understood by referring, in part, to the present disclosure and the accompany drawings, wherein:
-
FIG. 1 is a photograph illustrating aluminum powder particles, according to a specific example embodiment of the disclosure; -
FIG. 2 is a digital 3D model of the arrangement of specimens at the platform for selective laser alloying, according to a specific example embodiment of the disclosure; -
FIG. 3 is a photograph illustrating metallographic specimens produced from a powder according to the proposed alloy for determining porosity; and -
FIG. 4 is a graph illustrating a relationship between the hardness of specimens produced from the powder according to the proposed alloy and the annealing time and temperature in case of single-step annealing. - According to some embodiments, the present disclosure relates to producing an aluminum alloy with high-strength properties (ultimate tensile strength of at least 470 MPa) and an increased elongation level of at least of 11% and its powder for producing part blanks and finished parts by additive technologies. A distinctive feature is a low powder cost due to its optimized composition and a lower concentration of expensive elements compared to the closest prior art so that the production costs of finished parts may be substantially reduced due to the use of less expensive feed stock. The powder may be used for producing high-loaded finished parts for use, among other things, under exposure to an impact load requiring improved strength and plastic characteristics.
- Said problem is solved and said effect is achieved by preparing a powder having the proposed chemical composition (in wt. %):
-
Mg 4.0-6.5; Zr 0.5-1.0; Sc 0.2-0.6; O 0.001-0.2; Ca 0.005-0.2; Al and inevitable impurities as the remainder. - The content of magnesium in the alloy is limited because a narrow crystallization range has to be provided to improve processability as articles and parts are produced by selective laser melting. A content of magnesium higher than 6.5 wt. % of the alloy will result in an undesirable effect of reduced corrosion resistance because the Al3Mg2 phase tends to nucleate at the grain boundary leading to a fraction due to stress corrosion cracking. The content of scandium is limited because its maximum solubility at a room temperature is 0.02 wt. % and its maximum solubility does not exceed 0.8 wt. %, which makes it possible to avoid for sure formation of primary intermetalics both in the powder as such and in the produced finished parts. Alloying both with scandium and zirconium allows scandium to be partly replaced to form the Al3(Sc, Zr) phase which has an increased heat resistance and efficiently hardens the material in case of correctly selected heat treatment parameters.
- Oxygen is necessary to provide the required sphericity and reduced reactivity of the powder. An increased oxygen content of above 0.2 wt. % will result in a lower quality of the particle surface and disturbed spherical shape. Addition of calcium prevents aluminum oxide from being formed along the boundaries of the synthesized material in the process of repeated remelting. In addition, in the process of subsequent heat treatment, Al4Ca-type phase is formed to enable the grain retirement effect so that the micro grain size becomes smaller and the strength characteristics improve.
- Due to the general alloying level of the material with a small amount of transition metals compared to the closest prior art, improved elongation characteristics are provided. In addition, a further effect consists in preventing magnesium from burning out in the process of the melt preparation and spraying.
- As a feedstock for producing an alloy, aluminum of a purity grade not lower than A5 according to GOST 11069 (with the content of aluminum not lower than 99.5%) is generally used. The impurities present in the metal are below the limit of their maximum solubility and have no significant effect on the characteristics of the final specimens because of being found in a solid solution or as inter-metallides at a volume ratio of less than 0.1%.
- Importantly, the proposed alloy contains no additives of manganese and titanium because the hardening achievable due to the ageing of an aluminum solid solution with these transition metals (TM) is manifested far less than due to the disintegration of a zirconium and scandium solid solution in aluminum. In addition, the modifying effect of these additives is manifested less than in case of introducing zirconium, making unpractical introducing these additives. An increased content of intermetallics in the alloy may also decrease their resistance to pitting corrosion.
- EXAMPLE 1
- An aluminum powder was obtained as follows: scandium and zirconium were added batch-wise as alloying elements to an aluminum melt of a grade not lower than A7 according to GOST 11069 at a temperature of 850-950° C. to avoid super cooling of the melt to a temperature below 740° C. Calcium was added as alloying element after dissolution of scandium and zirconium.
- After complete dissolution of the aluminum-calcium master alloy, magnesium was added at a temperature not above 820° C., melt specimens were selected and the chemical composition was adjusted.
- Immediately before atomization, the chemical composition was finally inspected and additional alloying was performed as appropriate.
- After obtaining the required chemical composition, the melt was atomized using a nitrogen-oxygen or argon-oxygen mixture containing 0.2-1.0% of oxygen at a cooling rate not lower than 5.104 K/s to produce an oversaturated solid solution. The melt was sprayed at a temperature 160-250° C. above a liquidus point to avoid the presence of fine primary intermetallides of zirconium and scandium in the melt. Once produced, the powder was separated to sift out the fraction of below 20 μm and above 63 μm or above 130 μm depending on the requirements.
- The powder morphology was studied by scanning electron microscopy. Photographs illustrating the particles of the produced aluminum powder are shown in
FIG. 1 . - The oxygen content in the powder was studied using Leco gas analyzer depending on the oxygen content in the gas carrying mixture. The oxygen content varied from 0.2% to 2%.
- The following results were obtained:
-
Oxygen Oxygen content in content in the nitrogen, % powder, wt. % 0.2 0.003 0.6 0.08 1.0 0.19 2.0 0.36 - Laser diffraction was used to determine the dispersion degree of the aluminum powder. The following results were obtained: d10=12.7 μm, d50=33.1 μm, d90=59.8 μm.
- Part blanks were produced from the above powder according to Example 1 by selective laser melting.
- A digital 3D model of an article (for example of specimens for tensile testing as shown in
FIG. 2 ) was generated using CAD (SolidWorks, Catia, Creo, NX, Compas 3D), and then stored as a STL. The resulting file was then loaded to the machine. The 3D model was divided into layers (each of 30 μm in thickness) using special software packages. An article from the metal powder was produced based on these layers. - A certain amount of powder was transferred from an additional platform or from a hopper to the main operating platform. The platform comprises a removable metal plate. The plate is made of a material having a base similar to that of the powder for printing. Parts to be produced are attached to the plate by means of special supporting structures (emphasized in red in
FIG. 2 ). The supporting structures are removed after printing. - The powder was flatly spread throughout the platform by means of a special doctor blade which may comprise a cylinder, a metal or ceramic blade.
- The powder particles were melted along a predetermined contour by exposure to 180 Watt laser radiation. Printing process was then performed by repeatedly applying the powder layers and alloying the same along a predetermined contour.
- Once the printing process was completed, the excess of powder was removed from the chamber. The plate with the printed parts was withdrawn from the machine.
- The parts were cut from the platform mechanically or by electric discharge cutting.
-
FIG. 3 shows a photograph illustrating a metallographic specimen grown according to the above process. The level of porosity does not exceed 0.35%. -
FIG. 4 shows a relationship between the hardness of specimens produced from the inventive aluminum-based alloy powder and the soaking time at different annealing temperatures. Based on the curve data analysis, heat treatment modes were determined for carrying out tensile tests of cylindrical specimens in accordance with the requirements of GOST 1497. - Table 1 shows the chemical composition of the powders under study.
- Table 2 shows the tensile properties as determined after single-step annealing at 400° C.
-
TABLE 1 Chemical composition in wt. % No. Al Mg Zr Sc Ca O Mn Zn Ti Y 1 Base 6.5 1.0 0.2 0.01 0.01 — — — — 2 4.8 0.7 0.35 0.005 0.2 — — — — 3 4.0 0.5 0.6 0.2 0.005 — — — — 4 4.0 0.5 0.6 0.18 0.38 Prototype 5.0 0.7 0.9 — — 0.5 0.5 0.05 0.05 -
TABLE 2 Tensile properties Ultimate Tensile strength, yield point, Elongation, No. MPa MPa % 1 475 445 14.0 2 480 455 13.5 3 505 460 14.0 4 500 450 11.0 Prototype 510 470 10.0 - As seen from the above Tables, an increase in the oxygen content leads to a certain reduction in elongation caused by the presence of the oxide phase in the alloyed material, said oxide phase being sufficiently fine to maintain the hardening effect but having no affinity for the aluminum matrix.
- The powder cost was calculated based on the 35% yield of the required fraction and the use of the following feed stock:
- A7 aluminum ingots;
- Mg95 magnesium ingots;
- aluminum—2% scandium master alloy;
- aluminum—10% zirconium master alloy;
- aluminum—10% yttrium master alloy;
- Z0 grade zinc metal;
- aluminum—6% calcium master alloy;
- aluminum—5% titanium master alloy.
- Cost savings in the preparation of the proposed alloy estimated versus the prototype are shown in Table 3 below.
-
TABLE 3 Composition 1 Composition 2 Composition 3Reduction in the 7 kg 5.5 kg 3 kg amount of scandium used per 1 ton of the alloy compared to the prototype Reduction in the 350 kg 275 kg 150 kg amount of the Al-2% Sc preliminary alloy used per 1 ton of the alloy compared to the prototype Cost savings per $17,500 $13,750 $7,500 1 ton of the alloy due to reduced alloying with scandium compared to the prototype - As a result of reducing the scandium content to 0.2-0.6 wt. % and the cost of Al-2%Sc preliminary alloy to 50$/kg, a cost saving by $7,500-$17,500 per 1 ton of the alloy is achieved compared to the prototype (U.S. 20170165795). At the same time, the proposed alloy is similar in terms of the tensile strength to its high-scandium content prototype while having an elongation value higher by 20-30% so that it may be used to manufacture structural elements able to withstand severe strains. In this regard, the engineering and economic performance according to the claimed disclosure is far higher than that of the prototype.
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CA3050947A1 (en) | 2019-11-21 |
PL3623488T3 (en) | 2021-10-25 |
JP6880203B2 (en) | 2021-06-02 |
JP2021507088A (en) | 2021-02-22 |
EP3623488B1 (en) | 2021-05-05 |
CN110832093A (en) | 2020-02-21 |
CN110832093B (en) | 2022-05-17 |
US20210246535A1 (en) | 2021-08-12 |
EP3623488A1 (en) | 2020-03-18 |
KR102422213B1 (en) | 2022-07-18 |
WO2019226063A1 (en) | 2019-11-28 |
US11802325B2 (en) | 2023-10-31 |
KR20200087857A (en) | 2020-07-21 |
CA3050947C (en) | 2022-01-11 |
RU2717441C1 (en) | 2020-03-23 |
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