Aluminum alloy feedstocks for additive manufacturing
Some variations provide an aluminum alloy feedstock for additive manufacturing, the aluminum alloy feedstock comprising from 81.5 wt % to 88.8 wt % aluminum; from 1.1 wt % to 2.1 wt % copper; from 3.0 wt % to 4.6 wt % magnesium; and from 7.1 wt % to 9.0 wt % zinc. The aluminum alloy feedstock may be in the form of a free-flowing powder or a feedstock ingot, for example. In some variations, the aluminum alloy feedstock comprises from 84.9 wt % to 88.3 wt % aluminum; from 1.2 wt % to 2.0 wt % copper; from 3.2 wt % to 4.4 wt % magnesium; and from 7.3 wt % to 8.7 wt % zinc.
1. An aluminum alloy feedstock for additive manufacturing, said aluminum alloy feedstock comprising:
from 81.5 wt % to 88.3 wt % aluminum;
from 1.1 wt % to 2.1 wt % copper;
from 3.0 wt % to 4.6 wt % magnesium;
from 7.1 wt % to 9.0 wt % zinc; and
from 0.5 wt % to 2.8 wt % zirconium, wherein said zirconium is in the form of zirconium-containing nanoparticles.
2. The aluminum alloy feedstock of claim 1 , wherein said aluminum alloy feedstock is in the form of a powder.
3. The aluminum alloy feedstock of claim 1 , wherein said aluminum alloy feedstock is in the form of a feedstock ingot.
4. The aluminum alloy feedstock of claim 1 , wherein said aluminum alloy feedstock comprises from 0.005 wt % to 0.4 wt % silicon.
5. The aluminum alloy feedstock of claim 1 , wherein said aluminum alloy feedstock comprises from 0.005 wt % to 0.4 wt % iron.
6. The aluminum alloy feedstock of claim 1 , wherein said aluminum alloy feedstock comprises from 0.005 wt % to 0.3 wt % manganese.
7. The aluminum alloy feedstock of claim 1 , wherein said aluminum alloy feedstock comprises from 0.005 wt % to 0.1 wt % chromium.
8. The aluminum alloy feedstock of claim 1 , wherein said aluminum alloy feedstock comprises from 0.005 wt % to 0.05 wt % nickel.
9. The aluminum alloy feedstock of claim 1 , wherein said aluminum alloy feedstock comprises from 0.005 wt % to 0.2 wt % titanium.
10. The aluminum alloy feedstock of claim 1 , wherein said aluminum alloy feedstock comprises from 0.005 wt % to 0.05 wt % tin.
11. The aluminum alloy feedstock of claim 1 , wherein said aluminum alloy feedstock consists essentially of said aluminum, said copper, said magnesium, said zinc, and said zirconium.
12. The aluminum alloy feedstock of claim 1 , wherein said aluminum, said copper, said zinc, and said magnesium are contained in microparticles, and wherein said zirconium-containing nanoparticles are assembled onto surfaces of said microparticles.
13. The aluminum alloy feedstock of claim 1 , wherein said aluminum alloy feedstock comprises from 0.6 wt % to 2.8 wt % zirconium.
14. The aluminum alloy feedstock of claim 1 , wherein said aluminum alloy feedstock comprises:
from 82.1 wt % to 87.3 wt % aluminum;
from 1.2 wt % to 2.0 wt % copper;
from 3.2 wt % to 4.4 wt % magnesium;
from 7.3 wt % to 8.7 wt % zinc; and
from 1 wt % to 2.8 wt % zirconium.
15. The aluminum alloy feedstock of claim 14 , wherein said aluminum alloy feedstock comprises from 0.005 wt % to 0.12 wt % silicon.
16. The aluminum alloy feedstock of claim 14 , wherein said aluminum alloy feedstock comprises from 0.005 wt % to 0.15 wt % iron.
17. The aluminum alloy feedstock of claim 14 , wherein said aluminum alloy feedstock comprises from 0.005 wt % to 0.1 wt % manganese.
18. The aluminum alloy feedstock of claim 14 , wherein said aluminum alloy feedstock comprises from 0.005 wt % to 0.05 wt % chromium.
19. The aluminum alloy feedstock of claim 14 , wherein said aluminum alloy feedstock comprises from 0.005 wt % to 0.05 wt % nickel.
20. The aluminum alloy feedstock of claim 14 , wherein said aluminum alloy feedstock comprises from 0.005 wt % to 0.1 wt % titanium.
21. The aluminum alloy feedstock of claim 14 , wherein said aluminum alloy feedstock comprises from 0.005 wt % to 0.05 wt % tin.