Rapidly Solidified Aluminum Based, Silicon Containing Alloys for Elevated Temperature Applications

1. Field of the Invention

The invention relates to aluminum based, silicon containing, alloys having strength, ductility and toughness at ambient and elevated temperatures and relates to powder products produced from such alloys. More particularly, the invention relates to Al-Fe-Si-V alloys that have been rapidly solidified from the melt and thermomechanically processed into structural components having a combination of high strength, ductility and fracture toughness.

2. Brief Description of the Prior Art

Methods for obtaining improved tensile strength at 350.degree. C. in aluminum based alloys have been described in U.S. Pat. Nos. 2,963,780 to Lyle, et al.; 2,967,351 to Roberts, et al.; and 3,462,248 to Roberts, et al. The alloys taught by Lyle, et al. and by Roberts, et al. were produced by atomizing liquid metals into finely divided droplets by high velocity gas streams. The droplets were cooled by convective cooling at a rate of approximately 10.sup.4 .degree. C./sec. As a result of this rapid cooling, Lyle, et al. and Roberts, et al. were able to produce alloys containing substantially higher quantities of transition elements than has hitherto been possible.

Higher cooling rates using conductive cooling, such as splat quenching and melt spinning, have been employed to produce cooling rates of about 10.sup.5 to 10.sup.6 .degree. C./sec. Such cooling rates minimize the formation of intermetallic precipitates during the solidification of the molten aluminum alloy. Such intermetallic precipitates are responsible for premature tensile instability. U.S. Pat. No. 4,379,719 to Hildeman, et al. discusses rapidly quenched aluminum alloy powder containing 4 to 12 wt % iron and 1 to 7 wt % cerium or other rare earth metal from the lanthanum series. U.S. Pat. No. 4,347,076 to Adam discusses rapidly quenched aluminum alloy powder containing 5-15 wt. % Fe and 1-5 wt. % of other transition elements.

U.S. Pat. No. 4,347,076 to Ray, et al. discusses high strength aluminum alloys for use at temperatures of about 350.degree. C. that have been produced by rapid solidification techniques. These alloys, however, have low engineering ductility and fracture toughness at room temperature which precludes their employment in structural applications where a minimum tensile elongation of about 3% is required. An example of such an application would be in small gas turbine engines discussed by P. T. Millan, Jr.; Journal of Metals, Volume 35(3), page 76, 1983.

Ray, et al. discussed aluminum alloys composed of a metastable, face-centered cubic, solid solution of transition metal elements with aluminum. The as cast ribbons were brittle on bending and were easily comminuted into powder. The powder was compacted into consolidated articles having tensile strengths of up to 76 ksi at room temperature. The tensile ductility or fracture toughness of these alloys was not discussed in detail in Ray, et al. However, it is known that (NASA REPORT NASI-17578 May 1984) many of the alloys taught by Ray, et al., when fabricated into engineering test bars do not posses sufficient room temperature ductility or fracture toughness for use in structural components.

Thus, conventional aluminum alloys, such as those taught by Ray, et al. have lacked sufficient engineering toughness. As a result, these conventional alloys have not been suitable for use in structural components.

The invention provides fabricated gas turbine and automotive engine and missile components of an aluminum based alloy consisting essentially of the formula Al.sub.bal Fe.sub.a Si.sub.b V.sub.c, "a" ranges from 3.0 to 7.1 at %, "b" ranges from 1.0 to 3.0 at %, "c" ranges from 0.25 to 1.25 at % and the balance is aluminum plus incidental impurities, with the provisos that (i) the ratio [Fe+ V]:Si ranges from 2.33:1 to 3.33:1, and (ii) the ratio Fe:V ranges from 11.5:1 to 5:1.

The material requirements for engine control housing and other gas turbine engine static structures include operations at temperatures up to 550.degree. F. either in ambient air or the operating fluid. Operating fluid pressures range from 6000 to 8000 psig. An increasingly important design criterion is weight savings over titanium, the material at present most widely used. The utilization of high temperature aluminum alloys in engine control housings represents an application that to date has required titanium not because of the extreme high temperature capabilities of titanium alloys but the inability of conventional elevated temperature aluminum alloys to perform in the specified temperature/pressure regimes. The alloys of the present invention are excellent candidates for engine control housings because of their extreme thermal stability. Additional applications for which the extrusions and forgings of this invention are well suited comprise structural members of commercial and military aircraft including helicopters, airframes, missles, gas turbine engine components and automotive engine components, such as intake valves, pistons, connecting rods, valve lifters and the like.

To provide the desired levels of ductility, toughness and high temperature strength needed for commercially useful gas turbine and automotive engine components, aircraft structural parts, the alloys of the invention are subjected to rapid solidification processing, which modifies the alloy microstructure. The rapid solidification processing method is one wherein the alloy is placed into the molten state and then cooled at a quench rate of at least about 10.sup.5 to 10.sup.7 .degree. C./sec. to form a solid substance. Preferably this method should cool the molten metal at a rate of greater than about 10.sup.6 .degree. C./sec, i.e. via melt spinning, spat cooling or planar flow casting which forms a solid ribbon or sheet. These alloys have an as cast microstructure which varies from a microeutectic to a microcellular structure, depending on the specific alloy chemistry. In alloys of the invention the relative proportions of these structures is not critical.

Consolidated articles are produced by compacting particles composed of an aluminum based alloy consisting essentially of the formula Al.sub.bal Fe.sub.a Si.sub.b V.sub.c, "a" ranges from 3.00 to 7.1 at %, "b" ranges from 1.0 to 3.0 at %, "c" ranges from 0.25 to 1.25 at % and the balance is aluminum plus incidental impurities, with the provisos that i) the ratio [Fe+V]:Si ranges from 2.33:1 to 3.33:1, and ii) the ratio Fe:V ranges from 11.5:1 to 5:1. The particles are heated in a vacuum during the compacting step to a pressing temperature varying from about 300.degree. to 500.degree. C., which minimizes coarsening of the dispersed, intermetallic phases. Alternatively, the particles are put in a can which is then evacuated, heated to between 300.degree. C. and 500.degree. C., and then sealed. The sealed can is heated to between 300.degree. C. and 500.degree. C. in ambient atmosphere and compacted. The compacted article is fabricated by conventionally practiced methods such as extrusion, or forging, and the finished shape is machined from the consolidated article.

The fabricated gas turbine, missile and automotive engine components of the invention are composed of an aluminum solid solution phase containing a substantially uniform distribution of dispersed intermetallic phase precipitates of approximate composition Al.sub.12 (Fe, V).sub.3 Si.sub.1. These precipitates are fine intermetallics measuring less than 100 nm. in all linear dimensions thereof. Alloys of the invention, containing these fine dispersed intermetallics are able to tolerate the heat and pressure associated with conventional consolidation and forming techniques such as forging, rolling, and extrusion without substantial growth or coarsening of these intermetallics that would otherwise reduce the strength and ductility of the consolidated article to unacceptably low levels. Because of the thermal stability of the dispersoids in the alloys of the invention, the alloys can be used to produce near net shape articles, such as engine control housings, compressor impellors, automotive engine components, aircraft structural parts and missile components by extrusion or forging, that have a combination of strength and good ductility both at ambient temperature and at elevated temperatures of about 350.degree. C.

Thus, the articles of the invention are more suitable for high temperature structural applications in engine, control housings, compressor impellor, automotive engine components, missile components, aircraft structural parts etc.

To provide the desired levels of strength, ductility and toughness needed for commercially useful gas turbine engine components, rapid solidification from the melt is particularly useful for producing these aluminum based alloys. The alloys of the invention consist essentially of the formula Al.sub.bal Fe.sub.a Si.sub.b V.sub.c, "a" ranges from 3.0 to 7.1 at %, "b" ranges from 1.0 to 3.0 at %, "c" ranges from 0.25 to 1.25 at % and the balance is aluminum plus incidental impurities, with the provisos that i) the ratio [Fe+V]:Si ranges from about 2.33:1 to 3.33:1, and ii) the ratio Fe:V ranges from 11.5:1 to 5:1. The rapid solidification processing typically employs a casting method wherein the alloy is placed into a molten state and then cooled at a quench rate of at least about 10.sup.5 to 10.sup.7 .degree. C./sec. on a rapidly moving casting substrate to form a solid ribbon or sheet. This process should provide provisos for protecting the melt puddle from burning, excessive oxidation and physical disturbances by the air boundary layer carried with along with a moving casting surface. For example, this protection can be provided by a shrouding apparatus which contains a protective gas; such as a mixture of air or CO.sub.2 and SF.sub.6, a reducing gas, such as CO or an inert gas; around the nozzle. In addition, the shrouding apparatus excludes extraneous wind currents which might disturb the melt puddle.

Rapidly solidified alloys having the Al.sub.bal Fe.sub.a Si.sub.b V.sub.c compositions (with the provisos for [Fe+V]:Si ratio and Fe:V ratio described above) have been processed into ribbons and then formed into particles by conventional comminution devices such as pulverizers, knife mills, rotating hammer mills and the like. Preferably, the comminuted powder particles have a size ranging from about 40 to 200 mesh, U.S. standard sieve size.

The particles are placed in a vacuum of less than 10.sup.-4 torr (1.33.times.10.sup.-2 Pa.) preferably less than 10.sup.-5 torr (1.33.times.10.sup.-3 Pa.), and then compacted by conventional powder metallurgy techniques. In addition the particles are heated at a temperature ranging from about 300.degree. to 550.degree. C., preferably ranging from about 325 to 450.degree. C., minimizing the growth or coarsening of the intermetallic phases therein. The heating of the powder particles preferably occurs during the compacting step. Suitable powder metallurgy techniques include direct powder extrusion by putting the powder in a can which has been evacuated and sealed under vacuum, vacuum hot compaction, blind die compaction in an extrusion or forging press, direct and indirect extrusion, conventional and impact forging, impact extrusion and the combinations of the above. Compacted consolidated articles of the invention are composed of a substantially homogeneous dispersion of very small intermetallic phase precipitates within the aluminum solid solution matrix. With appropriate thermo-mechanical processing these intermetallic precipitates can be provided with optimized combinations of size, e.g. diameter, and interparticle spacing. These characteristics afford the desired combination of high strength and ductility. The precipitates are fine, usually spherical in shape, measuring less than about 100 nm. in all linear dimensions thereof. The volume fraction of these fine intermetallic precipitates ranges from about 16 to 45%, and preferably, ranges from about 20 to 37% to provide improved properties. Volume fractions of coarse intermetallic precipitates (i.e. precipitates measuring more than about 100 nm. in the largest dimention thereof) is not more than about 1%.

Compositions of the fine intermetallic precipitates found in the consolidated article of the invention is approximately Al.sub.12 (Fe,V).sub.3 Si.sub.1. For alloys of the invention this intermetallic composition represents about 95 to 100%, and preferably 100%, of the fine dispersed intermetallic precipitates found in the consolidated article. The addition of vanadium to Al-Fe-Si alloys when describing the alloy composition as the formula Al.sub.bal Fe.sub.a Si.sub.b V.sub.c (with the [Fe+V]:Si and Fe:V ratio provisos) stabilizes this metastable quaternary intermetallic precipitate resulting in a general composition of about Al.sub.12 (Fe,V).sub.3 Si.sub.1. The [Fe+V]:Si and Fe:V ratio provisos define the compositional boundaries within which about 95-100%, and preferably 100% of the fine dispersed intermetallic phases are of this general composition.

The prefered stabilized intermetallic precipitate has a structure that is body centered cubic and a lattice parameter that is about 1.25 to 1.28 nm.

Alloys of the invention, containing this fine dispersed intermetallic precipitate, are able to tolerate the heat and pressure of conventional powder metallurgy techniques without excessive growth or coarsening of the intermetallics that would otherwise reduce the strength and ducility of the consolidated article to unacceptably low levels. In addition, alloys of the invention are able to withstand unconventionally high processing temperatures and withstand long exposure times at high temperatures during processing. Such temperatures and times are encountered during the production at near net-shape articles by forging and sheet or plate by rolling, for example. As a result, alloys of the invention are particularly useful for forming high strength consolidated aluminum alloy articles. The alloys are particularly advantageous because they can be compacted over a broad range of consolidation temperatures and still provide the desired combinations of strength and ductility in the compacted article.

Further, by ensuring that about 95-100%, preferably 100% of the fine dispersed intermetallic phase are of the general composition Al.sub.12 (Fe,V).sub.3 Si.sub.1, by the application of the [Fe+V]:Si and Fe:V ratio provisos, applicable engineering properties can be enhanced, such as crack growth resistance and fracture toughness.

The following examples are presented to provide a more complete understanding of the invention. The specific techniques, conditions, materials, proportions of the invention are exemplary and should not be construed as limiting the scope of the invention.

Alloys of the invention were cast according to the formula and method of the invention and are listed in Table 1.

1. Al.sub.93.55 Fe.sub.4.24 V.sub.0.44 Si.sub.1.77

2. Al.sub.93.56 Fe.sub.4.13 V.sub.0.44 Si.sub.1.86

3. Al.sub.93.52 Fe.sub.4.03 V.sub.0.58 Si.sub.1.86

4. Al.sub.92.93 Fe.sub.4.77 V.sub.0.48 Si.sub.1.86

5. Al.sub.92.92 Fe.sub.4.67 V.sub.0.59 Si.sub.1.86

6. Al.sub.92.93 Fe.sub.4.49 V.sub.0.75 Si.sub.1.86

7. Al.sub.92.39 Fe.sub.5.12 V.sub.0.51 Si.sub.1.99

8. Al.sub.92.41 Fe.sub.4.99 V.sub.0.62 Si.sub.1.99

9. Al.sub.92.36 Fe.sub.4.84 V.sub.0.81 Si.sub.1.99

10. Al.sub.93.52 Fe.sub.4.06 V.sub.0.75 Si.sub.1.67

11. Al.sub.93.57 Fe.sub.4.29 V.sub.0.47 Si.sub.1.67

12. Al.sub.94 12 Fe.sub.3.92 V.sub.0.50 Si.sub.1.46

13. Al.sub.93.22 Fe.sub.4.33 V.sub.0.73 Si.sub.1.72

14. Al.sub.90.82 Fe.sub.6.06 V.sub.0.65 Si.sub.2.47

15. Al.sub.93.46 Fe.sub.4.37 V.sub.0.47 Si.sub.l.70

16. Al.sub.93.45 Fe.sub.4.27 V.sub.0.58 Si.sub.l.70

17. Al.sub.93.44 Fe.sub.4.11 V.sub.0.75 Si.sub.1.70

18. Al.sub.91.92 Fe.sub.5.40 V.sub.0.59 Si.sub.2.10

19. Al.sub.91.88 Fe.sub.5.29 V.sub.0.73 Si.sub.2.10

20. Al.sub.91.89 Fe.sub.5.09 V.sub.0.93 Si.sub.2.09

21. Al.sub.91.44 Fe.sub.5.73 V.sub.0.62 Si.sub.2.22

22. Al.sub.91.45 Fe.sub.5.57 V.sub.0.76 Si.sub.2.21

23. Al.sub.91.42 Fe.sub.5.36 V.sub.0.99 Si.sub.2.22

24. Al.sub.89.29 Fe.sub.7.07 V.sub.0.77 Si.sub.2.86

Table 2 below shows the mechanical properties of specific alloys measured in uniaxial tension at a strain rate of approximately 5.times.10.sup.-4 /sec. and at various elevated temperatures. Each selected alloy powder was vacuum hot pressed at a temperature of 350.degree. C. for 1 hr. to produce a 95 to 100% density preform slug. These slugs were extruded into rectangular bars with an extrusion ratio of 18:1 at 385.degree. to 400.degree. C. after holding at that temperature for 1 hr.

The alloys of the invention are capable of producing consolidated articles which have high fracture tougheness when measured at room temperature. Table 3 below shows the fracture toughness for selected consolidated articles of the invention. Each of the powder articles were consolidated by vacuum hot compaction at 350.degree. C. and subsequently extruded at 385.degree. C. at an extrusion ratio of 18:1. Fracture toughness measurements were made on compact tension (CT) specimens of the consolidated articles of the invention under the ASTM E399 standard.

The alloys of the invention are capable of producing consolidated articles which have an improved resistance to crack propogation as compared to those outside of the invention. Table 4 below indicates this improved resistance to crack growth for consolidated articles of the invention having essentially the same volume fracture and microstructural features as a consolidated article produced outside of this invention. Each of the powder articles were consolidated by vacuum hot compaction at 350.degree. C. and subsequently extruded at 385.degree. C. at an extrusion ratio of 18:1. Crack propagation measurements were made on compact tension (CT) specimens under the ASTM E-647 standard.

Table 5 below shows the room temperature mechanical properties of a specific alloy of the invention that has been consolidated by forging for use as compressor impellors. The alloy powder was vacuum hot pressed at a temperature of 350.degree. C. for 1 hr. to provide a 95 to 100% density preform slug. These slugs were subsequently forged at a temperature from about 450.degree. C. to 500.degree. C. after holding at that temperature for 1 hr.

An engine control housing was produced from a 3.25" by 3.25" extrusion having a composition consisting essentially of the alloy Al.sub.93.52 Fe.sub.4.06 V.sub.0.75 Si.sub.1.67. The extrusion was made by consolidating rapidly solidified powder particles of the alloy by canning under vacuum, compacting to a billet at 350.degree. C. and subsequently extruding the billet at 385.degree. C. at an extrusion ration of about 9 to 1. The properties of the extrusion are set forth below in TABLE 6:

Having thus described the invention in rather full detail, it will be understood that these details need not be strictly adhered to but that various changes and modifications may suggest themselves to one skilled in the art, all falling within the scope of the invention as defined by the subjoining claims.