Manufacturing method for aluminum alloy parts

Abstract

Successive metal layers (201···20 n 1. A method for manufacturing a component (20), comprising the formation of a filler metal (15, 25) in a layer of a molten or unmolten alloy, each layer being formed by depositing a filler metal (15, 25) which melts and then solidifies into said layer upon receiving a supply of energy, the method comprising the step of forming a filler metal (15, 25) containing (in % by weight) the following alloying elements: at least one alloying element selected from Zr, Hf and Er, each according to a mass fraction equal to or greater than 0.30% in total; at least one alloying element selected from Cr, V, Ti and Mn, each according to a mass fraction equal to or greater than 0.50% in total; 1. An aluminum alloy comprising: Fe according to a mass fraction of 0.10 to 2.50%; optionally Co, La, Ce, misch metal, W, Ta, Mo, Nb, Ni, Cu, Ag, Si, Sc, Mg, Zn, Li, Nd, Y, Tm, Lu, Yb, Sr, Ba, Sb, Bi, Ca, P, B, In, Sn and impurities; and the remainder being aluminum.

Description

[Technical Field]

[0001] The technical field of the invention is the manufacturing of aluminum alloy parts, implementing additive manufacturing techniques. [Background technology]

[0002] Since the 1980s, additive manufacturing techniques have been developed. These techniques involve forming parts by adding material, as opposed to machining techniques that aim to remove material. While additive manufacturing was previously limited to prototyping, it is now being used to mass-produce industrial products, including metal parts.

[0003] The term "additive manufacturing" is defined by French standard XP E67-001 as "the set of methods that allow the layer-by-layer production of physical objects from digital objects by the addition of material." Standard ASTM F2792 (January 2012) also defines additive manufacturing. Standard ISO / ASTM 17296-1 also defines and describes various additive manufacturing methods. International Publication No. WO 2015 / 006447 describes the use of additive manufacturing to create low-porosity aluminum parts. The application of successive layers is typically achieved by applying a material called a filler material, followed by melting or sintering the filler material using a laser beam, electron beam, plasma torch, or arc-type energy source. Regardless of the additive manufacturing method used, the thickness of each added layer is approximately tens or hundreds of microns.

[0004] Several other additive manufacturing methods can be used, such as, but not limited to, the melting or sintering of filler material in the form of a powder. It can be laser melting or laser sintering. US Patent Application Publication No. 2017 / 0016096 describes a method for manufacturing parts by local melting obtained by exposing the powder to an energy beam of the electron beam or laser beam type, a method also designated by the English acronym LPBF or "Electron Beam Melting", which stands for "Laser Powder Bed Fusion".

[0005] The mechanical properties of aluminum parts obtained by additive manufacturing depend on the alloy forming the filler metal, and more specifically its composition, as well as the heat treatment applied after the additive manufacturing operation. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] International Publication No. 2015 / 006447 [Patent Document 2] US Patent Application Publication No. 2017 / 0016096

[0007] The applicant has determined an alloy composition that makes it possible to obtain parts with outstanding mechanical performance when utilized in additive manufacturing processes, without the need to carry out solution and quench type heat treatments.

[0008] For aluminum alloys, the highest electrical or thermal conductivity is generally obtained with pure aluminum. However, pure aluminum has poor mechanical properties, limiting its application fields. To improve the mechanical strength of pure aluminum, the content of additive elements can be increased. Conversely, to improve the electrical conductivity of an aluminum alloy, the content of additive elements other than aluminum can be limited. Therefore, varying the total content of additive elements has a trade-off effect on the electrical conductivity and mechanical strength of the aluminum alloy. Similarly, it is difficult to conceive of an aluminum alloy that simultaneously has sufficient thermal conductivity in the as-processed state and sufficient mechanical strength after heat treatment.

[0009] According to one variant of the invention, by appropriately selecting the additive elements, the Applicant has identified aluminum alloy compositions for additive manufacturing processes, in particular LPBF, which make it possible to simultaneously obtain extremely good processability of the part in the LPBF process and good mechanical performance of the part during use. Good processability of the part in the LPBF process is obtained by combining a sufficiently low hardness level in the as-fabricated state (e.g., a Knoop hardness HK0.05 in the as-fabricated state of less than 140, preferably less than 130, preferably less than 120) with a sufficiently high thermal or electrical conductivity (e.g., an electrical conductivity greater than 6 MS / m, preferably greater than 7 MS / m, preferably greater than 8 MS / m in the as-fabricated state). This combination of hardness and conductivity makes it possible to limit the residual stress level of the part in the as-fabricated state, thus significantly limiting the risk of cracking, delamination, or distortion, and thus significantly improving the processability of the part in the LPBF process. Superior mechanical performance of the part during use is obtained by maximizing the hardness of the part after post-fabrication heat treatment (e.g., Knoop hardness HK0.05 greater than 70, preferably greater than 80, preferably greater than 90, preferably greater than 100, preferably greater than 114).

[0010] Pure aluminum powder can be used as a reducing agent in solid propellants for aerospace thrusters. As a result, aluminum powders with more than 97% aluminum are generally considered dual-use items (DUGs) in some countries, requiring an export license. This classification is one constraint that slows the commercialization of some aluminum powders containing more than 97% aluminum for additive manufacturing processes, such as LPBF. Therefore, it would be advantageous for solutions to be developed that have less than 97% aluminum, i.e., more than 3% added elements in total.

[0011] According to another variant of the invention, by appropriate selection of additive elements, the Applicant has identified aluminum alloy compositions for additive manufacturing processes, in particular LPBF, which compositions contain more than 3% additive elements in total, allowing excellent processability of the part in the LPBF process while maximizing the mechanical performance of the part during use. Summary of the Invention

[0012] [DISCLOSURE OF THE INVENTION] A first object of the present invention is a method for manufacturing a part, comprising the formation of successive metallic layers superimposed on one another, each layer being formed by the deposition of a filler metal which, upon receiving an energy supply, melts and then solidifies into said layer, the filler metal comprising, in weight percentages, the following alloying elements: at least one alloying element selected from Zr, Hf and Er, each in a mass fraction of at least 0.30%, preferably between 0.30 and 2.50%, preferably between 0.40 and 2.00%, more preferably between 0.40 and 1.80%, even more preferably between 0.50 and 1.60%, even more preferably between 0.60 and 1.50%, even more preferably between 0.70 and 1.40%, and even more preferably between 0.80 and 1.30%; at least one alloying element selected from among Cr, V, Ti and Mn, for V, Ti and Mn each and in total more than 0.50%, preferably more than 0.50 to 6.00%, preferably 1.00 to 6.00%, more preferably 1.00 to 5.00%, even more preferably 1.00 to 4.00%, even more preferably 1.00 to 3.00% by mass; and for Cr, more than 0.50 to 3.00% by mass; at least one alloying element selected from Co, La, Ce, misch metal, W, Ta, Mo and Nb, optionally each according to a mass fraction of at least 0.10%, preferably at least 0.25%, more preferably at least 0.50%, in total; and each according to a mass fraction of less than 5.00%, preferably less than 4.00%, preferably less than 3.00%; and in total according to a mass fraction of less than 7.00%, preferably less than 6.00%, preferably less than 5.00%, preferably less than 4.00%; Fe according to a mass fraction of 0.10 to 2.50%, preferably 0.15 to 2.50%, better still 0.20 to 2.50%, better still 0.30 to 2.50%, even better still 0.50 to 2.50%, even better still 0.75 to 2.25%; - optionally, Ni according to a mass fraction of less than 3.00%, preferably less than 2.00%, preferably less than 1.00% and suitably less than 0.50%; - at least one alloying element chosen from Cu and Ag, optionally each and in total according to a mass fraction of 0.10 to 3.00%, preferably 0.10 to 2.00%, preferably 0.10 to 1.60%, preferably 0.10 to 1.00%, preferably 0.10 to 0.70%; optionally, Si according to a mass fraction of less than 3.00%, preferably less than 2.00%, preferably less than 1.00%, preferably less than 0.50%; in one embodiment the Si content is less than 0.30%, preferably less than 0.20%; optionally Sc according to a mass fraction of less than 0.80%, preferably less than 0.70%, preferably less than 0.60%, preferably less than 0.50%, preferably less than 0.40%, preferably less than 0.30%; optionally Mg according to a mass fraction of less than 2.00%, preferably less than 1.00%, advantageously less than 0.50% and more advantageously less than 0.30%; Zn, optionally according to a mass fraction of less than 2.00%, preferably less than 1.00%, advantageously less than 0.50% and even better less than 0.30%; - optionally according to a mass fraction of Li less than 2.00%, preferably less than 1.00%, advantageously less than 0.50% and more advantageously less than 0.30%; at least one element chosen from among Nd, Y, Tm, Lu, Yb, Sr, Ba, Sb, Bi, Ca, P, B, In and Sn, optionally in a mass fraction of less than or equal to 1.00%, preferably less than or equal to 0.50%, preferably less than or equal to 0.30%, more preferably less than or equal to 0.10%, even more preferably less than or equal to 700 ppm each, and in total less than or equal to 2.00%, preferably less than or equal to 1.00%, preferably less than or equal to 0.50%, preferably less than or equal to 0.30%; - impurities individually less than 0.05% and preferably less than 0.15% in total; Including, The remainder is aluminum, and the aluminum alloy is characterized in that the remainder is aluminum.

[0013] Each layer can, among other things, follow a pattern defined from a numerical model.

[0014] In one embodiment, the filler material is in the form of a powder, and its exposure to a light beam or charged particle beam causes localized melting and subsequent solidification to form a solid layer. In another embodiment, the filler material comes from a filler wire, and its exposure to a heat source, such as an electric arc, causes localized melting and subsequent solidification to form a solid layer.

[0015] A second subject of the invention is a metal part obtained by a method according to the first or second subject of the invention.

[0016] A third subject of the invention is a filler material, in particular a filler wire or powder, intended to be used as a filler material in additive manufacturing processes, the filler material comprising the following alloying elements (% by weight): at least one alloying element selected from Zr, Hf and Er, each in a mass fraction of at least 0.30%, preferably between 0.30 and 2.50%, preferably between 0.40 and 2.00%, more preferably between 0.40 and 1.80%, even more preferably between 0.50 and 1.60%, even more preferably between 0.60 and 1.50%, even more preferably between 0.70 and 1.40%, and even more preferably between 0.80 and 1.30%; at least one alloying element selected from among Cr, V, Ti and Mn, for V, Ti and Mn each and in total more than 0.50%, preferably more than 0.50 to 6.00%, preferably 1.00 to 6.00%, more preferably 1.00 to 5.00%, even more preferably 1.00 to 4.00%, even more preferably 1.00 to 3.00% by mass; and for Cr, more than 0.50 to 3.00% by mass; at least one alloying element selected from Co, La, Ce, misch metal, W, Ta, Mo and Nb, optionally each according to a mass fraction of at least 0.10%, preferably at least 0.25%, more preferably at least 0.50%, in total; and each according to a mass fraction of less than 5.00%, preferably less than 4.00%, preferably less than 3.00%; and in total according to a mass fraction of less than 7.00%, preferably less than 6.00%, preferably less than 5.00%, preferably less than 4.00%; Fe according to a mass fraction of 0.10 to 2.50%, preferably 0.15 to 2.50%, better still 0.20 to 2.50%, better still 0.30 to 2.50%, even better still 0.50 to 2.50%, even better still 0.75 to 2.25%; - optionally, Ni according to a mass fraction of less than 3.00%, preferably less than 2.00%, preferably less than 1.00% and suitably less than 0.50%; - at least one alloying element chosen from Cu and Ag, optionally each and in total according to a mass fraction of 0.10 to 3.00%, preferably 0.10 to 2.00%, preferably 0.10 to 1.60%, preferably 0.10 to 1.00%, preferably 0.10 to 0.70%; optionally, Si according to a mass fraction of less than 3.00%, preferably less than 2.00%, preferably less than 1.00%, preferably less than 0.50%; in one embodiment the Si content is less than 0.30%, preferably less than 0.20%; optionally Sc according to a mass fraction of less than 0.80%, preferably less than 0.70%, preferably less than 0.60%, preferably less than 0.50%, preferably less than 0.40%, preferably less than 0.30%; optionally Mg according to a mass fraction of less than 2.00%, preferably less than 1.00%, advantageously less than 0.50% and more advantageously less than 0.30%; Zn, optionally according to a mass fraction of less than 2.00%, preferably less than 1.00%, advantageously less than 0.50% and even better less than 0.30%; - optionally according to a mass fraction of Li less than 2.00%, preferably less than 1.00%, advantageously less than 0.50% and more advantageously less than 0.30%; at least one element chosen from among Nd, Y, Tm, Lu, Yb, Sr, Ba, Sb, Bi, Ca, P, B, In and Sn, optionally in a mass fraction of less than or equal to 1.00%, preferably less than or equal to 0.50%, preferably less than or equal to 0.30%, more preferably less than or equal to 0.10%, even more preferably less than or equal to 700 ppm each, and in total less than or equal to 2.00%, preferably less than or equal to 1.00%, preferably less than or equal to 0.50%, preferably less than or equal to 0.30%; - Impurities less than 0.05% individually and less than 0.15% in total; Including, The remainder is aluminum, and the aluminum alloy is characterized by being made of aluminum.

[0017] The aluminum alloy forming the filler material may have the characteristics described in connection with the first subject of the invention.

[0018] The filler material may be in the form of a powder in which at least 80% of the particles constituting the powder have an average size in the range of 5 μm to 200 μm, preferably 5 to 150 μm, preferably 5 to 25 μm, or 20 to 60 μm, or 20 to 80 μm, or 20 to 90 μm, or 20 to 100 μm, or 20 to 110 μm, or 20 to 120 μm.

[0019] When the filler material is in the form of a wire, the diameter of the wire may in particular be comprised between 0.5 mm and 3 mm, and preferably between 0.5 mm and 2 mm, and even more preferably between 1 mm and 2 mm.

[0020] A fourth object of the present invention is the use of powder or filler wire as described above and elsewhere in the specification in a manufacturing process selected from electron beam melting, cold spray consolidation, laser metal deposition, friction additive manufacturing, electric field assisted sintering, or inertial rotary friction welding, preferably cold spray consolidation.

[0021] Other advantages and features will appear more clearly from the following description of particular embodiments of the invention, given as non-limiting examples and illustrated in the drawings listed below. [Brief explanation of the drawings]

[0022] [Figure 1] FIG. 1 illustrates an LPBF type additive manufacturing method. [Figure 2] FIG. 1 illustrates a WAAM type additive manufacturing method. [Figure 3] FIG. 1 is a diagram of a small plate after laser remelting used according to the examples. [Figure 4] FIG. 1 is a diagram showing a measurement test of Knoop hardness. DETAILED DESCRIPTION OF THE INVENTION

[0023] Disclosure of specific embodiments Unless otherwise indicated in the description, - The names of aluminum alloys follow the academic terminology of the Aluminum Association. - The content of chemical elements is expressed in % and indicates mass fraction. The symbol x%~y% indicates that the content is greater than or equal to x% and less than or equal to y%.

[0024] Impurities refer to chemical elements that are unintentionally present in the alloy.

[0025] FIG. 1 illustrates the operation of a selective laser melting type additive manufacturing process (laser powder bed fusion or LPBF). The filler material 15 is in the form of a powder that is placed on a base 10. An energy source, in this case a laser source 11, emits a laser beam 12. The laser source is coupled to the filler material by an optical system 13, the movement of which is determined according to a numerical model M. The laser beam 12 propagates along a propagation axis Z and follows a movement along a plane XY that describes a pattern that depends on the numerical model M. The plane is, for example, perpendicular to the expansion axis Z. The interaction of the laser beam 12 with the powder 15 causes selective melting of the powder and its subsequent solidification, resulting in the formation of layers 201...20. n After one layer is formed, it is covered with filler powder 15 and another layer is formed on top of the previously formed layer. The thickness of the layer may be, for example, 10 to 250 μm, such as 30 μm, or 60 μm, or 80 μm, or 90 μm, or 100 μm, or 110 μm, or 120 μm, or 130 μm, or 140 μm, or 150 μm, or 160 μm, or 170 μm, or 180 μm, or 190 μm, or 200 μm.

[0026] Increasing the layer thickness can be beneficial for increasing productivity during printing and for limiting susceptibility to thermal cracking associated with residual stresses during heat treatment during and / or after part production. Increasing the layer thickness can be accompanied by adapting the laser power and vector deviation (the distance between two successive laser passes) and the laser scanning speed to ensure complete melting of each powder layer under optimal conditions. The layer thickness can be, for example, 60-250 μm, preferably 80-200 μm, preferably 90-180 μm, preferably 100-180 μm, preferably 110-170 μm, preferably 120-160 μm.

[0027] For aluminum alloys, the base 10 or tray can be heated to a preheating temperature T of up to 500°C. Equipment currently available on the market generally allows tray heating up to 200°C. The tray heating temperature (= preheating temperature T) can be, for example, approximately 50°C, 100°C, 150°C, 200°C, 250°C, 300°C, 350°C, 400°C, 450°C, or 500°C. Tray heating generally makes it possible to reduce the moisture at the powder bed and also reduce residual stresses in the part during manufacture. The moisture level at the powder bed appears to have a direct impact on the porosity of the final part. In fact, the higher the moisture content of the powder, the higher the porosity of the final part. It should be noted that tray heating is one of the existing means for realizing thermal additive manufacturing. However, the present invention cannot be limited to the use of this single heating means. All other heating means capable of realizing a preheating step, such as infrared lamps, can be used within the scope of the present invention for heating and temperature regulation. The method according to the invention can thus be carried out at preheating temperatures T up to 500°C.

[0028] For some compositions, the inventors have determined that parts have better resistance to thermal cracking associated with residual stresses when the preheat temperature T is 160°C or less and 25°C or more. Preferably, preheating of the tray and therefore the powder bed can be carried out at a preheat temperature T of 140°C or less, or even better, 130°C or less. The preheat temperature T is higher than ambient temperature. Preferred ranges for the preheat temperature T are 25°C < T < 160°C, preferably 30°C < T < 150°C, preferably 50°C < T < 150°C, preferably 50°C < T < 140°C, preferably 60°C < T < 140°C, preferably 70°C < T < 135°C, preferably 80°C < T < 130°C.

[0029] According to one variant, the preheating temperature T corresponds to conditions that allow effective stress relief to be obtained. The preheating temperature T can then be in the range of 300°C to 500°C, preferably 300 to 400°C, preferably 300 to 350°C. It is believed that in this range of preheating temperatures T the manufacturing conditions of the part generate fewer residual stresses. According to this variant, a post-manufacturing stress relief heat treatment, as explained hereinafter, is likewise appropriate.

[0030] The powder according to the invention may have at least one of the following characteristics: - an average particle size of 5 μm to 200 μm, preferably 5 to 150 μm, preferably 5 to 25 μm, or 20 to 60 μm, or 20 to 80 μm, or 20 to 90 μm, or 20 to 100 μm, or 20 to 110 μm, or 20 to 120 μm, the given values ​​indicating that at least 80% of the particles have an average size in the specified range. - Spherical shape: The sphericity of a powder can be determined, for example, by utilizing a morphogranulometer. - Good castability. The flowability of the powder can be determined, for example, according to standard ASTM B213 or standard ISO 4490:2018. According to standard ISO 4490:2018, the flow time is preferably less than 50. - a low porosity, preferably between 0 and 5% by volume, more preferably between 0 and 2% by volume, even more preferably between 0 and 1% by volume. The porosity can be determined inter alia by image analysis from optical micrographs or by helium pycnometer (see standard ASTM B923). - A low or no amount (less than 10% by volume, preferably less than 5% by volume) of small particles (1-20% of the average size of the powder) called satellite particles that are attached to larger particles.

[0031] The implementation of this method requires 200 cm per laser. 3 This allows for high-yield part production, reaching and even exceeding 1000kJ / h.

[0032] The applicant has also noticed that the application of quenching-type post-manufacturing heat treatments can induce distortion of the part due to the sudden change in temperature. The distortion of the part is generally more pronounced the larger its dimensions. However, the advantage of additive manufacturing is precisely to obtain parts whose shape after manufacturing is final or near-final. Sudden significant distortion resulting from post-manufacturing heat treatments should therefore be avoided. Near-final means that finishing operations are performed on the part after its manufacturing, i.e., parts produced by additive manufacturing will extend according to their final shape, excluding finishing operations.

[0033] As previously mentioned, the applicant sought an alloy composition for forming the filler material that makes it possible to obtain acceptable mechanical and electrical or thermal conductivity properties without the need to apply heat treatments that could induce distortion immediately after the formation of the layers, i.e., after the formation of the final part. In particular, it is important to avoid heat treatments that result in sudden changes in temperature. The invention thus makes it possible to obtain, by additive manufacturing, parts with satisfactory mechanical properties, in particular in terms of yield stress and electrical or thermal conductivity properties. Depending on the type of additive manufacturing method chosen, the filler material can be in the form of a wire or a powder.

[0034] The following elements may be used in the aluminum alloy:

[0035] [Zr, Hf and / or Er] According to the present invention, at least one alloying element selected from Zr, Hf, and Er is present in the aluminum alloy in a mass fraction of at least 0.30%, preferably 0.30-2.50%, preferably 0.40-2.00%, more preferably 0.40-1.80%, even more preferably 0.50-1.60%, even more preferably 0.60-1.50%, even more preferably 0.70-1.40%, and even more preferably 0.80-1.30%. Preferably, the mass fraction of the at least one alloying element selected from Zr, Hf, and Er is at least 0.30%, or 0.35%, or 0.40%, or 0.45%, or 0.50%, or 0.55%, or 0.60%, or 0.65%, or 0.70%. Preferably, the mass fraction of at least one alloying element selected from among Zr, Hf and Er is each and in total not more than 2.50%, or 2.40%, or 2.30%, or 2.20%, or 2.10%, or 2.00%, or 1.90%, or 1.80%, or 1.70%, or 1.60%, or 1.50%, or 1.40%, or 1.30%.

[0036] These elements have high solubility in the as-processed state. Therefore, their addition can significantly reduce the electrical conductivity in the as-processed state. However, additional post-processing heat treatment, for example at temperatures between 300 and 450°C for 0.5 to 10 hours, can significantly reduce their content in solid solution through the formation of hardenable dispersoids of the Al3X (X = Zr, Hf, or Er) type. The formation of these dispersoids during heat treatment can simultaneously increase hardness and electrical conductivity compared to the as-processed state.

[0037] These elements may also allow for control of the granular structure during laser melting by promoting the appearance of equiaxed grains.

[0038] Furthermore, the presence of at least one alloying element selected from Zr, Hf, and Er in the alloy may impart excellent processability to the alloy, where the term processability corresponds to the English term "processability" describing the suitability of an alloy to be formed by additive manufacturing methods, which may be manifested by a near absence of crack-type defects and low porosity in additively manufactured parts.

[0039] [Cr, V, Ti and / or Mn] According to the present invention, at least one alloying element selected from among Cr, V, Ti, and Mn is present in the aluminum alloy in a mass fraction of greater than 0.50%, preferably greater than 0.50 to 6.00%, preferably 1.00 to 6.00%, more preferably 1.00 to 5.00%, even more preferably 1.00 to 4.00%, and even more preferably 1.00 to 3.00%, for V, Ti, and Mn, respectively, and in total; and in a mass fraction of greater than 0.50 to 3.00% for Cr. Preferably, the mass fraction of the at least one alloying element selected from among Cr, V, Ti, and Mn, respectively, is greater than 0.50%, or 0.60%, or 0.70%, or 0.80%, or 0.90%, or 1.00% or more. Preferably, the mass fraction of at least one alloying element selected from among Cr, V, Ti and Mn is each and in total not more than 6.00%, or 5.50%, or 5.00%, or 4.50%, or 4.00%, or 3.50%, or 3.00%, or 2.50%, or 2.00%, or 1.50%, or 1.00%.

[0040] These elements can increase the mechanical strength of the alloy through solid solutions and / or dispersoids that may form during component manufacturing or post-manufacturing heat treatment. However, these elements have a high solubility in aluminum and a negative effect on electrical conductivity. The addition of these elements is advantageous for alloys targeted at certain applications, such as structural components, hydraulic blocks, etc., that do not require specific performance in terms of electrical or thermal conductivity but do require high mechanical strength.

[0041] [Co, La, Ce, misch metal, W, Ta, Mo and / or Nb] According to the present invention, at least one alloying element selected from among Co, La, Ce, misch metal, W, Ta, Mo and / or Nb may be present in the aluminum alloy according to a mass fraction each and in total of at least 0.10%, preferably at least 0.25%, more preferably at least 0.50%; and according to a mass fraction each of less than 5.00%, preferably less than 4.00%, preferably less than 3.00%; and according to a mass fraction in total of less than 7.00%, preferably less than 6.00%, preferably less than 5.00%, preferably less than 4.00%. Preferably, the mass fraction of at least one alloying element selected from Co, La, Ce, misch metal, W, Ta, Mo, and Nb is each and in total equal to or greater than 0.10%, or 0.15%, or 0.20%, or 0.25%, or 0.30%, or 0.35%, or 0.40%, or 0.45%, or 0.50%. Preferably, the mass fraction of at least one alloying element selected from Co, La, Ce, misch metal, W, Ta, Mo, and Nb is each less than 5.00%, or 4.50%, or 4.00%, or 3.50%, or 3.00%. Preferably, the mass fraction of at least one alloying element selected from Co, La, Ce, misch metal, W, Ta, Mo and Nb is less than 7.00%, or 6.50%, or 6.00%, or 5.50%, or 5.00%, or 4.50%, or 4.00% in total.

[0042] These elements can increase the mechanical strength of the alloy through solid solutions and / or dispersoids that can form during component manufacturing or post-manufacturing heat treatment. These elements have low solubility in aluminum. The addition of these elements can make it possible to harden the alloy without significantly negatively affecting its electrical conductivity.

[0043] Preferably, the aluminum alloy contains at least one alloying element selected from Co, La, Ce, misch metal, W, Ta, Mo and Nb.

[0044] [Fe] According to the present invention, the element Fe is present in the aluminum alloy in a mass fraction of 0.10-2.50%, preferably 0.15-2.50%, suitably 0.20-2.50%, more suitably 0.20-2.50%, even more suitably 0.30-2.50%, even more suitably 0.50-2.50%, and even more suitably 0.75-2.25%. Preferably, the mass fraction of Fe is 0.10%, or 0.15%, or 0.20%, or 0.25%, or 0.30%, or 0.35%, or 0.40%, or 0.45%, or 0.50%, or 0.55%, or 0.60%, or 0.65%, or 0.70%, or 0.75% or more. Preferably, the mass fraction of Fe is less than or equal to 2.50%, or 2.40%, or 2.30%, or 2.20%, or 2.25%.

[0045] This element can increase the mechanical strength of the alloy through solid solutions and / or dispersoids that can form during component manufacturing or post-manufacturing heat treatment. This element has low solubility in aluminum. The addition of this element can make it possible to harden the alloy without significantly negatively affecting its conductivity.

[0046] [Ni] According to the invention, the element Ni may be present in the aluminum alloy according to a mass fraction of less than 3.00%, preferably less than 2.00%, preferably less than 1.00%, suitably less than 0.50%. Preferably, the mass fraction of Ni is greater than 500 ppm, preferably greater than 0.10%, preferably greater than 0.15%, preferably greater than 0.20%, preferably greater than 0.30%, preferably greater than 0.40%.

[0047] This element may increase the mechanical strength of the alloy through solid solutions and / or dispersoids that may form during component manufacturing or post-manufacturing heat treatment. This element has low solubility in aluminum. The addition of this element may make it possible to harden the alloy without significantly affecting its conductivity.

[0048] [Cu and / or Ag] According to the present invention, the elements Cu and / or Ag may be present in the aluminum alloy according to a mass fraction of 0.10-3.00%, preferably 0.10-2.00%, preferably 0.10-1.60%, preferably 0.10-1.00%, preferably 0.10-0.70%, each and in total.

[0049] These elements may make it possible to increase the mechanical strength of the alloy through solid solutions and / or hardening precipitates which may form during manufacture or post-manufacture heat treatment of the part.

[0050] [Si] According to the present invention, the element Si may be present in the aluminum alloy according to a mass fraction of less than 3.00%, preferably less than 2.00%, preferably less than 1.00%, preferably less than 0.50%; in one embodiment, the content of Si is less than 0.30%, preferably less than 0.20%. Preferably, the mass fraction of Si is greater than 500 ppm, preferably greater than 0.10%, preferably greater than 0.15%.

[0051] The addition of Si in the presence of Zr can lead to the formation of coarse AlZrSi phases that limit the hardening ability of Zr after heat treatment.

[0052] [Sc] According to the invention, the element Sc may be present in the aluminium alloy according to a mass fraction of less than 0.80%, preferably less than 0.70%, preferably less than 0.60%, preferably less than 0.50%, preferably less than 0.40%, preferably less than 0.30%. Preferably, the mass fraction of Sc is greater than 500 ppm, preferably greater than 0.10%, preferably greater than 0.15%, preferably greater than 0.20%.

[0053] This element may have the same technical effect as the elements Zr, Hf and Er, but according to one variant of the invention, the inventors have determined that it is also possible to obtain a good trade-off between mechanical properties and conductivity by at least partially substituting Sc for the group of the elements Co, La, Ce, misch metal, W, Ta, Mo and / or Nb, preferably after heat treatment, according to the mass fractions as indicated above.

[0054] [Mg, Zn and / or Li] According to the invention, the elements Mg, Zn and / or Li may be present in the aluminum alloy according to a mass fraction of less than 2.00%, preferably less than 1.00%, suitably less than 0.50%, more suitably less than 0.30%. Preferably, the mass fraction of Mg, Zn and / or Li is each more than 500 ppm, preferably more than 0.10%, preferably more than 0.15%.

[0055] These elements may increase the mechanical strength of the alloy through solid solution. However, these elements are sensitive to evaporation during laser melting, which may lead to the formation of smoke and instability of the molten bath. Excessive addition of these elements may significantly reduce the electrical conductivity. Therefore, according to one embodiment, the addition of these elements should preferably be avoided.

[0056] [Nd, Y, Tm, Lu, Yb, Sr, Ba, Sb, Bi, Ca, P, B, In and / or Sn] According to the present invention, at least one element selected from Nd, Y, Tm, Lu, Yb, Sr, Ba, Sb, Bi, Ca, P, B, In, and Sn may be present in the aluminum alloy in a mass fraction of not more than 1.00%, preferably not more than 0.50%, suitably not more than 0.30%, more suitably not more than 0.10%, even more suitably not more than 700 ppm each, and in total not more than 2.00%, preferably not more than 1.00%, preferably not more than 0.50%, preferably not more than 0.30%. Preferably, the mass fractions of Nd, Y, Tm, Lu, Yb, Sr, Ba, Sb, Bi, Ca, P, B, In, and Sn, in total, are greater than 100 ppm, preferably greater than 300 ppm, preferably greater than 500 ppm.

[0057] These elements may make it possible to increase the mechanical strength of the alloy through solid solutions and / or dispersoids that may form during the manufacture or post-manufacture heat treatment of the part. However, excessive addition of these elements may decrease the conductivity of the alloy, and for this reason, according to one embodiment, their addition is preferably according to a mass fraction of less than 700 ppm each.

[0058] It should be noted that the alloy according to the invention is preferably not an AA6xxx type alloy, since there is no simultaneous addition of Si and Mg in an amount exceeding 0.2%.

[0059] The method can include applying at least one heat treatment after layer formation, i.e., after formation of the final part. This treatment is also called post-fabrication heat treatment or post-treatment heat treatment. The post-fabrication heat treatment can be or include tempering or annealing. It can also include solution treatment and quenching, although these are preferably avoided. It can also include hot isostatic pressing.

[0060] According to a first variant, a post-manufacturing heat treatment can be carried out at the following temperatures, with the aim of prioritizing the mechanical properties: a temperature T' above 400 ° C, in which case the duration of the post-production heat treatment is between 0.1 and 50 hours, preferably between 0.1 and 10 hours; or a temperature T' between 300°C and 400°C, in which case the duration of the post-production heat treatment is between 0.1 hours and 200 hours.

[0061] According to a second variant, with the aim of prioritizing the thermal or electrical conductivity properties, a post-production heat treatment can be carried out at a temperature T' of 350°C or higher or 400°C or higher for a time period between 0.1 and 200 hours in order to obtain an optimum thermal or electrical conductivity.

[0062] According to another variant, a two-stage post-production heat treatment can make it possible to maximize the electrical conductivity: these treatments consist of a first stage at a temperature T'1 above 450°C for 0.1 to 100 hours, followed by a second stage at a temperature T'2 between 300°C and 450°C for 0.1 to 200 hours.

[0063] According to another variant, a two-stage post-manufacturing heat treatment can make it possible to maximize the electrical conductivity and / or hardness, consisting of a first stage at a temperature T'1 below 380°C for 0.1 to 200 hours, followed by a second stage at a temperature T'2 between 380°C and 450°C for 0.1 to 200 hours.

[0064] According to another variant, a three-stage post-manufacturing heat treatment can make it possible to maximize the electrical conductivity and / or hardness, consisting of a first stage at a temperature T'1 between 250°C and 450°C for 0.1 to 200 hours, followed by a second stage at a temperature T'2 above 450°C for 0.1 to 100 hours, followed by a third stage at a temperature T'3 between 250°C and 450°C for 0.1 to 200 hours.

[0065] Multi-stage processes involving more than three stages may also be contemplated.

[0066] According to one embodiment, the method can include hot isostatic pressing (HIP). HIP treatment can in particular make it possible to improve the elongation and fatigue properties. Hot isostatic pressing can be carried out before, after or instead of the post-manufacturing heat treatment. Advantageously, hot isostatic pressing is carried out at a temperature between 250°C and 500°C, preferably between 300°C and 450°C, at a pressure between 500 and 3000 bar, for a duration between 0.5 and 100 hours.

[0067] According to one advantageous embodiment, the method does not include a quench after layer formation, i.e. after forming the final part, or after a post-manufacturing heat treatment. Preferably, the method therefore does not include a solution treatment step followed by a quench.

[0068] Since the manufacturing is carried out by additive manufacturing methods, it may be possible to create stress relief conditions capable of eliminating residual stresses as well as the precipitation of hardening phases by using a post-manufacturing heat treatment. This may also be thermal stress relief. The inventors have found that the set temperature T' of the post-manufacturing heat treatment is preferably between 300°C and 500°C.

[0069] Optional heat treatment and / or hot isostatic pressing can increase, among other things, the hardness or yield strength and electrical conductivity of the resulting product, although it should be noted that higher temperatures generally favor (electrical or thermal) conductivity at the expense of mechanical strength.

[0070] According to one embodiment, it is preferable that the temperature T' of the post-fabrication heat treatment, as well as the temperature increase at which the post-fabrication heat treatment is initiated, be as rapid as possible. For example, during the temperature increase, the temperature increase rate ΔT' (usually referred to by those skilled in the art as the "heating rate" in °C per minute or °C per second) is preferably greater than 5 °C per minute, or greater than 10 °C per minute, or even more preferably greater than 20 °C per minute, and even more advantageously greater than 40 °C per minute, and even more advantageously greater than 100 °C per minute. By temperature increase, we mean the temperature increase experienced by the part during the post-fabrication heat treatment. It seems optimal that the temperature increase is instantaneous, i.e., the manufactured part is subjected to the set temperature T' of the post-fabrication heat treatment from the start of the post-fabrication heat treatment. An instantaneous temperature increase can be obtained by placing the manufactured part in a high-temperature furnace already at the set temperature T', or by rapid heating means of the fluidized bed or molten salt bath type. The temperature increase can also be ensured by induction heating.

[0071] For the same temperature rise outside the part, the temperature variation inside the part depends, inter alia, on the heating medium (liquid, air, or inert gas) and the part geometry. In particular, the temperatures within the thickness or at the surface of the part may be different. For this reason, the aforementioned temperature rise corresponds to the temperature outside the part. By combining the temperature rise rate ΔT' during the temperature rise of the post-production heat treatment with the preheating temperature T and the post-production heat treatment temperature T' within the above-mentioned value ranges, it is possible to obtain a part with good resistance to thermal cracking.

[0072] According to another embodiment adapted to structurally hardened alloys, a solution treatment followed by quenching and tempering of the formed part and / or hot isostatic pressing can be carried out, in which case the solution treatment can advantageously be replaced by hot isostatic pressing.

[0073] However, the method according to the invention is advantageous because it preferably does not require a solution treatment followed by quenching, which may in certain cases have a detrimental effect on the mechanical strength, since it involves the formation of thin intermetallic compounds or dispersoids. Preferably, the method according to the invention does not include a solution treatment and / or quenching after layer formation, i.e., after the formation of the final part, or after a post-manufacturing heat treatment.

[0074] Preferably, the method according to the invention comprises the steps of: - an electrical conductivity in the raw state of greater than 6 MS / m, preferably greater than 7 MS / m, preferably greater than 8 MS / m; and - in the unprocessed state, a Knoop hardness HK0.05 of less than 140, preferably less than 130, preferably less than 120; and after an aftertreatment at 400 ° C for 4 hours, a Knoop hardness HK0.05 of more than 70, preferably more than 80, preferably more than 90, preferably more than 100, preferably more than 114, It is as if we have

[0075] According to one embodiment, the method according to the invention further optionally comprises a machining treatment and / or a chemical, electrochemical or mechanical surface treatment and / or a tribo-finishing, which may be carried out in order to, inter alia, reduce roughness and / or improve corrosion resistance and / or improve fatigue crack initiation resistance.

[0076] Optionally, it is possible to carry out mechanical deformation of the part, for example after additive manufacturing and / or before heat treatment.

[0077] Although the method is described in relation to an LPBF type additive manufacturing method, it can be applied to other additive manufacturing methods of the WAAM (Wire plus Arc Additive Manufacturing) type, as mentioned in relation to the prior art. Figure 2 illustrates such an option. An energy source 31, in this case a torch, generates an arc 32. In this arrangement, the torch 31 is held by a welding robot 33. The part 20 to be manufactured is placed on a base 10. In this example, the part to be manufactured is a wall extending along a transverse axis Z, perpendicular to the plane XY defined by the base 10. A filler wire 35 melts under the influence of the arc 12 to form a weld bead. The welding robot is controlled by a numerical model M, which changes position and stacks the various layers 201...20 that are stacked on top of each other to form the wall 20. n Each layer corresponds to a weld bead. n spreads in the plane XY according to a pattern defined by the numerical model M.

[0078] The diameter of the filler wire is preferably less than 3 mm. It can be comprised between 0.5 mm and 3 mm, preferably between 0.5 mm and 2 mm, or even between 1 mm and 2 mm. It is, for example, 1.2 mm.

[0079] For example, and without limitation, other methods are also contemplated. - Selective Laser Sintering - Direct Metal Laser Sintering - Selective Heat Sintering - Electron Beam Melting - Laser Melting Deposition - Direct Energy Deposition - Direct Metal Deposition - Direct Laser Deposition - Laser Deposition Technology - Laser Engineering Net Shaping - Laser Cladding Technology - Laser Freeform Manufacturing Technology - Laser Metal Deposition - Cold Spray Consolidation - Additive Friction Stir - Field Assisted Sintering Technology or spark plasma sintering, or - Inertia Rotary Friction Welding.

[0080] The solution according to the invention is particularly suited to the cold spray consolidation method (so-called "cold spray"), in particular due to the low hardness of the powder, which makes the deposition easy. The part can then be hardened by hardening annealing (post-heat treatment).

[0081] The solution according to the invention is particularly adapted for applications in the electrical, electronic and heat exchanger fields.

[0082] The present invention is described in further detail in the following examples, which are provided by way of illustration and not by way of limitation.

[0083] [Experimental Example] [Example 1] The alloys to be tested were poured into copper moulds using an Induthem VC 650V machine to obtain ingots 130 mm high, 95 mm wide and 5 mm thick.

[0084] The alloys listed in Table 1 below were tested by rapid prototyping. From the ingots obtained above, specimens were machined in the form of small plates measuring 60 x 22 x 3 mm for laser surface scanning. The small plates were placed in an LPBF machine and the surfaces were scanned with a laser, following the same scanning strategy and process conditions representative of those used for the LPBF method. In fact, in this way it was confirmed that the suitability of the alloys for the LPBF method could be evaluated, in particular their susceptibility to cracking at high temperatures, their hardness in the green state and after heat treatment, and their electrical conductivity in the green state and after heat treatment.

[0085] Under the laser beam, the metal melts into a bath approximately 500 μm thick. After the laser passes, the metal cools rapidly, as in the LPBF method. After laser scanning, a thin layer approximately 500 μm thick is melted on the surface and then solidifies. Due to the appropriate selection of scanning parameters, the properties of the metal in this layer are close to those of the metal in the core of the parts produced by LPBF. Laser scanning of the surfaces of different samples was performed using an AddUp brand selective laser powder bed fusion (LPBF) machine, Form UP® 350. The power of the laser source was 400 W, the vector deviation was 60 μm, the scanning speed was 500 mm / s, and the beam diameter was 65 μm.

[0086] On each small plate, two rectangular surfaces, each 5 mm x 35 mm, were remelted for hardness measurements, and a rectangular surface, 15 mm x 18 mm, was remelted for electrical conductivity measurements.

[0087] Figure 3 shows an example of a small plate after laser remelting, where reference number 1 corresponds to the two rectangular surfaces that were remelted and used for hardness measurements, reference number 2 corresponds to the rectangular surface that was remelted and used for electrical conductivity measurements, and reference number 3 corresponds to the non-remelted surface of the initial small plate.

[0088] After each test, a thermal post-treatment was applied to some samples, which was of the annealing type at a temperature of 400°C for 1 hour, or for 4 hours or 7 hours.

[0089] [Knoop hardness measurement] Hardness is an important property of an alloy: in fact, if the hardness is high in the remelted layer after scanning the surface with a laser, a part made from the same alloy will have a high yield strength.

[0090] To evaluate the hardness of the remelted layer, the resulting small plate was cut in a plane perpendicular to the laser path direction and then polished. After polishing, hardness measurements were performed within the remelted layer. Hardness measurements were performed using a Struers Durascan model instrument. The 50 g Knoop hardness method was selected, with the long diagonal of the indentation parallel to the plane of the remelted layer, ensuring a sufficient distance between the indentation and the edge of the sample. Thirty indentations were placed at half the thickness of the remelted layer. Figure 4 shows an example of hardness measurements. Reference number 4 corresponds to the remelted layer, reference number 5 corresponds to the Knoop hardness indentation, and reference number 6 corresponds to the non-remelted zone.

[0091] The hardness was measured according to the Knoop scale with a load of 50 g after laser treatment (in the raw state) and after a supplementary heat treatment at 400 °C for variable durations, making it possible to evaluate in particular the suitability of the alloy for hardening during heat treatment and the effect of any HIP treatment on the mechanical properties and electrical conductivity.

[0092] [Measurement of electrical conductivity] Based on the fact that electrical conductivity varies similarly to thermal conductivity, a 15 mm × 18 mm remelted rectangular surface of each small platelet was subjected to electrical conductivity measurements. The linear dependence between thermal and electrical conductivity according to the Wiedemann-Franz law was verified in Hatch's publication, "Aluminum Properties and Physical Metallurgy," ASM Metals, Park, OH, 1988. Electrical conductivity measurements were performed at the center of the remelted surface in the plane of the large surface of the small platelet (the plane parallel to the direction of the laser path). Conductivity measurements were performed in the raw state (without post-fabrication heat treatment) and after heat treatment at 400°C for variable durations of 1, 4, or 7 hours. An average of five separate measurements was performed for each condition.

[0093] The conductivity measurements were carried out at a temperature of approximately 20° C. using a measuring instrument of the Förster Sigmatest 2.069 type at a frequency of 960 kHz. By choosing this frequency, it is possible to limit the depth of the electrical conductivity measurements to the remelted zone of the platelet.

[0094] The compositions of the aluminum alloys tested are presented in mass percentages in Table 1 below.

[0095] As a reference alloy, composition number 1 was used, which contains aluminum and alloying elements Fe (1.00%) and Zr (1.20%).

[0096] [Table 1]

[0097] Table 2 below shows the Knoop hardness (HK0.05) and electrical conductivity values ​​measured for each alloy in the unprocessed state (0 hours of heat treatment) after laser remelting.

[0098] [Table 2]

[0099] Table 3 below shows the Knoop hardness (HK0.05) and electrical conductivity values ​​measured for each alloy after laser remelting and after annealing at 400° C. for 1 hour after laser remelting.

[0100] [Table 3]

[0101] Table 4 below shows the Knoop hardness (HK0.05) and electrical conductivity values ​​measured for each alloy after laser remelting and after annealing at 400° C. for 4 hours after laser remelting.

[0102] [Table 4]

[0103] Table 5 below shows the Knoop hardness (HK0.05) and electrical conductivity values ​​measured for each alloy after laser remelting and after annealing at 400°C for 7 hours after laser remelting.

[0104] [Table 5]

[0105] The results in Tables 2, 3, 4 and 5 show that for all the tested solutions, the conductivity and hardness values ​​were lowest in the raw state. The supplementary heat treatment carried out at 400 °C made it possible to simultaneously increase the electrical conductivity and the Knoop hardness (HK0.05) compared to the raw state.

[0106] For all solutions tested, the maximum conductivity was obtained after 7 hours at 400°C.

[0107] For all the solutions tested, the maximum hardness was obtained after 1 to 7 hours of treatment at 400°C. The duration allowing maximum hardness appeared to be between 0.5 and 10 hours for all the solutions tested.

[0108] Extending the duration of the heat treatment at 400°C beyond 10 hours would likely further increase the thermal conductivity, but would decrease the hardness.

[0109] Therefore, the choice of final heat treatment can be selected depending on the intended application. For alloys containing Sc, a heat treatment temperature of 300-400°C for a duration of 0.5-10 hours appears to be optimal for maximizing hardness. For example, a temperature of 325°C and a duration of 4 hours.

[0110] Alloy No. 1 allowed us to obtain the highest overall electrical conductivity under the conditions tested, i.e., in the raw state (without post-fabrication heat treatment) and after heat treatment at 400°C for variable durations of 1, 4, or 7 hours. The best trade-off in Knoop hardness (HK0.05) / electrical conductivity (MS / m) for this alloy was obtained with a post-fabrication heat treatment at 400°C for 4 hours, with values ​​of 113.32 HK0.05 for hardness and 28.64 MS / m for conductivity, respectively. This alloy offers an excellent candidate for applications requiring high thermal or electrical conductivity, such as heat exchangers, heat sinks, electronic cases, and RF antennas. However, the maximum hardness offered by this alloy (113.32 HK0.05) still remains insufficient for some applications requiring high mechanical strength, such as structural parts and hydraulic blocks, without requiring special performance in terms of electrical conductivity.

[0111] Tables 4 and 5 show that the alloys of the present invention overall provide Knoop hardness (HK0.05) after heat treatment that exceeds that of alloy Reference No. 1, allowing for a maximum hardness of 149.69 HK0.05 obtained for Alloy No. 4 after a post-fabrication heat treatment at 400°C for 4 hours.

[0112] The overall alloy of the present invention may make it possible to obtain very good workability of parts by the LPBF process while at the same time obtaining excellent mechanical performance of the parts during use. Good workability of parts in the LPBF process can be obtained by combining a sufficiently low hardness level (Knoop hardness HK0.05 in the as-fabricated state less than 140, preferably less than 130, preferably less than 120) and a sufficiently high thermal or electrical conductivity (electrical conductivity greater than 6 MS / m, preferably greater than 7 MS / m, preferably greater than 8 MS / m in the as-fabricated state) in the as-fabricated state. This combination of hardness and conductivity makes it possible to limit the residual stress level of the part in the as-fabricated state, thus significantly limiting the risk of cracking, delamination, or distortion, and therefore significantly improving the workability of the part in the LPBF process. Excellent mechanical performance of the part during use can be obtained while maximizing the hardness of the part after post-fabrication heat treatment (e.g., Knoop hardness HK0.05 greater than 70, preferably greater than 80, preferably greater than 90, preferably greater than 100, preferably greater than 114 after heat treatment at 400°C for 4 hours).

[0113] Table 1 shows that, contrary to alloy 1, all of the alloys of the present invention had a total additive element content of more than 3%. [Explanation of symbols]

[0114] 1 Two rectangular surfaces were remelted and used for hardness measurements. 2. The rectangular surface that was remelted and used for the electrical conductivity measurement 3. Unremelted surface of initial platelet 4 Remelted layer 5 Knoop hardness indentation 6. Non-remelted zone 10 Pedestal 12 Arc 20 parts 31 Energy Sources 32 Arc 33 Welding robot 35 Filler wire

Claims

1. Continuous metal layers (20) superimposed on each other １ ...20 ｎ 1. A method for manufacturing a component (20) comprising forming a layer (15, 25) of a filler metal (15, 25) in a layer-by-layer structure, the filler metal (15, 25) melting and then solidifying into said layer upon receiving a supply of energy, the method comprising: forming a filler metal (15, 25) containing (in weight percent) the following alloying elements: at least one alloying element chosen from Zr, Hf and Er, each and in total according to a mass fraction of greater than or equal to 0.30%, preferably between 0.30 and 2.50%, preferably between 0.40 and 2.00%, more preferably between 0.40 and 1.80%, even more preferably between 0.50 and 1.60%, even more preferably between 0.60 and 1.50%, even more preferably between 0.70 and 1.40%, even more preferably between 0.80 and 1.30%, at least one alloying element selected from among Cr, V, Ti and Mn, for V, Ti and Mn each and in total according to a mass fraction of more than 0.50%, preferably from 0.50 to 6.00%, suitably from 1.00 to 5.00%, more suitably from 1.00 to 4.00%, even more suitably from 1.00 to 3.00%; and for Cr according to a mass fraction of more than 0.50 to 3.00%, at least one alloying element selected from among Co, La, Ce, misch metal, W, Ta, Mo and Nb, optionally each according to a mass fraction of at least 0.10%, preferably at least 0.25%, more preferably at least 0.50%, in total; and each according to a mass fraction of less than 5.00%, preferably less than 4.00%, preferably less than 3.00%; and in total according to a mass fraction of less than 7.00%, preferably less than 6.00%, preferably less than 5.00%, preferably less than 4.00%, Fe according to a mass fraction of 0.10 to 2.50%, preferably 0.15 to 2.50%, advantageously 0.20 to 2.50%, better still 0.30 to 2.50%, even better still 0.50 to 2.50% and even better still 0.75 to 2.25%, Ni, optionally according to a mass fraction of less than 3.00%, preferably less than 2.00%, preferably less than 1.00% and suitably less than 0.50%, at least one alloying element chosen from among Cu and Ag, optionally according to a mass fraction of 0.10 to 3.00%, preferably 0.10 to 2.00%, preferably 0.10 to 1.60%, preferably 0.10 to 1.00%, preferably 0.10 to 0.70%, each and in total; Si optionally according to a mass fraction of less than 3.00%, preferably less than 2.00%, preferably less than 1.00%, preferably less than 0.50%; preferably less than 0.30%, preferably less than 0.20%, Sc, optionally according to a mass fraction of less than 0.80%, preferably less than 0.70%, preferably less than 0.60%, preferably less than 0.50%, preferably less than 0.40%, preferably less than 0.30%, Mg, optionally according to a mass fraction of less than 2.00%, preferably less than 1.00%, advantageously less than 0.50% and more advantageously less than 0.30%, Zn, optionally according to a mass fraction of less than 2.00%, preferably less than 1.00%, advantageously less than 0.50% and better still less than 0.30%, Li, optionally according to a mass fraction of less than 2.00%, preferably less than 1.00%, advantageously less than 0.50% and more advantageously less than 0.30%, at least one element chosen from among Nd, Y, Tm, Lu, Yb, Sr, Ba, Sb, Bi, Ca, P, B, In and Sn, optionally according to a mass fraction of less than or equal to 1.00%, preferably less than or equal to 0.50%, preferably less than or equal to 0.30%, more preferably less than or equal to 0.10%, even more preferably less than or equal to 700 ppm each, and in total less than or equal to 2.00%, preferably less than or equal to 1.00%, preferably less than or equal to 0.50%, preferably less than or equal to 0.30%, impurities individually less than 0.05% and in total less than 0.15%; Including, The remainder is aluminum, the aluminum alloy.

2. 2. The method of claim 1, wherein the aluminum alloy includes at least one alloying element selected from the group consisting of Co, La, Ce, misch metal, W, Ta, Mo, and Nb.

3. 3. The method according to claim 1, wherein the mass fraction of aluminum is less than 97%.

4. The part (20) an electrical conductivity in the raw state of greater than 6 MS / m, preferably greater than 7 MS / m, preferably greater than 8 MS / m, and a Knoop hardness HK0.05 in the as-manufactured state of less than 140, preferably less than 130, preferably less than 120, and - after a post-treatment at 400°C for 4 hours, a Knoop hardness HK0.05 of more than 70, preferably more than 80, preferably more than 90, preferably more than 100, preferably more than 114, 4. The method according to claim 1, wherein the

5. layer (20 １ ...20 ｎ 5. The method according to claim 1, further comprising applying a post-manufacturing heat treatment, preferably tempering or annealing, after the formation of said first and second layers, i.e. after the formation of the final part.

6. 6. The method according to any one of claims 1 to 5, wherein no solution treatment and / or quenching is involved after forming the layer, i.e. after forming the final part, or after any post-manufacturing heat treatment.

7. 7. The method according to claim 1, wherein the method is carried out at a preheating temperature T of up to 500°C.

8. The filler metal is in the form of a powder (15), which is exposed to a light beam (12) or a charged particle beam, resulting in localized melting and subsequent solidification, forming a solid layer (20 １ ...20 ｎ 8. The method of claim 1, wherein a hydroxyl group is formed.

9. The filler metal comes from a filler wire (25), and exposure of it to a heat source (22) results in localized melting and subsequent solidification, forming a solid layer (20 １ ...20 ｎ 8. The method of claim 1, wherein a hydroxyl group is formed.

10. A metal part obtained by the method according to any one of claims 1 to 9.

11. A powder intended for use as a filler material in additive manufacturing, comprising the following alloying elements (by weight): at least one alloying element chosen from Zr, Hf and Er, each and in total according to a mass fraction of greater than or equal to 0.30%, preferably between 0.30 and 2.50%, preferably between 0.40 and 2.00%, more preferably between 0.40 and 1.80%, even more preferably between 0.50 and 1.60%, even more preferably between 0.60 and 1.50%, even more preferably between 0.70 and 1.40%, even more preferably between 0.80 and 1.30%, at least one alloying element selected from among Cr, V, Ti and Mn, for V, Ti and Mn each and in total according to a mass fraction of more than 0.50%, preferably from 0.50 to 6.00%, suitably from 1.00 to 5.00%, more suitably from 1.00 to 4.00%, even more suitably from 1.00 to 3.00%; and for Cr according to a mass fraction of more than 0.50 to 3.00%, at least one alloying element selected from among Co, La, Ce, misch metal, W, Ta, Mo and Nb, optionally each according to a mass fraction of at least 0.10%, preferably at least 0.25%, more preferably at least 0.50%, in total; and each according to a mass fraction of less than 5.00%, preferably less than 4.00%, preferably less than 3.00%; and in total according to a mass fraction of less than 7.00%, preferably less than 6.00%, preferably less than 5.00%, preferably less than 4.00%, Fe according to a mass fraction of 0.10 to 2.50%, preferably 0.15 to 2.50%, advantageously 0.20 to 2.50%, better still 0.30 to 2.50%, even better still 0.50 to 2.50% and even better still 0.75 to 2.25%, Ni, optionally according to a mass fraction of less than 3.00%, preferably less than 2.00%, preferably less than 1.00% and suitably less than 0.50%, at least one alloying element chosen from among Cu and Ag, optionally according to a mass fraction of 0.10 to 3.00%, preferably 0.10 to 2.00%, preferably 0.10 to 1.60%, preferably 0.10 to 1.00%, preferably 0.10 to 0.70%, each and in total; Si optionally according to a mass fraction of less than 3.00%, preferably less than 2.00%, preferably less than 1.00%, preferably less than 0.50%; preferably less than 0.30%, preferably less than 0.20%, Sc, optionally according to a mass fraction of less than 0.80%, preferably less than 0.70%, preferably less than 0.60%, preferably less than 0.50%, preferably less than 0.40%, preferably less than 0.30%, Mg, optionally according to a mass fraction of less than 2.00%, preferably less than 1.00%, advantageously less than 0.50% and more advantageously less than 0.30%, Zn, optionally according to a mass fraction of less than 2.00%, preferably less than 1.00%, advantageously less than 0.50% and better still less than 0.30%, Li, optionally according to a mass fraction of less than 2.00%, preferably less than 1.00%, advantageously less than 0.50% and more advantageously less than 0.30%, at least one element chosen from among Nd, Y, Tm, Lu, Yb, Sr, Ba, Sb, Bi, Ca, P, B, In and Sn, optionally according to a mass fraction of less than or equal to 1.00%, preferably less than or equal to 0.50%, preferably less than or equal to 0.30%, more preferably less than or equal to 0.10%, even more preferably less than or equal to 700 ppm each, and in total less than or equal to 2.00%, preferably less than or equal to 1.00%, preferably less than or equal to 0.50%, preferably less than or equal to 0.30%, impurities individually less than 0.05% and in total less than 0.15%; Including, A powder characterized in that it is composed of an aluminum alloy, the remainder being aluminum.

12. 12. Use of the powder according to claim 11 in a manufacturing process selected from electron beam melting, cold spray consolidation, laser metal deposition, friction additive manufacturing, electric field assisted sintering or inertial rotational friction welding, preferably cold spray consolidation.

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