METHOD OF FUSION WELDING

1 . A method comprising:

a. fusion welding a filler metal to a first aluminum component;

i. wherein the first aluminum component comprises a 7xxx series aluminum alloy;

ii. wherein the filler metal comprises an aluminum alloy, in weight percent:

1. up to 0.15 Fe;

2. up to 0.15 Si;

3. from 2.3 to 2.7 Mg;

4. from 1.4 to 1.8 Cu;

5. from 6.0 to 9.0 Zn; and

6. from 0.06 to 0.14 Zr.

2 . The method of claim 1 wherein the 7xxx series aluminum alloy comprises 0.5-2.6 wt. % Cu.

3 . The method of claim 1 wherein the filler metal consists essentially of, in weight percent:

a. up to 0.15 Fe;

b. up to 0.15 Si;

c. from 2.3 to 2.7 Mg;

d. from 1.4 to 1.8 Cu;

e. from 6.0 to 9.0 Zn;

f. from 0.06 to 0.14 Zr; and

g. optionally, up to 0.45 Sc,

h. the remainder being aluminum, incidental elements and impurities.

4 . The method of claim 1 wherein the filler metal comprises, in weight percent, up to 0.45 Sc.

5 . The method of claim 1 wherein the filler metal comprises, in weight percent, 0.25-0.35 Sc.

6 . The method of claim 1 wherein the filler metal comprises, in weight percent, up to 0.10 Fe.

7 . The method of claim 1 wherein the filler metal comprises, in weight percent, up to 0.10 Si.

8 . The method of claim 1 wherein the filler metal comprises, in weight percent, 7.3 to 7.7 Zn.

9 . The method of claim 1 wherein the filler metal comprises, in weight percent, 0.10 to 0.12 Zr.

10 . The method of claim 1 wherein the filler metal comprises, in weight percent, up to 0.03 B.

11 . The method of claim 1 wherein the filler metal comprises, in weight percent, 0.015 to 0.025 B.

12 . The method of claim 1 wherein the 7xxx series alloy comprises one of: 7x09, 7x10, 7x12, 7x14, 7x16, 7x20, 7x21, 7x22, 7x23, 7x24, 7x25, 7x26, 7x28, 7x29, 7x30, 7x32, 7x33, 7x34, 7x35, 7x36, 7x37, 7x40, 7x41, 7x42, 7046, 7x49, 7x50, 7x55, 7x56, 7x60, 7x64, 7x65, 7x68, 7x75, 7x76, 7x78, 7x79, 7x81, 7x85, 7x90, 7x93, 7x95 and 7x99.

13 . The method of claim 12 wherein the 7xxx series alloy comprises one of: 7x09, 7x10, 7x12, 7x14, 7x16, 7x22, 7x23, 7x24, 7x25, 7x26, 7x29, 7x32, 7x33, 7x34, 7x36, 7x37, 7x40, 7x41, 7x42, 7x49, 7x50, 7x55, 7x56, 7x60, 7x64, 7x65, 7x68, 7x75, 7x76, 7x78, 7x79, 7x81, 7x85, 7x90, 7x93, 7x95 and 7x99.

14 . The method of claim 1 wherein the 7xxx series alloy comprises, in weight percent:

a. up to 0.06 Si;

b. up to 0.08 Fe;

c. 1.3 to 2.0 Cu;

d. up to 0.04 Mn;

e. 1.2 to 1.8 Mg;

f. up to 0.04 Cr;

g. 7.0 to 8.0 Zn;

h. up to 0.15 Ti; and

i. 0.08 to 00.15 Zr.

15 . A method comprising:

a. abutting a first aluminum component against a second aluminum component, wherein an abutment is formed, and

b. fusion welding a filler metal to the first aluminum component and to the second aluminum component so that a welded joint is formed at the abutment;

i. wherein the first aluminum component comprises a 7xxx series alloy;

ii. wherein the filler metal is an aluminum alloy comprising, in weight percent:

1. up to 0.15 Fe;

2. up to 0.15 Si;

3. from 2.3 to 2.7 Mg;

4. from 1.4 to 1.8 Cu;

5. from 6.0 to 9.0 Zn; and

6. from 0.06 to 0.14 Zr.

16 . The method of claim 15 wherein the filler metal comprises, in weight percent, up to 0.45 Sc.

17 . The method of claim 15 wherein the 7xxx series alloy comprises 0.5-2.6 wt. % Cu.

18 . The method of claim 15 wherein the welded joint is one of a: butt, corner, edge, lap, and tee.

19 . A method comprising:

a. locating a surface defect of a mold block;

i. wherein the surface defect has a first volume;

ii. wherein the surface defect is at least partially surrounded by an original volume;

iii. wherein the mold block includes the original volume;

iv. wherein the mold block is made of an aluminum alloy; and

b. wherein the aluminum alloy is a lox series aluminum alloy;

c. repairing the surface defect, wherein the repairing comprises fusion welding a filler metal to at least a portion of the original volume to produce a repaired volume;

i. wherein the repaired volume includes the first volume of the surface defect and at least a portion of the original volume; and

ii. wherein the filler metal is an aluminum alloy comprising, in weight percent:

1. up to 0.15 Fe;

2. up to 0.15 Si;

3. from 2.3 to 2.7 Mg;

4. from 1.4 to 1.8 Cu;

5. from 6.0 to 9.0 Zn; and

6. from 0.06 to 0.14 Zr.

20 . The method of claim 19 wherein the filler metal comprises, in weight percent, up to 0.45 Sc.

21 . The method of claim 19 wherein the 7xxx series aluminum alloy comprises0.5-2.6 wt. % Cu.