WO2020014146A1

WO2020014146A1 - Methods for producing additively manufactured aluminum alloy products

Info

Publication number: WO2020014146A1
Application number: PCT/US2019/040846
Authority: WO
Inventors: Tyler Borchers; Justin K. Williams; Kyle L. Williams; Jerri F. Mcmichael
Original assignee: Arconic Inc.
Priority date: 2018-07-10
Filing date: 2019-07-08
Publication date: 2020-01-16

Abstract

The present disclosure relates to methods for producing additively manufactured aluminum alloy products. The new additively manufactured aluminum alloy products may be produced by fusing a connecting layer to a high copper aluminum alloy substrate, producing an additively manufactured body, and connecting the additively manufactured body to the connecting layer. The connecting step may occur concomitant to, or after the producing step.

Description

METHODS FOR PRODUCING ADDITIVELY MANUFACTURED ALUMINUM

ALLOY PRODUCTS

FIELD OF THE INVENTION

[0001] The present invention relates to methods for producing additively manufactured aluminum alloy products.

BACKGROUND OF THE INVENTION

[0002] Additive manufacturing is defined as“a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies”, in ASTM F2792-l2a entitled“Standard Terminology for Additively Manufacturing Technologies.” Cracking of additively manufactured metal alloy products is a problem. See, e.g., Martin, John H. et al. “3D printing of high-strength aluminium alloys,” Nature volume 549, pages 365-369 (21 September 2017).

SUMMARY OF THE DISCLOSURE

[0003] Broadly, the present disclosure relates to methods for producing additively manufactured aluminum alloy products. In this regard, the methods generally include fusing a connecting layer to a high copper aluminum alloy substrate, producing an additively manufactured body, and connecting the additively manufactured body to the connecting layer. The methods described herein may enable the joining of high copper aluminum alloy substrates and additively manufactured bodies. For instance, such high copper aluminum alloy substrates and additively manufactured bodies may not be joined directly to one another due to cracking issues. The joining of a high copper aluminum alloy substrate and an additively manufactured body may be enabled via a connecting layer. Further, the connecting layer may facilitate, for instance, the production of a crack-free product.

[0004] Throughout the specification and claims, the following terms take the meanings explicitly associated herein, unless the context clearly dictates otherwise. The phrases“in one embodiment” and“in some embodiments” as used herein do not necessarily refer to the same embodiment(s), though they may. Furthermore, the phrases“in another embodiment” and“in some other embodiments” as used herein do not necessarily refer to a different embodiment, although they may. Thus, as described below, various embodiments of the invention may be readily combined, without departing from the scope or spirit of the invention.

[0005] In addition, as used herein, the term“or” is an inclusive“or” operator, and is equivalent to the term“and/or,” unless the context clearly dictates otherwise. The term“based on” is not exclusive and allows for being based on additional factors not described, unless the context clearly dictates otherwise. In addition, throughout the specification, the meaning of “a,” “an,” and “the” include plural references, unless the context clearly dictates otherwise. The meaning of“in” includes“in” and“on”, unless the context clearly dictates otherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIG. la is a flowchart of an embodiment of a method for producing an additively manufactured aluminum alloy product.

[0007] FIG. lb is a flowchart of another embodiment of a method for producing an additively manufactured aluminum alloy product.

[0008] FIG. lc is a flowchart of yet another embodiment of a method for producing an additively manufactured aluminum alloy product.

[0009] FIG. 2 is a schematic side view (not to scale) of one embodiment of an additively manufactured aluminum alloy product.

DETAILED DESCRIPTION

i. Methods

[0010] Broadly, the present disclosure relates to methods for producing additively manufactured aluminum alloy products. In this regard, the methods generally include fusing a connecting layer to a high copper aluminum alloy substrate, producing an additively manufactured body, and connecting the additively manufactured body to the connecting layer. The methods described herein may enable the joining of high copper aluminum alloy substrates and additively manufactured bodies. For instance, such high copper aluminum alloy substrates and additively manufactured bodies may not be joined directly to one another due to cracking issues. The joining of a high copper aluminum alloy substrate and an additively manufactured body may be enabled via a connecting layer. Further, the connecting layer may facilitate, for instance, the production of a crack-free product.

[0011] As used herein, “high copper aluminum alloy” means an aluminum alloy comprising 0.5 to 5.0 wt. % copper. The amount of copper in the aluminum alloy may influence the ability of the alloy to be joined to other aluminum alloys. For instance, 2xxx series alloys comprise copper as their main alloying ingredient. In 2xxx series aluminum alloys, an amount of copper of not greater than 5.0 wt. % may realize poor weldability. Conversely, alloys that do not comprise copper as their main alloying ingredient (e.g., 5xxx series, 6xxx series, and 7xxx series) that comprise at least 0.5 wt. % copper may realize poor weldability. Aluminum alloys with poor weldability may not be readily joined to other aluminum alloys (e.g., due to cracking issues). In one embodiment, a high copper aluminum alloy is a 2xxx series aluminum alloy. In another embodiment, a high copper aluminum alloy is a 5xxx series aluminum alloy. In yet another embodiment, a high copper aluminum alloy is a 6xxx series aluminum alloy. In another embodiment, a high copper aluminum alloy is a 7xxx series aluminum alloy. Also as used herein, an“aluminum alloy” is an alloy having aluminum as the predominant alloying element.

[0012] As used herein,“substrate” means a material capable of being fused to another material. Substrates may be in the form of plates, extrusions, sheets, forgings, and castings, among others.

[0013] In some embodiments, an additively manufactured aluminum alloy product is a crack-free product. In some embodiments,“crack-free” means that the product is sufficiently free of cracks such that it can be used for its intended, end-use purpose. The determination of whether a product is“crack-free” may be made by any suitable method, such as, by visual inspection, dye penetrant inspection, and/or by non-destructive test methods. In some embodiments, the non-destructive test method is a computed topography scan (“CT scan”) inspection (e.g., by measuring density differences within the product). In one embodiment, an additively manufactured aluminum alloy product is determined to be crack-free by visual inspection. In another embodiment, an additively manufactured aluminum alloy product is determined to be crack-free by dye penetrant inspection. In yet another embodiment, an additively manufactured aluminum alloy product is determined to be crack-free by CT scan inspection, as evaluated in accordance with ASTM E1441. In another embodiment, an additively manufactured aluminum alloy product is determined to be crack-free during an additive manufacturing process, wherein in situ monitoring of the additively manufactured build is employed. The crack-free product may be a final product (e.g., a final additively manufactured aluminum alloy product, a final worked product).

[0014] As noted above, the methods described herein may enable the joining of high copper aluminum alloy substrates and additively manufactured bodies. With reference to FIG. la, the new methods for producing additively manufacturing aluminum alloy products generally include fusing a connecting layer (10) to a high copper aluminum alloy substrate, producing an additively manufactured body (20), and connecting the additively manufactured body to the connecting layer (30). In the illustrated embodiment, the connecting (30) is shown as occurring after the producing (20) or concomitant to the producing (20). Further illustrations of these various embodiments are shown in FIGS lb-lc.

[0015] With reference to FIGS la-lc, the fusing (10) may be performed by any suitable method, such as by welding and additive manufacturing, among others. Suitable welding methods include fusion welding processes (e.g., gas metal arc welding, gas tungsten arc welding) and solid-state based welding processes (e.g., friction stir welding, friction welding). The producing step (20) generally comprises utilizing any suitable additive manufacturing process, such as Selective Laser Sintering (SLS), Selective Laser Melting (SLM), and Electron Beam Melting (EBM), among others. In one embodiment, an additive manufacturing process uses an EOSINT M 280 Direct Metal Laser Sintering (DMLS) additive manufacturing system, or comparable system, available from EOS GmbH (Robert-Stirling-Ring 1, 82152 Krailling/Munich, Germany). In one embodiment, additive manufacturing process uses a LENS additive manufacturing system, or comparable system, available from OPTOMEC, 3911 Singer N.E., Albuquerque, NM 87109.

[0016] As used herein,“additive manufacturing” means,“a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies”, as defined in ASTM F2792-l2a entitled “Standard Terminology for Additively Manufacturing Technologies”. Additively manufactured aluminum alloy bodies may be manufactured via any appropriate additive manufacturing technique described in this ASTM standard, such as binder jetting, directed energy deposition, material extrusion, material jetting, powder bed fusion, or sheet lamination, among others. Any suitable feedstock may be used, including one or more powders, one or more wires, and combinations thereof. In some embodiments the additive manufacturing feedstock is comprised of one or more powders. In some embodiments, the additive manufacturing feedstock is comprised of one or more wires.

[0017] The methods for additive manufacturing generally include (a) selectively heating at least a portion of an additive manufacturing feedstock (e.g., via a laser, electron beam) to a temperature above the liquidus temperature of the particular body to be formed, thereby forming a molten pool, and (b) cooling the molten pool thereby forming a solidified mass. In one embodiment, a method of additively manufacturing includes the steps of: (a) dispersing an additive manufacturing feedstock in a bed (or other suitable container), (b) selectively heating at least a portion of the additive manufacturing feedstock to a temperature above the liquidus temperature of the particular body to be formed, thereby forming a molten pool, and (c) cooling the molten pool thereby forming a solidified mass. In one embodiment, the cooling comprises cooling at a rate of at least l000°C per second. In another embodiment, the cooling rate is at least l0,000°C per second. In yet another embodiment, the cooling rate is at least l00,000°C per second. In another embodiment, the cooling rate is at least l,000,000°C per second. Steps (a)-(c) may be repeated as necessary until the body is completed, i.e., until the additively manufactured body is formed / completed. In some embodiments, a connecting layer is additively manufactured onto a high copper aluminum substrate. In such embodiments, steps (a)-(c) may be repeated until the additively manufactured connecting layer is completed.

[0018] As noted above, the connecting step (30) may occur concomitant to the producing step (20). With reference now to FIG. lb, the illustrated embodiment shows a method where the connecting step (30) occurs concomitant to the producing step (20). In some embodiments, the connecting comprises creating an interface that is integral with the additively manufactured body and the connecting layer (32). In one embodiment, the interface comprises a second fusion zone. The second fusion zone may be produced, for instance, as a result of an additive manufacturing process. For instance, the additively manufactured body may be directly additively manufactured onto the connecting layer, thereby forming the fusion zone. In this regard, the connecting layer may enable the joining of a variety of combinations of high copper aluminum alloy substrates and additive manufacturing feedstocks (i.e., the precursor to an additively manufactured body).

[0019] As used herein, a“fusion zone” is a region formed by the joining of at least two materials. The joining may be performed, for instance, by fusion welding, and additive manufacturing (e.g., via an electron beam, laser, among others), among others.

[0020] With reference to FIG. lc, in another approach the connecting step (30) occurs after the producing step (20). In some embodiments, the connecting comprises creating an interface comprising an adhesive material, wherein the adhesive material binds the connecting layer (130) to the additively manufactured body (150). Suitable adhesives that may be used include, for instance, polymeric adhesives. Non-limiting types of polymeric adhesives include epoxy, polyurethane, acrylic, vinyl, polyester, and combinations thereof.

[0021] In embodiments where the producing (20) occurs concomitant to the connecting (30), upon completion of the producing (20) step, a final additively manufactured aluminum alloy product may be realized. For instance, a final additively manufactured aluminum alloy product may be extracted from an additive manufacturing apparatus after the producing (20) (i.e., the additive manufacturing) is complete. In embodiments where the connecting (30) occurs after the producing (20), upon completion of the connecting step (30), a final additively manufactured aluminum alloy product may be realized. In any of these embodiments, the final additively manufactured aluminum alloy product may be utilized as-is for its intended end-use purpose (e.g., an industrial application). Alternatively, in any of these embodiments, the additively manufactured aluminum alloy product may be further processed to a final additively manufactured aluminum alloy product. For instance, the additively manufactured aluminum alloy product may be thermally treated and/or subjected to thermomechanical processing (“TMP”) to realize the final additively manufactured aluminum alloy product. As described in greater detail below, the final additively manufactured aluminum alloy product may be a final worked product (e.g., a final forged product). In any of the above embodiments, the final additively manufactured aluminum alloy product may comprise the substrate therein. Alternatively, the final additively manufactured aluminum alloy product may be separated from the high copper aluminum alloy substrate, and the final additively manufactured aluminum alloy product may optionally comprise a portion of the connecting layer therein.

[0022] In one approach, the method comprises separating the high copper aluminum alloy substrate from the additively manufactured body. In this aspect, the high copper aluminum alloy substrate may be a disposable material. The high copper aluminum alloy substrate may be separated from the additively manufactured body to realize a final additively manufactured aluminum alloy product. The final additively manufactured product may subsequently be used for its intended end-use purpose (e.g., an industrial application). The separating may occur, for instance, above the connecting layer, below the connecting layer, or through a portion of the connecting layer. Thus, in one embodiment, a final additively manufactured aluminum alloy product includes at least a portion of the connecting layer. In another embodiment, a final additively manufactured aluminum alloy product includes the connecting layer (i.e., the entirety of the connecting layer). In yet another embodiment, a final additively manufactured aluminum alloy product does not include the connecting layer. The separating may be performed by any suitable method, for instance, such as by electrical discharge machining, conventional machining, sawing, and abrasive cutting.

[0023] In another approach, the high copper aluminum alloy substrate is not separated from the additively manufactured body, and the additively manufactured product comprises the high copper aluminum alloy substrate therein. Thus, a final additively manufactured aluminum alloy product having the high copper aluminum alloy substrate therein may be realized. The final additively manufactured product may subsequently be used for its intended end-use purpose (e.g., an industrial application). In this regard, the high copper aluminum alloy substrate may realize a first set of properties, and the additively manufactured body may realize a second set of properties different than the first set of properties. Thus, additively manufactured products having at least two tailored regions of physical properties may be realized. In some embodiments, the additively manufactured product may be further processed by thermal and/or thermomechanical treatments. For instance, the additively manufactured products may be subsequently worked per commonly owned U.S. Patent Pub. No 2015/0013144 Al entitled,“Methods for Producing Forged Products and Other Worked Products”. In accordance with the methods described in commonly owned U.S. Patent Pub. No 2015/0013144, a final worked product (e.g., a final forged product) may be realized. The final worked product may be used for its intended end-use purpose (e.g., an industrial application). ii. Products

[0024] With reference now to FIG. 2, an illustrative embodiment of an additively manufactured aluminum alloy product (100) is shown. In this regard, the additively manufactured product (100) comprises a build platform (105) and an additively manufactured body (150). The build platform (105) generally comprises a high copper aluminum alloy substrate (110), a fusion zone (120) connected to the high copper aluminum alloy substrate (110), and a connecting layer (130) connected to the fusion zone (120). The build platform (105) is joined to the additively manufactured body (150) via an interface (140) between the connecting layer (130) and the additively manufactured body (150). As illustrated, the fusion zone (120) is integral with the high copper aluminum alloy substrate (110) and the connecting layer (130). Further, the interface (140) is integral with the connecting layer (130) and additively manufactured body (150).

[0025] With continued reference to FIG. 2, the additively manufactured aluminum alloy products described herein generally comprise a build platform (105) and an additively manufactured body (150). The build platform generally comprises a high copper aluminum alloy substrate (110) and a connecting layer (130). The high copper aluminum alloy substrate (110) is generally connected to the connecting layer (130) via a fusion zone (120). In one embodiment, the fusion zone (120) comprises a mixture of the connecting layer (130) aluminum alloy material and the additively manufactured body (150) aluminum alloy material. The additively manufactured body (150) is generally connected to the connecting layer (130) of the build platform (105) via an interface (140). In one embodiment, the interface (140) comprises an adhesive, and the adhesive binds the connecting layer to the additively manufactured body. In another embodiment, the interface (140) comprises a second fusion zone. In one embodiment, the second fusion zone comprises a mixture of the high copper aluminum alloy substrate (110) aluminum alloy material and the connecting layer (130) aluminum alloy material.

[0026] The high copper aluminum alloy substrate (110), connecting layer (130), and additively manufactured body (150) may each comprise (or in some instances, consist of, or consist essentially of) an aluminum alloy. That is, the connecting layer (130) may comprise a first aluminum alloy, the additively manufactured body (150) may comprise a second aluminum alloy, and the high copper aluminum alloy substrate (110) may comprise a third aluminum alloy. In one embodiment, the connecting layer comprises an aluminum alloy different than the high copper aluminum alloy substrate (110). In one embodiment, the additively manufactured body (150) comprises an aluminum alloy different than the high copper aluminum alloy substrate (110). To enable joining of the high copper aluminum alloy substrate (110) and the additively manufactured body (150), the additively manufactured body (150) generally comprises an aluminum alloy different than the connecting layer (130). iii. Composition

[0027] In one embodiment, the connecting layer comprises one of a 2xxx series aluminum alloy or a 7xxx series aluminum alloy. In one embodiment, the connecting layer comprises one of a 2xxx series aluminum alloy or a 7xxx series aluminum alloy, and the high copper aluminum alloy substrate comprises the other of the 2xxx series aluminum alloy or 7xxx series aluminum alloy. In one embodiment, the high copper aluminum alloy substrate comprises one of a 2xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy. In one embodiment, the additively manufactured body comprises one of a 2xxx series aluminum alloy, a 4xxx series aluminum alloy, a 5xxx series aluminum alloy, or a 7xxx series aluminum alloy. In some of these embodiments, the high copper aluminum alloy substrate, connecting layer, and/or additively manufactured body may consist of, or consist essentially of the aluminum alloys described above. [0028] Definitions of 2xxx, 4xxx, 5xxx, 6xxx, and 7xxx series aluminum alloys are provided in International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys (2015), by the Aluminum Association.

[0029] In one embodiment, the connecting layer comprises a 2xxx series aluminum alloy. In one embodiment, the connecting layer comprises a 7xxx series aluminum alloy, wherein the 7xxx series aluminum alloy comprises at least 4.5 wt. % Mg. In one embodiment, the connecting layer comprises a 7xxx series aluminum alloy, wherein the 7xxx series aluminum alloy comprises 6.0 to 9.0 wt. % Zn, 2.3 to 2.7 wt. % Mg, and 1.4 to 1.8 wt. % Cu. In one embodiment, the connecting layer comprises a 7xxx series aluminum alloy, wherein the 7xxx series aluminum alloy comprises 2.75 to 3.25 wt. % Cu, 2.4 to 2.9 wt. % Mg, 5.4 to 5.9 wt. % Zn. In some of these embodiments, the balance of the aluminum alloy is aluminum, incidental elements (e.g., grain refining elements; grain structure control elements), and impurities. In some embodiments, the connecting layer may consist of, or consist essentially of one of the aluminum alloys described above.

[0030] The above-described final products (e.g., a final worked product, a final additively manufactured aluminum alloy product) may be used in any suitable industrial application. The final products may be used with or without the high copper aluminum alloy substrate therein. Further, in embodiments where the high copper aluminum alloy substrate is separated from the additively manufactured body, the final products may be used with or without a portion of the connecting layer therein. In this regard, the final products may be used in suitable applications, such as aerospace, automotive, defense, consumer electronics, and industrial engineering applications, among others. Non-limiting examples of aerospace components may include aero-engine blades, rocket and missile bodies, and vanes, among others.

[0031] Aspects of the invention will now be described with reference to the following numbered clauses:

Clause 1. A method for producing an additively manufactured aluminum alloy product, comprising:

(i) fusing a connecting layer to a high copper aluminum alloy substrate;

wherein the connecting layer comprises a first aluminum alloy material;

wherein the fusing comprises creating a fusion zone integral with the high copper aluminum alloy substrate and the connecting layer;

(ii) producing an additively manufactured body; wherein the additively manufactured body comprises a second aluminum alloy material different than the first aluminum alloy material;

(iii) connecting the additively manufactured body to the connecting layer;

wherein the connecting step occurs concomitant to or after the producing step. Clause 2. The method of clause 1, wherein the connecting step occurs concomitant to the producing step.

Clause 3. The method of any preceding clause, comprising:

creating an interface;

wherein the interface is integral with the additively manufactured body and the connecting layer.

Clause 4. The method of any preceding clause, wherein the fusion zone is a first fusion zone, and wherein the interface comprises a second fusion zone.

Clause 5. The method of any preceding clause, wherein the connecting step occurs after the producing step.

Clause 6. The method of any preceding clause, comprising:

creating an interface;

wherein the interface comprises an adhesive material; and

wherein the adhesive material binds the connecting layer to the additively manufactured body.

Clause 7. The method of any preceding clause, wherein the high copper aluminum alloy substrate comprises a third aluminum alloy.

Clause 8. The method of clause 7, wherein the first aluminum alloy is different than the third aluminum alloy.

Clause 9. The method of any preceding clause, wherein the first aluminum alloy comprises one of a 2xxx series aluminum alloy or a 7xxx series aluminum alloy.

Clause 10. The method of clause 9, wherein the third aluminum alloy comprises one of a 2xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy.

Clause 11. The method of clause 10, wherein the first aluminum alloy comprises one of a 2xxx series aluminum alloy or a 7xxx series aluminum alloy, and wherein the third aluminum alloy comprises the other of the 2xxx series aluminum alloy or 7xxx series aluminum alloy.

Clause 12. The method of any preceding clause, wherein the first aluminum alloy comprises a 2xxx series aluminum alloy. Clause 13. The method of any preceding clause, wherein the first aluminum alloy comprises a 7xxx series aluminum alloy.

Clause 14. The method of clause 13, wherein the first aluminum alloy comprises at least 4.5 wt. % Mg.

Clause 15. The method of clause 13, wherein the first aluminum alloy comprises 6.0 to 9.0 wt. % Zn, 2.3 to 2.7 wt. % Mg, and 1.4 to 1.8 wt. % Cu.

Clause 16. The method of clause 13, wherein the first aluminum alloy comprises 2.75 to 3.25 wt. % Cu, 2.4 to 2.9 wt. % Mg, 5.4 to 5.9 wt. % Zn.

Clause 17. The method of any preceding clause, wherein the second aluminum alloy comprises one of a 2xxx series aluminum alloy, a 4xxx series aluminum alloy, a 5xxx series aluminum alloy, or a 7xxx series aluminum alloy.

Clause 18. The method of clause 18, wherein the additively manufactured body comprises the high copper aluminum alloy substrate therein.

Clause 19. The method of any preceding clause, comprising:

separating the high copper aluminum alloy substrate from the additively manufactured body.

Clause 20. The method of any preceding clause, wherein the additively manufactured aluminum alloy product is crack-free.

Clause 21. The method of any preceding clause, wherein the additively manufactured aluminum alloy product is a final additively manufactured aluminum alloy product.

Clause 22. A product comprising:

(a) a build platform comprising:

(i) a high copper aluminum alloy substrate;

(ii) a connecting layer;

wherein the high copper aluminum alloy substrate is connected to the connecting layer via a fusion zone;

(b) an additively manufactured body;

wherein the additively manufactured body is connected to the connecting layer of the build platform via an interface.

Clause 23. The product of clause 22, wherein the connecting layer comprises a first aluminum alloy, the additively manufactured body comprises a second aluminum alloy, and wherein the high copper aluminum alloy substrate comprises a third aluminum alloy.

Clause 24. The product of any of clauses 22-23, wherein the fusion zone comprises a mixture of the first aluminum alloy and second aluminum alloy. Clause 25. The product of any of clauses 22-24, wherein the fusion zone is a first fusion zone, and wherein the interface comprises a second fusion zone.

Clause 26. The product of any of clauses 22-25, wherein the interface comprises an adhesive, and wherein the adhesive binds the connecting layer to the additively manufactured body. Clause 27. The product of any of clauses 23-26, wherein the second aluminum alloy is different than the first aluminum alloy.

Clause 28. The product of any of clauses 23-27, wherein the first aluminum alloy is different than the third aluminum alloy.

Clause 29. The product of any of clauses 23-28, wherein the first aluminum alloy comprises one of a 2xxx series aluminum alloy or a 7xxx series aluminum alloy.

Clause 30. The product of any of clauses 23-29, wherein the second aluminum alloy comprises one of a 2xxx series aluminum alloy, a 4xxx series aluminum alloy, a 5xxx series aluminum alloy, or a 7xxx series aluminum alloy.

Clause 31. The product of any of clauses 23-30, wherein the third aluminum alloy comprises one of a 2xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy.

Clause 32. The product of any of clauses 23-31, wherein the additively manufactured aluminum alloy product is crack-free.

Clause 33. The product of any of clauses 23-32, wherein the additively manufactured aluminum alloy product is a final additively manufactured aluminum alloy product.

Clause 34. The final additively manufactured aluminum alloy product of clause 33, wherein the final additively manufactured aluminum alloy product is in the form of an aerospace product, automotive product, defense product, consumer electronics product, and an industrial engineering product.

Clause 35. The final additively manufactured aluminum alloy product of clause 34, wherein the final additively manufactured aluminum alloy product is an aerospace product in the form of an aerospace component, wherein the aerospace component is one of an aero-engine blade, a rocket body, a missile body, and a vane.

[0032] While a number of embodiments of the present invention have been described, it is understood that these embodiments are illustrative only, and not restrictive, and that many modifications may become apparent to those of ordinary skill in the art. Further still, unless the context clearly requires otherwise, the various steps may be carried out in any desired order, and any applicable steps may be added and/or eliminated.

Claims

CLAIMS What is claimed is:

1. A method for producing an additively manufactured aluminum alloy product, comprising:

(i) fusing a connecting layer to a high copper aluminum alloy substrate;

wherein the connecting layer comprises a first aluminum alloy material;

(ii) producing an additively manufactured body;

wherein the additively manufactured body comprises a second aluminum alloy material different than the first aluminum alloy material;

(iii) connecting the additively manufactured body to the connecting layer;

wherein the connecting step occurs concomitant to or after the producing step.

2. The method of claim 1, wherein the connecting step occurs concomitant to the producing step.

3. The method of claim 2, comprising:

creating an interface;

4. The method of claim 3, wherein the fusion zone is a first fusion zone, and wherein the interface comprises a second fusion zone.

5. The method of claim 1, wherein the connecting step occurs after the producing step.

6. The method of claim 5, comprising:

creating an interface;

wherein the interface comprises an adhesive material; and

7. The method of claim 1, wherein the high copper aluminum alloy substrate comprises a third aluminum alloy.

8. The method of claim 7, wherein the first aluminum alloy is different than the third aluminum alloy.

9. The method of claim 8, wherein the first aluminum alloy comprises one of a 2xxx series aluminum alloy or a 7xxx series aluminum alloy.

10. The method of claim 9, wherein the third aluminum alloy comprises one of a 2xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy.

11. The method of claim 10, wherein the first aluminum alloy comprises one of a 2xxx series aluminum alloy or a 7xxx series aluminum alloy, and wherein the third aluminum alloy comprises the other of the 2xxx series aluminum alloy or 7xxx series aluminum alloy.

12. The method of claim 11, wherein the first aluminum alloy comprises a 2xxx series aluminum alloy.

13. The method of claim 11, wherein the first aluminum alloy comprises a 7xxx series aluminum alloy.

14. The method of claim 13, wherein the first aluminum alloy comprises at least 4.5 wt. % Mg.

15. The method of claim 13, wherein the first aluminum alloy comprises 6.0 to 9.0 wt. % Zn, 2.3 to 2.7 wt. % Mg, and 1.4 to 1.8 wt. % Cu.

16. The method of claim 13, wherein the first aluminum alloy comprises 2.75 to 3.25 wt. %

Cu, 2.4 to 2.9 wt. % Mg, 5.4 to 5.9 wt. % Zn.

17. The method of claim 1, wherein the second aluminum alloy comprises one of a 2xxx series aluminum alloy, a 4xxx series aluminum alloy, a 5xxx series aluminum alloy, or a 7xxx series aluminum alloy.

18. The method of claim 1, wherein the additively manufactured body comprises the high copper aluminum alloy substrate therein.

19. The method of claim 18, comprising:

20. The method of claim 1, wherein the additively manufactured aluminum alloy product is crack-free.

21. The method of claim 1, wherein the additively manufactured aluminum alloy product is a final additively manufactured aluminum alloy product.

22. A product comprising:

(a) a build platform comprising:

(i) a high copper aluminum alloy substrate;

(ii) a connecting layer;

(b) an additively manufactured body; wherein the additively manufactured body is connected to the connecting layer of the build platform via an interface.

23. The product of claim 22, wherein the connecting layer comprises a first aluminum alloy, the additively manufactured body comprises a second aluminum alloy, and wherein the high copper aluminum alloy substrate comprises a third aluminum alloy.

24. The product of claim 24, wherein the fusion zone comprises a mixture of the first aluminum alloy and second aluminum alloy.

25. The product of claim 23, wherein the fusion zone is a first fusion zone, and wherein the interface comprises a second fusion zone.

26. The product of claim 25, wherein the interface comprises an adhesive, and wherein the adhesive binds the connecting layer to the additively manufactured body.

27. The product of claim 23, wherein the second aluminum alloy is different than the first aluminum alloy.

28. The product of claim 27, wherein the first aluminum alloy is different than the third aluminum alloy.

29. The product of claim 28, wherein the first aluminum alloy comprises one of a 2xxx series aluminum alloy or a 7xxx series aluminum alloy.

30. The product of claim 29, wherein the second aluminum alloy comprises one of a 2xxx series aluminum alloy, a 4xxx series aluminum alloy, a 5xxx series aluminum alloy, or a 7xxx series aluminum alloy.

31. The product of claim 30, wherein the third aluminum alloy comprises one of a 2xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy.

32. The product of claim 23, wherein the additively manufactured aluminum alloy product is crack-free.

33. The product of claim 23, wherein the additively manufactured aluminum alloy product is a final additively manufactured aluminum alloy product.

34. The final additively manufactured aluminum alloy product of claim 33, wherein the final additively manufactured aluminum alloy product is in the form of an aerospace product, automotive product, defense product, consumer electronics product, and an industrial engineering product.

35. The final additively manufactured aluminum alloy product of claim 34, wherein the final additively manufactured aluminum alloy product is an aerospace product in the form of an aerospace component, wherein the aerospace component is one of an aero-engine blade, a rocket body, a missile body, and a vane.