Developing cost-effective aluminum alloys for long-term service at 250–400°C remains a significant challenge. This work presents a novel additively manufactured near-eutectic Al-10La-1Fe-0.4Zr-0.2Ti (wt.%) alloy. The as-fabricated microstructure comprises a refined heterogeneous α-Al grain structure reinforced by a continuous eutectic network of Al 11 La 3 and Al 6 Fe phases. By strategically pairing La and Fe to reduce diffusivity mismatch, the synergistic coarsening typically observed in Al-Ce-Ni systems is effectively suppressed, ensuring exceptional microstructural stability. Furthermore, microalloying with Zr/Ti as a cost-effective alternative to Sc promotes the formation of primary Al 3 (Zr,Ti) nanoparticles for grain refinement and effectively stabilizes the metastable Al 6 Fe phase. The alloy exhibits superior tensile properties, outperforming most additive manufacturing Al-Ce/Ni systems with yield strengths of 331 ± 7 MPa (RT) and 73 ± 5 MPa (400°C). This study demonstrates that the strategic synergy of La/Fe and Zr/Ti enables the high-value utilization of recycled aluminum and abundant rare-earth elements, establishing a cost-effective and sustainable design strategy for additively manufactured heat-resistant aluminum alloys.
Song et al. (Fri,) studied this question.
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