Process-specific design strategy enables exceptional as-deposited strength-ductility synergy in novel Al–Ce alloys via additive friction stir deposition (AFSD)
A process-specific alloy design strategy was employed to achieve exceptional as-deposited strength-ductility synergy in Al–Ce alloys, eliminating the need for post-aging treatments. Al–Ce alloys, known for their excellent creep resistance and thermal stability due to the Al11Ce3 phase, were optimize...
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| Language: | English |
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Elsevier
2025-03-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785425001243 |
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| author | Vishal Soni Roberto Liam Menchaca Devin Davis N. Naveen Kumar Maria Gonzalez Prithvi Awasthi Ravi Sankar Haridas Adam Loukus David Weiss Rajiv S. Mishra Vijay K. Vasudevan |
| author_facet | Vishal Soni Roberto Liam Menchaca Devin Davis N. Naveen Kumar Maria Gonzalez Prithvi Awasthi Ravi Sankar Haridas Adam Loukus David Weiss Rajiv S. Mishra Vijay K. Vasudevan |
| author_sort | Vishal Soni |
| collection | DOAJ |
| description | A process-specific alloy design strategy was employed to achieve exceptional as-deposited strength-ductility synergy in Al–Ce alloys, eliminating the need for post-aging treatments. Al–Ce alloys, known for their excellent creep resistance and thermal stability due to the Al11Ce3 phase, were optimized using CALPHAD simulations to incorporate solid solution and precipitation strengthening in addition to composite strengthening from the Al11Ce3 phase. Additive friction stir deposition (AFSD) was used to fabricate 3D builds from cast material, refining the grain size and microstructure by fragmenting Al11Ce3 lamellae into smaller, uniformly dispersed particles and inducing Al3Sc nanoprecipitates during deposition. Microstructural and mechanical analyses revealed remarkable improvements: while the cast alloy fractured at 230 MPa with no ductility, the AFSD alloy achieved a yield strength of 385 MPa, UTS of 530 MPa, and 12.6% plastic strain. These as-deposited properties surpassed those of cast, extruded, HIPPed, or LPBF/DED Al–Ce alloys, including the previous results obtained after aging. This strategy leverages AFSD-specific process dynamics, such as intense deformation and localized high temperatures, to enable in-situ precipitation and microstructural refinement with exceptional mechanical properties, offering a transformative pathway for designing energy-efficient, high-performance materials. |
| format | Article |
| id | doaj-art-033e472c0632436fa7b66f7c5d26f972 |
| institution | Kabale University |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-03-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-033e472c0632436fa7b66f7c5d26f9722025-01-26T05:03:56ZengElsevierJournal of Materials Research and Technology2238-78542025-03-013518891900Process-specific design strategy enables exceptional as-deposited strength-ductility synergy in novel Al–Ce alloys via additive friction stir deposition (AFSD)Vishal Soni0Roberto Liam Menchaca1Devin Davis2N. Naveen Kumar3Maria Gonzalez4Prithvi Awasthi5Ravi Sankar Haridas6Adam Loukus7David Weiss8Rajiv S. Mishra9Vijay K. Vasudevan10Department of Materials Science and Engineering, University of North Texas, 3940 N. Elm Street, Denton, TX, 76207-7102, USA; Corresponding author.Department of Materials Science and Engineering, University of North Texas, 3940 N. Elm Street, Denton, TX, 76207-7102, USADepartment of Materials Science and Engineering, University of North Texas, 3940 N. Elm Street, Denton, TX, 76207-7102, USADepartment of Materials Science and Engineering, University of North Texas, 3940 N. Elm Street, Denton, TX, 76207-7102, USADepartment of Materials Science and Engineering, University of North Texas, 3940 N. Elm Street, Denton, TX, 76207-7102, USADepartment of Materials Science and Engineering, University of North Texas, 3940 N. Elm Street, Denton, TX, 76207-7102, USADepartment of Mechanical Engineering, University of North Texas, 3940 N. Elm Street, Denton, TX, 76207-7102, USA; Center for Friction Stir Processing, University of North Texas, Denton, TX, 76201, USALoukus Technologies Inc., 58390 Centennial Number 6 Rd. Calumet, MI, 49913, USALoukus Technologies Inc., 58390 Centennial Number 6 Rd. Calumet, MI, 49913, USADepartment of Materials Science and Engineering, University of North Texas, 3940 N. Elm Street, Denton, TX, 76207-7102, USA; Center for Friction Stir Processing, University of North Texas, Denton, TX, 76201, USADepartment of Materials Science and Engineering, University of North Texas, 3940 N. Elm Street, Denton, TX, 76207-7102, USA; Corresponding author.A process-specific alloy design strategy was employed to achieve exceptional as-deposited strength-ductility synergy in Al–Ce alloys, eliminating the need for post-aging treatments. Al–Ce alloys, known for their excellent creep resistance and thermal stability due to the Al11Ce3 phase, were optimized using CALPHAD simulations to incorporate solid solution and precipitation strengthening in addition to composite strengthening from the Al11Ce3 phase. Additive friction stir deposition (AFSD) was used to fabricate 3D builds from cast material, refining the grain size and microstructure by fragmenting Al11Ce3 lamellae into smaller, uniformly dispersed particles and inducing Al3Sc nanoprecipitates during deposition. Microstructural and mechanical analyses revealed remarkable improvements: while the cast alloy fractured at 230 MPa with no ductility, the AFSD alloy achieved a yield strength of 385 MPa, UTS of 530 MPa, and 12.6% plastic strain. These as-deposited properties surpassed those of cast, extruded, HIPPed, or LPBF/DED Al–Ce alloys, including the previous results obtained after aging. This strategy leverages AFSD-specific process dynamics, such as intense deformation and localized high temperatures, to enable in-situ precipitation and microstructural refinement with exceptional mechanical properties, offering a transformative pathway for designing energy-efficient, high-performance materials.http://www.sciencedirect.com/science/article/pii/S2238785425001243Additive friction stir depositionAl–Ce alloysComposite strengtheningAlloy designAdditive manufacturing |
| spellingShingle | Vishal Soni Roberto Liam Menchaca Devin Davis N. Naveen Kumar Maria Gonzalez Prithvi Awasthi Ravi Sankar Haridas Adam Loukus David Weiss Rajiv S. Mishra Vijay K. Vasudevan Process-specific design strategy enables exceptional as-deposited strength-ductility synergy in novel Al–Ce alloys via additive friction stir deposition (AFSD) Journal of Materials Research and Technology Additive friction stir deposition Al–Ce alloys Composite strengthening Alloy design Additive manufacturing |
| title | Process-specific design strategy enables exceptional as-deposited strength-ductility synergy in novel Al–Ce alloys via additive friction stir deposition (AFSD) |
| title_full | Process-specific design strategy enables exceptional as-deposited strength-ductility synergy in novel Al–Ce alloys via additive friction stir deposition (AFSD) |
| title_fullStr | Process-specific design strategy enables exceptional as-deposited strength-ductility synergy in novel Al–Ce alloys via additive friction stir deposition (AFSD) |
| title_full_unstemmed | Process-specific design strategy enables exceptional as-deposited strength-ductility synergy in novel Al–Ce alloys via additive friction stir deposition (AFSD) |
| title_short | Process-specific design strategy enables exceptional as-deposited strength-ductility synergy in novel Al–Ce alloys via additive friction stir deposition (AFSD) |
| title_sort | process specific design strategy enables exceptional as deposited strength ductility synergy in novel al ce alloys via additive friction stir deposition afsd |
| topic | Additive friction stir deposition Al–Ce alloys Composite strengthening Alloy design Additive manufacturing |
| url | http://www.sciencedirect.com/science/article/pii/S2238785425001243 |
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