L12 strengthened amorphous aluminum alloys

Abstract

An improved amorphous aluminum alloy having high strength, ductility, corrosion resistance and fracture toughness is disclosed. The alloy has an amorphous phase and a coherent L12 phase. The alloy has nickel, cerium, at least one of scandium, erbium, thulium, ytterbium, and lutetium; and at least one of gadolinium, yttrium, zirconium, titanium, hafnium, niobium and iron. The volume fraction of the amorphous phase ranges from about 50 percent to about 95 percent and the volume fraction of the coherent L12 phase ranges from about 5 percent to about 50 percent.

Description

BACKGROUND

The present invention relates generally to aluminum alloys and more specifically to L1₂ phase dispersion strengthened aluminum alloys having ceramic reinforcement particles.

The combination of high strength, ductility, and fracture toughness, as well as low density, make aluminum alloys natural candidates for aerospace and space applications. However, their use is typically limited to temperatures below about 300° F. (149° C.) since most aluminum alloys start to lose strength in that temperature range as a result of coarsening of strengthening precipitates.

The development of aluminum alloys with improved elevated temperature mechanical properties is a continuing process. Some attempts have included aluminum-iron and aluminum-chromium based alloys such as Al—Fe—Ce, Al—Fe—V—Si, Al—Fe—Ce—W, and Al—Cr—Zr—Mn that contain incoherent dispersoids. These alloys, however, also lose strength at elevated temperatures due to particle coarsening. In addition, these alloys exhibit ductility and fracture toughness values lower than other commercially available aluminum alloys.

Other attempts have included the development of mechanically alloyed Al—Mg and Al—Ti alloys containing ceramic dispersoids. These alloys exhibit improved high temperature strength due to the particle dispersion, but the ductility and fracture toughness are not improved.

U.S. Pat. No. 6,248,453 discloses aluminum alloys strengthened by dispersed Al₃X L1₂ intermetallic phases where X is selected from the group consisting of Sc, Er, Lu, Yb, Tm, and U. The Al₃X particles are coherent with the aluminum alloy matrix and are resistant to coarsening at elevated temperatures. The improved mechanical properties of the disclosed dispersion strengthened L1₂ aluminum alloys are stable up to 572° F. (300° C.). U.S. Patent Application Publication No. 2006/0269437 A1 discloses an aluminum alloy that contains scandium and other elements.

Amorphous alloys have received interest in recent years because materials with an amorphous structure are usually very strong and corrosion resistant in comparison with crystalline structures having the same composition. However, amorphous aluminum alloys have been found to have lower ductility and fracture toughness than the crystalline form. Aluminum based amorphous alloys with high strength and low density are desirable because of their lower density and their applicability in the aerospace and space industries. Amorphous aluminum alloys would also be useful in armor applications where lightweight materials are desired.

SUMMARY

The present invention is an improved amorphous aluminum alloy having a crystalline L1₂ aluminum alloy phase dispersed in an amorphous aluminum alloy matrix. The L1₂ phase results in improved ductility and fracture toughness while maintaining the strength and corrosion resistance of the amorphous phase. The desired volume fraction of the amorphous phase is from about 50 percent to about 95 percent, more preferably about 60 percent to about 90 percent, and even more preferably about 70 percent to about 80 percent.

The aluminum alloy of this invention is formed into the amorphous phase and a fine, coherent L1₂ phase by use of the rapid solidification process.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an aluminum nickel phase diagram.

FIG. 2 is an aluminum cerium phase diagram.

FIG. 3 is an aluminum scandium phase diagram.

FIG. 4 is an aluminum erbium phase diagram.

FIG. 5 is an aluminum thulium phase diagram.

FIG. 6 is an aluminum ytterbium phase diagram.

FIG. 7 is an aluminum lutetium phase diagram.

DETAILED DESCRIPTION

The alloys of this invention comprises an amorphous matrix of aluminum, nickel and cerium strengthened by having dispersed therein a fine, coherent L1₂ phase based on Al₃X where X is least one first element selected from scandium, erbium, thulium, ytterbium, lutetium, and at least one second element selected from iron, gadolinium, yttrium, zirconium, titanium, hafnium, and niobium.

The aluminum nickel phase diagram is shown in FIG. 1. The aluminum nickel binary system is a simple eutectic at 5.7 weight percent nickel and 1183.8° F. (639.9° C.). There is little solubility of nickel in aluminum. However, the solubility can be extended significantly by utilizing rapid solidification processes. The equilibrium phase in the aluminum nickel eutectic system is intermetallic Al₃Ni.

The aluminum cerium phase diagram is shown in FIG. 2. The aluminum cerium binary system is a simple eutectic at 18 weight percent cerium and 1184° F. (640° C.). There is little or no solubility of cerium in aluminum. However the solubility can be extended significantly by utilizing rapid solidification processes. Metastable Al₃Ce can form in rapidly cooled hypereutectic aluminum cerium alloys. The equilibrium phase in eutectic alloys is Al₁₁Ce₃ Cerium helps in forming an amorphous structure in aluminum in the presence of nickel due to deep eutectics.

Scandium forms Al₃Sc dispersoids that are fine and coherent with the aluminum matrix. Lattice parameters of aluminum and Al₃Sc are very close (0.405 nm and 0.410 nm respectively), indicating that there is minimal or no driving force for causing growth of the Al₃Sc dispersoids. This low interfacial energy makes the Al₃Sc dispersoids thermally stable and resistant to coarsening up to temperatures as high as about 842° F. (450° C.). In the alloys of this invention these Al₃Sc dispersoids are made stronger and more resistant to coarsening at elevated temperatures by adding suitable alloying elements such as gadolinium, yttrium, zirconium, titanium, hafnium, niobium, iron or combinations thereof, that enter Al₃Sc in solution.

Erbium forms Al₃Er dispersoids in the aluminum matrix that are fine and coherent with the aluminum matrix. The lattice parameters of aluminum and Al₃Er are close (0.405 nm and 0.417 nm respectively), indicating there is minimal driving force for causing growth of the Al₃Er dispersoids. This low interfacial energy makes the Al₃Er dispersoids thermally stable and resistant to coarsening up to temperatures as high as about 842° F. (450° C.). In the alloys of this invention, these Al₃Er dispersoids are made stronger and more resistant to coarsening at elevated temperatures by adding suitable alloying elements such as gadolinium, yttrium, zirconium, titanium, hafnium, niobium, iron or combinations thereof that enter Al₃Er in solution.

Thulium forms metastable Al₃Tm dispersoids in the aluminum matrix that are fine and coherent with the aluminum matrix. The lattice parameters of aluminum and Al₃Tm are close (0.405 nm and 0.420 nm respectively), indicating there is minimal driving force for causing growth of the Al₃Tm dispersoids. This low interfacial energy makes the Al₃Tm dispersoids thermally stable and resistant to coarsening up to temperatures as high as about 842° F. (450° C.). In the alloys of this invention these Al₃Tm dispersoids are made stronger and more resistant to coarsening at elevated temperatures by adding suitable alloying elements such as gadolinium, yttrium, zirconium, titanium, hafnium, niobium, iron or combinations thereof that enter Al₃Tm in solution.

Ytterbium forms Al₃Yb dispersoids in the aluminum matrix that are fine and coherent with the aluminum matrix. The lattice parameters of Al and Al₃Yb are close (0.405 nm and 0.420 nm respectively), indicating there is minimal driving force for causing growth of the Al₃Yb dispersoids. This low interfacial energy makes the Al₃Yb dispersoids thermally stable and resistant to coarsening up to temperatures as high as about 842° F. (450° C.). In the alloys of this invention, these Al₃Yb dispersoids are made stronger and more resistant to coarsening at elevated temperatures by adding suitable alloying elements such as gadolinium, yttrium, zirconium, titanium, hafnium, niobium, iron or combinations thereof that enter Al₃Yb in solution.

Lutetium forms Al₃Lu dispersoids in the aluminum matrix that are fine and coherent with the aluminum matrix. The lattice parameters of Al and Al₃Lu are close (0.405 nm and 0.419 nm respectively), indicating there is minimal driving force for causing growth of the Al₃Lu dispersoids. This low interfacial energy makes the Al₃Lu dispersoids thermally stable and resistant to coarsening up to temperatures as high as about 842° F. (450° C.). In the alloys of this invention, these Al₃Lu dispersoids are made stronger and more resistant to coarsening at elevated temperatures by adding suitable alloying elements such as gadolinium, yttrium, zirconium, titanium, hafnium, niobium, iron or mixtures thereof that enter Al₃Lu in solution.

Gadolinium forms metastable Al₃Gd dispersoids in the aluminum matrix that are stable up to temperatures as high as about 842° F. (450° C.) due to their low diffusivity in aluminum. The Al₃Gd dispersoids have an L1₂ structure in the metastable condition and a D0₁₉ structure in the equilibrium condition. Despite its large atomic size, gadolinium has fairly high solubility in the Al₃X intermetallic dispersoids (where X is scandium, erbium, thulium, ytterbium or lutetium). Gadolinium can substitute for the X atoms in Al₃X intermetallic, thereby forming an ordered L1₂ phase which results in improved thermal and structural stability.

Yttrium forms metastable Al₃Y dispersoids in the aluminum matrix that have an L1₂ structure in the metastable condition and a D0₁₉ structure in the equilibrium condition. The metastable Al₃Y dispersoids have a low diffusion coefficient which makes them thermally stable and highly resistant to coarsening. Yttrium has a high solubility in the Al₃X intermetallic dispersoids allowing large amounts of yttrium to substitute for X in the Al₃X L1₂ dispersoids which results in improved thermal and structural stability.

Zirconium forms Al₃Zr dispersoids in the aluminum matrix that have an L1₂ structure in the metastable condition and D0₂₃ structure in the equilibrium condition. The metastable Al₃Zr dispersoids have a low diffusion coefficient which makes them thermally stable and highly resistant to coarsening. Zirconium has a high solubility in the Al₃X dispersoids allowing large amounts of zirconium to substitute for X in the Al₃X dispersoids, which results in improved thermal and structural stability.

Titanium forms Al₃Ti dispersoids in the aluminum matrix that have an L1₂ structure in the metastable condition and D0₂₂ structure in the equilibrium condition. The metastable Al₃Ti despersoids have a low diffusion coefficient which makes them thermally stable and highly resistant to coarsening. Titanium has a high solubility in the Al₃X dispersoids allowing large amounts of titanium to substitute for X in the Al₃X dispersoids, which result in improved thermal and structural stability.

Hafnium forms metastable Al₃Hf dispersoids in the aluminum matrix that have an L1₂ structure in the metastable condition and a D0₂₃ structure in the equilibrium condition. The Al₃Hf dispersoids have a low diffusion coefficient, which makes them thermally stable and highly resistant to coarsening. Hafnium has a high solubility in the Al₃X dispersoids allowing large amounts of hafnium to substitute for scandium, erbium, thulium, ytterbium, and lutetium in the above mentioned Al₃X dispersoides, which results in stronger and more thermally stable dispersoids.

Niobium forms metastable Al₃Nb dispersoids in the aluminum matrix that have an L1₂ structure in the metastable condition and a D0₂₂ structure in the equilibrium condition. Niobium has a lower solubility in the Al₃X dispersoids than hafnium or yttrium, allowing relatively lower amounts of niobium than hafnium or yttrium to substitute for X in the Al₃X dispersoids. Nonetheless, niobium can be very effective in slowing down the coarsening kinetics of the Al₃X dispersoids because the Al₃Nb dispersoids are thermally stable. The substitution of niobium for X in the above mentioned Al₃X dispersoids results in stronger and more thermally stable dispersoids.

Iron forms Al₆Fe dispersoids in the aluminum matrix in the metastable condition, and forms Al₃Fe dispersoids in the equilibrium condition. Iron has a little solubility in aluminum matrix in the equilibrium condition which can be extended significantly by a rapid solidification process. Iron can be very effective in slowing down the coarsening kinetics because the Al₆Fe dispersoids are thermally stable due to its very low diffusion coefficient in aluminum. Iron provides solid solution and dispersion strengthening in aluminum.

The amount of nickel present in the matrix of this invention may vary from about 4 to about 25 weight percent, more preferably from about 6 to about 20 weight percent, and even more preferably from about 8 to about 15 weight percent.

The amount of cerium present in the matrix of this invention may vary from about 2 to about 25 weight percent, more preferably from about 4 to about 20 weight percent, and even more preferably from about 6 to about 15 weight percent.

The amount of scandium present in the alloys of this invention, if any, may vary from about 0.1 to about 4 weight percent, more preferably from about 0.1 to about 3 weight percent, and even more preferably from about 0.2 to about 2.5 weight percent. The Al—Sc phase diagram shown in FIG. 3 indicates a eutectic reaction at about 0.5 weight percent scandium at about 1219° F. (659° C.) resulting in a solid solution of scandium and aluminum and Al₃Sc dispersoids. Aluminum alloys with less than 0.5 weight percent scandium can be quenched from the melt to retain scandium in solid solution that may precipitate as dispersed L1₂ intermetallic Al₃Sc following an aging treatment. Alloys with scandium in excess of the eutectic composition (hypereutectic alloys) can only retain scandium in solid solution by rapid solidification processing (RSP) where cooling rates are in excess of about 10³° C./second. Alloys with scandium in excess of the eutectic composition cooled normally will have a microstructure consisting of relatively large Al₃Sc dispersoids in a finally divided aluminum-Al₃Sc eutectic phase matrix.

The amount of erbium present in the alloys of this invention, if any, may vary from about 0.1 to about 20 weight percent, more preferably from about 0.3 to about 15 weight percent, and even more preferably from about 0.5 to about 10 weight percent. The Al—Er phase diagram shown in FIG. 4 indicates a eutectic reaction at about 6 weight percent erbium at about 1211° F. (655° C.). Aluminum alloys with less than about 6 weight percent erbium can be quenched from the melt to retain erbium in solid solutions that may precipitate as dispersed L1₂ intermetallic Al₃Er following an aging treatment. Alloys with erbium in excess of the eutectic composition can only retain erbium in solid solution by rapid solidification processing (RSP) where cooling rates are in excess of about 10³° C./second. Alloys with erbium in excess of the eutectic composition cooled normally will have a microstructure consisting of relatively large Al₃Er dispersoids in a finely divided aluminum-Al₃Er eutectic phase matrix.

The amount of thulium present in the alloys of this invention, if any, may vary from about 0.1 to about 15 weight percent, more preferably from about 0.2 to about 10 weight percent, and even more preferably from about 0.4 to about 6 weight percent. The Al—Tm phase diagram shown in FIG. 5 indicates a eutectic reaction at about 10 weight percent thulium at about 1193° F. (645° C.). Thulium forms metastable Al₃Tm dispersoids in the aluminum matrix that have an L1₂ structure in the equilibrium condition. The Al₃Tm dispersoids have a low diffusion coefficient which makes them thermally stable and highly resistant to coarsening. Aluminum alloys with less than 10 weight percent thulium can be quenched from the melt to retain thulium in solid solution that may precipitate as dispersed metastable L1₂ intermetallic Al₃Tm following an aging treatment. Alloys with thulium in excess of the eutectic composition can only retain Tm in solid solution by rapid solidification processing (RSP) where cooling rates are in excess of about 10³° C./second.

The amount of ytterbium present in the alloys of this invention, if any, may vary from about 0.1 to about 25 weight percent, more preferably from about 0.3 to about 20 weight percent, and even more preferably from about 0.4 to about 10 weight percent. The Al—Yb phase diagram shown in FIG. 6 indicates a eutectic reaction at about 21 weight percent ytterbium at about 1157° F. (625° C.). Aluminum alloys with less than about 21 weight percent ytterbium can be quenched from the melt to retain ytterbium in solid solution that may precipitate as dispersed L1₂ intermetallic Al₃Yb following an aging treatment. Alloys with ytterbium in excess of the eutectic composition can only retain ytterbium in solid solution by rapid solidification processing (RSP) where cooling rates are in excess of about 10³° C./second.

The amount of lutetium present in the alloys of this invention, if any, may vary from about 0.1 to about 25 weight percent, more preferably from about 0.3 to about 20 weight percent, and even more preferably from about 0.4 to about 10 weight percent. The Al—Lu phase diagram shown in FIG. 7 indicates a eutectic reaction at about 11.7 weight percent Lu at about 1202° F. (650° C.). Aluminum alloys with less than about 11.7 weight percent lutetium can be quenched from the melt to retain Lu in solid solution that may precipitate as dispersed L1₂ intermetallic Al₃Lu following an aging treatment. Alloys with Lu in excess of the eutectic composition can only retain Lu in solid solution by rapid solidification processing (RSP) where cooling rates are in excess of about 10³° C./second.

The amount of gadolinium present in the alloys of this invention, if any, may vary from about 2 to about 30 weight percent, more preferably from about 4 to about 25 weight percent, and even more preferably from about 6 to about 20 weight percent.

The amount of yttrium present in the alloys of this invention, if any, may vary from about 2 to about 30 weight percent, more preferably from about 4 to about 25 weight percent, and even more preferably from about 6 to about 20 weight percent.

The amount of zirconium present in the alloys of this invention, if any, may vary from about 0.5 to about 5 weight percent, more preferably from about 1 to about 4 weight percent, and even more preferably from about 1 to about 3 weight percent.

The amount of titanium present in the alloys of this invention, if any, may vary from about 0.5 to about 10 weight percent, more preferably from about 1 to about 8 weight percent, and even more preferably from about 1 to about 4 weight percent.

The amount of hafnium present in the alloys of this invention, if any, may vary from about 0.5 to about 10 weight percent, more preferably from about 1 to about 8 weight percent, and even more preferably from about 1 to about 4 weight percent.

The amount of niobium present in the alloys of this invention, if any, may vary from about 0.5 to about 5 weight percent, more preferably from about 1 to about 4 weight percent, and even more preferably from about 1 to about 3 weight percent.

The amount of iron present in the matrix of this invention may vary from about 0.5 to about 15 weight percent, more preferably from about 1 to about 10 weight percent, and even more preferably from about 2 to about 8 weight percent.

Forming the amorphous structure of this invention enhances the strength of the alloys, whereas ductility, fracture toughness and thermal stability are increased by the dispersed, fine, coherent L1₂ particles in the microstructure.

Exemplary aluminum alloys of this invention include, but are not limited to (in weight percent):

about Al-(4-25)Ni-(2-25)Ce-(0.1-4)Sc-(2-30)Gd;

about Al-(4-25)Ni-(2-25)Ce-(0.1-20)Er-(2-30)Gd;

about Al-(4-25)Ni-(2-25)Ce-(0.1-15)Tm)-(2-30)Gd;

about Al-(4-25)Ni-(2-25)Ce-(0.1-25)Lu)-(2-30)Gd;

about Al-(4-25)Ni-(2-25)Ce-(0.1-25)Yb-(2-30)Gd;

about Al-(4-25)Ni-(2-25)Ce-(0.1-4)Sc-(2-30)Y;

about Al-(4-25)Ni-(2-25)Ce-(0.1-20)Er-(2-30)Y;

about Al-(4-25)Ni-(2-25)Ce-(0.1-15)Tm)-(2-30)Y;

about Al-(4-25)Ni-(2-25)Ce-(0.1-25)Lu)-(2-30)Y;

about Al-(4-25)Ni-(2-25)Ce-(0.1-25)Yb-(2-30)Y;

about Al-(4-25)Ni-(2-25)Ce-(0.1-4)Sc-(0.5-5)Zr;

about Al-(4-25)Ni-(2-25)Ce-(0.1-20)Er-(0.5-5)Zr;

about Al-(4-25)Ni-(2-25)Ce-(0.1-15)Tm)-(0.5-5)Zr;

about Al-(4-25)Ni-(2-25)Ce-(0.1-25)Lu)-(0.5-5)Zr;

about Al-(4-25)Ni-(2-25)Ce-(0.1-25)Yb-(0.5-5)Zr;

about Al-(4-25)Ni-(2-25)Ce-(0.1-4)Sc-(0.5-10)Ti;

about Al-(4-25)Ni-(2-25)Ce-(0.1-20)Er-(0.5-10)Ti;

about Al-(4-25)Ni-(2-25)Ce-(0.1-15)Tm-(0.5-10)Ti;

about Al-(4-25)Ni-(2-25)Ce-(0.1-25)Lu-(0.5-10)Ti;

about Al-(4-25)Ni-(2-25)Ce-(0.1-25)Yb-(0.5-10)Ti;

about Al-(4-25)Ni-(2-25)Ce-(0.1-4)Sc-(0.5-10)Hf;

about Al-(4-25)Ni-(2-25)Ce-(0.1-20)Er-(0.5-10)Hf;

about Al-(4-25)Ni-(2-25)Ce-(0.1-15)Tm-(0.5-10)Hf;

about Al-(4-25)Ni-(2-25)Ce-(0.1-25)Lu)-(0.5-10)Hf;

about Al-(4-25)Ni-(2-25)Ce-(0.1-25)Yb-(0.5-10)Hf,

about Al-(4-25)Ni-(2-25)Ce-(0.1-4)Sc-(0.5-5)Nb;

about Al-(4-25)Ni-(2-25)Ce-(0.1-20)Er)-(0.5-5)Nb;

about Al-(4-25)Ni-(2-25)Ce-(0.1-15)Tm-(0.5-5)Nb;

about Al-(4-25)Ni-(2-25)Ce-(0.1-25)Lu)-(0.5-5)Nb;

about Al-(4-25)Ni-(2-25)Ce-(0.1-25)Yb-(0.5-5)Nb;

about Al-(4-25)Ni-(2-25)Ce-(0.1-4)Sc-(0.5-15)Fe;

about Al-(4-25)Ni-(2-25)Ce-(0.1-20)Er)-(0.5-15)Fe;

about Al-(4-25)Ni-(2-25)Ce-(0.1-15)Tm-(0.5-15)Fe;

about Al-(4-25)Ni-(2-25)Ce-(0.1-25)Lu)-(0.5-15)Fe; and

about Al-(4-25)Ni-(2-25)Ce-(0.1-25)Yb-(0.5-15)Fe.

In the inventive aluminum based alloys disclosed herein, scandium forms an equilibrium Al₃Sc intermetallic dispersoid that has an L1₂ structure that is an ordered face centered cubic structure with the Sc atoms located at the corners and aluminum atoms located on the cube faces of the unit cell.

In order to have the best properties for the alloys of this invention, it is desirable to limit the amount of other elements. Specific elements that should be reduced or eliminated include no more that about 0.1 weight percent chromium, 0.1 weight percent manganese, 0.1 weight percent vanadium and 0.1 weight percent cobalt. The total quantity of additional elements should not exceed about 1% by weight, including the above listed impurities and other elements.

These aluminum alloys may be made by rapid solidification processing. The rapid solidification process should have a cooling rate greater that about 10³° C./second including but not limited to powder processing, atomization, melt spinning, splat quenching, spray deposition, cold spray, plasma spray, laser melting and deposition, ball milling and cryomilling.

More exemplary aluminum alloys of this invention include, but are not limited to (in weight percent):

about Al-(6-20)Ni-(4-20)Ce-(0.1-3)Sc-(4-25)Gd;

about Al-(6-20)Ni-(4-20)Ce-(0.3-15)Er-(4-25)Gd;

about Al-(6-20)Ni-(4-20)Ce-(0.2-10)Tm)-(4-25)Gd;

about Al-(6-20)Ni-(4-20)Ce-(0.3-20)Lu)-(4-25)Gd;

about Al-(6-20)Ni-(4-20)Ce-(0.3-20)Yb-(4-25)Gd;

about Al-(6-20)Ni-(4-20)Ce-(0.1-3)Sc-(4-25)Y;

about Al-(6-20)Ni-(4-20)Ce-(0.3-15)Er-(4-25)Y;

about Al-(6-20)Ni-(4-20)Ce-(0.2-10)Tm)-(4-25)Y;

about Al-(6-20)Ni-(4-20)Ce-(0.3-20)Lu)-(4-25)Y;

about Al-(6-20)Ni-(4-20)Ce-(0.3-20)Yb-(4-25)Y;

about Al-(6-20)Ni-(4-20)Ce-(0.1-3)Sc-(1-4)Zr;

about Al-(6-20)Ni-(4-20)Ce-(0.3-15)Er-(1-4)Zr;

about Al-(6-20)Ni-(4-20)Ce-(0.2-10)Tm)-(1-4)Zr;

about Al-(6-20)Ni-(4-20)Ce-(0.3-20)Lu)-(1-4)Zr;

about Al-(6-20)Ni-(4-20)Ce-(0.3-20)Yb-(1-4)Zr;

about Al-(6-20)Ni-(4-20)Ce-(0.1-3)Sc-(1-8)Ti;

about Al-(6-20)Ni-(4-20)Ce-(0.3-15)Er-(1-8)Ti;

about Al-(6-20)Ni-(4-20)Ce-(0.2-10)Tm-(1-8)Ti;

about Al-(6-20)Ni-(4-20)Ce-(0.3-20)Lu-(1-8)Ti;

about Al-(6-20)Ni-(4-20)Ce-(0.3-20)Yb-(1-8)Ti;

about Al-(6-20)Ni-(4-20)Ce-(0.1-3)Sc-(1-8)Hf;

about Al-(6-20)Ni-(4-20)Ce-(0.3-15)Er-(1-8)Hf;

about Al-(6-20)Ni-(4-20)Ce-(0.2-10)Tm-(1-8)Hf;

about Al-(6-20)Ni-(4-20)Ce-(0.3-20)Lu-(1-8)Hf;

about Al-(6-20)Ni-(4-20)Ce-(0.3-20)Yb-(1-8)Hf;

about Al-(6-20)Ni-(4-20)Ce-(0.1-3)Sc-(1-3)Nb;

about Al-(6-20)Ni-(4-20)Ce-(0.3-15)Er-(1-3)Nb;

about Al-(6-20)Ni-(4-20)Ce-(0.2-10)Tm-(1-3)Nb;

about Al-(6-20)Ni-(4-20)Ce-(0.3-20)Lu-(1-3)Nb;

about Al-(6-20)Ni-(4-20)Ce-(0.3-20)Yb-(1-3)Nb;

about Al-(6-20)Ni-(4-20)Ce-(0.1-3)Sc-(1-10)Fe;

about Al-(6-20)Ni-(4-20)Ce-(0.3-15)Er)-(1-10)Fe;

about Al-(6-20)Ni-(4-20)Ce-(0.2-10)Tm-(1-10)Fe;

about Al-(6-20)Ni-(4-20)Ce-(0.3-20)Lu)-(1-10)Fe; and

about Al-(6-20)Ni-(4-20)Ce-(0.3-20)Yb-(1-10)Fe.

More preferred examples of similar alloys to these are alloys with about 8 to about 15 weight percent nickel and about 6 to about 15 weight percent cerium, and include, but are not limited to (in weight percent):

about Al-(8-15)Ni-(6-15)Ce-(0.2-2.5)Sc-(6-20)Gd;

about Al-(8-15)Ni-(6-15)Ce-(0.5-10)Er-(6-20)Gd;

about Al-(8-15)Ni-(6-15)Ce-(0.4-6)Tm-(6-20)Gd;

about Al-(8-15)Ni-(6-15)Ce-(0.4-10)Lu-(6-20)Gd;

about Al-(8-15)Ni-(6-15)Ce-(0.4-10)Yb-(6-20)Gd;

about Al-(8-15)Ni-(6-15)Ce-(0.2-2.5)Sc-(6-20)Y;

about Al-(8-15)Ni-(6-15)Ce-(0.5-10)Er-(6-20)Y;

about Al-(8-15)Ni-(6-15)Ce-(0.4-6)Tm-(6-20)Y;

about Al-(8-15)Ni-(6-15)Ce-(0.4-10)Lu-(6-20)Y;

about Al-(8-15)Ni-(6-15)Ce-(0.4-10)Yb-(6-20)Y;

about Al-(8-15)Ni-(6-15)Ce-(0.2-2.5)Sc-(1-3)Zr;

about Al-(8-15)Ni-(6-15)Ce-(0.5-10)Er-(1-3)Zr;

about Al-(8-15)Ni-(6-15)Ce-(0.4-6)Tm-(1-3)Zr;

about Al-(8-15)Ni-(6-15)Ce-(0.4-10)Lu-(1-3)Zr;

about Al-(8-15)Ni-(6-15)Ce-(0.4-10)Yb-(1-3)Zr;

about Al-(8-15)Ni-(6-15)Ce-(0.2-2.5)Sc-(1-4)Ti;

about Al-(8-15)Ni-(6-15)Ce-(0.5-10)Er-(1-4)Ti;

about Al-(8-15)Ni-(6-15)Ce-(0.4-6)Tm-(1-4)Ti;

about Al-(8-15)Ni-(6-15)Ce-(0.4-10)Lu-(1-4)Ti;

about Al-(8-15)Ni-(6-15)Ce-(0.4-10)Yb-(1-4)Ti;

about Al-(8-15)Ni-(6-15)Ce-(0.2-2.5)Sc-(1-4)Hf;

about Al-(8-15)Ni-(6-15)Ce-(0.5-10)Er-(1-4)Hf;

about Al-(8-15)Ni-(6-15)Ce-(0.4-6)Tm-(1-4)Hf;

about Al-(8-15)Ni-(6-15)Ce-(0.4-10)Lu-(1-4)Hf;

about Al-(8-15)Ni-(6-15)Ce-(0.4-10)Yb-(1-4)Hf;

about Al-(8-15)Ni-(6-15)Ce-(0.2-2.5)Sc-(1-3)Nb;

about Al-(8-15)Ni-(6-15)Ce-(0.5-10)Er)-(1-3)Nb;

about Al-(8-15)Ni-(6-15)Ce-(0.4-6)Tm-(1-3)Nb;

about Al-(8-15)Ni-(6-15)Ce-(0.4-10)Lu)-(1-3)Nb;

about Al-(8-15)Ni-(6-15)Ce-(0.4-10)Yb-(1-3)Nb;

about Al-(8-15)Ni-(6-15)Ce-(0.2-2.5)Sc-(2-8)Fe;

about Al-(8-15)Ni-(6-15)Ce-(0.5-10)Er)-(2-8)Fe;

about Al-(8-15)Ni-(6-15)Ce-(0.4-6)Tm-(2-8)Fe;

about Al-(8-15)Ni-(6-15)Ce-(0.4-10)Lu)-(2-8)Fe; and

about Al-(8-15)Ni-(6-15)Ce-(0.4-10)Yb-(2-8)Fe.

Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.

Claims

1. An aluminum alloy having high strength, ductility, corrosion resistance and fracture toughness, comprising: an amorphous phase aluminum alloy comprising about 4 to 25 weight percent of nickel and about 2 to about 25 weight percent of cerium;a coherent L12 phase comprising: about 4 to about 25 weight percent nickel and about 2 to about 25 weight percent of cerium,at least one first element selected from the group comprising: about 0.1 to about 4 weight percent scandium, about 0.1 to about 20 weight percent erbium, about 0.1 to about 15 weight percent thulium, about 0.1 to about 25 weight percent ytterbium, and about 0.1 to about 25 weight percent lutetium;at least one second element selected from the group comprising: about 2 to about 30 weight percent gadolinium, about 2 to about 30 weight percent yttrium, about 0.5 to about 5 weight percent zirconium, about 0.5 to about 10 weight percent titanium, about 0.5 to about 10 weight percent hafnium, about 0.5 to about 5 weight percent niobium, and about 0.5 to about 15 weight percent iron; andthe balance substantially aluminum.

2. The alloy of claim 1, wherein the volume fraction of the amorphous phase ranges from about 50 percent to about 95 percent and the volume fraction of the coherent L12 phase ranges from about 5 percent to about 50 percent.

3. The alloy of claim 1, comprising no more than about 1 weight percent total impurities.

4. The alloy of claim 1, comprising no more than about 0.1 weight percent chromium, about 0.1 weight percent manganese, about 0.1 weight percent vanadium, and about 0.1 weight percent cobalt.

5. The alloy of claim 1, where the alloy is formed by a rapid solidification process.

6. The aluminum alloy of claim 5, wherein the rapid solidification process has a cooling rate greater that about 103° C./second.

7. The alloy of claim 6, wherein the rapid solidification process comprises at least one of powder processing, atomization, melt spinning, splat quenching, spray deposition, cold spray, plasma spray, laser melting and deposition, ball milling and cryomilling.

8. An aluminum alloy having high strength, ductility, corrosion resistance and fracture toughness, comprising: nickel;cerium;at least one first element selected from the group comprising: about 0.1 to about 4 weight percent scandium, about 0.1 to about 20 weight percent erbium, about 0.1 to about 15 weight percent thulium, about 0.1 to about 25 weight percent ytterbium, and about 0.1 to about 25 weight percent lutetium;at least one second element selected from the group comprising: gadolinium, yttrium, zirconium, titanium, hafnium, niobium and iron; andthe balance substantially aluminum.

9. The alloy of claim 8, wherein the alloy comprises: about 4 to about 25 weight percent nickel;about 2.0 to about 25 weight percent cerium;at least one first element selected from the group comprising: about 0.1 to about 4 weight percent scandium, about 0.1 to about 20 weight percent erbium, about 0.1 to about 15 weight percent thulium, about 0.1 to about 25 weight percent ytterbium, and about 0.1 to about 25 weight percent lutetium; andat least one second element selected from the group comprising about 2 to about 30 weight percent gadolinium, about 2 to about 30 weight percent yttrium, about 0.5 to about 5 weight percent zirconium, about 0.5 to about 10 weight percent titanium, about 0.5 to about 10 weight percent hafnium, about 0.5 to about 5 weight percent niobium, and 0.5 to about 15 weight percent iron.

10. The alloy of claim 8, wherein the volume fraction of the amorphous phase ranges from about 50 percent to about 95 percent and the volume fraction of the coherent L12 phase ranges from about 5 percent to about 50 percent.

11. A method of forming an aluminum alloy having high strength, ductility and toughness, the method comprising: (a) forming an alloy powder comprising:about 4 to 25 weight percent of nickel and about 2 to about 25 weight percent of cerium;at least one first element selected from the group comprising: about 0.1 to about 4 weight percent scandium, about 0.1 to about 20 weight percent erbium, about 0.1 to about 15 weight percent thulium, about 0.1 to about 25 weight percent ytterbium, and about 0.1 to about 25 weight percent lutetium;at least one second element selected from the group comprising: about 2 to about 30 weight percent gadolinium, about 2 to about 30 weight percent yttrium, about 0.5 to about 5 weight percent zirconium, about 0.5 to about 10 weight percent titanium, about 0.5 to about 10 weight percent hafnium, about 0.5 to about 5 weight percent niobium, and about 0.5 to about 15 weight percent iron; andthe balance substantially aluminum;(b) treating the alloy powder with a rapid solidification process to form an amorphous phase aluminum alloy comprising about 4 to about 25 weight percent of nickel and about 2 to about 25 weight percent of cerium; anda coherent L12 phase comprising:about 4 to about 25 weight percent of nickel;about 2 to about 25 weight percent of cerium;at least one first element selected from the group comprising: about 0.1 to about 4 weight percent scandium, about 0.1 to about 20 weight percent erbium, about 0.1 to about 15 weight percent thulium, about 0.1 to 25 weight percent ytterbium, and about 0.1 to about 25 weight percent lutetium; andat least one second element selected from the group comprising: about 2 to about 30 weight percent gadolinium, about 2 to about 30 weight percent yttrium, about 0.5 to about 5 weight percent zirconium, about 0.5 to about 10 weight percent titanium, about 0.5 to about 10 weight percent hafnium, about 0.5 to about 5 weight percent niobium, and about 0.5 to about 15 weight percent iron.

12. The method of claim 11, wherein the rapid solidification process has a cooling rate greater that about 103° C./second.

13. The method of claim 12, wherein the rapid solidification process comprises at least one of powder processing, atomization, melt spinning, splat quenching, spray deposition, cold spray, plasma spray, laser melting and deposition, ball milling and cryomilling.

14. The method of claim 11, wherein the volume fraction of the amorphous phase ranges from about 50 percent to about 95 percent and the volume fraction of the coherent L12 phase ranges from about 5 percent to about 50 percent.