# US 12,000,009 B2 · Homogenizing heterogeneous foils for light alloy metal parts

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- Number: US 12,000,009 B2
- Document ID: US12000009B2
- Status: Granted
- Kind: B2
- Application number: 18/238,310
- Filed: 2023-08-25
- Published: 2023-12-28
- Granted: 2024-06-04
- Earliest claimed: 2020-12-28
- Assignees: Alloy Enterprises Inc.
- Applicants: Alloy Enterprises, Inc.
- Inventors: Nicholas Mykulowycz; Alison Forsyth; Alan Lai; Lyle Cheatham
- Web page: https://patentgrep.com/patent/US12000009B2

## CPC

- C21D 9/46: for sheet metals
- B32B 15/016: {all layers being formed of aluminium or aluminium alloys}
- B33Y 10/00: Processes of additive manufacturing
- B33Y 80/00: Products made by additive manufacturing
- C22C 1/04: by powder metallurgy (C22C1/08 takes precedence)
- C22C 21/02: with silicon as the next major constituent
- C22C 21/08: with silicon
- C22C 21/10: with zinc as the next major constituent
- C22C 21/14: with silicon
- C22C 21/16: with magnesium
- C22F 1/002: {by rapid cooling or quenching; cooling agents used therefor}
- C22F 1/043: of alloys with silicon as the next major constituent
- C22F 1/053: of alloys with zinc as the next major constituent
- C22F 1/057: of alloys with copper as the next major constituent
- B22F 7/02: of composite layers {(B22F7/002 takes precedence)}
- B22F 2007/042: {characterised by the layer forming method}
- B23K 20/002: {specially adapted for particular articles or work (B23K20/129 takes precedence)}
- B23P 2700/12: Laminated parts
- B32B 7/02: Physical, chemical or physicochemical properties
- B32B 2250/03: 3 layers
- B32B 2307/7376: Thickness
- B32B 2311/24: Aluminium
- Y02E 60/10: Energy storage using batteries
- C21D: MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING (surface treatment of metallic material involving at least one process provided for in class C23 and at least one process covered by this subclass C23F17/00; unidirectional solidification of eutectic materials or unidirectional demixing of eutectoid materials C30B)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- C22F: CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS (surface treatment of metallic material involving at least one process provided for in class C23 and at least one process covered by this subclass, C23F17/00)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23P: METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS (arrangements for copying or controlling B23Q)
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

A method for the manufacturing of an object. The method includes receiving a desired alloy composition for the object, depositing a plurality of foils in a stack to form the object, applying heat to the stack at a first temperature to bond the plurality of foils to each other, and applying heat to the stack at a second temperature to homogenize the composition of the stack. The homogenized stack has the desired alloy composition.

## Claims

### Claim 1

A cladded foil comprising:
a core comprising a balance of Al and between 1.0-1.6 wt. % Cu, between 0.9-1.3 wt. % Mg, and between 6.6-7.0 wt. % Zn; and
a cladding comprising a balance of Al between 1.8-2.2 wt. % Cu, between 1.4-2.0 wt. % Mg, and between 8.0-8.6 wt. % Zn.

### Claim 2 (depends on 1)

The cladded foil of claim 1, with the trace elements in the core and clad compositions comprising between 0-0.06 wt. % Si, between 0-0.08 wt. % Fe, between 0-0.4 wt. % Mn, between 0-0.04 wt. % Cr, and between 0-0.06 wt. % Ti, and the total of all other elements less than 0.15 wt. %.

### Claim 3 (depends on 1)

The cladded foil of claim 1, wherein each foil is between 25 μm and 1000 μm in thickness.

### Claim 4 (depends on 1)

The cladded foil of claim 1, wherein the core is a first layer of the foil and the cladding is a second layer of the foil.

### Claim 5 (depends on 1)

The cladded foil of claim 1, wherein a first layer forms a first cladding of the foil, a second layer forms the core of the foil, and a third layer forms a second cladding of the foil.

### Claim 6 (depends on 1)

The cladded foil of claim 1, wherein the cladding is between 5% and 50% of the total thickness of the cladded foil.

### Claim 7

A cladded foil comprising:
a core comprising a balance of Al and between 1.0-1.6 wt. % Cu, between 0.9-1.3 wt. % Mg, and between 6.6-7.0 wt. % Zn; and
a cladding comprising a balance of Al between 1.8-2.2 wt. % Cu, between 1.4-2.0 wt. % Mg, and between 8.0-8.6 wt. % Zn,
wherein the proportions of the core and cladding and selected so that the homogenization of the core and cladding yields an aluminum alloy having between 1.3-2.0 wt % Cu, 1.2-1.8 wt % Mg, and 7.0-8.0 wt % Zn.

### Claim 8 (depends on 7)

The cladded foil of claim 7, with the trace elements in the core and clad compositions comprising between 0-0.06 wt. % Si, between 0-0.08 wt. % Fe, between 0-0.4 wt. % Mn, between 0-0.04 wt. % Cr, and between 0-0.06 wt. % Ti, and the total of all other elements less than 0.15 wt. %.

### Claim 9 (depends on 7)

The cladded foil of claim 7, wherein each foil is between 25 μm and 1000 μm in thickness.

### Claim 10 (depends on 7)

The cladded foil of claim 7, wherein the core is a first layer of the foil and the cladding is a second layer of the foil.

### Claim 11 (depends on 7)

The cladded foil of claim 7, wherein a first layer forms a first cladding of the foil, a second layer forms the core of the foil, and a third layer forms a second cladding of the foil.

### Claim 12 (depends on 7)

The cladded foil of claim 7, wherein the cladding is between 5% and 50% of the total thickness of the cladded foil.

### Claim 13 (depends on 7)

The cladded foil of claim 7, wherein the resulting alloy is 7085 aluminum alloy.