New aluminum alloys having an improved combination of properties are disclosed. In one approach, anew aluminum alloys may include from 0.50 to 3.0 wt. % of X, wherein X comprises (wt. % Bi+wt. % Sn), from 0.50 to 4.0 wt. % Si, from 0.30 to 2.5 wt. % Mg, up to 1.5 wt. % Cu, up to 2.0 wt. % Zn, from 0.05 to 1.5 wt. % Mn, up to 0.70 wt. % Fe, up to 0.35 wt. % of Cr, up to 0.25 wt. % each of Zr and V, and up to 0.15 wt. % Ti, the balance being aluminum, incidental elements and impurities. The new aluminum alloys may comprise at least 0.20 wt. % excess silicon.

Provided is an aluminum alloy diecast that can be unlikely to crack at a part to be press-fitted while the proof stress of a main body part is being secured, and can eliminate the need for heat treatment to the main body part at the time of production. The aluminum alloy diecast (11) includes a part to be press-fitted (13) into which a joining member (20) is press-fitted and a main body part (14) in which the part to be press-fitted (13) is integrally formed, in which an average hardness of the part to be press-fitted (13) is lower than an average hardness of the main body part (14) or an average roundness of crystals other than a primary crystal of Al in the part to be press-fitted (13) is larger than an average roundness of crystals other than a primary crystal of Al in the main body part (14).

Provided is an aluminum alloy diecast that can be unlikely to crack at a part to be press-fitted while the proof stress of a main body part is being secured, and can eliminate the need for heat treatment to the main body part at the time of production. The aluminum alloy diecast (11) includes a part to be press-fitted (13) into which a joining member (20) is press-fitted and a main body part (14) in which the part to be press-fitted (13) is integrally formed, in which an average hardness of the part to be press-fitted (13) is lower than an average hardness of the main body part (14) or an average roundness of crystals other than a primary crystal of Al in the part to be press-fitted (13) is larger than an average roundness of crystals other than a primary crystal of Al in the main body part (14).

Provided is an alloy-coated steel sheet and a manufacturing method thereof. The alloy-coated steel sheet includes: a steel sheet; and an Al—Mg—Si alloy layer disposed on the steel sheet, wherein the Al—Mg—Si alloy layer has a form in which Mg—Si alloy grains are included in an alloy layer consisting of an Al—Mg alloy phase.

New aluminum alloys are disclosed and generally include 0.6-1.4 wt. % Si, 0.25-0.90 wt. % Mg, wherein the ratio of wt. % Si to wt. % Mg is from 1.05:1 to 5.0:1, 0.25-2.0 wt. % Cu, 0.10-3.5 wt. % Zn, 0.01-1.0 wt. % Fe, up to 0.8 wt. % Mn, up to 0.25 wt. % Cr, up to 0.20 wt. % Zr, up to 0.20 wt. % V, and up to 0.15 wt. % Ti, wherein the total of Fe+Mn+Cr+Zr+V+Ti is not greater than 2.0 wt. %, the balance being aluminum and impurities. The new aluminum alloys may include Q phase precipitates. In some embodiments, the solvus temperature of the Q phase precipitates is not greater than 950° F.

The invention relates to a manufacturing process for obtaining 6xxx-series aluminium alloy solid extruded products, comprising Si: 0.3-1.7 wt. %; Mg: 0.1-1.4 wt. %, Cu: 0.1-0.8 wt. %, Zn 0.005-0.7 wt %, one or more dispersoid element, from the group consisting of Mn 0.15-1 wt. %, Cr 0.05-0.4 wt. % and Zr 0.05-0.25 wt. %, Fe at most 0.5 wt. %, other elements at most 0.05 wt. % the rest being aluminium, having particularly high mechanical properties, typically an ultimate tensile strength higher than 400 MPa, preferably 430 MPa, and more preferably 450 MPa without the need for a post-extrusion solution heat treatment operation. The invention also concerns a manufacturing process for obtaining a bumper system in which is integrated a towing eye, said towing eye being made with said high mechanical properties aluminium alloys.

The invention relates to a manufacturing process for obtaining 6xxx-series aluminium alloy solid extruded products, comprising Si: 0.3-1.7 wt. %; Mg: 0.1-1.4 wt. %, Cu: 0.1-0.8 wt. %, Zn 0.005-0.7 wt %, one or more dispersoid element, from the group consisting of Mn 0.15-1 wt. %, Cr 0.05-0.4 wt. % and Zr 0.05-0.25 wt. %, Fe at most 0.5 wt. %, other elements at most 0.05 wt. % the rest being aluminium, having particularly high mechanical properties, typically an ultimate tensile strength higher than 400 MPa, preferably 430 MPa, and more preferably 450 MPa without the need for a post-extrusion solution heat treatment operation. The invention also concerns a manufacturing process for obtaining a bumper system in which is integrated a towing eye, said towing eye being made with said high mechanical properties aluminium alloys.

An additive manufacturing method of producing a metal alloy article may involve: Providing a supply of a metal alloy in powder form; providing a supply of a nucleant material, the nucleant material lowering the nucleation energy required to crystallize the metal alloy; blending the supply of metal alloy powder and nucleant material to form a blended mixture; forming the blended mixture into a first layer; subjecting at least a portion of the first layer to energy sufficient to raise the temperature of the first layer to at least the liquidus temperature of the metal alloy; allowing at least a portion of the first layer to cool to a temperature sufficient to allow the metal alloy to recrystallize; forming a second layer of the blended mixture on the first layer; and repeating the subjecting and allowing steps on the second layer to form an additional portion of the metal alloy article.

An additive manufacturing method of producing a metal alloy article may involve: Providing a supply of a metal alloy in powder form; providing a supply of a nucleant material, the nucleant material lowering the nucleation energy required to crystallize the metal alloy; blending the supply of metal alloy powder and nucleant material to form a blended mixture; forming the blended mixture into a first layer; subjecting at least a portion of the first layer to energy sufficient to raise the temperature of the first layer to at least the liquidus temperature of the metal alloy; allowing at least a portion of the first layer to cool to a temperature sufficient to allow the metal alloy to recrystallize; forming a second layer of the blended mixture on the first layer; and repeating the subjecting and allowing steps on the second layer to form an additional portion of the metal alloy article.

An Al—Mg-based or Al—Mg—Si-based or Al—Zn-based or Al—Si-based starting material in the form of a powder or wire for an additive manufacturing process, the use thereof, and an additive manufacturing process using this starting material are disclosed.