# US 2021/0276099 A1 · Process for manufacturing aluminium alloy parts > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2021/0276099 A1 - Document ID: US20210276099A1 - Status: Published application - Kind: A1 - Application number: 17/257,443 - Filed: 2019-04-05 - Published: 2021-09-09 - Earliest claimed: 2018-07-09 - Assignees: C-TEC Constellium Technology Center - Applicants: C-TEC Constellium Technology Center - Inventors: Bechir CHEHAB - Web page: https://patentgrep.com/patent/US20210276099A1 ## CPC - C22C 21/00: Alloys based on aluminium - B22F 3/15: Hot isostatic pressing - B22F 3/24: After-treatment of workpieces or articles {(B22F3/1146 takes precedence)} - B22F 10/25: Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS] - B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] - B22F 10/64: by thermal means (control of energy beam parameters for post heating B22F10/364) - B33Y 10/00: Processes of additive manufacturing - B33Y 40/20: Post-treatment, e.g. curing, coating or polishing - B33Y 70/00: Materials specially adapted for additive manufacturing - C22C 21/12: with copper as the next major constituent - C22C 21/14: with silicon - C22F 1/04: of aluminium or alloys based thereon - B22F 2003/248: {Thermal after-treatment} - B22F 2301/052: Aluminium - B22F 2998/10: Processes characterised by the sequence of their steps - Y02P 10/25: Process efficiency - C22C: ALLOYS (treatment of alloys C21D, C22F) - 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 - 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 - 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) - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract There is provided a method for manufacturing a part (20) including a formation of successive solid metal layers (201 . . . 20n), superimposed on one another, each layer describing a pattern defined from a digital model (M), each layer being formed by the deposition of a metal (25), referred to as a solder, the solder being subjected to an input of energy so as to melt and, in solidifying, to constitute said layer, wherein the solder takes the form of a powder (25), the exposure of which to an energy beam (32) results in melting followed by solidification so as to form a solid layer (201 . . . 20n). ## Claims ### Claim 1 Method for manufacturing a part including a formation of successive solid metal layers, superimposed on one another, each layer describing a pattern defined from a digital model (M), each layer being formed by the deposition of a metal comprising a solder, the solder being subjected to an input of energy so as to melt and, in solidifying, to constitute said layer, wherein the solder takes the form of a powder, the exposure of which to an energy beam results in melting followed by solidification so as to form a solid layer, wherein the solder is an aluminum alloy comprising at least the following alloy elements: Ni, in a proportion by mass of 1 to 6%, optionally 1 to 5%, optionally 2 to 4%; Mn, in a proportion by mass of 1 to 7%, optionally 1 to 6%, optionally 2 to 5%; Zr, in a proportion by mass of 0.5 to 4%, optionally 1 to 3%; Fe, in a proportion by mass of less than or equal to 1%, optionally 0.05 to 0.5%, optionally 0.1 to 0.3%; Si, in a proportion by mass of less than or equal to 1%, optionally less than or equal to 0.5%. ### Claim 2 (depends on 1) Method according to claim 1, wherein the aluminum alloy also comprises Cu in a fraction by mass of 0 to 8%, optionally 0 to 6%, optionally 0.5 to 6%, even optionally 1 to 5%. ### Claim 3 (depends on 1) Method according to claim 1, wherein the aluminum alloy also comprises at least one element chosen from: Ti, W, Nb, Ta, Y, Yb, Nd, Er, Cr, Hf, Ce, Sc, La, V, Co and/or mischmetal, in accordance with a fraction by mass of less than or equal to 5%, optionally less than or equal to 3% each, and less than or equal to 15%, optionally less than or equal to 12%, even optionally less than or equal to 5% in total. ### Claim 4 (depends on 1) Method according to claim 1, wherein the aluminum alloy also comprises at least one element chosen from: Sr, Ba, Sb, Bi, Ca, P, B, In and/or Sn, in a proportion by mass of less than or equal to 1%, optionally less than or equal to 0.1%, even optionally less than or equal to 700 ppm each, and less than or equal to 2%, optionally less than or equal to 1% in total. ### Claim 5 (depends on 1) Method according to claim 1, wherein the aluminum alloy also comprises at least one element chosen from: Ag in a proportion by mass of 0.06 to 1%, Li in a proportion by mass of 0.06 to 1%, and/or Zn in a proportion by mass of 0.06 to 1%. ### Claim 6 (depends on 1) Method according to claim 1, wherein the aluminum alloy also comprises at least one element for refining the grains, optionally AlTiC or Al-TiB2, in a quantity of less than or equal to 50 kg/tonne, optionally less than or equal to 20 kg/tonne, optionally less than or equal to 12 kg/tonne each, and less than or equal to 50 kg/tonne, optionally less than or equal to 20 kg/tonne in total. ### Claim 7 (depends on 1) Method according to claim 1, comprising, following the formation of the layers a solution heat treatment followed by quenching and aging, or heat treatment typically at a temperature of at least 100° C. and no more than 550° C., and/or hot isostatic compression. ### Claim 8 (depends on 1) Metal part obtained by a method of claim 1. ### Claim 9 Powder comprising, or optionally consisting of, an aluminum alloy comprising: Ni, in a proportion by mass of 1 to 6%, optionally 1 to 5%, optionally 2 to 4%; Mn, in a proportion by mass of 1 to 7%, optionally 1 to 6%, optionally 2 to 5%; Zr, in a proportion by mass of 0.5 to 4%, optionally 1 to 3%; Fe, in a proportion by mass of less than or equal to 1%, optionally 0.05 to 0.5%, optionally 0.1 to 0.3%; Si, in a proportion by mass of less than or equal to 1%, optionally less than or equal to 0.5%.