Enhanced anodization functionality in al-rare earth element-based alloys

Abstract

A product includes an aluminum alloy having an anodized layer. The alloy has a bulk composition including at least 1 wt. % of one or more rare earth elements (REEs). A product includes microstructures extending across a boundary defined between an anodized layer and an unoxidized alloy. Each microstructure includes an intermetallic phase transitioning to an oxidized intermetallic phase across the boundary. A product includes an anodized layer where up to 90% of a thickness of the layer includes voids resulting at least in part from dissolution of a rare earth element oxidized intermetallic phase. The voids are in a morphology of the dissolved oxidized intermetallic phase.

What is claimed is: 
     
         1 . A product, the product comprising:
 an aluminum alloy having an anodized layer,   the alloy having a bulk composition comprising at least 1 wt. % of one or more rare earth elements (REEs).   
     
     
         2 . The product of  claim 1 , the bulk composition comprising at least one additional element selected from the group consisting of: silicon (Si), copper (Cu), iron (Fe), magnesium (Mg), zinc (Zn), lithium (Li), nickel (Ni), titanium (Ti), manganese (Mn), and zirconium (Zr). 
     
     
         3 . The product of  claim 2 , wherein the at least one additional element is present in a weight percentage of the bulk composition in a range of greater than 0% to about 10%. 
     
     
         4 . The product of  claim 1 , wherein the one or more rare earth elements includes cerium (Ce). 
     
     
         5 . The product of  claim 1 , wherein at least one of the one or more rare earth elements is selected from the group consisting of: yttrium (Y), lanthanum (La), praseodymium (Pr), neodymium (Nd), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er), thulium (Tm), ytterbium (Yb), lutetium (Lu), and mischmetal. 
     
     
         6 . The product of  claim 1 , wherein the one or more rare earth element is present in a weight percentage of the bulk composition in a range of about 6% to about 12%. 
     
     
         7 . The product of  claim 1 , wherein the one or more rare earth element is present in a weight percentage of the bulk composition in a range of about 2% to about 20%. 
     
     
         8 . The product of  claim 1 , wherein up to 90% of a thickness of the anodized layer comprises voids resulting at least in part from dissolution of a rare earth element oxidized intermetallic phase, the voids being in a morphology of the dissolved oxidized intermetallic phase. 
     
     
         9 . The product of  claim 1 , wherein the anodized layer comprises first and second zones, the second zone being positioned between the first zone and the alloy, the first zone having voids having a morphology of a rare earth element oxidized intermetallic phase removed from the first zone, the second zone having the rare earth element oxidized intermetallic phase. 
     
     
         10 . The product of  claim 1 , comprising a substrate having a different composition than the alloy, wherein the alloy is coupled to an outer surface of the substrate. 
     
     
         11 . A product, the product comprising:
 microstructures extending across a boundary defined between an anodized layer and an unoxidized alloy, each microstructure comprising an intermetallic phase transitioning to an oxidized intermetallic phase across the boundary.   
     
     
         12 . The product of  claim 11 , wherein the anodized layer comprises a plurality of ceramic oxide phases, the plurality of ceramic oxide phases comprising an aluminum-rare earth element oxide phase and an aluminum oxide phase in an interconnected structure. 
     
     
         13 . The product of  claim 12 , wherein the ceramic oxide phases include amorphous phases. 
     
     
         14 . The product of  claim 12 , comprising a substrate having a different composition than the alloy, wherein the alloy is coupled to an outer surface of the substrate. 
     
     
         15 . The product of  claim 12 , wherein the anodized layer comprises first and second zones, the second zone being positioned between the first zone and the alloy, the first zone having voids having a morphology of a rare earth element oxidized intermetallic phase removed from the first zone, the second zone having the rare earth element oxidized intermetallic phase. 
     
     
         16 . A product, the product comprising:
 an anodized layer where up to 90% of a thickness of the layer comprises voids resulting at least in part from dissolution of a rare earth element oxidized intermetallic phase, the voids being in a morphology of the dissolved oxidized intermetallic phase.   
     
     
         17 . The product of  claim 16 , wherein the anodized layer has a composition characteristic of anodization of an alloy having a bulk composition comprising at least 1 wt. % of one or more earth elements (REEs). 
     
     
         18 . The product of  claim 17 , wherein at least one of the one or more rare earth elements is selected from the group consisting of: yttrium (Y), lanthanum (La), praseodymium (Pr), neodymium (Nd), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er), thulium (Tm), ytterbium (Yb), lutetium (Lu), and mischmetal. 
     
     
         19 . The product of  claim 17 , comprising a substrate having a different composition than the alloy, wherein the alloy is coupled to an outer surface of the substrate. 
     
     
         20 . The product of  claim 17 , wherein the anodized layer comprises first and second zones, the second zone being positioned between the first zone and the alloy, the first zone having voids having a morphology of a rare earth element oxidized intermetallic phase removed from the first zone, the second zone having the rare earth element oxidized intermetallic phase.