# US 12,180,567 B2 · Ultra-high strength multphase high-entropy alloys

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- Number: US 12,180,567 B2
- Document ID: US12180567B2
- Status: Granted
- Kind: B2
- Application number: 17/803,779
- Filed: 2022-11-21
- Published: 2023-05-25
- Granted: 2024-12-31
- Earliest claimed: 2021-11-22
- Assignees: Iowa State University Research Foundation, Inc.; National Technology & Engineering Solutions of Sandia, LLC
- Applicants: Iowa State University Research Foundation, Inc.; National Technology & Engineering Solutions of Sandia, LLC
- Inventors: Iver E. Anderson; Emma Marie Hamilton White; Duane Johnson; Nicolas Argibay; Andrew B. Kustas; Michael Chandross; Raymond V. Puckett
- Web page: https://patentgrep.com/patent/US12180567B2

## CPC

- C22C 30/00: Alloys containing less than 50% by weight of each constituent
- B33Y 70/00: Materials specially adapted for additive manufacturing
- B33Y 80/00: Products made by additive manufacturing
- C22C 1/0458: {Alloys based on titanium, zirconium or hafnium}
- C22C 14/00: Alloys based on titanium
- B22F 1/05: Metallic powder characterised by the size or surface area of the particles
- B22F 3/105: by using electric current {other than for infrared radiant energy}, laser radiation or plasma (B22F3/11 takes precedence){; by ultrasonic bonding (B22F3/115 takes precedence)}
- B22F 9/04: starting from solid material, e.g. by crushing, grinding or milling ({C22C1/1084 takes precedence}; crushing, grinding or milling, in general, see the relevant subclasses, e.g. B02C)
- B22F 9/082: {atomising using a fluid (using centrifugal force B22F9/10)}
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B22F 2003/1051: {by electric discharge}
- B22F 2009/041: {by mechanical alloying, e.g. blending, milling}
- B22F 2009/043: {by ball milling}
- B22F 2202/13: Use of plasma
- B22F 2301/052: Aluminium
- B22F 2304/10: Micron size particles, i.e. above 1 micrometer up to 500 micrometer
- B22F 2998/10: Processes characterised by the sequence of their steps
- B33Y 10/00: Processes of additive manufacturing
- Y02P 10/25: Process efficiency
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

Refractory-reinforced multiphase high entropy alloys (RHEAs) advantageously providing high strength and fracture toughness in an as-AM deposited condition and other conditions are described.

## Claims

### Claim 1

An alloy having Al and Ti as major alloy constituents and Nb, Zr, Mo, and Ta as minor alloy constituents whose minor collective content is effective to provide a polyphase microstructure including at least four compositionally distinct intermetallic phases.

### Claim 2 (depends on 1)

The alloy of claim 1 having Al+Ti content that is greater than 50 atomic %.

### Claim 3 (depends on 1)

The alloy of claim 1 having substantially coherent interphase boundaries having a misorientation less than 2° between boundary phases.

### Claim 4 (depends on 1)

A structure comprising the alloy of claim 1 that is at least one of an as-built AM structure, a sintered structure, and a solidified structure.

### Claim 5 (depends on 1)

A 3D structure comprising the alloy of claim 1.

### Claim 6 (depends on 1)

A method comprising building a 3D structure that comprises the alloy of claim 1 by additive manufacturing.

### Claim 7 (depends on 1)

A method comprising building a sintered structure that comprises the alloy of claim 1 by sintering powders of the alloy.

### Claim 8

An alloy having a composition represented by Al0.42Ti0.25Nb0.13Zr0.08Mo0.08Ta0.04 that has a polyphase microstructure including at least four (4) compositionally distinct intermetallic phases or variants of the composition wherein content of at least one of Al, Ti, Nb, Zr, Mo, and Ta is so varied that the alloy has Al+Ti content greater than 50 atomic % and that the alloy has a polyphase microstructure including four (4) compositionally distinct intermetallic phases and exhibits a mechanical strength that is independent of temperature up to 800° C.

### Claim 9

An alloy having a composition represented by Al0.42Ti0.25Nb0.13Zr0.08Mo0.08Ta0.04 that has a polyphase microstructure including at least four (4) compositionally distinct intermetallic phases or variants of the composition wherein content of at least one of Al, Ti, Nb, Zr, Mo, and Ta is so varied that Al+Ti content is greater than 50 atomic % and that the alloy has a polyphase microstructure including at least four (4) compositionally distinct intermetallic phases.

### Claim 10 (depends on 9)

The alloy of claim 9 having substantially coherent interphase boundaries having a misorientation of less than 2° between boundary phases.

### Claim 11 (depends on 9)

The alloy of claim 9 that exhibits a specific strength equal 15 to hardness:density ratio at room temperature of 1.8 to 2.6 GPa-cm3/g.

### Claim 12 (depends on 9)

A structure comprising the alloy of claim 9.

### Claim 13 (depends on 12)

The structure of claim 12 that is at least one of an as-built AM structure, a sintered structure, and a solidified structure.

### Claim 14 (depends on 9)

A deposited layer comprising the alloy of claim 9.

### Claim 15

An alloy having an Al content greater than 20 atomic % to less than about 70 atomic %, an Al+Ti content greater than 55 atomic % and less than about 75 atomic %, and a collective content of Nb, Zr, Mo, and Ta of about 25 atomic % to about 45 atomic % wherein the alloy has a polyphase microstructure including at least four compositionally distinct intermetallic phases.

### Claim 16 (depends on 15)

The alloy of claim 15 having Al content from 20 to 70 atomic %, and an Al+Ti content from 65 to less than 75 atomic %.

### Claim 17 (depends on 15)

The alloy of claim 15 having substantially coherent interphase boundaries having a misorientation less than 2° between boundary phases.

### Claim 18 (depends on 15)

The alloy of claim 15 that exhibits a mechanical strength or hardness that is independent of temperature up to 800° C.

### Claim 19 (depends on 15)

The alloy of claim 15 that exhibits a specific strength equal to hardness:density ratio at room temperature of 1.8 to 2.6 GPa-cm3/g.

### Claim 20 (depends on 15)

A deposited layer comprising the alloy of claim 15.