China Aluminum Network: Researchers at the US Department of Energy's Oak Ridge National Laboratory have partnered with Lawrence Livermore National Laboratory and Eck Industries of Wisconsin to develop a new type of aluminum alloy that is more practical than existing products. Good and more resistant to high temperatures. More importantly, this aluminum alloy containing antimony may greatly increase the output of rare earths in the United States.
Germanium is a rare earth element that forms an intermetallic compound with aluminum and has a melting point of more than 1000 degrees Celsius. Aluminum-antimony alloys are very suitable for internal combustion engines. Tests have shown that the alloys can work stably at 300 degrees Celsius. The castability of aluminum-beryllium alloys is comparable to that of aluminum-silicon alloys and is very easy to process. The stability of intermetallic compounds eliminates many heat treatment steps. The researchers also pointed out that due to the wide application of aluminum alloys, the discovery of aluminum-beryllium alloys will initiate and rapidly promote the development of the cerium-earth element industry. According to preliminary estimates, even if the 1% addition amount, the market demand for cerium each year can also be Achieve 3,000 tons. Zach Sims, Michael Mc Guire, and Orlando Rios, Oak Ridge National Laboratory scientists, and colleagues from Eck Industries, Lawrence Livermore National Laboratory, Ames Laboratory, Iowa, discussed in an article. The technical and economic feasibility of aluminum-antimony alloys was published in the JOM publication of the Minerals, Metals and Materials Association.
Rare earths are a group of elements that are important for electronic devices, alternative energy sources, and other modern technologies. For example, modern wind power and hybrid cars rely heavily on powerful permanent magnets made from rare earth elements such as lanthanum and neodymium. However, there is no production of rare earths in North America. One of the problems is that, including rare earth minerals in the United States, the content of antimony is up to more than half of rare-earth content, but rare-earth producers can hardly find the antimony ore market. In fact, in the rare earth ore that is more common in the United States, the content of cerium is more than three times that of cerium and more than 500 times that of cerium.
Aluminium-antimony alloys are expected to increase domestic demand for rare-earth minerals and ultimately increase the value of antimony. Rios explained that we have enough rare earths to meet the needs of energy technology, but when you extract rare earths, most of the elements you get are cesium and rubidium, limiting the large-scale use of rare earths. For example, if aluminum-antimony alloys are used on internal combustion engines, they can quickly convert helium from a bad byproduct to a valuable product.
Rios explained: “The aluminum industry is huge, and the automotive industry uses a lot of aluminum, so even a very small breakthrough for aluminum-antimony alloys will lead to a lot of helium in the market. In fact, 1% of the market The addition of niobium to the aluminum alloy will generate 3000 tons of niobium demand.
Rios said that compared with traditional aluminum alloys, aluminum-antimony alloys have low cost, high castability, low heat treatment requirements, and good high temperature stability. David Weiss, vice president of engineering research and development at Eck Industries, said: "Most of the alloys with excellent properties are difficult to cast, but the aluminum-bismuth alloys have excellent properties and their casting characteristics are very similar to aluminum-silicon alloys."
The key to the high-temperature properties of the alloy is the formation of a special aluminum-antimony compound, the intermetallic compound that is formed inside the alloy when the alloy is melted and cast. This intermetallic compound only melts above 2000 degrees Fahrenheit. Rios pointed out that the heat resistance of aluminum-antimony alloys is very attractive for internal combustion engines. Tests have shown that the new alloy will remain stable at 300 degrees Celsius (572 degrees Fahrenheit), and the traditional alloy begins to disintegrate at this temperature. In addition, the stability of the intermetallic compound can sometimes eliminate the heat treatment process usually required for the aluminum alloy. Aluminium-antimony alloys directly increase engine fuel efficiency by increasing the operating temperature, and can also indirectly improve fuel efficiency by reducing the weight of the engine by replacing the cast iron components with lightweight aluminum-based components or aluminum alloys, such as cylinder blocks, transmissions, and cylinder heads. .
The team cast the cylinder heads of the prototype aircraft in a conventional sand mold; it also cast a full-function cylinder head for a fossil fuel-driven generator in a 3D printed sand mold. This rare demonstration of the American Transportation Research Center at the Oak Ridge National Laboratory led to the success of an engine test that demonstrated that the engine can perform exhaust gas temperatures exceeding 600 degrees Celsius.
Zachary Sims, a physicist at the Oak Ridge National Laboratory, said: "3D printed models are often difficult to fill, but the exception is aluminum-antimony alloys with excellent casting properties."
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