Process for manufacturing an aluminium alloy part

A method for manufacturing a part comprising forming successive metal layers, superposed on top of one another, each layer being formed by the deposition of a filler metal, the filler metal being subjected to an energy input so as to melt down and form, when solidifying, said layer, wherein the filler metal is an aluminum alloy including the following alloying elements in weight percents:

• at least one alloying element selected from among:
• Zr, Hf, and Er, according to a mass fraction higher than or equal to 0.30%, optionally from 0.30 to 2.50%, optionally from 0.40 to 2.00%, optionally from 0.40 to 1.80%, optionally from 0.50 to 1.60%, optionally from 0.60 to 1.50%, optionally from 0.70 to 1.40%, optionally from 0.80 to 1.30% each and in total;
• Sc, according to a mass fraction lower than 0.80%, optionally lower than 0.70%, optionally lower than 0.60%, optionally lower than 0.50%, optionally lower than 0.40%, optionally lower than 0.30%;
• and
• according to a mass fraction higher than 500 ppm, optionally higher than 0.10%, optionally higher than 0.15%, optionally higher than 0.20%;
• optionally at least one alloying element selected from among:
• Co, La, Ce, mischmetal, W, Ta, Mo and Nb, according to a mass fraction of at least 0.10%, optionally at least 0.25%, optionally at least 0.50% each and in total;
• and according to a mass fraction lower than 5.00%, optionally lower than 4.00%, optionally lower than 3.00% each;
• and according to a mass fraction lower than 7.00%, optionally lower than 6.00%, optionally lower than 5.00%, optionally lower than 4.00% in total;
• optionally Fe, according to a mass fraction lower than 3.00%, optionally lower than 2.00%, optionally lower than 1.00%, optionally lower than 0.50%;
• optionally Ni, according to a mass fraction lower than 3.00%, optionally lower than 2.00%, optionally lower than 1.00%, optionally lower than 0.50%;
• optionally at least one alloying element selected from among:
• Cu and Ag, according to a mass fraction of 0.10 to 3.00%, optionally from 0.10 to 2.00%, optionally from 0.10 to 1.60%, optionally from 0.10 to 1.00%, optionally from 0.10 to 0.70% each and in total;
• optionally Si, according to a mass fraction lower than 3.00%, optionally lower than 2.00%, optionally lower than 1.00%, optionally lower than 0.50%;
• in one embodiment, the Si content is lower than 0.30%, optionally lower than 0.20%, optionally lower than 0.10%;
• optionally at least one alloying element selected from among Cr, V, Ti and Mn, according to a fraction lower than 0.50%, optionally lower than 0.30%, optionally lower than 0.20%, optionally lower than 0.10%, optionally lower than 0.05% each and lower than or equal to 2.00%, optionally lower than or equal to 1.00%, optionally lower than 0.50%, optionally lower than 0.10%, optionally lower than 0.05% in total;
• optionally Mg, according to a mass fraction lower than 2.00%, optionally lower than 1.00%, optionally lower than 0.50%, optionally lower than 0.30%, optionally lower than 0.10%, optionally lower than 0.05%;
• optionally Zn, according to a mass fraction lower than 2.00%, optionally lower than 1.00%, optionally lower than 0.50%, optionally lower than 0.30%, optionally lower than 0.10%, optionally lower than 0.05%;
• optionally Li, according to a mass fraction lower than 2.00%, optionally lower than 1.00%, optionally lower than 0.50%, optionally lower than 0.30%, optionally lower than 0.10%, optionally lower than 0.05%;
• optionally at least one element selected from among:
• Nd, Y, Tm, Lu, Yb, Sr, Ba, Sb, Bi, Ca, P, B, In and Sn, according to a mass fraction lower than or equal to 1.00%, optionally lower than or equal to 0.50%, optionally lower than or equal to 0.30%, optionally lower than or equal to 0.10%, optionally lower than or equal to 700 ppm each, and lower than or equal to 2.00%, optionally lower than or equal to 1.00%, optionally lower than or equal to 0.50%, optionally lower than or equal to 0.30% in total;
• impurities:
• <0.05% each, and optionally <0.15% in total;
• remainder being aluminum.

A powder, intended to be used as a filler material of an additive manufacturing method, wherein said powder is formed by an aluminum alloy, including the following alloying elements (weight %):

• at least one alloying element selected from among:
• Zr, Hf, and Er, according to a mass fraction higher than or equal to 0.30%, optionally from 0.30 to 2.50%, optionally from 0.40 to 2.00%, optionally from 0.40 to 1.80%, optionally from 0.50 to 1.60%, optionally from 0.60 to 1.50%, optionally from 0.70 to 1.40%, optionally from 0.80 to 1.30% each and in total;
• at least one alloying element selected from among:
• Co, La, Ce, mischmetal, W, Ta, Mo and Nb, according to a mass fraction of at least 0.10%, optionally at least 0.25%, optionally at least 0.50% each and in total;
• and according to a mass fraction lower than 5.00%, optionally lower than 4.00%, optionally lower than 3.00% each;
• and according to a mass fraction lower than 7.00%, optionally lower than 6.00%, optionally lower than 5.00%, optionally lower than 4.00% in total;
• optionally Fe, according to a mass fraction lower than 3.00%, optionally lower than 2.00%, optionally lower than 1.00%, optionally lower than 0.50%;
• optionally Ni, according to a mass fraction lower than 3.00%, optionally lower than 2.00%, optionally lower than 1.00%, optionally lower than 0.50%;
• optionally at least one alloying element selected from among:
• Cu and Ag, according to a mass fraction of 0.10 to 3.00%, optionally from 0.10 to 2.00%, optionally from 0.10 to 1.60%, optionally from 0.10 to 1.00%, optionally from 0.10 to 0.70% each and in total;
• optionally Si, according to a mass fraction lower than 3.00%, optionally lower than 2.00%, optionally lower than 1.00%, optionally lower than 0.50%;
• in one embodiment, the Si content is lower than 0.30%, optionally lower than 0.20%, optionally lower than 0.10%;
• optionally Sc, according to a mass fraction lower than 0.80%, optionally lower than 0.70%, optionally lower than 0.60%, optionally lower than 0.50%, optionally lower than 0.40%, optionally lower than 0.30%, optionally lower than 0.20%, optionally lower than 0.10%;
• optionally at least one alloying element selected from among Cr, V, Ti and Mn, according to a fraction lower than 0.50%, optionally lower than 0.30%, optionally lower than 0.20%, optionally lower than 0.10%, optionally lower than 0.05% each and lower than or equal to 2.00%, optionally lower than or equal to 1.00%, optionally lower than 0.50%, optionally lower than 0.1%, optionally lower than 0.05% in total;
• optionally Mg, according to a mass fraction lower than 2.00%, optionally lower than 1.00%, optionally lower than 0.50%, optionally lower than 0.30%, optionally lower than 0.10%, optionally lower than 0.05%;
• optionally Zn, according to a mass fraction lower than 2.00%, optionally lower than 1.00%, optionally lower than 0.50%, optionally lower than 0.30%, optionally lower than 0.10%, optionally lower than 0.05%;
• optionally Li, according to a mass fraction lower than 2.00%, optionally lower than 1.00%, optionally lower than 0.50%, optionally lower than 0.30%, optionally lower than 0.10%, optionally lower than 0.05%;
• optionally at least one element selected from among:
• Nd, Y, Tm, Lu, Yb, Sr, Ba, Sb, Bi, Ca, P, B, In and Sn, according to a mass fraction lower than or equal to 1.00%, optionally lower than or equal to 0.50%, optionally lower than or equal to 0.30%, optionally lower than or equal to 0.10%, optionally lower than or equal to 700 ppm each, and lower than or equal to 2.00%, optionally lower than or equal to 1.00%, optionally lower than or equal to 0.50%, optionally lower than or equal to 0.30% in total;
• impurities:
• <0.05% each, and <0.15% in total;
• the remainder being aluminum.

A powder, intended to be used as a filler material of an additive manufacturing method, wherein said powder is formed by an aluminum alloy, including the following alloying elements (weight %):

• at least one alloying element selected from among:
• Zr, Hf, and Er, according to a mass fraction higher than or equal to 0.30%, optionally from 0.30 to 2.50%, optionally from 0.40 to 2.00%, optionally from 0.40 to 1.80%, optionally from 0.50 to 1.60%, optionally from 0.60 to 1.50%, optionally from 0.70 to 1.40%, optionally from 0.80 to 1.30% each and in total;
• Sc, according to a mass fraction lower than 0.80%, optionally lower than 0.70%, optionally lower than 0.60%, optionally lower than 0.50%, optionally lower than 0.40%, optionally lower than 0.30%;
• and
• according to a mass fraction higher than 500 ppm, optionally higher than 0.10%, optionally higher than 0.15%, optionally higher than 0.20%;
• optionally at least one alloying element selected from among:
• Co, La, Ce, mischmetal, W, Ta, Mo and Nb, according to a mass fraction of at least 0.10%, optionally at least 0.25%, optionally at least 0.50% each and in total;
• and according to a mass fraction lower than 5.00%, optionally lower than 4.00%, optionally lower than 3.00% each;
• and according to a mass fraction lower than 7.00%, optionally lower than 6.00%, optionally lower than 5.00%, optionally lower than 4.00% in total;
• optionally Fe, according to a mass fraction lower than 3.00%, optionally lower than 2.00%, optionally lower than 1.00%, optionally lower than 0.50%;
• optionally Ni, according to a mass fraction lower than 3.00%, optionally lower than 2.00%, optionally lower than 1.00%, optionally lower than 0.50%;
• optionally at least one alloying element selected from among:
• Cu and Ag, according to a mass fraction of 0.10 to 3.00%, optionally from 0.10 to 2.00%, optionally from 0.10 to 1.60%, optionally from 0.10 to 1.00%, optionally from 0.10 to 0.70% each and in total;
• optionally Si, according to a mass fraction lower than 3.00%, optionally lower than 2.00%, optionally lower than 1.00%, optionally lower than 0.50%;
• in one embodiment, the Si content is lower than 0.30%, optionally lower than 0.20%, optionally lower than 0.10%;
• optionally at least one alloying element selected from among Cr, V, Ti and Mn, according to a fraction lower than 0.50%, optionally lower than 0.30%, optionally lower than 0.20%, optionally lower than 0.10%, optionally lower than 0.05% each and lower than or equal to 2.00%, optionally lower than or equal to 1.00%, optionally lower than 0.50%, optionally lower than 0.1%, optionally lower than 0.05% in total;
• optionally Mg, according to a mass fraction lower than 2.00%, optionally lower than 1.00%, optionally lower than 0.50%, optionally lower than 0.30%, optionally lower than 0.10%, optionally lower than 0.05%;
• optionally Zn, according to a mass fraction lower than 2.00%, optionally lower than 1.00%, optionally lower than 0.50%, optionally lower than 0.30%, optionally lower than 0.10%, optionally lower than 0.05%;
• optionally Li, according to a mass fraction lower than 2.00%, optionally lower than 1.00%, optionally lower than 0.50%, mere optionally lower than 0.30%, optionally lower than 0.10%, optionally lower than 0.05%;
• optionally at least one element selected from among:
• Nd, Y, Tm, Lu, Yb, Sr, Ba, Sb, Bi, Ca, P, B, In and Sn, according to a mass fraction lower than or equal to 1.00%, optionally lower than or equal to 0.50%, optionally lower than or equal to 0.30%, optionally lower than or equal to 0.10%, optionally lower than or equal to 700 ppm each, and lower than or equal to 2.00%, optionally lower than or equal to 1.00%, optionally lower than or equal to 0.50%, optionally lower than or equal to 0.30% in total;
• impurities:
• <0.05% each, and <0.15% in total;
• remainder being aluminum.