摘要：
Materials, methods and techniques disclosed and contemplated herein relate to aluminum alloys. Generally, multicomponent aluminum alloys include aluminum, magnesium, silicon, and, in some instances, iron and/or manganese, and include Mg2Si phase precipitates. Example multicomponent aluminum alloys disclosed and contemplated herein are particularly suited for use in additive manufacturing operations.
技术问题语段：
The technical problem addressed in this patent is the need for improved aluminum alloys that can be used in additive manufacturing processes, such as 3-D printing. The current options for aluminum alloys used in additive manufacturing are limited, which can result in inflexible designs and high costs. The patent proposes a solution by developing a new alloy that includes specific amounts of magnesium, silicon, iron, and manganese, as well as aluminum. The new alloy has been tested and shown to have improved resistance to corrosion and high temperatures, making it suitable for aerospace applications. The patent also describes an atomized alloy powder that can be used in additive manufacturing and a method for using the powder to create manufactured articles with improved mechanical performance.
技术功效语段：
The present patent is about materials, methods, and techniques for manufacturing Al-Mg-Si alloys, which are used in additive manufacturing processes. The technical effects of this patent include providing alloys that have improved resistance to high-temperature aerospace applications, such as gearboxes, by reducing the Si eutectic that remains throughout post-build processing and is detrimental to mechanical performance. Additionally, the patent provides atomized alloy powders that can be used in additive manufacturing processes, as well as methods for using these powders to generate manufactured articles with improved mechanical performance.
权利要求：
CLAIMS
What is claimed is:
1. An alloy 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.
2. The alloy according to claim 1, wherein the alloy includes Mg2Si phase precipitates.
3. The alloy according to claim 2, wherein the alloy, after being subjected to an additive manufacturing process and after aging for 120 minutes at l85°C, has a yield strength of greater than 60 ksi at 22°C.
4. The alloy according to claim 2, wherein the alloy, after being subjected to an additive manufacturing process and after aging for 120 minutes at l85°C, has a yield strength of greater than 35 ksi at 200°C.
5. The alloy according to claim 2, wherein the alloy, after being subjected to an additive manufacturing process and after aging for 120 minutes at l85°C, has an ultimate tensile strength of greater than 70 ksi at 22°C.
6. The alloy according to claim 2, wherein the alloy, after being subjected to an additive manufacturing process and after aging for 120 minutes at l85°C, has an ultimate tensile strength of greater than 40 ksi at 200°C.
7. The alloy according to claim 2, wherein the alloy, after being subjected to an additive manufacturing process and after aging for 120 minutes at l85°C, has an elongation of at least 4.5 at 22°C.
8. The alloy according to claim 2, wherein the alloy, after being subjected to an additive manufacturing process and after aging for 120 minutes at l85°C, has an elongation of at least 4.5% at 200°C.
9. The alloy according to claim 2, wherein the alloy, after being subjected to an additive manufacturing process and after aging for 60 minutes at 200°C, 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.
10. An atomized alloy powder usable in additive manufacturing, the atomized alloy powder comprising:
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.
11. The atomized alloy powder according to claim 10, wherein the atomized alloy powder includes Mg2Si phase precipitates.
12. The atomized alloy powder according to claim 11, wherein the atomized alloy powder, after being subjected to an additive manufacturing process and after aging for 120 minutes at l85°C, has a yield strength of greater than 60 ksi at 22°C.
13. The atomized alloy powder according to claim 11, wherein the atomized alloy powder, after being subjected to an additive manufacturing process and after aging for 120 minutes at l85°C, has a yield strength of greater than 35 ksi at 200°C.
14. The atomized alloy powder according to claim 11, wherein the atomized alloy powder, after being subjected to an additive manufacturing process and after aging for 120 minutes at l85°C, has an ultimate tensile strength of greater than 70 ksi at 22°C.
15. The atomized alloy powder according to claim 11, wherein the atomized alloy powder, after being subjected to an additive manufacturing process and after aging for 120 minutes at l85°C, has an elongation of at least 4.5% at 22°C.
16. The atomized alloy powder according to claim 11, wherein the atomized alloy powder, after being subjected to an additive manufacturing process and after aging for 120 minutes at l85°C, has an elongation of at least 4.5% at 200°C.
17. The atomized alloy powder according to claim 11, wherein the atomized alloy powder, after being subjected to an additive manufacturing process and after aging for 60 minutes at 200°C, 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.
18. A method of using an atomized alloy powder in additive manufacturing, the method comprising:
receiving the atomized alloy powder comprising alloyed particles, the alloyed 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,
wherein the atomized alloy powder includes Mg2Si phase precipitates; performing additive manufacturing to generate a manufactured article; and positioning the manufactured article in a heated container such as a furnace for a predetermined period of time; and
removing the manufactured article from the heated container and cooling in air to room temperature.
19. The method according to claim 18, wherein a temperature within the heated container isl70-200 °C; and
wherein the predetermined period of time is 60-120 minutes.
20. The method according to claim 18, wherein the manufactured article has a yield strength of greater than 60 ksi at 22°C; and
wherein the manufactured article has a yield strength at least 35 ksi at 200°C.
21. The method according to claim 20, wherein the manufactured article has an ultimate tensile strength of greater than 70 ksi at 22°C;
wherein the manufactured article has an ultimate tensile strength of greater than 40 ksi at 200°C; and
wherein the manufactured article has an elongation of at least 4.5% at 200°C.