Method of casting an aluminum alloy by controlled solidification

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A castable high temperature aluminum alloy is cast by controlled solidification that combines composition design and solidification rate control to synergistically enhance the performance and versatility of the castable aluminum alloy for a wide range of elevated temperature applications. The method of casting an aluminium alloy comprises the steps of : forming the aluminium alloy including aluminium, at least one rare earth element selected form the group consisting of ytterbium, gadolinium, yttrium, erbium and cerium, and at least one minor alloy element selected from the group consisting of copper, nickel, zinc, silver, magnesium, strontium, manganese, tin, calcium, cobalt and titanium; and controlling solidification of the alumimium alloy in quenchant. In one example, the aluminum alloy contains by weight approximately 1.0-20.0% of rare earth elements that contribute to the elevated temperature strength by forming a dispersion of insoluble particles via a eutectic microstructure. The aluminum alloy also includes approximately 0.1 to 15% by weight of minor alloy elements. Controlled solidification improves microstructural uniformity and refinement and provides the optimum structure and properties for the specific casting condition. The molten aluminum alloy is poured into an investment casing shell and lowered into a quenchant at a controlled rate. The molten aluminum alloy cools from the bottom of the investment casting shell upwardly to uniformly and quickly cool the aluminum alloy.