WO2020150056A1 - Aluminum alloys - Google Patents

Aluminum alloys Download PDF

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Publication number
WO2020150056A1
WO2020150056A1 PCT/US2020/012733 US2020012733W WO2020150056A1 WO 2020150056 A1 WO2020150056 A1 WO 2020150056A1 US 2020012733 W US2020012733 W US 2020012733W WO 2020150056 A1 WO2020150056 A1 WO 2020150056A1
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WO
WIPO (PCT)
Prior art keywords
composition
weight
alloys
present disclosure
alloy
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2020/012733
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English (en)
French (fr)
Inventor
Prabir Kanti CHAUDHURY
Chan Cheong PUN
Chor Yen YAP
Taiki Thomas SHIRAI
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Divergent Technologies Inc
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Divergent Technologies Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by Divergent Technologies Inc filed Critical Divergent Technologies Inc
Priority to KR1020217024858A priority Critical patent/KR20210113640A/ko
Priority to AU2020209472A priority patent/AU2020209472A1/en
Priority to MX2021008668A priority patent/MX2021008668A/es
Priority to CA3127038A priority patent/CA3127038A1/en
Priority to EP20741246.1A priority patent/EP3911775A4/en
Priority to CN202080018077.5A priority patent/CN113508184A/zh
Priority to JP2021541462A priority patent/JP2022524275A/ja
Publication of WO2020150056A1 publication Critical patent/WO2020150056A1/en
Anticipated expiration legal-status Critical
Priority to JP2024211679A priority patent/JP2025041669A/ja
Ceased legal-status Critical Current

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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
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • 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
    • B22F10/10—Formation of a green body
    • B22F10/14—Formation of a green body by jetting of binder onto a bed of metal powder
    • 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
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/165—Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
    • 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 generally to alloys, and more specifically to aluminum alloys.
  • AM additive Manufacturing
  • CAD computer-aided design
  • AM process is powder bed fusion (PBF), which uses a laser, electron beam, or other source of energy to sinter or melt metallic powder deposited in a powder bed, thereby consolidating powder particles together in targeted areas to produce a 3-D structure having the desired geometry.
  • PBF powder bed fusion
  • materials or combinations of materials such as metals, plastics, and ceramics, may be used in PBF to create the 3-D object.
  • Other more advanced AM techniques including those discussed further below, are also available or under current development, and each may be applicable to the present disclosure.
  • Binder Jet Another example of an AM process is called Binder Jet (BJ) process that uses a powder bed (similar to PBF) in which metallic powder is spread in layers and bonded by using an organic binder. The resulting part is a green part which requires burning off the binder and sintering to consolidate the layers into full density.
  • the metallic powder material can have the same chemical composition and similar physical characteristics as PBF powders.
  • DED Directed Energy Deposition
  • DED is an AM technology that uses a laser, electron beam, plasma, or other method of energy supply, such as those in Tungsten Inert Gas (TIG), or Metal Inert Gas (MIG) welding to melt the metallic powder or wire and rod, thereby transforming it into a solid metal object.
  • Tungsten Inert Gas Tungsten Inert Gas
  • MIG Metal Inert Gas
  • DED is not based on a powder bed. Instead, DED uses a feed nozzle to propel the powder or mechanical feed system to deliver wire and rod into the laser beam, electron beam, plasma beam, or other energy stream. The powdered metal or the wire and rod are then fused by the respective energy beam.
  • While supports or a freeform substrate may in some cases be used to maintain the structure being built, almost all the raw material (powder, wire, or rod) in DED is transformed into solid metal, and consequently, little waste powder is left to recycle.
  • the print head comprised of the energy beam or stream and the raw material feed system, can scan the substrate to deposit successive layers directly from a CAD model.
  • PBF, BJ, DED, and other AM processes may use various raw materials such as metallic powders, wires, or rods.
  • the raw material may be made from various metallic materials.
  • Metallic materials may include, for example, aluminum, or alloys of aluminum. It may be advantageous to use alloys of aluminum that have properties that improve functionality within AM processes. For example, particle shape, powder size, packing density, melting point, flowability, stiffness, porosity, surface texture, density electrostatic charge, as well as other physical and chemical properties may impact how well an aluminum alloy performs as a material for AM.
  • raw materials for AM processes can be in the form of wire and rod whose chemical composition and physical characteristics may impact the performance of the material. Some alloys may impact one or more of these or other traits that affect the performance of the alloy for AM.
  • one or more alloys or compositions thereof may be aluminum alloys.
  • the one or more alloys may be used in three-dimensional (3-D) printing and/or additive manufacturing to produce additively manufactured structures with the one of more alloys.
  • an alloy may include a composition containing a plurality of materials (e.g., elements, metals, etc.).
  • an alloy may comprise: a composition that includes: magnesium (Mg) that is approximately 5 to 12% by weight of the composition; silicon (Si) that is approximately 0.3 to 3% by weight of the composition; Manganese (Mn) that is approximately 0.1 to 2% by weight of the composition; and aluminum (Al) that is a balance of the composition.
  • the composition may further include at least one of: iron (Fe), chromium (Cr); titanium (Ti); zirconium (Zr); and Yttrium (Y).
  • the composition includes up to approximately 5% by weight of the include Cr.
  • the composition contains up to approximately 0.25% by weight of the Fe.
  • the composition includes at least 0.05% by weight of the Fe. In one configuration, the composition includes at least approximately 1% by weight of the Cr. In one configuration, the composition includes at least approximately 0.1% by weight of the Ti. In one configuration, the composition includes up to 0.6% by weight of the Ti. In one configuration, the composition includes up to approximately 2% by weight of the Zr. In one configuration, the composition includes at least 0.3% by weight of the Zr. In one configuration, the composition includes at least approximately 0.1% by weight of the Y. In one configuration, the composition includes up to 4% by weight of the Y. In one configuration, the composition includes all of the elements listed above (Al, Mg, Mn, Si, Fe, Cr, Ti, Zr, and Y). In one configuration, the balance of the Al of the composition includes up to approximately 0.1% by weight of trace impurities cumulatively and 0.01% individually.
  • FIGs. 1A-1B are graphs illustrating properties of alloys.
  • FIGs. 2A-2D illustrate respective side views of an exemplary 3-D printer system.
  • Metal alloys such as aluminum alloys
  • these engineering applications may benefit from alloys that offer high performance and sustainability.
  • alloys that are economical may be more advantageous, e.g., as alloys that include rare and/or expensive elements may be impractical for relatively large-scale and/or commercial applications.
  • AM additive manufacturing
  • SLM Selective Laser Melting
  • PPF Powder Bed Fusion
  • AM processes may include a very small melt pool and/or very high cooling rate from liquid to solid states for alloys, e.g., in comparison with traditional manufacturing processes. Therefore, alloys used in AM processes may be expected to develop microstructure and/or other characteristics (e.g., through the relatively small melt pool and/or relatively high cooling rate) that yield high strength, ductility, fracture toughness, fatigue strength, corrosion resistance, and/or elevated temperature strength and, therefore, result in satisfactory products.
  • alloys that are high performance and economically feasible for AM in various automotive, aerospace, and/or other engineering applications.
  • the present disclosure describes alloys that may be implemented in AM processes, such as SLM, PBF neighbor DED, and others. In this way, for example, additively manufactured structures of the alloys disclosed in this invention may be produced.
  • the alloys of the present disclosure may provide improved properties for AM in automotive, aerospace, and/or other engineering applications.
  • the alloys may yield improved performance in AM contexts, such as one or more of high strength (e.g., yield strength), ductility, fracture toughness, fatigue strength, corrosion resistance, elevated temperature strength, percent elongation, and/or any combination thereof.
  • application of the alloys of the present disclosure may be economically feasible, for example, in a commercial context and/or production scale for AM in automotive, aerospace, and/or other engineering applications.
  • Crashworthiness is a combination of tensile, shear, and compression strengths that make up a material’s crash performance.
  • the analytical and experimental data are utilized by a variety of industries (e.g., automotive) while designing and engineering structures incorporating the materials.
  • High-performance aluminum alloys processed with conventional techniques may obtain various properties through one or combination of the following processes: solid solution strengthening, strain hardening, precipitation strengthening, and/or dispersion strengthening.
  • the processes of solid solution strengthening, strain hardening, precipitation strengthening, grain or phase boundary strengthening, and/or dispersion strengthening may take place during solidification, subsequent thermal processing, intermediate cold working, or some combination of these.
  • Solidification processes and subsequent cooling in solid state in AM may differ from those processes occurring through conventional techniques.
  • the solidification in PBF processing occurs on a microscale, layer by layer, with each layer undergoing one or more melting, solidification, and cooling cycles.
  • melting may begin at approximately 610°C and may conclude at approximately 696°C.
  • the cooling rate is extremely high relative to conventional techniques - e.g., the cooling rate may be from approximately 10 3 °C/second (s) to approximately 10 6 °C/s. Therefore, non equilibrium thermodynamics and phase transformation kinetics may become the dominate drivers during AM, thereby making alloys exhibit different properties with AM, such as through inheriting element supersaturation and alloy partitioning.
  • AM which may include relatively small weld pools (and may include a rate of approximately 10 3 °C/ s to approximately 10 6 °C/s).
  • the present disclosure describes alloys that may provide high performance with AM, e.g., in comparison to currently available alloys.
  • the performance of these alloys of the present disclosure may be improved in the as-printed state, e.g., after undergoing thermal processing (post AM), or some combination of both in the as-printed state and after undergoing thermal processing.
  • one or more alloys of the present disclosure may be tailored for superior strengthening where the one or more alloys would have high ultimate and tensile strength at room and elevated temperature.
  • one or more of the alloys of the present disclosure may be designed for superior ductility where the one or more alloys would have high elongation at room and elevated temperature.
  • One or more alloys of the present disclosure may be specifically designed in order to accommodate the rapid melting, solidification, and/or cooling experienced by alloys in AM (e.g., PBF process).
  • the alloying elements and concentrations thereof may be configured such that intermetallics may be formed with other alloying elements during rapid cooling.
  • the alloying elements and concentrations thereof may be configured based on the liquid and/or solid solubilities of the alloying elements in the aluminum matrix.
  • the alloying elements and concentrations thereof may be configured such that the alloying elements may form supersaturated solid solutions and/or nano-precipitates after rapid solidification and cooling during AM (e.g., PBF process).
  • the alloying elements and the concentrations thereof may be configured to form intermetallics and the phases thereof during subsequent thermal processing, for example, including precipitation heat treatment and/or Hot Isostatic Pressing (HIP).
  • the alloying elements and concentrations thereof may be configured to form targeted specific intermetallics during rapid solidification and cooling such that the phases formed thereby may enhance the performance of the one or more alloys of the present disclosure.
  • the configurations of the alloying elements and the concentrations thereof may result in the formation of phases during subsequent thermal processing that improves the mechanical performance of the one or more alloys of the present disclosure.
  • One or more alloys of the present disclosure are configured with a balance of Al.
  • the balance may include at most 0.1% by weight of trace elements.
  • the Al may be alloyed with a set of other materials, such as one or more elements.
  • Example elements that may be used to form Al alloys in some configurations may include magnesium (Mg), manganese (Mn), silicon (Si), chromium (Cr), titanium (Ti), zirconium (Zr), Yttrium (Y), and/or some combination of all or subset of the foregoing set of elements.
  • One or more alloys of the present disclosure may be a composition that includes Mg,
  • compositions of the one or more alloys of the present disclosure may include at least one of Fe, Cr, Ti, Zr, and/or Y.
  • various properties may be derived through different elements, e.g., when included in a solid solution with Al.
  • strengthening properties may be derived through Mg and/or Mn when included in a solid solution with Al.
  • the addition of Mg and/or Mn may reduce ductility due to intermetallic compound formation based on the solubility of Mg and/or Mn.
  • Table 1 illustrates the solid solution strengthening capabilities of various alloying elements in aluminum alloys. As shown, the greatest solid solution strengthening capabilities may be derived though Mg and Mn, e.g., when measured on the order of thousands of pounds-force per square inch or kilopounds per square inch(ksi).
  • Some existing A1 alloys (e.g., A1 alloys of in the 3000 and 5000 series) produced through conventional processing are based on the addition of Mg and Mn in Al.
  • the Mn content in Al alloys of the 3000 series may be between 0.2% and 1.2%
  • the Mg content in Al alloys of the 5000 series may be between 0.5% and 5.51%.
  • aluminum alloy (AA) 6061 may have high strength and ductility, e.g., for applications in aerospace engineering. However, AA 6061 may be unsuitable for AM applications. In particular, PBF processes using AA 6061 may produce undesirable results.
  • AM may be associated with relatively high-temperature melting and relatively fast cooling, e.g., in comparison with conventional or non-AM processing techniques.
  • the fast cooling rate associated with AM may increase the solubility limits of various elements included in one or more alloys described herein, thereby resulting in microstructures that are relatively finer in comparison with those of conventional or non-AM processing techniques.
  • one or more alloys of the present disclosure may include, in addition to Al, Mg that is inclusively between 5% and 12% by weight of the alloy, which may be alloyed in conjunction with Mn to derive a relative high strength and/or ductility (e.g., in comparison with Al alloys of in the 3000 and 5000 series).
  • Mg that is at least 7% by weight of the alloy.
  • FIGs. 1A and IB illustrate two graphs 100, 120 of properties of A1 alloyed with Mg and Mn. Referring to FIG.
  • the first graph 100 shows both the yield strength (in megapascals (MPa)) and the tensile strength (in ksi) of A1 alloyed with percentages by weight of Mg and Mn.
  • MPa megapascals
  • ksi tensile strength
  • both the yield strength and the tensile strength of A1 alloys increase for at least the percentages by weight between approximately 2% Mg and exceeding 7% Mg, which may be alloyed in combination with percentages by weight between approximately 0.0% Mn and 0.9% Mn.
  • the second graph 120 shows the percent elongation (in 50 millimeters (mm) / ⁇ 2 inches (in)) of A1 alloyed with percentages by weight of Mg and Mn.
  • the percent elongation of A1 alloys may remain relatively high (e.g., greater than 20%, but may be less than 40%) for at least the percentages by weight between approximately 2% Mg and exceeding 7% Mg, which may be alloyed in combination with percentages by weight between approximately 0.0% Mn and 0.9% Mn.
  • the percent elongation of A1 alloys may remain relatively high (e.g., greater than 20%, but may be less than 40%) for at least the percentages by weight between approximately 2% Mg and exceeding 7% Mg, which may be alloyed in combination with percentages by weight between approximately 0.0% Mn and 0.9% Mn.
  • A1 may be alloyed with approximately 7% by weight of Mg (e.g., potentially less than and/or potentially greater than 7% by weight of Mg) and in order to configure one or more alloys of the present disclosure with relatively high strength and ductility. As shown in Table 2, an exemplary configuration of an alloy having high strength and high ductility is illustrated.
  • A1 alloyed with Mg and/or Mn may provide relatively high strength and/or high ductility, the relatively high strength may be derived through solid solution strengthening, but such alloys may not be heat treatable.
  • one or more alloys of the present disclosure may be configured for solid solution strengthening and, additionally, for precipitation hardening. In so doing, the one or more alloys of the present disclosure may be suitable for AM applications, including 3-D printing.
  • one or more alloys of the present disclosure may be configured with one or more other elements, in addition to Mg and Mn with a balance of Al.
  • the one or more alloys described herein may be suitable for AM applications, such as 3-D printing, while still providing relatively high strength, ductility, and/or durability.
  • Configuring one or more alloys of the present disclosure with Si may contribute to precipitation hardening of the one or more alloys.
  • Si may be included in an Al-Mg-Mn alloy.
  • a configuration with Si may contribute to precipitation hardening.
  • Table 3 shows various examples of an Al-Mg-Mn- Si alloy that may be suitable for AM. According to some configurations, one or more of the alloys shown in Table 3 may be alloyed with one or more other elements, e.g., as described herein.
  • one or more alloys of the present disclosure may include a set of primary elements: Al, Mg, Mn, and Si.
  • Table 4 illustrates ranges for percentages of weights of the one or more primary elements with which one or more alloys of the present disclosure may be configured.
  • one or more alloys of the present disclosure may be configured with one or more of a set of secondary elements: Fe, Ti, Zr, Cr, and/or Y.
  • Table 5 illustrates ranges of percentages of weights of the one or more secondary elements with which one or more alloys of the present disclosure may be configured.
  • One or more alloys of the present disclosure may be configured with all, none, or a subset of the set of secondary elements.
  • one configuration of the composition may include the balance of Al, the aforementioned percentages by weight of Mg, Mn, and Si, and may further include up to approximately 0.25% by weight of the Fe.
  • the composition of the first example may include at least approximately 0.05% by weight of the Fe.
  • Iron is the most common impurity found in aluminum. Iron has a high solubility in molten aluminum, and is therefore easily dissolved at all molten stages of production. The solubility of iron in the solid state is very low and, depending on the cooling rate, it can precipitate by forming FeAF . and more complex AlFeMgSi, in the alloy to provide additional strength if controlled in the disclosed level in the composition.
  • one configuration of the composition may include the balance of Al, the aforementioned percentages by weight of Mg, Mn, and Si, and may further include up to approximately 0.6% by weight of the Ti.
  • the composition of the second example may include at least approximately 0.1% by weight of the Ti.
  • Titanium can be used primarily as a grain refiner of aluminum alloys. When used alone, the effect of titanium decreases with time of holding in the molten state and with repeated re-melting. However, titanium depresses electrical conductivity and, therefore, can be used with chromium, which has a large effect on the resistivity of aluminum alloys.
  • one configuration of the composition may include the balance of Al, the aforementioned percentages by weight of Mg, Mn, and Si, and may further include up to approximately 2.0% by weight of the Zr.
  • the composition of the third example may include at least approximately 0.3% by weight of the Zr.
  • one configuration of the composition may include the balance of Al, the aforementioned percentages by weight of Mg, Mn, and Si, and may further include up to approximately 5% by weight of the Cr.
  • the composition of the fourth example may include at least approximately 1% by weight of the Cr.
  • Chromium increases the elastic modulus in solid solution and increases the strength of the composition when in the form of submicron precipitates. Because chromium has a slow diffusion rate, the chromium may form extremely fine dispersed phases in the composition, and may be retained in the solid solution of the composition to increase both elastic modulus and strength. Chromium also reduces stress corrosion susceptibility and improves toughness.
  • one configuration of the composition may include the balance of Al, the aforementioned percentages by weight of Mg, Mn, and Si, and may further include up to approximately 4% by weight of the Y.
  • the composition of the fifth example may include at least approximately 0.1% by weight of the Y.
  • both elements may form complex but nano precipitates when available in small quantities.
  • the present disclosure describes relatively higher amounts of both zirconium and yttrium, which may increase solid solution strength and toughness of the alloy, thereby reducing the susceptibility to cracking at high cooling rates.
  • Yttrium may be more effective than zirconium (e.g., in increasing solid solution strengthening and/or toughness), and the inclusion of one or both of two elements in the amounts disclosure herein may balance their effects with their costs (e.g., in production of one or more of the alloys of the present disclosure).
  • the one or more alloys of the present disclosure may be used for AM in automotive engineering.
  • the one or more alloys described herein may be additively manufactured for the production of nodes, joints, and/or other structures, which may be applied in vehicles (e.g., cars, trucks, etc.).
  • the one or more alloys described herein may be additively manufactured to produce all or a portion of a chassis, frame, body, etc. of a vehicle.
  • the characteristics of the one or more alloys described herein may contribute to the crashworthiness of structures produced from the one or more alloys described herein.
  • the one or more alloys of the present disclosure may be configured with the materials (e.g., elements) described herein so that products additively manufactured using at least a portion of the one or more alloys may reduce the weight of vehicles at a suitable insertion point (e.g., in comparison with existing approaches to vehicle manufacture).
  • the one or more alloys of the present disclosure may feature characteristics and/or properties that exceed the corresponding characteristics and/or properties of various existing alloys, e.g., in the context of AM applications.
  • Table 6 shows exemplary compositions of alloys described in the present disclosure, with the illustrated values of the enumerated elements being the percentage by weight of each corresponding element.
  • the values include mechanical properties of the as-printed parts, without any subsequent machining or post-processing operations.
  • the alloys of Tables 4-6 may include resultant mechanical properties that exceed those of conventional wrought AA 6061 -T6.
  • the yield strength of an alloy illustrated in Table 6 may be 266 MPa
  • the tensile strength of an alloy illustrated in Table 6 may be 391 MPa
  • the percent elongation of the alloy illustrated in Table 6 may be 11.3%.
  • FIGS. 2A-2D illustrate respective side views of an exemplary 3-D printer system.
  • the 3-D printer system is a powder-bed fusion (PBF) system 200.
  • FIGS. 2A-2D show PBF system 200 during different stages of operation. It should also be noted that features of FIGS. 2A-2D and the other figures in this disclosure are not necessarily drawn to scale, but may be drawn larger or smaller for the purpose of better illustration of concepts described herein.
  • FIGs. 2A-D are some suitable examples of a PBF system employing principles of the present disclosure.
  • one or more of the aluminum alloys described herein may be used in at least one PBF system 200 described in FIGs. 2A-D.
  • one or more aluminum alloys described in the present disclosure may be suitable for various AM processes (e.g., using a PBF system, as shown in FIGs. 2A-D), it will be appreciated that one or more aluminum alloys of the present disclosure may be suitable for other applications, as well.
  • one or more aluminum alloys described herein may be used in other fields or areas of manufacture without departing from the scope of the present disclosure. Accordingly, AM processes employing the one or more aluminum alloys of the present disclosure are to be regarded as illustrative, and are not intended to limit the scope of the present disclosure.
  • PBF system 200 may be a composition that includes a balance of Al, Mg that is at least 2% by weight of the composition, Mn that is up to 2.5% by weight of the composition, and Si that is up to 4% by weight of the composition.
  • Mg may be 5 to 12% by weight of the composition
  • Mn may be 0.1 to 2% by weight of the composition
  • Si may be 0.3 to 3% by weight of the composition.
  • the composition may further include at least one element selected from a group of Fe, Ti, Zr, Cr, and/or Y.
  • the composition may include Fe that is up to 1% by weight of the composition - e.g., the composition may include Fe that is inclusively between 0.05% to 0.25% by weight of the composition.
  • the composition may include Ti that is 0 to 1% by weight of the composition - e.g., the composition may include Ti that is inclusively between 0.1% to 0.6% by weight of the composition.
  • the composition may include Zr that is 0.15-5% by weight of the composition - e.g., the composition may include Zr that is inclusively between 0.3% to 2% by weight of the composition.
  • the composition may include Cr that is at least 1% by weight of the composition - e.g., the composition may include Cr that is inclusively between 1% to 5% by weight of the composition.
  • the composition may include Y that is at least 0.1% by weight of the composition - e.g., the composition may include Y that is inclusively between 0.1% to 4% by weight of the composition.
  • the composition includes all of the elements listed above (Al, Mg, Mn, Si, Fe, Cr, Ti, Zr, and Y). In one configuration, the composition includes up to approximately 0.1% by weight of trace impurities cumulatively, and 0.01% individually (e.g., in each individual element that is alloyed with the balance of Al).
  • the elements of an aluminum alloy may be combined into a composition according to one of the examples/configurations described herein.
  • the elements in respective concentrations described in one of the examples/configurations of the present disclosure may be combined when the elements are molten.
  • the composition may be mixed while the elements are molten, e.g., in order to promote even distribution of each element with the balance of Al.
  • the molten composition may be cooled and atomized. Atomization of the composition may yield a metallic powder that includes the elements of the one of the examples/configurations of the present disclosure, and can be used in additive manufacturing systems such as PBF system 200.
  • PBF system 200 can include a depositor 201 that can deposit each layer of metal powder, an energy beam source 203 that can generate an energy beam, a deflector 205 that can apply the energy beam to fuse the powder material, and a build plate 207 that can support one or more build pieces, such as a build piece 209.
  • PBF system 200 can also include a build floor 211 positioned within a powder bed receptacle.
  • the walls 212 of the powder bed receptacle generally define the boundaries of the powder bed receptacle, which is sandwiched between the walls 212 from the side and abuts a portion of the build floor 211 below.
  • Build floor 211 can progressively lower build plate 207 so that depositor 201 can deposit a next layer.
  • Depositor 201 can include a hopper 215 that includes a powder 217, such as a metal powder, and a level er 219 that can level the top of each layer of deposited powder.
  • FIG. 2A shows PBF system 200 after a slice of build piece 209 has been fused, but before the next layer of powder has been deposited.
  • FIG. 2A illustrates a time at which PBF system 200 has already deposited and fused slices in multiple layers, e.g., 150 layers, to form the current state of build piece 209, e.g., formed of 150 slices.
  • the multiple layers already deposited have created a powder bed 221, which includes powder that was deposited but not fused.
  • FIG. 2B shows PBF system 200 at a stage in which build floor 211 can lower by a powder layer thickness 223.
  • the lowering of build floor 211 causes build piece 209 and powder bed 221 to drop by powder layer thickness 223, so that the top of the build piece and powder bed are lower than the top of powder bed receptacle wall 212 by an amount equal to the powder layer thickness.
  • a space with a consistent thickness equal to powder layer thickness 223 can be created over the tops of build piece 209 and powder bed 221.
  • FIG. 2C shows PBF system 200 at a stage in which depositor 201 is positioned to deposit the powder 217 in a space created over the top surfaces 226 of build piece 209 and powder bed 221 and bounded by powder bed receptacle walls 212.
  • depositor 201 progressively moves over the defined space while releasing the powder 217 from hopper 215.
  • Leveler 219 can level the released powder to form a powder layer 225 that has a thickness substantially equal to the powder layer thickness 223 (see, e.g., FIG. 2B).
  • the powder in a PBF system can be supported by a powder material support structure, which can include, for example, a build plate 207, a build floor 211, a build piece 209, walls 212, and the like.
  • the illustrated thickness of powder layer 225 i.e., powder layer thickness 223 (FIG. 2B) is greater than an actual thickness used for the example involving 150 previously-deposited layers discussed above with reference to FIG. 2A.
  • FIG. 2D shows PBF system 200 at a stage in which, following the deposition of powder layer 225 (FIG. 2C), energy beam source 203 generates an energy beam 227 and deflector 205 applies the energy beam to fuse the next slice in build piece 209.
  • energy beam source 203 can be an electron beam source, in which case, energy beam 227 constitutes an electron beam.
  • Deflector 205 can include deflection plates that can generate an electric field or a magnetic field that selectively deflects the electron beam to cause the electron beam to scan across areas designated to be fused.
  • energy beam source 203 can be a laser, in which case, the energy beam 227 is a laser beam.
  • Deflector 205 can include an optical system that uses reflection and/or refraction to manipulate the laser beam to scan selected areas to be fused.
  • the deflector 205 can include one or more gimbals and actuators that can rotate and/or translate the energy beam source to position the energy beam.
  • energy beam source 203 and/or deflector 205 can modulate the energy beam, e.g., turn the energy beam on and off as the deflector scans so that the energy beam is applied only in the appropriate areas of the powder layer.
  • the energy beam can be modulated by a digital signal processor (DSP).
  • DSP digital signal processor
  • An alloy may be a substance composed of two or more materials (e.g., metals or nonmetals). The two or more materials may be combined together by being merged together, for example, when molten.
  • one or more alloys of the present disclosure may be a composition that may be mixed to include a balance of A1 and the following materials: (1) Mg that is approximately 5-12% by weight of the composition; (2) Mn that is approximately 0.1-2% by weight of the composition; (3) Si that is 0.3-3% by weight of the composition.
  • the balance of A1 may include up to 0.1% of trace elements.
  • one or more alloys of the present disclosure may be the aforementioned composition of Al, Mg, Mn, and Si, and the composition may include at least one of the following other materials: Fe, Ti, Zr, Cr, and/or Y.
  • Fe When an alloy of the present disclosure is a composition that includes Fe, Fe may be 0.05-0.25% by weight of the composition.
  • Ti When an alloy of the present disclosure is a composition that includes Ti, Ti may be 0.1-0.6% by weight of the composition.
  • Zr Zr may be 0.3-2% by weight of the composition.
  • Cr When an alloy of the present disclosure is a composition that includes Cr, Cr may be 1-5% by weight of the composition.
  • an alloy of the present disclosure is a composition that includes Y
  • Y may be 0.1-4% by weight of the composition.
  • the one or more alloys of the present disclosure may include all, none, or some of the other materials Fe, Ti, Zr, Cr, and/or Y.
  • An example alloy of the present disclosure may be processed with the L-PBF method to print test bars. Tensile properties may be obtained from the example alloy.
  • AM raw materials can be manufactured by powder making processes as well as other methods such as Ingot Metallurgy (I/M) in which a solid ingot is manufactured by melting the metal along with added alloying elements and solidifying in a mold such as ingot. The molded solid or the ingot is then deformed by various wrought material production methods such as rolling, extrusion, drawing etc. The ingots, wires and rods are either melted and atomized to make powders or fed directly into the laser, electron, plasma beams, or electrical arc such as TIG, MIG, to melt the metal layer by layer manufacture AM products.
  • I/M Ingot Metallurgy
  • Powder characteristics may be important for successful fusion within an AM machine such as PBF and/or DED.
  • Some aspects of alloy powders that may be advantageous for use with AM may include but are not limited to, good flow, close packing of particles and spherical particle shape. These aspects may lead to consistent and predictable layers.
  • the previous description is provided to enable any person skilled in the art to practice the various aspects described herein. Various modifications to these exemplary embodiments presented throughout this disclosure will be readily apparent to those skilled in the art, and the concepts disclosed herein may be applied to aluminum alloys. Thus, the claims are not intended to be limited to the exemplary embodiments presented throughout the disclosure but are to be accorded the full scope consistent with the language claims.

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