Abstract: A method of manufacturing a crystalline aluminum-iron-silicon alloy and a crystalline aluminum-iron-silicon alloy part. An aluminum-, iron-, and silicon-containing composite powder is provided that includes an amorphous phase and a first crystalline phase having a hexagonal crystal structure at ambient temperature. The composite powder is heated at a temperature in the range of 850° C. to 950° C. to transform at least a portion of the amorphous phase into the first crystalline phase and to transform the composite powder into a crystalline aluminum-iron-silicon (Al—Fe—Si) alloy. The first crystalline phase is a predominant phase in the crystalline Al—Fe—Si alloy.

Abstract: Provided is a method of manufacturing a crystalline aluminum-iron-silicon alloy, and optionally an automotive component comprising the same, comprising forming a composite ingot including a plurality of crystalline phases by melting aluminum, iron, and silicon raw materials in an inert environment to form a substantially homogenous melt, subsequently solidifying the melt, and annealing the ingot under vacuum by heating at a temperature in the range of 850° C. to 1000° C. yield an annealed crystalline ingot wherein the predominant crystalline phase is FCC Al3Fe2Si. The raw materials can further include one or more additives such as zinc, zirconium, tin, and chromium. Melting can occur above the FCC Al3Fe2Si crystalline phase melting point, or at a temperature of about 1100° C. to about 1400° C. Annealing can occur under vacuum conditions.

Abstract: Disclosed are methods for manufacturing a pouch-type battery cells, and include disposing an anode and a cathode, and optionally a reference electrode, between a first pouch layer and a second pouch layer, and applying heat to the outer corrosion resistant polymer layer of the first pouch layer or the second pouch layer via a laser along a peripheral seal path forming a peripheral seal joining the first pouch layer and the second pouch layer to form a pouch encasing the anode and the cathode, and optionally the reference electrode. Each pouch layer includes an inner heat-activated polymer adhesive layer, a middle aluminum layer, and an outer corrosion resistant polymer layer. The outer corrosion resistant polymer layer of the first pouch layer and/or the second pouch layer can have a laser absorptivity of less than about 10%. The laser can have a wavelength of about 800 nanometers to about 2,000 nanometers.

Abstract: A lithium-based electrode assembly and methods of formation relating thereto are provided. The lithium-based electrode assembly comprises a metal current collector, an electrode comprising lithium metal, and an intermediate layer disposed therebetween. The intermediate layer comprising an intermetallic compound comprising the lithium metal of the electrode and a metal selected from the group consisting of: aluminum, silver, gold, barium, bismuth, boron, calcium, cadmium, carbon, gallium, germanium, mercury, indium, iridium, lead, palladium, platinum, rhodium, antimony, selenium, silicon, tin, strontium, sulfur, tellurium, zinc, and combinations thereof.

Abstract: Provided is a method of manufacturing a crystalline aluminum-iron-silicon alloy, and optionally an automotive component comprising the same, comprising forming a composite ingot including a plurality of crystalline phases by melting aluminum, iron, and silicon raw materials in an inert environment to form a substantially homogenous melt, subsequently solidifying the melt, and annealing the ingot under vacuum by heating at a temperature in the range of 850° C. to 1000° C. yield an annealed crystalline ingot wherein the predominant crystalline phase is FCC Al3Fe2Si. The raw materials can further include one or more additives such as zinc, zirconium, tin, and chromium. Melting can occur above the FCC Al3Fe2Si crystalline phase melting point, or at a temperature of about 1100° C. to about 1400° C. Annealing can occur under vacuum conditions.

Abstract: A lithium-based electrode assembly and methods of formation relating thereto are provided. The lithium-based electrode assembly comprises a metal current collector, an electrode comprising lithium metal, and an intermediate layer disposed therebetween. The intermediate layer comprising an intermetallic compound comprising the lithium metal of the electrode and a metal selected from the group consisting of: aluminum, silver, gold, barium, bismuth, boron, calcium, cadmium, carbon, gallium, germanium, mercury, indium, iridium, lead, palladium, platinum, rhodium, antimony, selenium, silicon, tin, strontium, sulfur, tellurium, zinc, and combinations thereof.

Abstract: A method of manufacturing a crystalline aluminum-iron-silicon alloy and a crystalline aluminum-iron-silicon alloy part. An aluminum-, iron-, and silicon-containing composite powder is provided that includes an amorphous phase and a first crystalline phase having a hexagonal crystal structure at ambient temperature. The composite powder is heated at a temperature in the range of 850° C. to 950° C. to transform at least a portion of the amorphous phase into the first crystalline phase and to transform the composite powder into a crystalline aluminum-iron-silicon (Al—Fe—Si) alloy. The first crystalline phase is a predominant phase in the crystalline Al—Fe—Si alloy.

Abstract: In an example of a method for forming a high-strength, lightweight alloy, starting materials are provided. The starting materials include aluminum, iron, and silicon. The starting materials are ball milled to generate the high-strength, lightweight alloy of a stable AlxFeySiz phase, wherein x ranges from about 3 to about 5, y ranges from about 1.5 to about 2.2, and z is about 1.

Abstract: In an example of a method for forming a high-strength, lightweight alloy, starting materials are provided. The starting materials include aluminum, iron, and silicon. The starting materials are ball milled to generate the high-strength, lightweight alloy of a stable AlxFeySiz phase, wherein x ranges from about 3 to about 5, y ranges from about 1.5 to about 2.2, and z is about 1.