Method for producing high strength aluminum alloy powder containing L12 intermetallic dispersoids

A method for producing high strength aluminum alloy powder containing L12 dispersoids, comprising the steps of:

• melting an aluminum alloy containing L12 dispersoid forming elements therein to a superheat temperature of from about 100° F. (38° C.) to about 300° F. (149° C.), wherein the L12 dispersoid forming elements form Al3X dispersoids wherein X is at least one first element selected from the group comprising:
• about 0.1 to about 4.0 weight percent scandium, about 0.1 to about 20.0 weight percent erbium, about 0.1 to about 15.0 weight percent thulium, about 0.1 to about 25.0 weight percent ytterbium, and about 0.1 to about 25.0 weight percent lutetium;
• at least one second element selected from the group comprising:
• about 0.1 to about 20.0 weight percent gadolinium, about 0.1 to about 20.0 weight percent yttrium, about 0.05 to about 4.0 weight percent zirconium, about 0.05 to about 10.0 weight percent titanium, about 0.05 to about 10.0 weight percent hafnium, and about 0.05 to about 5.0 weight percent niobium;
• and
• the balance substantially aluminum;
• forcing the melted alloy through a confined gas atomization nozzle having a nozzle diameter ranging from 0.01 inches (254 microns) to about 0.2 inches (5.1 microns), at a metal flow rate of from 0.5 lb/min to 25 lb/min (11.3 kg/min);
• contacting the melted alloy leaving the nozzle with an inert gas stream to form liquid droplets, the inert gas stream having a pressure of 50 psi (0.34 MPa) to about 750 psi (5.17 MPa);
• cooling the droplets at a rate of at least 103° C./second to form an alloy powder;
• and
• sorting the powder to a mesh size of about minus 100 to about minus 635.

A high strength aluminum alloy powder containing L12 dispersoids, formed by the steps comprising:

• melting an aluminum alloy containing an L12 dispersoid forming element therein to a superheat temperature of from about 100° F. (38° C.) to about 300° F. (149° C.), wherein the L12 dispersoids comprise Al3X dispersoids wherein X is at least one first element selected from the group comprising:
• about 0.1 to about 4.0 weight percent scandium, about 0.1 to about 20.0 weight percent erbium, about 0.1 to about 15.0 weight percent thulium, about 0.1 to about 25.0 weight percent ytterbium, and about 0.1 to about 25.0 weight percent lutetium;
• at least one second element selected from the group comprising about 0.1 to about 20.0 weight percent gadolinium, about 0.1 to about 20.0 weight percent yttrium, about 0.05 to about 4.0 weight percent zirconium, about 0.05 to about 10.0 weight percent titanium, about 0.05 to about 10.0 weight percent hafnium, and about 0.05 to about 5.0 weight percent niobium;
• and
• the balance substantially aluminum;
• forcing the melted alloy through a gas atomization nozzle at a metal flow rate of from 0.5 lb/min (0.23 kg/min) to 25 lb/min (11.3 kg/min);
• contacting the melted alloy leaving the nozzle with an inert gas stream to form liquid droplets, the inert gas stream having a pressure of 50 psi (0.34 MPa) to about 750 psi (5.17 MPa);
• cooling the droplets at a rate of at least 103° C./second to form an alloy powder;
• and
• sorting the powder to a mesh size of about minus 100 to about minus 635.