Rapidly solidified aluminum-rare earth element alloy and method of making the same

A method, comprising:

• combining aluminum with (i) 0.1 wt % to 8 wt % of an additional alloying element selected from magnesium, zinc, titanium, manganese, zirconium, vanadium, scandium, copper, or nickel, or one or more of magnesium, zinc, titanium, manganese, zirconium, vanadium, and scandium in combination with copper or in combination with nickel;
• (ii) at least one rare earth component selected from lanthanum, cerium, mischmetal, or a combination thereof;
• and (iii) 0.1 wt % to 2 wt % of an additive component selected from iron, strontium, boron, manganese, titanium, chromium, cobalt, carbon, or a combination thereof to form an aluminum-based alloy composition;
• wherein the aluminum-based alloy composition does not comprise both copper and nickel in combination;
• and
• performing a cooling step, wherein the mixed aluminum-based alloy composition is cooled at an average cooling rate range from greater than 100 K/s to 108 K/s to provide an aluminum-based alloy comprising an aluminum matrix phase, an Al11X3 intermetallic phase where X is one of lanthanum, cerium, or mischmetal, or a combination thereof, and (i) a semi- to fully-eutectic phase with a maximum spacing between morphologic features of the semi- to fully-eutectic phase being no greater than 8 μm;
• or (ii) a phase comprising laths and/or rods, wherein the aluminum matrix phase, the Al11X3 intermetallic phase, and the semi- to fully-eutectic phase, or the phase comprising laths and/or rods are obtained without a heat treatment;
• provided that the cooling step does not comprise continuous cast rolling to cool the mixed aluminum-based alloy composition.