Rare earth aluminum alloy powder applicable for additive manufacturing and preparation method thereof

Patent metadata

Field	Value
Publication number	US-12540377-B2
Application number	US-202318163859-A
Country	US
Kind code	B2
Filing date	Feb 2, 2023
Priority date	Dec 30, 2020
Publication date	Feb 3, 2026
Grant date	Feb 3, 2026

Abstract

A method for preparing a rare earth aluminum alloy powder applicable for additive manufacturing includes: heating and melting aluminum ingots into an aluminum melt; adding required alloy elements to the aluminum melt to obtain an alloy melt in which the alloy elements are present in the following preset percentages by weight: 1.00% to 10.00% of Ce, 0.05% to 8.00% of Mg, 0.10% to 7.50% of Y, 0.10% to 2.50% of Zr, less than 0.1% of impurities, and the balance aluminum; leading out the alloy melt through a fluid guiding pipe, and impacting the alloy melt with a high-pressure gas flow so that the alloy melt is atomized into fine droplets under an action of surface tension, and solidified into spherical alloy powder; and collecting the spherical alloy powder in a vacuum collector, and screening and drying the spherical alloy powder to obtain the rare earth aluminum alloy powder.

First claim

What is claimed is:

1 . A method for preparing a rare earth aluminum alloy powder applicable for additive manufacturing, comprising the following steps:
S1, heating and melting aluminum ingots into an aluminum melt at a temperature of 730° C. to 780° C. in presence of a protective atmosphere; S2, adding required alloy elements to the aluminum melt to obtain an alloy melt: adjusting a proportion of each element with an intermediate alloy, and performing degassing and deslagging so that the alloy elements are present in the following preset percentages by weight: 6.00% to 8.00% of Ce, 0.40% to 1.00% of Mg, 0.10% to 0.25% of Y, 0.10% to 0.25% of Zr, less than 0.1% of impurities, and the balance being aluminum; S3, leading out the alloy melt through a fluid guiding pipe, and impacting the alloy melt with a gas flow at an outlet of the fluid guiding pipe, so that the alloy melt is atomized into fine droplets under an action of surface tension, and solidified into spherical alloy powder; and S4, collecting the spherical alloy powder in a vacuum collector, and screening and drying the spherical alloy powder to obtain the rare earth aluminum alloy powder applicable for additive manufacturing.

2 . The method according to claim 1 , wherein in step S3 of leading out the alloy melt through the fluid guiding pipe,
a lead-out temperature of the alloy melt is controlled between 630° C. and 680° C.; a lead-out velocity of the alloy melt is between 5 kg/min and 10 kg/min; the fluid guiding pipe is made of zirconium oxide, silicon nitride or titanium nitride; a diameter of the fluid guiding pipe is 2 mm to 6 mm.

3 . The method according to claim 1 , wherein in step S3, the alloy melt is impacted with a high-pressure argon flow or a high-pressure nitrogen flow at a pressure of 6 MPa to 8 MPa.

4 . The method according to claim 1 , wherein the spherical alloy powder has an average particle size of 40 μm to 50 μm and a particle size distribution of 10 μm to 75 μm.

Assignees

• Univ Shanghai Jiaotong

Inventors

• Gao Haiyan
• Lv Haiyang
• Wang Mengmeng
• Peng Peng
• Wu Yun
• Zhang Chi
• Li Min
• Wang Yufei
• Wang Jun
• Sun Baode

Classifications

• B22F2304/10

  Micron size particles, i.e. above 1 micrometer up to 500 micrometer · CPC title

• B22F2301/052

  Aluminium · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• B22F2009/0824

  with a specific atomising fluid · CPC title

• C22C21/06

  with magnesium as the next major constituent · CPC title