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Wolf - JAC - Designing New QC Compositions in Al Based Alloys
Wolf - JAC - Designing New QC Compositions in Al Based Alloys
a r t i c l e i n f o a b s t r a c t
Article history: In the present work, we present and discuss the most important results that were obtained in the past
Received 26 September 2019 few years related with the development of new quaternary quasicrystalline alloys and composites. We
Received in revised form present the alloy design strategies that we have used and that led to the discovery of over 60 new
18 December 2019
quasicrystalline compositions, 2 new quasicrystal-forming systems and 1 new Al-matrix composite. New
Accepted 8 January 2020
Available online 9 January 2020
results are also presented and discussed here. Results of interest discussed in this work include: reas-
sessment of quasicrystal and approximant phase formation on the AleCoeFeeCr system; influence of Cr
and Ni additions on the icosahedral AleCueFe quasicrystal stability; discovery of a decagonal AleNieCo
Keywords:
Quasicrystals
eCr quasicrystal; composition range of formation of the decagonal AleCueFeeCr quasicrystal using
Al alloys combinatorial strategies; fabrication of aluminum matrix composites reinforced with quasicrystals using
Alloy design conventional metallurgy fabrication methods.
Al-matrix composites © 2020 Elsevier B.V. All rights reserved.
* Corresponding author.
E-mail addresses: witorw@gmail.com (W. Wolf), cbolfa@ufscar.br (C. Bolfarini),
kiminami@ufscar.br (C.S. Kiminami), wjbotta@ufscar.br (W.J. Botta).
https://doi.org/10.1016/j.jallcom.2020.153765
0925-8388/© 2020 Elsevier B.V. All rights reserved.
2 W. Wolf et al. / Journal of Alloys and Compounds 823 (2020) 153765
2. Designing new quasicrystalline compositions formed a QC phase even for a sample which solidified with cooling
rates in the range of 102 C/s. However, the presence of high Pd
2.1. Revisiting QC forming systems contents is a huge obstacle for applying this QC system due to its
cost. The AleNieCo alloy formed a decagonal QC with some AleNi
QCs were first reported by Daniel Shechtman in an AleMn melt- based intermetallic phases. High cooling rates did not prevent
spun alloy [16]. Although refuted at first, his discovery led to huge formation of such phases, as opposed to what was observed in the
efforts in the sense of understanding their atomic structure and AleCueFe alloys. This can be observed by comparing the XRD
physical properties. pattern of this ternary alloy fabricated by melt-spinning (see
Since this first metallic QC-forming system, many others have Ref. [10]) and by arc-melting a 1 mm thick plate sample that was
been discovered, most of them Al-based, such as AleCueFe, Cu-quenched (see Supplemental Material).
AleCueFeeCr, AleNieCo, AleFeeCr-(M ¼ transition metal), The quaternary system AleCoeFeeCr was studied aiming ap-
AlePdeMn, AleMneSi, AleLieCu among others [17e24]. Some QC plications as thermal barrier coatings. The literature information
phases are considered thermodynamically stable while others can about the most famous alloy of this system, Al71Co13Fe8Cr8, was
only be obtained with metastable processing routes. somewhat contradictory. We showed, by fabricating this alloy with
The interest on stable QCs is related to the ability to fabricate different processing routes, that the microstructure of as-cast
them using conventional casting techniques. In the past few years, samples is always composed by a hexagonal, m-Al5Co2, and a
our work has been focused on developing new QC alloys, based on monoclinic Al13Co4 phases. Both are QC approximants and exhibit
traditionally known QC forming systems by adding alloying ele- interesting physical properties for application as protective coat-
ments on them. Table 1 shows the previously known QC systems ings. Aiming to find new QC compositions, two other alloys from
that we have revisited, the chemical compositions we fabricated, this system were fabricated by rapid solidification processes.
processing routes used and the phases that were obtained. In this However, no QC phases were found. The chemical compositions
table we did not add the AleCueFeeCr system because, although were selected based on the valence electron concentration (e/a)
this system was already known to form QCs, we have made an which would be closer to the usually found on ternary QCs [27],
extensive work on it to find its compositional range of formation which however, was unsuccessful.
and thus it will be discussed in more detail in the sequence. The
references where phase formation, shown in Table 1, can be found 2.2. Designing new quaternary QC alloys based on AleCueFe and
are in the Table’s 1 legend. XRD patterns of alloys that have not AleNieCo systems
been published yet are available in Supplemental Material.
Three ternary systems have been studied and formation of QC From the systems studied in Table 1, two were selected based on
was observed in all of them, as expected from previously published the ability to form QCs and costs related to the alloying elements.
studies. High energy ball milling to alloy Al, Cu and Fe requires These systems were AleCueFe and AleNieCo. Based on selected
posterior annealing to form QCs. We confirm the influence of ternary compositions, we have systematically added Cr and Ni on
cooling rates on the icosahedral phase formation from the the AleCueFe system and Cr and Cu on the AleNieCo system
AleCueFe system, which is favored by high cooling rates, > 104 C/ aiming to retain the QC atomic structure even after the alloying
s. In the supplemental material, three XRD patterns of an additions. The choice of chemical composition of each alloy was
Al65Cu22.5Fe12.5 alloy fabricated in three different processing con- based on trying to increase the fourth element fraction and
ditions (a 10 g arc-melted button, a melt-spun ribbon and a 1 mm selecting values of valence electron concentration (e/a) as close as
arc-melted thick plate sample that was Cu-quenched) are shown. possible to the values found for AleCueFe and AleNieCo QCs.
The cooling rates in each case were in the range of 102 C/s, 106 C/s Table 2 shows the quaternary alloys that were studied, including
and 104 C/s respectively and it can be observed that the relative the fabrication processes and the phases identified. The references
peak intensity of the QC phase increases with increasing cooling where details about phase formation, shown in Table 2, can be
rates. This was expected as reported in previous studies [17,25]. found are in the Table’s 2 legend. XRD patterns of alloys that have
These cooling rates values were calculated using the same pro- not been published yet are available in Supplemental Material.
cedure of reference [26]. The AlePdeMn alloy studied easily Cr addition on the AleCueFe QC leads to a gradual change on
Table 1
Previously known QC-forming systems that we have revisited with their chemical compositions, processing routes used, and the phases obtained. Results taken from ref-
erences: [2,9,10,12,15].
AleCueFe Al65Cu20Fe15 High energy ball milling Al, Cu, Fe, q-Al2Cu
Arc-melting þ annealing at 700 C i-QC
Al65Cu22.5Fe12.5 Arc-melting i-QC þ b-AlCu(Fe) þ l-Al13Fe4 þ Al2Cu
Melt-spinning i-QC þ t-AlCu(Fe)
1 mm plate - Cu-quenched i-QC þ t-AlCu(Fe)
AlePdeMn Al70.5Pd21Mn8.5 Arc-melting i-QC
AleCoeFeeCr Al71Co13Fe8Cr8 1 mm plate - Cu-quenched m-Al5Co2 þ M Al13Co4 þ Cr-rich-unknown
Melt-spinning m-Al5Co2 þ M-Al13Co4
Gas-atomization m-Al5Co2 þ M-Al13Co4
Gas-atomization þ annealing at 1000 C m-Al5Co2
HVOF m-Al5Co2 þ M-Al13Co4
Al77Co11Fe6Cr6 1 mm plate - Cu-quenched M Al13Co4 þ OeAl13Co4
Melt-spinning M Al13Co4 þ OeAl13Co4 þ YeAl13Co4
Al76Co19Fe4Cr1 1 mm plate - Cu-quenched M Al13Co4 þ Al9Co2
Melt-spinning M-Al13Co4
AleNieCo Al71Ni20Co9 Melt-spinning d-QC þ Al3Ni(Co) Al3Ni2(Co)
1 mm plate - Cu-quenched d-QC þ Al3Ni(Co) Al3Ni2(Co)
W. Wolf et al. / Journal of Alloys and Compounds 823 (2020) 153765 3
Table 2
New quaternary alloys that were studied, including the fabrication processes used and the phases observed [8,10,11].
the atomic structure of the QC phase. Small additions, ~3 at. % Cr symmetry. The bright-field micrograph was taken from the QC
results in the coexistence of the icosahedral and decagonal QCs, phase oriented in the 5-fold symmetry axis.
with some presence of the cubic t-AlCu phase when the alloy is In addition to the interesting results we obtained regarding the
fabricated using lower cooling rates, as shown in the XRD pattern in relatively easiness of fabricating QCs in the quaternary
Supplemental Material. Fig. 1 shows an energy dispersive X-ray AleCueFeeCr system, formation of QC phases in this system has
spectroscopy (EDX) mapping of a melt-spun Al65Cu22Fe10Cr3 alloy, also been reported by other authors and with a number of different
which forms an icosahedral QC with small amounts of the deca- atomic compositions [6,29e35]. This motivated an extensive study
gonal QC (Cr-enriched). More details of this alloy’s phase formation we performed using combinatorial strategies [11]. This included
and characterization can be found in Ref. [8]. fabrication of compositional libraries by magnetron co-sputtering
Increasing Cr content above a certain limit leads to only one QC of Al, Cu, Fe and Cr targets on a Si wafer, which produced sam-
phase, with decagonal structure. The Al67Cu20Fe5Cr8 alloy was ples with gradient composition containing hundreds of alloys from
processed by fast and low solidification methods and in all the this system. The samples were than characterized by scanning X-
experiments, a decagonal phase co-existed with a cubic phase, with ray diffraction and EDX with fast data acquisition to identify phases
the same structure of the t-AlCu(Fe) phase forming in ternary rapid in the libraries. Using this strategy, we were able to screen the
solidified AleCueFe QC forming alloys. The same cubic phase was decagonal QC range of formation on the AleCueFeeCr system for
observed in Ref. [28]. Fig. 2a shows an EDX mapping of a melt-spun Al atomic contents from 65 to 70%. We have studied over 300
Al67Cu20Fe5Cr8 alloy, which is formed by a decagonal QC matrix different alloy compositions and found 59 new decagonal QC
with the presence of the t-AlCu(Fe) phase (phase enriched in Cu) dominant compositions. The QC composition range of formation
forming at the grain boundaries. Details of this alloy’s phase for- can be found in Wolf et al. [11].
mation can be found in Ref. [8]. In Fig. 2b, the same EDX mapping On the other hand, Ni additions on the AleCueFe QC did not
analysis-type was performed in the ternary melt-spu- lead to formation of a decagonal QC. We found that the icosahedral
nAl65Cu22.5Fe12.5 alloy which has an icosahedral QC matrix but also QC can dissolve up to 4 at. % Ni in its atomic structure. However,
forms the t-AlCu(Fe) phase, in the same way observed in the additions superior to that led to destabilization of the QC in favor of
quaternary alloy. Fig. 2c shows a TEM bright-field micrograph and a B2 cubic phase, which was the major phase in the higher Ni-
the selected area electron diffraction pattern (SAED) of this t- containing alloy, Al64Cu20Fe13Ni9.
AlCu(Fe) phase taken along the [111] zone axis, from the ternary It is also interesting to comment on the morphological differ-
alloy. This phase is cubic with a CsCl-type structure and lattice ences that QC phases can be produced, which strongly depends on
parameter a ¼ 2.94 Å. Fig. 2d shows the icosahedral QC phase, with the cooling rates applied during solidification and on the QC atomic
the respective SAED, taken along the 5-fold axis of rotational structure. For instance, the AleCueFe icosahedral QC can be formed
with a nanometric QC grain size, if fast cooling rates are applied
(Fig. 2d), or it can form an envelope-like and micrometric grain-
sized microstructure, which is a consequence of the peritectic re-
action that results in its formation under low cooling rates during
solidification [17]. The AleCueFeeCr decagonal QC also forms as
nanometric QC grains if fast cooling rates are applied (Fig. 2a) or it
forms as elongated micrometric-sized columnar grains if low
cooling rates are applied [11].
Cr addition on the AleNieCo decagonal QC led to discovery of a
new quaternary QC, also decagonal, which formed in two melt-spun
alloys. The composition of this phase was measured by EDX and it
was found to be Al78.2Ni8.7Cr10Co3.1. However, the alloys studied also
formed two AleNi based intermetallic phases, even when applying
rapid solidification processes. The thermal stability of this new QC
continues for future elucidation. Cu additions enhanced interme-
tallic phase formation in detriment of the QC phase. This can be seen
in the XRD patterns of melt spun Al71Ni20Co7Cu2 and Al70Ni20Co5Cu5
alloys, shown in the Supplemental Material. If compared to XRD
patterns of the AleNieCoeCr melt spun alloys (see Ref. [10]), the Cu-
containing alloys show significantly higher contents of Al3Ni and
Fig. 1. STEM EDX mapping from the Al65Cu22Fe10Cr3alloy. The matrix is the icosahedral
QC and the Cr-rich phase is the decagonal QC. Details of the phase formation in this
Al3Ni2 phases. For this reason, this system was the less promising
alloy can be found elsewhere [8]. one and was not further studied.
4 W. Wolf et al. / Journal of Alloys and Compounds 823 (2020) 153765
Fig. 2. (a) EDX mapping of a melt-spun Al67Cu20Fe5Cr8 alloy, showing the t-AlCu(Fe) phase, which is located in the Cu-rich regions. (b) EDX mapping from the ternary melt-spun
Al65Cu22.5Fe12.5 alloy also showing the t-AlCu(Fe) phase. (c) Bright-field TEM micrograph of the ternary alloy with a SAED pattern of the t-AlCu(Fe) phase taken along the [111] zone
axis. (d) Bright-field TEM micrograph of the ternary alloy showing the icosahedral QC and the SAED pattern taken along the 5-fold axis.
The design strategies used here to produce new QC composi- This process allows fabrication of composites reinforced with stable
tions proved to be efficient and led to the discovery of more than 60 QCs, however, nanosized QC particles embedded in the ductile
new QC-based alloys. The main idea behind this strategy is: define a matrix are hard to be obtained.
ternary QC to be used as a base alloy. Using empirical QC-forming Following the results obtained in our combinatorial studies of
rules, such as the valence electron concentration, add a fourth the AleCueFeeCr system and from literature data regarding pre-
element in different proportions. Applying rapid solidification viously published AleCueFeeCr QC compositions, we have devel-
fabrication processes is the most adequate way to produce the oped an Al-matrix composite reinforced with QCs by arc-melting an
quaternary alloys, because since QCs usually form around several Al85Cu6.75Fe3.375Cr4.875 alloy and subsequently annealing it at
intermetallic phases, whose formation can be suppressed by fast 600 C. The details of the annealed alloy’s microstructure and
cooling rates. If this fourth element addition leads to QC formation, fabrication can be found in Ref. [13]. This was the first time such
then this quaternary system is a potential candidate for the second microstructure could be obtained by conventional fabrication
step of the alloy design. This second step would be applying a methods. Here we will show the details of the as-cast alloy, which
method, in which the fabrication and characterization of hundreds was the precursor of the QC composite. Fig. 3 shows the XRD
of alloy compositions can be performed so that the compositional pattern and SEM micrograph of the Al85Cu6.75Fe3.375Cr4.875 arc-
range where the quaternary phase can be fabricated will be dis- melted alloy in the as-cast condition. The XRD pattern of the as-
closed. This can be done by magnetron co-sputtering [36e38] or by cast sample is very different from the one of the annealed sam-
using diffusion multiples [39]. ple, from Ref. [13].
In the as-cast sample, the decagonal QC could not be identified
3. Al-matrix composites reinforced with quasicrystals and intense peaks of the Al2Cu phase can be seen. The XRD pattern
also show some peaks of the Al7Cu2Fe phase. The Al-FCC phase can
In addition to discovering new QC forming compositions, our be seen in the SEM micrograph (phase with the darker contrast)
research has also focused on developing Al-matrix composites rein- and the Al2Cu is observed, forming an eutectic constituent with the
forced with QCs. Although QCs show remarkable functional physical Al-FCC phase. In addition, a third phase (the one with intermediate
properties that could be used for tribological protection [40,41], their contrast) seems to solidify with acicular morphology. EDX analysis
inherent brittleness makes their use very limited. To overcome this was performed in this phase showing an average atomic compo-
difficulty, QC phases must be embedded in a ductile matrix. sition of Al80.79±0.27Cu2.05±0.11Fe5.16±0.52Cr12.0±0.35. This is an
There are two traditional methods to produce such composites. AleFeeCr-based phase and its atomic structure could not be
The first one involves rapid solidification techniques, such as melt- identified with the analysis performed in this work. The AleFeeCr
spinning, Cu-mold quenching and gas-atomization [14,22,42e45] phase diagram [47] shows the formation of a significant number of
and can lead to the fabrication of composites reinforced with complex ternary phases around this composition and its proper
nanosized QCs, which is very interesting and can result in high identification would require an extensive electron diffraction
strength composites. The main drawbacks are related to the com- analysis (which was not done for this work).
plex fabrication processes needed and the fact that QCs forming in Fig. 4 shows the results from DSC analysis of the arc-melted
these systems are metastable and usually transform to crystalline sample in the as-cast and after annealing (at 600 C, see Ref. [13])
phases after heating around 350e500 C. The second way to conditions; both curves are shown in the same scale for compari-
fabricate these composites is based on powder metallurgy [15,46]. son. It is interesting to note that in the as-cast condition, an intense
W. Wolf et al. / Journal of Alloys and Compounds 823 (2020) 153765 5
Fig. 3. XRD pattern and SEM micrograph of the Al85Cu6.75Fe3.375Cr4.875 arc-melted alloy in the as-cast condition.
W.W., C.B., C.S.K and W.J.B designed the study. W.W. fabricated
and characterized the samples. All authors contributed on data
Fig. 4. DSC analysis of the as cast and annealed Al85Cu6.75Fe3.375Cr4.875 arc-melted analysis, discussing and manuscript writing.
alloy.
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