High-strength aluminum alloy laminated molding and production method therefor

Patent metadata

Field	Value
Publication number	US-11555229-B2
Application number	US-201916665832-A
Country	US
Kind code	B2
Filing date	Oct 28, 2019
Priority date	Apr 27, 2017
Publication date	Jan 17, 2023
Grant date	Jan 17, 2023

Abstract

An aluminum alloy additive manufacturing product and a method manufactures the same. The aluminum alloy additive manufacturing product is formed by molding a raw metal by an additive manufacturing method. The raw metal is made of an aluminum alloy. The aluminum alloy contains Fe and one or more of Mn and Cr. The Fe is an inevitable impurity of 0.3 weight % or less. The one or more of Mn and Cr have a total weight of 0.3 to 10 weight %. The aluminum alloy additive manufacturing product contains any one or more of an intermetallic compound and an aluminum alloy solid solution. The intermetallic compound contains two or more of Al, Mn, Fe, and Cr. One or more elements of Mn, Fe, and Cr are dissolved in the aluminum alloy solid solution.

First claim

The invention claimed is:

1. A method for manufacturing an aluminum alloy additive manufacturing product, comprising
performing additive manufacturing including depositing a metal powder, the metal powder being made of an aluminum alloy, the aluminum alloy containing:
Fe as an inevitable impurity of 0.3 weight % or less,
Si in an amount that is in a range of from 7 to 20 weight %,
Mn in an amount that is in a range of from 0.7 to 10 weight %,
Cu in an amount that is 0.01 weight % or more and is 1.1 weight % or less,
optionally additive components containing any one or more elements being selected from a first group consisting of 0.2 to 7 weight % Mg, and 0.5 to 3 weight % Ni, or any one or more elements being selected from the first group and any one or more elements being selected from a second group consisting of 0.2 to 5 weight % Zr, 0.2 to 5 weight % Sc, 0.2 to 10 weight % Li, and 0.2 to 5 weight % V, and
a balance being Al,

wherein
the aluminum alloy contains no added Ti.

2. The method for manufacturing the aluminum alloy additive manufacturing product according to claim 1 , wherein the additive manufacturing is performed with a measurement temperature of a substrate plate controlled to 150 to 250° C., and when depositing the metal powder, the metal powder is placed on the substrate plate.

3. The method for manufacturing the aluminum alloy additive manufacturing product according to claim 1 , wherein
the amount of Si is in a range of from 7 to 15 weight %,
the aluminum alloy contains 0.2 to 1.0 weight % Mg, and
the amount of Mn is in a range of from 0.7 to 2.5 weight %.

4. The method for manufacturing the aluminum alloy additive manufacturing product according to claim 1 , wherein
the amount of Si is in a range of from 8 to 20 weight %,
the aluminum alloy contains:
0.5 to 2.0 weight % Mg, and
0.5 to 3 weight % Ni, and

the amount of Mn is 1.5 to 5.0 weight %.

5. A method for manufacturing an aluminum alloy additive manufacturing product, comprising
performing additive manufacturing including depositing a metal powder, the metal powder being made of an aluminum alloy, the aluminum alloy containing:
Fe in an amount that exceeds 0.3 weight % and is 2 weight % or less,
Si in an amount that is in a range of from 4 to 30 weight %,
Mn in an amount that exceeds 1.5 weight % and is 10 weight % or less,
optionally additive components containing any one or more elements being selected from a first group consisting of 0.5 to 5 weight % Mg, 0.5 to 5 weight % Cu, and 0.5 to 3 weight % Ni, or any one or more elements being selected from the first group and any one or more elements being selected from a second group consisting of 0.2 to 5 weight % Zr, 0.2 to 5 weight % Sc, 0.2 to 10 weight % Li, and 0.2 to 5 weight % V, and
a balance being Al,

wherein
the aluminum alloy contains no added Ti.

6. A method for manufacturing an aluminum alloy additive manufacturing product, comprising
performing additive manufacturing including depositing a metal powder, the metal powder being made of an aluminum alloy, the aluminum alloy containing:
Fe in an amount that is 1 weight % or more and 10 weight % or less,
Si in an amount that is in a range of from 4 to 30 weight %,
Mn in an amount that is 1.5 weight % or less,
Cu in an amount that is 0.5 weight % or more and is 1.3 weight % or less,
optionally additive components containing any one or more elements being selected from a first group consisting of 0.5 to 5 weight % Mg and 0.5 to 3 weight % Ni, or any one or more elements being selected from the first group and any one or more elements being selected from a second group consisting of 0.2 to 5 weight % Zr, 0.2 to 5 weight % Sc, 0.2 to 10 weight % Li, and 0.2 to 5 weight % V, and
a balance being Al,

wherein
the aluminum alloy contains no added Ti.

7. The method for manufacturing the aluminum alloy additive manufacturing product according to claim 5 , wherein
the additive manufacturing is performed with a measurement temperature of a substrate plate controlled to 150 to 300° C., and when depositing the metal powder, the metal powder is placed on the substrate plate.

8. A method for manufacturing an aluminum alloy additive manufacturing product, comprising
performing additive manufacturing including depositing a metal powder, the metal powder being made of an aluminum alloy containing:
Fe and Mn wherein a total weight of Fe and Mn is in a range of from 2 to 10 weight %,
Si in an amount that is in a range of from 4 to 30 weight %,
optionally additive components containing any one or more elements being selected from a first group consisting of 0.5 to 5 weight % Mg, 0.5 to 5 weight % Cu, and 0.5 to 3 weight % Ni, or any one or more elements being selected from the first group and any one or more elements being selected from a second group consisting of 0.2 to 5 weight % Zr, 0.2 to 5 weight % Sc, 0.2 to 10 weight % Li, and 0.2 to 5 weight % V, and
a balance being Al,

wherein a measurement temperature of a substrate plate during the additive manufacturing is controlled to exceeding 250° C. and 450° C. or less,

wherein
the aluminum alloy contains no added Ti.

9. The method for manufacturing the aluminum alloy additive manufacturing product according to claim 6 , wherein
the additive manufacturing is performed with a measurement temperature of a substrate plate controlled to 150 to 300° C., and when depositing the metal powder, the metal powder is placed on the substrate plate.

Assignees

• Koiwai Co Ltd
• Toyo Aluminium Kk
• Toyo Aluminum Kk

Inventors

• Adachi Mitsuru
• Kusui Jun
• Terada Daisuke
• NAKASHIMA Hideharu
• Mitsuhara Masatoshi
• Yamasaki Shigeto

Classifications

• B22F12/17

  to heat the build chamber or platform · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• B22F2003/248

  Thermal after-treatment · CPC title

• B22F3/24

  After-treatment of workpieces or articles {(B22F3/1146 takes precedence)} · CPC title

• B22F10/25

  Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS] · CPC title