This disclosure relates to the field of metallurgy, namely, to the composition of an aluminum-based heat-resistant alloy and a powder from it to be used for the production of parts using additive technologies. A new aluminum-based material has been created, which is intended for producing a powder and its utilisation in the additive production of various products, which has high processability at laser melting and high strength characteristics in the heat-treated state: the yield strength exceeding 400 MPa, the ultimate strength exceeding 470 MPa, and elongation at break of at least 4%. The powdered aluminum material contains copper, magnesium, manganese, cerium, silicon, zirconium and/or titanium, where the material contains thermally stable Al.sub.8Cu.sub.4Ce dispersoids with a size of less than 1 μm, which are formed at crystallisation rates of at least 10.sup.3 K/s, which contribute to the material strengthening under operating conditions at room and elevated temperatures.

Described herein are additive manufacturing methods and products made using such methods. The alloy compositions described herein are specifically selected for the additive manufacturing methods and provide products that exhibit superior mechanical properties as compared to their cast counterparts. Using the compositions and methods described herein, products that do not exhibit substantial coarsening, such as at elevated temperatures, can be obtained. The products further exhibit uniform microstructures along the print axis, thus contributing to improved strength and performance. Additives also can be used in the alloys described herein.

Described herein are additive manufacturing methods and products made using such methods. The alloy compositions described herein are specifically selected for the additive manufacturing methods and provide products that exhibit superior mechanical properties as compared to their cast counterparts. Using the compositions and methods described herein, products that do not exhibit substantial coarsening, such as at elevated temperatures, can be obtained. The products further exhibit uniform microstructures along the print axis, thus contributing to improved strength and performance. Additives also can be used in the alloys described herein.

Described are processes for shaping age hardenable aluminum alloys, such as 2XXX, 6XXX and 7XXX aluminum alloys in T4 temper, or articles made of such alloys, including aluminum alloy sheets. The processes involve heating the sheet or article before and/or concurrently with a forming step. In some examples, the sheet is heated to a specified temperature in the range of about 100-600° C. at a specified heating rate within the range of about 3-600° C./s, for example about 3-90° C./s. Such a combination of temperature and heating rate results in an advantageous combination of sheet properties.

Described are processes for shaping age hardenable aluminum alloys, such as 2XXX, 6XXX and 7XXX aluminum alloys in T4 temper, or articles made of such alloys, including aluminum alloy sheets. The processes involve heating the sheet or article before and/or concurrently with a forming step. In some examples, the sheet is heated to a specified temperature in the range of about 100-600° C. at a specified heating rate within the range of about 3-600° C./s, for example about 3-90° C./s. Such a combination of temperature and heating rate results in an advantageous combination of sheet properties.

The invention relates to a method for manufacturing a thin sheet made from aluminum-based alloy comprising, as % by weight, 2.2 to 2.7% Cu, 1.3 to 1.6% Li, less than 0.1% Ag, 0.2 to 0.5% Mg, 0.1 to 0.5% Mn, 0.01 to 0.15% Ti, a quantity of Zn of less than 0.3, a quantity of Fe and of Si of less than or equal to 0.1% each, and unavoidable impurities with a content of less than or equal to 0.05% by weight each and 0.15% by weight in total, the remainder aluminum, wherein optionally the hot-rolling input temperature being between 400° C. and 460° C. and the hot-rolling output temperature being less than 300° C. and the mean heating speed during the solution heat treatment is at least approximately 17° C./min between 300° C. and 400° C., aging conditions such that the yield strength in the long-transverse direction Rp0.2 is between 350 and 380 MPa.

The invention relates to a method for manufacturing a thin sheet made from aluminum-based alloy comprising, as % by weight, 2.2 to 2.7% Cu, 1.3 to 1.6% Li, less than 0.1% Ag, 0.2 to 0.5% Mg, 0.1 to 0.5% Mn, 0.01 to 0.15% Ti, a quantity of Zn of less than 0.3, a quantity of Fe and of Si of less than or equal to 0.1% each, and unavoidable impurities with a content of less than or equal to 0.05% by weight each and 0.15% by weight in total, the remainder aluminum, wherein optionally the hot-rolling input temperature being between 400° C. and 460° C. and the hot-rolling output temperature being less than 300° C. and the mean heating speed during the solution heat treatment is at least approximately 17° C./min between 300° C. and 400° C., aging conditions such that the yield strength in the long-transverse direction Rp0.2 is between 350 and 380 MPa.

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.

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.

A method of producing a wrought aluminum alloy product is disclosed comprising Cu, Mn, Zr, Sc and Ti. The method includes casting an unwrought billet, ingot or shape from a liquid metal bath, and homogenizing the unwrought billet, ingot or shape at an equivalent time at temperature. The homogenization process includes first stage heating within a relatively low temperature range, second stage heating within an intermediate temperature range, and third stage heating at a relatively high temperature. After homogenizing, the billet, ingot or shape is worked into an extruded product, solution heat treated, quenched, stretched to a permanent set, and artificially aged. The extruded aluminum alloy product has desirable mechanical properties and electrical conductivity.