Classifications

• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C21/00—Alloys based on aluminium
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C1/00—Making non-ferrous alloys
  • C22C1/04—Making non-ferrous alloys by powder metallurgy
  • C22C1/0408—Light metal alloys
  • C22C1/0416—Aluminium-based alloys
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
  • B22F10/60—Treatment of workpieces or articles after build-up
  • B22F10/64—Treatment of workpieces or articles after build-up by thermal means
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
  • B22F3/24—After-treatment of workpieces or articles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F9/00—Making metallic powder or suspensions thereof
  • B22F9/02—Making metallic powder or suspensions thereof using physical processes
  • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
  • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
  • B33Y40/10—Pre-treatment
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y70/00—Materials specially adapted for additive manufacturing
• • C—CHEMISTRY; METALLURGY
  • C21—METALLURGY OF IRON
  • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
  • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C21/00—Alloys based on aluminium
  • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
  • C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
  • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
  • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
  • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
  • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
  • C22F1/047—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with magnesium as the next major constituent
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
  • B22F10/20—Direct sintering or melting
  • B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
  • B22F10/20—Direct sintering or melting
  • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
  • B22F10/30—Process control
  • B22F10/34—Process control of powder characteristics, e.g. density, oxidation or flowability
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
  • B22F10/30—Process control
  • B22F10/36—Process control of energy beam parameters
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
  • B22F10/30—Process control
  • B22F10/36—Process control of energy beam parameters
  • B22F10/366—Scanning parameters, e.g. hatch distance or scanning strategy
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
  • B22F10/30—Process control
  • B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
  • B22F3/24—After-treatment of workpieces or articles
  • B22F2003/248—Thermal after-treatment
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F2301/00—Metallic composition of the powder or its coating
  • B22F2301/05—Light metals
  • B22F2301/052—Aluminium
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
  • B22F2998/10—Processes characterised by the sequence of their steps
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y10/00—Processes of additive manufacturing
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P10/00—Technologies related to metal processing
  • Y02P10/25—Process efficiency

Definitions

• the present disclosure relates to materials, methods and techniques for manufacturing Al-Mg-Si alloys.
• Example applications of Al-Mg-Si alloys disclosed and contemplated herein include additive manufacturing processes.
• additive manufacturing also known as 3-D printing, is a fabrication technique that utilizes successive layer generation to produce an item of manufacture.
• additive manufacturing methods use powders, wires, or liquid bases to generate layers under direction of computer-aided design data.
• Example additive manufacturing processes include
• SLS selective laser sintering
• DMLS direct metal laser sintering
• EBM electron beam melting
• LPD laser powder deposition
• additive manufacturing allows for rapid component production, one-off production of difficult-to-source parts, and production of parts difficult to produce by conventional means (such as complex geometries that cannot be machined or cast). As a result, additive manufacturing can provide flexibility in part manufacturing to original equipment manufacturers as well as end users acquiring custom or replacement parts.
• Al-Si alloys including AlSiioMg
• DMLS direct metal laser sintering
• Si eutectic that remains throughout post-build processing and is detrimental to mechanical performance. Accordingly, improved aluminum alloys, specifically alloys for additive manufacturing processes, are needed.
• the aluminum alloys may be aluminum-based alloys.
• the aluminum-based alloys include aluminum (Al), magnesium (Mg), silicon (Si), manganese (Mn), and iron (Fe).
• an alloy in one aspect, includes, by weight percentage, 5% to 8% magnesium, 1.5% to 4% silicon, no more than 0.3% manganese, no more than 0.2% iron, and the balance of weight percent comprising aluminum and incidental elements and impurities.
• an atomized alloy powder usable in additive manufacturing comprises alloy particles.
• the alloy particles include, by weight percentage, 5% to 8% magnesium, 1.5% to 4% silicon, no more than 0.3% manganese, no more than 0.2% iron, and the balance of weight percent comprising aluminum and incidental elements and impurities.
• a method of using an atomized alloy powder in additive manufacturing includes receiving the atomized alloy powder comprising alloy particles, conducting additive manufacturing with the atomized alloy powder to generate a manufactured article, and aging the manufactured article in a heated container for a period of time.
• the atomized alloy powder comprises alloy particles.
• the alloy particles include, by weight percentage, 5% to 8% magnesium, 1.5% to 4% silicon, no more than 0.3%
• manganese no more than 0.2% iron, and the balance of weight percent comprising aluminum and incidental elements and impurities.
• FIG. 1 shows an example method of using an atomized alloy powder in additive manufacturing.
• FIG. 2 is a graph showing yield strength plotted as a function of test temperature for an exemplary multicomponent aluminum alloy (Mg 2 Si).
• 2618-T6 is a wrought alloy
• A356 is a casting alloy
• AlSilOMg is a conventional additive manufacturing alloy
• Scalmalloy is an additive manufacturing alloy with Scandium.
• FIG. 3 is a graph showing ultimate tensile strength as a function of test temperature for an exemplary multicomponent aluminum alloy (Mg 2 Si).
• FIG. 4 is a graph showing elongation as a function of test temperature for an exemplary multicomponent aluminum alloy (Mg 2 Si).
• FIG. 5A and FIG. 5B show images of a 7050 baseline alloy and an example MgSi alloy disclosed herein before testing (5 A). And after 24 hours (5B). Alloys were evaluated in accordance with ASTM G34 procedures in an exfoliation corrosion (Exco) test. The disclosed alloy demonstrates improved resistance over 7050.
• Example aluminum alloys include alloys comprising aluminum, magnesium, silicon, and, in some instances, iron and/or manganese.
• the aluminum alloys can include Mg 2 Si phase precipitates.
• an atomized alloy powder usable in additive manufacturing can include alloy particles comprising aluminum alloys disclosed and
• example aluminum alloys disclosed and contemplated herein can display improved processability, strength, and/or corrosion resistance in harsh environments, for instance, when compared to 7000 series aluminum alloys.
• Example applications of aluminum- based alloys disclosed and contemplated herein include aerospace, automotive, energy industries, as well as other applications where materials can be subjected to extreme temperature and/or loading conditions.
• Example applications of aluminum alloys disclosed and contemplated herein also include those requiring materials that have high strength and are corrosion resistant.
• Various manufactured articles can be prepared using the aluminum alloys disclosed herein, including for the aforementioned industries and the aforementioned applications.
• Example aluminum alloys can have a combination of hot tear resistance and strength, making them amenable to additive manufacturing for production of articles requiring high strength (e.g., aircraft components).
• Example aluminum alloys are described below regarding example components and amounts, phase and nanostructure characteristics, physical properties, methods of manufacture, exemplary articles of manufacture, and exemplary methods of use.
• Aluminum alloys disclosed and contemplated herein include various components at various amounts.
• example aluminum alloys include magnesium, silicon, manganese, and iron.
• “aluminum alloys” mean alloys including aluminum, magnesium, and silicon.
• the aluminum alloys may further include manganese, and iron.
• Example aluminum alloys disclosed and contemplated herein include magnesium (Mg).
• aluminum alloys include 5-8 weight percent (“wt %”) Mg.
• the aluminum alloys may include 5%, 5.1%, 5.2%, 5.3%, 5.4%, 5.5%, 5.6%, 5.7%, 5.8%, 5.9%, 6%, 6.1%, 6.2%, 6.3%, 6.4%, 6.5%, 6.6%, 6.7%, 6.8%, 6.9%, 7%, 7.1%, 7.2%, 7.3%, 7.4%, 7.5%, 7.6%, 7.7%, 7.8%, 7.9%, or 8% Mg.
• Example aluminum alloys disclosed and contemplated herein include silicon (Si).
• aluminum alloys include 1.5-4 weight percent (“wt %”) Si.
• the aluminum alloys may include 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, 2%, 2.1%, 2.2%, 2.3%, 2.4%, 2.5%, 2.6%, 2.7%, 2.8%, 2.9%, 3%, 3.1%, 3.2%, 3.3%, 3.4%, 3.5%, 3.6%, 3.7%, 3.8%, 3.9%, or 4% Si.
• Example aluminum alloys disclosed and contemplated herein include manganese (Mn).
• aluminum alloys include no more than 0.3% weight percent (“wt %”) Mn.
• the aluminum alloys may include 0.3%, less than 0.3%, less than 0.25%, less than 0.2%, less than 0.15%, less than 0.1%, less than 0.05%, or less than 0.01% Mn.
• example aluminum alloys may not contain Mn.
• Example aluminum alloys disclosed and contemplated herein include Iron (Fe).
• aluminum alloys include no more than 0.2 weight percent (“wt %”) Fe.
• the aluminum alloys may include 0.2%, less than 0.2%, less than 0.15%, less than 0.1%, less than 0.05%, or less than 0.01% Fe.
• example aluminum alloys may not contain Fe.
• the balance of weight percent comprises aluminum and incidental elements and impurities.
• Incidental elements and impurities in the disclosed aluminum alloys may include, but are not limited to, iron, oxygen, manganese, chromium, gallium, palladium, sulfur, carbon, elements adhering to raw material stock, or mixtures thereof.
• Incidental elements and impurities may be present in the alloys disclosed herein in amounts totaling no more than 0.15%, no more than 0.14%, no more than 0.13%, no more than 0.12%, no more than 0.11%, no more than 0.10%, no more than 0.9%, no more than 0.8%, no more than 0.7%, no more than 0.6%, no more than 0.5%, no more than 0.4%, no more than 0.3%, no more than 0.2%, no more than 0.1%, no more than 0.05%, no more than 0.01%, or no more than 0.001%.
• multicomponent alloys described herein may consist only of the above-mentioned constituents, may consist essentially of such constituents, or, in other embodiments, may include additional constituents.
• example aluminum alloys disclosed and contemplated herein have various phase and nanostructure characteristics.
• example aluminum alloys can include a stable Mg 2 Si eutectic phase.
• Grain structures within example aluminum alloys can be maintained using a grain pinning dispersion combined with an oxygen gettering phase. These grain structures can aid in maintaining fine grain sizes through building and optional post-build thermal treatments.
• Example aluminum alloys can include Mg 2 Si phase precipitates in addition to the Mg 2 Si eutectic phase.
• Example aluminum alloys disclosed and contemplated herein can have one or more desirable physical properties.
• example aluminum alloys may have hot tear resistance during an additive manufacturing process and resulting alloys may have high strength.
• the following section describes certain physical characteristics of example aluminum alloys, including mechanical properties such as yield strength, ultimate tensile strength, and elongation resistance, as well as corrosion resistance.
• Yield strength can be determined by evaluation of data obtained during tensile strength testing. Generally, yield strength relates to a yield point of a material during tensile strength testing; beyond the yield strength point deformations to the material are not recoverable upon removal of the load.
• Example aluminum alloys after being subjected to an additive manufacturing process and aging for 120 minutes at l85°C, may have a yield strength of greater than 60 ksi at 22°C. For example, the aluminum alloys may have a yield strength of 60-70 ksi at 22°C.
• the aluminum alloys may have a yield strength of 60 ksi, 61 ksi, 62 ksi, 63 ksi, 64 ksi, 65 ksi, 66 ksi, 67 ksi, 68 ksi, 69 ksi, or 70 ksi at 22°C.
• Example aluminum alloys, after subjected to an additive manufacturing process and aging for 120 minutes at l85°C, may have a yield strength of greater than 35 ksi at 200°C.
• the aluminum alloys may have a yield strength of 35-45 ksi at 200°C.
• the aluminum alloys may have a yield strength of 35 ksi, 36 ksi, 37 ksi, 38 ksi, 39 ksi, 40 ksi, 41 ksi, 42 ksi, 43 ksi, 44 ksi, or 45 ksi at 200°C.
• ultimate tensile strength is the maximum stress that a material can withstand while experiencing tensile elongation.
• Tensile strength testing conducted on example aluminum alloys was performed at room temperature in accordance with ASTM E8.
• Tensile strength testing conducted on example aluminum alloys was performed at elevated temperatures in accordance with ASTM E21.
• Example aluminum alloys, after being subjected to an additive manufacturing process and after aging for 120 minutes at l85°C, may have an ultimate tensile strength of greater than 70 ksi at 22°C.
• the aluminum alloys may have an ultimate tensile strength of 70-80 ksi at 22°C.
• the aluminum alloys may have an ultimate tensile strength of 70 ksi, 71 ksi, 72 ksi, 73 ksi, 74 ksi, 75 ksi, 76 ksi, 77 ksi, 78 ksi, 79 ksi, or 80 ksi at 22°C.
• Example aluminum alloys after being subjected to an additive manufacturing process and after aging for 120 minutes at l85°C, have an ultimate tensile strength of greater than 40 ksi at 200°C.
• aluminum alloys may have an ultimate tensile strength of 40- 50 ksi at 200°C.
• aluminum alloys may have an ultimate tensile strength of 40 ksi, 41 ksi, 42 ksi, 43 ksi, 44 ksi, 45 ksi, 46 ksi, 47 ksi, 48 ksi, 49 ksi, or 50 ksi at 200°C.
• Percent elongation may be used as an indication of strengthen alloy’s ductility.
• Example aluminum alloys after being subjected to an additive manufacturing process and after aging for 120 minutes at l85°C, may have an elongation of at least about 4.5% at 22°C.
• aluminum alloys may have an elongation of 4.5%, 5%, 5.5%, 6%, 6.5%, 7%, 7.5%,
• Example aluminum alloys after being subjected to an additive manufacturing process and after aging for 120 minutes at l85°C, may have an elongation of at least about 4.5% at 200°C.
• aluminum alloys may have an elongation of 4.5%, 5%, 5.5%, 6%, 6.5%, 7%, 7.5%, 8%, 8.5%, 9%, 9.5%, or 10% at 200°C.
• corrosion resistance refers to how well a substance can withstand damage caused by oxidization or other chemical reactions. Corrosion resistance tests were performed on example aluminum alloys in accordance with ASTM G34. Example aluminum alloys, after being subjected to an additive manufacturing process and after aging for 60 minutes at 200°C, may have improved corrosion resistance as compared to aluminum alloy 7050 in its T74511 temper condition when subjected to a 24 hour test according to ASTM G34.
• Example aluminum alloys disclosed and contemplated herein can be fabricated into various input stock forms relevant to the additive manufacturing system of interest.
• example aluminum alloys disclosed and contemplated herein can be manufactured into atomized alloy powder using available atomization techniques such as inert gas atomization. Resulting atomized alloy powders can be used in powder-bed fusion and directed energy deposition systems.
• An example method of manufacturing an atomized alloy powder includes melting elemental metal feedstock or prealloyed feedstock such that a desired chemistry is produced.
• atomization processes should take place.
• the melt is a homogenous distribution of the feedstock elements.
• Example components in the feedstock are described herein, and include, for instance, magnesium, silicon, manganese, iron, and aluminum, in amounts disclosed and contemplated herein. Additional components in the feedstock are contemplated, such as incidental elements and impurities.
• the melt is passed through a nozzle and immediately exposed to high velocity inert gas, such as argon.
• high velocity inert gas such as argon.
• the high velocity inert gas breaks up the molten stream and produces spherical powders.
• the spherical powders then cool and fall into an atomizing tower.
• This example method can produce spherical powder with desirable flow characteristics and high chemical purity.
• Example atomized alloy powders can have particles sized for a particular use and/or fabrication system.
• example atomized alloy powders include particles having diameters of from 20pm to 63 pm.
• Example aluminum alloys disclosed and contemplated herein can also be fabricated into wire form via conventional ingot metallurgy and wire drawing techniques for use in wire- based additive manufacturing systems.
• Example aluminum alloys disclosed and contemplated herein can be used in additive manufacturing systems.
• Additive manufacturing is a process by which parts are built in a layered fashion by selectively fusing metal using a computer-controlled energy source (e.g., laser, electron beam, weld torch, or the like).
• a computer-controlled energy source e.g., laser, electron beam, weld torch, or the like.
• Additive manufacturing is also defined in ASTM F2792- l2a entitled“Standard Terminology for Additively Manufacturing Technologies.”
• Example additive layer manufacturing processes include: selective laser sintering in which a laser is used to sinter a powder media in precisely controlled locations; laser wire deposition in which a wire feedstock is melted by a laser and then deposited and solidified in precise locations to build the product; electron beam melting; laser engineered net shaping; and direct metal deposition.
• additive manufacturing techniques provide flexibility in firee- form fabrication without geometric constraints, fast material processing time, and innovative joining techniques.
• Suitable additive manufacturing systems include the EOSINT M 280 Direct Metal Laser Sintering (DMLS) additive manufacturing system, available from EOS GmbH (Robert-Stirling-Ring 1, 82152 Krailling/Munich, Germany).
• direct metal laser sintering is used to produce articles comprising the disclosed and contemplated example aluminum alloys.
• an atomized alloy powder may be spread in a bed and a laser is used to selectively melt and fuse regions of the bed.
• Articles of manufacture can be built in a layer-by-layer fashion by continually spreading and fusing layers of powder.
• laser settings can be selected to, for a manufactured article, minimize porosity, maximize elongation and reduction in area (RA%), and provide proper strength characteristics.
• Example DMLS laser parameters in one possible implementation include: laser power of 370 W, scan speed of 1040 mm/s, scan spacing 0.17 mm, and layer depth 30 pm.
• post-processing operations can be performed after the build process.
• post-processing operations improve one or more characteristics of the“as-built” article of manufacture.
• certain articles may contain defects that preclude use“as-built.” For example, certain articles may include unacceptable porosity, chemical inhomogeneity, or anisotropy. Post-processing operations can eliminate or minimize such defects.
• Post-processing operations can include various heat treatments.
• the manufactured article can be directly transferred from the additive manufacturing system to a heated enclosure, such as a furnace, without first requiring solutionizing (also referred to as solution heat treating) the article.
• solution heat treating also referred to as solution heat treating
• the heated enclosure may be pressurized to perform hot isostatic pressing of the material to reduce porosity.
• Post-processing thermal treatment may relieve stress and/or strengthen one or more portions of the aluminum alloy article.
• thermal treatments may result in
• Aging can include placing an as-built article in a heated environment at a temperature for a given period of time. In some instances, aging can be conducted at two distinct temperatures for two distinct times.
• Post processing heat treatment can occur at any suitable temperature. As a non limiting example, post processing heat treatment can occur at a temperature of from 175 to 225 °C. In some implementations, heat treatment can occur at a temperature between 185 °C-200 °C. In some implementations, heat treatment may have a duration of 0.5-4 hours. In some
• heat treatment may have a duration of 1-2 hours. .
• FIG. 1 shows an example method 100 of using an atomized alloy powder in additive manufacturing.
• Example method 100 begins by receiving an atomized alloy powder (operation 102).
• the atomized alloy powder can be example atomized alloy powders disclosed and contemplated herein.
• the atomized alloy powder includes alloy particles comprising, by weight percentage: 5% to 8% magnesium, 1.5% to 4% silicon, no more than 0.3% manganese, no more than 0.2% iron, and the balance of weight percent comprising aluminum and incidental elements and impurities.
• additive manufacturing is conducted (operation 104) with the atomized alloy powder.
• Conducting additive manufacturing (operation 104) includes operating an additive manufacturing system in such a way as to produce a desired manufactured article.
• Example apparatus and laser parameters are discussed above, although different apparatus and
• Aluminum alloys in the manufactured article can solidify with about 10% of non-equilibrium (soluble) eutectic constituents for improved resistance to hot tearing during additive
• Heat treatment (operation 106) can include post-processing aging operations as disclosed and contemplated herein.
• heat treatment (operation 106) includes positioning the manufactured article in a heated container, such as a furnace, for a predetermined period of time at one or more temperatures. This process is also referred to herein as an aging process.
• eutectic constituents can be dissolved to restore a single-phase aluminum matrix, which can be free of coarse eutectic constituents that provided hot tearing resistance.
• Cooling can include positioning the manufactured article in an uncirculated air environment at room temperature.
• the disclosed aluminum alloys can be used to manufacture a variety of articles.
• Exemplary articles include, but are not limited to, gearbox housings (e.g., helicopter gearbox housing) and aerospace structural components.
• Corrosion resistance was evaluated in accordance with ASTM G34 procedures. As shown in FIG. 5, the multicomponent aluminum alloy has improved corrosion resistance as compared to aluminum alloy 7050 in its T74511 temper condition when subjected to a 24 hour test according to ASTM G34.
• each intervening number there between with the same degree of precision is contemplated.
• the numbers 7 and 8 are contemplated in addition to 6 and 9, and for the range 6.0-7.0, the numbers 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, and 7.0 are contemplated.
• a pressure range is described as being between ambient pressure and another pressure, a pressure that is ambient pressure is expressly contemplated.

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• 2018
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