Fabrication method and the monolithic binary rare-earth-aluminum, REE-Aloy, matrices thereof

Abstract

This invention relates to a system of monolithic binary rare-earth element (REE)-aluminum (Al) intermetallic alloy series of mass composition range of 30 wt %<REE<85 wt %, where REE=Sc, Y, La, Ce, Pr, Nd, Sm, Eu, Tb, Dy, Ho, Er, Tm, Yb, Lu and, the general methodology to fabricate any monolithic binary rare-earth-element aluminum matrix thereof. The alloys system consists of 15 unique advanced series, each based on an individual REE=Sc, Y, La, Ce, Pr, Nd, Sm, Eu, Tb, Dy, Ho, Er, Tm, Yb, Lu. Each series defines a range of monolithic binary rare-earth-element-aluminum matrices generally defined as REE-Aloy xxyy. It is observed that when a rare-earth element (REE) is alloyed with aluminum in the relatively comparable ratios from 30 wt % REE to 85 wt % REE, it exhibits superior alloys qualities. The overall quality of the alloy formed is vastly improved beyond both the REE and aluminum. Optimally, all REE-Aloy series are comparable or advantageous in one way or another to aluminum, steel, and titanium alloys for multiple application technologies including, advanced alloys, permanent magnets, nuclear energy, and microwave engineering. The impact of REE-Aloy advanced material can revolutionize the course for the necessary technologies to achieve the goal outlined in the renewed agreement under the Paris Convention to address climate change and green energy. For showcases of this invention, high-purity prototypes of monolithic binary neodymium-aluminum (i.e., REE-Aloy 6000 series) and samarium-aluminum matrices (i.e., REE-Aloy 6200 series) obtained in large quantities establishes efficient production. Determined by STEM and HRTEM analyses, the REE-Aloy 6062 (i.e., 62 wt. % Nd—Al) is an [Al+Nd 5 Al 11 ] intermetallic matrix, and the REE-Aloy 6267 (i.e., 67 wt. % Sm—Al) is an [Al+SmAl 4 ] were invented. Both REE-Aloy 6062 and REE-Aloy 6267 alloys exhibit significantly improved thermo-mechanical and physical stability and corrosion-resistant properties beyond the respective REE and Al. Long range order, evident for crystalline solids, is revealed by the HRTEM diffraction patterns for the REE-Aloy 6267 intermetallic species. After further heat-treatment, REE-Aloy 6062 and REE-Aloy 6267, REE-Aloy 6079, and REE-Aloy 6277 were produced. From observations, the REE-Aloy 6267 and REE-Aloy 6079 were deduced to be exclusive NdAl 2 and SmAl 2 intermetallic phases, respectively. REE-Aloy 6079 and REE-Aloy 6277 alloys achieve the maximum thermo-mechanical stability comparable to steel and titanium. Robust corrosion resistance for the REE-Aloy 6000 and 6200 alloy series are revealed by the presence of the respective surface REE-aluminate (REE x Al y O z ) using HRTEM and STEM electron-energy-loss spectrum analyses (EELs). A similar outcome is expected for all other REE-Aloy series. A description of the invention is presented in full detail.

1 . A method, described in Section 1.3, that produces monolithic binary rare-earth-element (REE)-aluminum (Al), intermetallic alloy with composition in the range of 30 wt %≤REE≤wt 85% with the balance aluminum. 
     
     
         2 . A method as in  claim 1  utilizing a multi-layered melting vessel in  FIG. 1  that consists of an exterior isolation vessel with an inner insulation layer, and an inner melting vessel that contains a pure alumina reaction vessel with its inner surface coated with an REE-aluminate layer of the general formula REE x Al y O z  for use within an oxygen-free environment. 
     
     
         3 . A method as in  claim 1  producing a matrix with a monolithic binary rare-earth element-aluminum alloy having its purity greater than 90.0 weight percent. 
     
     
         4 . A method as  claim 1  producing REE-aluminum alloy with optimal thermo-mechanical stabilities greater than or comparable to the alloying rare-earth element and that of aluminum. 
     
     
         5 . A method as in  claim 1  producing corrosion resistance REE-aluminum alloy that exceeds that of the binding REE and that of aluminum due to the formation of surface perovskite and or garnet type REE-aluminate of the general formula REE x Al y O z . 
     
     
         6 . A system of monolithic binary rare-earth-element (REE)-aluminum (Al) alloy series in the mass range 30 wt %≤REE≤wt 85% with the balance being aluminum defined as REE-Aloy xxyy, where xx is the REE atomic number and yy is the REE weight percent, that has direct applications as superior alloy technology as replacement options for steels, aluminum, and titanium alloy, where, REE=Sc, Y, La, Ce, Pr, Nd, Sm, Eu, Tb, Dy, Ho, Er, Tm, Yb, Lu. 
     
     
         7 . A tertiary alloy containing 50 wt % or more of a monolithic binary REE-aluminum REE-alloy matrix as in  claim 6 . 
     
     
         8 . The series of monolithic binary rare-earth-element (REE)-aluminum (Al) alloy  claim 6 , having applications as superior alloy technology for advanced clad-less nuclear reactor control rod and neutron-absorber material, where REE=Sm, Eu, Dy, Er. 
     
     
         9 . The series of monolithic binary rare-earth-element (REE)-aluminum (Al) alloy in  claim 6 , having applications as superior alloy technology for clad-less nuclear reactor pressure vessel manufacturing, where REE=Y, La, Ce, Pr. 
     
     
         10 . The series of monolithic binary rare-earth-element (REE)-aluminum (Al) alloy in  claim 6 , having applications as advanced materials for use as metal-oxide-metal (MOM) capacitors and On-chip transformers components technology utilizing an REE-aluminum REE-Aloy alloy as a conductor and its REE-aluminate (REE x Al y O 2 ) surface layer as a dielectric medium, where, REE=Sc, Y, La, Ce, Pr, Nd, Sm, Eu, Tb, Dy, Ho, Er, Tm, Yb, Lu. 
     
     
         11 . The series of monolithic binary rare-earth-element (REE)-aluminum (Al) alloy in  claim 6 , having the application in making permanent magnets material, using an REE-aluminum REE-Aloy alloy series in combination with iron, cobalt, or nickel, where REE=Sc, Y, La, Ce, Pr, Nd, Sm, Eu, Tb, Dy, Ho, Er, Tm, Yb, Lu.