7075-type aluminum alloy products produced using solid-state manufacturing

Abstract

Solid-state additively manufactured aluminum alloy products and methods for producing them are described. After heat treatment of the additively manufactured aluminum alloy product, at least 60% volume percent of the aluminum in the additively manufactured aluminum alloy product exists as equiaxed grains with an aspect ratio of less than 2:1. Minimal voids exist between metal atoms in the additively manufactured aluminum alloy product. Various parts, including 7075-type aluminum alloy products, are described.

Description

[Technical Field]

[0001] [Priority application] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 416,755, filed October 17, 2022, the entire disclosure of which is hereby incorporated by reference herein.

[0002] Certain embodiments described herein relate to aluminum alloy products. More particularly, certain configurations described relate to aluminum alloy products produced using 7075-type aluminum alloy and solid state additive manufacturing. [Background technology]

[0003] Metal parts are often produced using forging or extrusion processes, which often require the use of expensive components to form or produce the metal part. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] U.S. Patent No. 11,311,959 Summary of the Invention [Means for solving the problem]

[0005] Certain aspects, embodiments, features, and attributes of aluminum alloy products produced using solid state additive manufacturing components are described. The aluminum alloy products can have similar or better properties than forged or extruded products. Large and complex parts can be produced using aluminum alloys.

[0006] In certain embodiments, a solid-state additively manufactured aluminum alloy product is described. In certain configurations, at least 60 volume percent of the aluminum in the additively manufactured aluminum alloy product exists as equiaxed grains with an aspect ratio of less than 2:1 after heat treatment of the additively manufactured aluminum alloy product. In some embodiments, only minimal voids exist between metal atoms in the additively manufactured aluminum alloy product. In certain examples, the solid-state additively manufactured aluminum product includes 5-6 weight percent zinc, 2.1-2.9 weight percent magnesium, 1.2-2 weight percent copper, no more than 0.5 weight percent silicon, titanium, chromium, iron, or manganese, with the remainder being aluminum and incidental impurities totaling 100 weight percent.

[0007] In some configurations, the solid phase additively manufactured aluminum alloy product comprises an ultimate tensile strength (Ftu) of at least 420 MPa. In other configurations, the solid phase additively manufactured aluminum alloy product comprises a tensile yield strength (Fty) of at least 352 MPa. In additional configurations, the solid phase additively manufactured aluminum alloy product comprises an elongation to fracture or ductility (e) of at least 7%.

[0008] In some embodiments, the solid phase additively manufactured aluminum alloy product comprises a single orbit of deposited solid phase additively manufactured aluminum alloy product.

[0009] In other embodiments, the solid phase additively manufactured aluminum alloy product comprises a plurality of overlapping tracks of deposited solid phase additively manufactured aluminum alloy products, in some examples, adjacent tracks overlap by at least 10%.

[0010] In certain configurations, the solid state additively manufactured aluminum alloy product includes a substrate that receives the solid state additively manufactured aluminum alloy product.

[0011] In other embodiments, at least 75% volume percent of the aluminum in the additively manufactured aluminum alloy product is present as equiaxed grains, hi some embodiments, at least 90% volume percent of the aluminum in the additively manufactured aluminum alloy product is present as equiaxed grains.

[0012] In another aspect, a solid-state additively manufactured aluminum alloy is disclosed, produced by adding an aluminum alloy to a surface of a substrate using a solid-state additive manufacturing process. In some configurations, the aluminum alloy is solid-state applied as a first aluminum alloy layer to the surface of the substrate at a first tool temperature between 360 degrees Celsius and 485 degrees Celsius and then heat-treated. In some examples, at least 60 volume percent of the aluminum in the applied and heat-treated first aluminum alloy layer exists as equiaxed grains with an aspect ratio of less than 2:1, and minimal voids exist between the metal atoms in the applied and heat-treated first aluminum alloy layer. In certain embodiments, the solid-state additively manufactured aluminum alloy includes 5-6 weight percent zinc, 2.1-2.9 weight percent magnesium, 1.2-2 weight percent copper, no more than 0.5 weight percent silicon, titanium, chromium, iron, or manganese, with the remainder being aluminum and incidental impurities totaling 100 weight percent.

[0013] In some examples, the solid phase additively manufactured aluminum alloy comprises an ultimate tensile strength (Ftu) of at least 420 MPa. In other examples, the solid phase additively manufactured aluminum alloy comprises a tensile yield strength (Fty) of at least 352 MPa. In some embodiments, the solid phase additively manufactured aluminum alloy comprises an elongation to fracture or ductility (e) of at least 7%.

[0014] In certain embodiments, the solid phase additively manufactured aluminum alloy comprises a single orbit of deposited solid phase additively manufactured aluminum alloy. In other embodiments, the solid phase additively manufactured aluminum alloy comprises multiple overlapping orbits of deposited solid phase additively manufactured aluminum alloy. In some cases, adjacent orbits overlap by at least 10%.

[0015] In some embodiments, the solid state additively manufactured aluminum alloy comprises a substrate that receives the solid state additively manufactured aluminum alloy.

[0016] In other embodiments, at least 75% volume percent of the aluminum in the additively manufactured aluminum alloy is present as equiaxed grains, hi some embodiments, at least 90% volume percent of the aluminum in the additively manufactured aluminum alloy is present as equiaxed grains.

[0017] In an additional aspect, an additive manufacturing system for producing an aluminum alloy product is described. In certain configurations, the additive manufacturing system includes a feeding unit, a spindle, a tool, a temperature sensor, and a processor. The feeding unit can be configured to receive an aluminum alloy filler material. The spindle includes an internal passage configured to receive the aluminum alloy filler material from the feeding unit. The tool is coupled to the spindle and configured to receive the aluminum alloy filler material from the spindle and apply the received aluminum alloy filler material in a solid state as a first aluminum alloy layer to a surface of a substrate. The temperature sensor is configured to measure a temperature of the tool during application of the aluminum alloy filler material as the first aluminum alloy layer to the surface of the workpiece. The processor is electrically coupled to the temperature sensor and the spindle and, optionally, other components. The system also includes a computer-readable medium electrically coupled to the processor. A computer-readable medium can have instructions stored thereon that, when executed by a processor, cause the processor to control movement of a spindle to control a first tool temperature of a tool between 360 degrees Celsius and 485 degrees Celsius during application of a first aluminum alloy layer to a surface of a substrate. The applied first aluminum alloy layer comprises at least 60 volume percent aluminum as equiaxed grains having an aspect ratio of less than 2:1, and after heat treatment, minimal voids exist between metal atoms in the applied and heat-treated first aluminum alloy layer. The applied and heat-treated first aluminum alloy layer comprises 5-6 weight percent zinc, 2.1-2.9 weight percent magnesium, 1.2-2 weight percent copper, not more than 0.5 weight percent silicon, titanium, chromium, iron, or manganese, with the remainder being aluminum and incidental impurities totaling 100 weight percent.

[0018] In certain embodiments, the processor is configured to increase the temperature of the tool from the first tool temperature to a second tool temperature that is about 20 degrees Celsius greater than the first tool temperature to add a vertical layer of aluminum alloy to the added first aluminum alloy layer.

[0019] In some embodiments, the tool comprises tool steel, copper, a copper alloy, tungsten, or a tungsten alloy. In other embodiments, the tool comprises at least one protrusion. In some examples, the feeding unit includes an actuator that forces the aluminum alloy filler material into the spindle and the tool.

[0020] In another aspect, a method for producing an additively manufactured aluminum alloy is provided. In certain embodiments, the method includes applying an aluminum alloy as a first aluminum alloy layer to a surface of a substrate using an additive manufacturing process including a rotary tool, wherein the aluminum alloy is applied in the solid phase to the surface of the workpiece at a first tool temperature. In other embodiments, the method includes heat treating the solid-phase applied first aluminum alloy layer, wherein the applied first aluminum alloy layer comprises at least 60 volume percent aluminum as equiaxed grains having an aspect ratio of less than 2:1, and wherein after heat treatment, minimal voids exist between metal atoms in the applied and heat-treated first aluminum alloy layer, and wherein the applied and heat-treated first aluminum alloy layer comprises 5-6 weight percent zinc, 2.1-2.9 weight percent magnesium, 1.2-2 weight percent copper, no more than 0.5 weight percent silicon, titanium, chromium, iron, or manganese, with the remainder being aluminum and incidental impurities totaling 100 weight percent.

[0021] In some embodiments, the first tool temperature is between 360 degrees Celsius and 485 degrees Celsius.

[0022] In other embodiments, the first tool temperature is maintained by one or more of: changing the speed of a spindle coupled to the rotary tool; changing the torque of a spindle coupled to the rotary tool; changing the power of a spindle coupled to the rotary tool; changing the deposition rate of the aluminum alloy being applied; changing the traverse speed of the rotary tool; changing the filler feed rate into the rotary tool; changing the layer height; changing the filler force; changing the pressure under the rotary tool; using an external heating / cooling source adjacent to the rotary tool; using an external heating / cooling source adjacent to the face of the substrate; or changing the tool geometry during application.

[0023] In some embodiments, the method includes solid-state applying a second aluminum alloy layer to a first aluminum alloy layer applied using a rotary tool, wherein the second aluminum alloy layer is applied using a second tool temperature that is 20 degrees Celsius higher than the first tool temperature. In certain embodiments, after heat treating the applied second aluminum alloy layer, the applied and heat-treated second aluminum alloy layer comprises at least 60 volume percent aluminum as equiaxed grains having an aspect ratio of less than 2:1, minimal voids exist between metal atoms in the applied and heat-treated second aluminum alloy layer, and the applied and heat-treated second aluminum alloy layer comprises 5-6 weight percent zinc, 2.1-2.9 weight percent magnesium, 1.2-2 weight percent copper, not more than 0.5 weight percent silicon, titanium, chromium, iron, or manganese, with the remainder being aluminum and incidental impurities totaling 100 weight percent.

[0024] In another aspect, a subtractive and additive method of producing an aluminum alloy includes adding an aluminum alloy as a first aluminum alloy layer to a surface of a substrate using an additive manufacturing process including a rotary tool, wherein the aluminum alloy is added in a solid phase at a first tool temperature to the surface of the workpiece; removing a portion of the added first aluminum alloy layer using a subtractive process to provide a subtracted first aluminum alloy layer on the substrate; and heat treating the subtracted first aluminum alloy layer, wherein the subtracted first aluminum alloy layer is at least 60% by volume. percent aluminum as equiaxed grains having an aspect ratio of less than 2:1, and after heat treating there is minimal void space between metal atoms in the deducted heat treated first aluminum alloy layer, and the deducted heat treated first aluminum alloy layer contains 5-6 weight percent zinc, 2.1-2.9 weight percent magnesium, 1.2-2 weight percent copper, not more than 0.5 weight percent silicon, titanium, chromium, iron, or manganese, the balance being aluminum and incidental impurities totaling 100 weight percent.

[0025] In certain configurations, the first tool temperature is between 360 degrees Celsius and 450 degrees Celsius. In some embodiments, the first tool temperature is maintained by one or more of changing the speed of a spindle coupled to the rotary tool, or changing the torque of a spindle coupled to the rotary tool, or changing the power of a spindle coupled to the rotary tool, or changing the deposition rate of the aluminum alloy being applied, or changing the traverse speed of the rotary tool, or changing the filler feed rate into the rotary tool, or changing the layer height, or changing the filler force, or changing the pressure under the rotary tool, or using an external heating / cooling source adjacent to the rotary tool, or using an external heating / cooling source adjacent to the face of the substrate, or changing the tool geometry during application.

[0026] In some embodiments, the method includes solid-state applying a second aluminum alloy layer to the subtracted aluminum alloy layer using a rotary tool, wherein the second aluminum alloy layer is applied using a second tool temperature that is 20 degrees Celsius higher than the first tool temperature. In certain embodiments, after heat treating the applied second aluminum alloy layer, the applied and heat-treated second aluminum alloy layer comprises at least 60 volume percent aluminum as equiaxed grains having an aspect ratio of less than 2:1, minimal voids exist between metal atoms in the applied and heat-treated second aluminum alloy layer, and the applied and heat-treated second aluminum alloy layer comprises 5-6 weight percent zinc, 2.1-2.9 weight percent magnesium, 1.2-2 weight percent copper, not more than 0.5 weight percent silicon, titanium, chromium, iron, or manganese, with the remainder being aluminum and incidental impurities totaling 100 weight percent.

[0027] Additional aspects, embodiments, configurations, and features are described in more detail below.

[0028] Certain aspects are described in more detail below with reference to the accompanying drawings. [Brief explanation of the drawings]

[0029] [Figure 1] FIG. 1 illustrates certain components of a solid phase additive manufacturing system including a feeding unit, a spindle, and a tool in accordance with certain embodiments. [Figure 2] FIG. 1 illustrates a feeding unit, a spindle, a tool, and certain other components of a solid phase additive manufacturing system in accordance with certain embodiments. [Figure 3] FIG. 10 is another diagram illustrating a feeding unit, a spindle, a tool, and certain other components of a solid phase additive manufacturing system in accordance with certain embodiments. [Figure 4] FIG. 10 is an additional diagram illustrating a feeding unit, a spindle, a tool, and certain other components of a solid phase additive manufacturing system in accordance with certain embodiments. [Figure 5] 1A-1C illustrate a tool including surface features in accordance with certain embodiments. [Figure 6] 1A-1C illustrate temperature sensors positioned within or adjacent to a tool according to certain embodiments. [Figure 7] FIG. 1 illustrates various components of a control system including a processor that can be used to control the operation of various components within a solid phase additive manufacturing system. [Figure 8] FIG. 1 illustrates a hybrid additive manufacturing and subtractive system in accordance with certain embodiments. [Figure 9] FIG. 1 is a diagram of an aircraft landing gear according to certain embodiments. [Figure 10] FIG. 1 is a diagram of a rocket nozzle according to certain embodiments. [Figure 11] FIG. 1 is a diagram of an aircraft fuel nozzle according to certain embodiments. [Figure 12] FIG. 1 is an illustration of an aircraft fuselage according to certain embodiments. [Figure 13] 1 is an illustration of an aircraft wing in accordance with certain embodiments. [Figure 14] 1 is an illustration of an aircraft cockpit in accordance with certain embodiments. [Figure 15] 1 is an illustration of an aircraft engine according to certain embodiments. [Figure 16] FIG. 1 is a diagram of an aircraft propeller according to certain embodiments. [Figure 17] FIG. 1 is a diagram of an aircraft tail section according to certain embodiments. [Figure 18] 1 is a diagram of an aircraft rotor, according to certain embodiments. [Figure 19] FIG. 1 is an illustration of an unmanned aerial vehicle in accordance with certain embodiments. [Figure 20] FIG. 1 illustrates equiaxed grains produced from depositing 7075-0 aluminum alloy using a solid state additive manufacturing system. [Figure 21] 1 is a photograph illustrating a build using 7075 alloy material, according to certain embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0030] Certain embodiments described herein use 7075-type aluminum alloys, e.g., 7x75 aluminum alloys, in combination with solid-state additive manufacturing to produce products and articles comprising the 7075-type aluminum alloy. Generally, the 7075 aluminum alloy has a composition of 5.6-6.1 weight percent zinc, 2.1-2.5 weight percent magnesium, 1.2-1.6 weight percent copper, less than 0.5 weight percent silicon, iron, manganese, titanium, chromium, and other metals that add up to 100 weight percent in addition to the aluminum. Unless otherwise specified below, references to "alloy" refer to the 7075 aluminum alloy.

[0031] In certain configurations, the alloy can be artificially aged or heat treated to impart the desired temper after addition / deposition. For example, alloy tempers may vary, including, but not limited to, 7075-0, 7075-T6, 7075-T651, 7075-T7, and 7075-RRA. Fully annealed 7075 aluminum alloy (7075-0 temper) has an ultimate tensile strength of up to 280 MPa (40,000 psi) and an ultimate yield strength of up to 140 MPa (21,000 psi). This material has an elongation to fracture (extension before ultimate fracture) of 9-10%. 7075-0 has high corrosion resistance. 7075 aluminum alloy in the T6 temper has an ultimate tensile strength of 510-540 MPa (74,000-78,000 psi) and a yield strength of at least 430-480 MPa (63,000-69,000 psi). This aluminum alloy has an elongation at break of 5-11%. The T6 temper is typically achieved by homogenizing 7075 alloy castings at temperatures ranging from 460°C to 490°C for several hours, quenching, and then aging at 120°C for 24 hours. This produces the peak strength of 7075-type alloys. This strength is derived primarily from finely dispersed eta- and eta'-precipitates, both within the grains and along grain boundaries. 7075 in the T651 temper has an ultimate tensile strength of 570 MPa (83,000 psi) or higher and a yield strength of 500 MPa (73,000 psi) or higher. This temper has an elongation at break of 3-9%. These properties may vary depending on the form of the material used. The T7 temper, e.g., the T73X temper, may have an ultimate tensile strength of 505 MPa (73,200 psi) or higher and a yield strength of 435 MPa (63,100 psi) or higher. This temper has an elongation at break of 13%. The T7 temper is achieved by overaging the material (i.e., aging above its peak hardness). This temper is often achieved by aging at 100-120°C for several hours, followed by a further aging at 160-180°C for 24 hours or longer. The T7 temper produces a microstructure composed primarily of eta precipitates.In contrast to the T6 temper, these eta grains are significantly larger and tend to grow along grain boundaries. This makes them less susceptible to stress corrosion cracking. The recovery re-aging (RRA) temper is a multi-stage heat treatment temper. This temper begins with sheet in the T6 temper and involves overaging beyond peak hardness (T6 temper) to near the T7 temper. A subsequent 24-hour re-aging treatment at 120°C restores hardness and strength to or very near T6 temper levels. RRA treatment can be achieved by many different procedures. The basic guideline is a 15-minute 10-second recovery between 180°C and 240°C.

[0032] In some embodiments, alloy 7075 is a widely used, high-strength aerospace aluminum alloy. This alloy is produced by wrought processes, including rolling, extrusion, and forging, or any combination. However, thicker 7075 products present strength, cost, and lead-time challenges. Producing thick, three-dimensional shapes from 7075 is typically accomplished by one of two process routes: 1) machining from plate or hand forging, which is hindered by the low strength of thick 7075 due to its quench sensitivity and rolling thickness limitations; or 2) forging in a forming die, which helps overcome the limitations of plate but requires expensive setup operations with long lead times. While the industry has a long history of developing casting alloys, none has yet achieved the integrity and strength of 7075. While forging can produce many identical parts, it is significantly more expensive and has a long lead time. Conventional additive manufacturing techniques require either melting aluminum alloys, which is not preferred for alloy 7075, or using powder metallurgy or rapidly solidified feedstocks, which are very expensive and primarily developed for smaller parts.

[0033] In solid-state additive manufacturing, the various alloys described herein can be used in bar, sheet, pellet, rod, beam, square rod, or other forms to produce products and articles containing the alloy. For example, alloy bar can be added to a solid-state additive (SSA) manufacturing system to achieve large articles containing the alloy. Generally, solid-state additive manufacturing produces parts and articles with similar or superior properties to existing processes, such as die forging, but at a lower cost and material usage. (SSA) manufacturing does not require dedicated forging tooling, which can be very expensive and time-consuming to design and shape. Lead times for new forging designs are often six months and can be longer than a year. The cost of such tooling varies depending on the size and complexity of the design, but is often $100,000 or more. The equipment required for forging operations is very expensive, and expansions to add capacity can take years from approval to code qualification.

[0034] SSA System Components

[0035] In some cases, SSA manufacturing systems can use friction stir additive processes to build parts using solid-state methods that can produce large three-dimensional shapes without melting and resolidifying metal or using expensive tooling. Compared to casting, SSA manufacturing processes offer significantly better properties and metal integrity (density, constituent grain, porosity). Unlike forging, no expensive tooling is required, thereby saving costs and shortening lead times when producing parts. Machined plates can produce significantly thicker parts because they are limited to walls approximately 200 mm high and only use 200 mm thick plates, which have significantly lower strength due to slower quenching for thicker products. Because SSA manufacturing processes have fewer constraints on shape, they allow parts to be tailored and designed in ways not possible with forging. For example, the walls move closer together as they are deposited, allowing for shapes to be closed cones. The resulting articles can have properties similar to those of plate and forgings.

[0036] In certain configurations, the exact process steps used in SSA fabrication can vary, as noted in detail below. Generally, and without intending to limit the specific process steps and conditions that can be used, the manufacturing process begins with a substrate, usually a plate, although the substrate can be other product forms such as extrusions and forgings. The manufacturing process then involves building a part layer-by-layer, either single-wall for thin sections or multiple overlapping walls for thick sections. By moving the deposition spindle relative to a reference point, a 3D part with a selected shape is built. The process controls the deposition by monitoring temperature over a range of careful parameters, including external heating / cooling, deposition rate, rotational speed, and spindle travel, and uses temperature feedback to affect other parameters to achieve excellent adhesion and metallurgical bonding between each layer and overlapping layers. As noted herein, the resulting product or article can contain equiaxed grains in most volumetric quantities, i.e., greater than 50 volume percent. The material applied in solid form to the substrate is typically a non-heat-treatable alloy that can then be heat-treated / aged after deposition to impart a desired temper. This material can be removed from the substrate after deposition, or the substrate can remain in contact with the additional material and be used to form the final part.

[0037] A schematic diagram of various components of a solid phase additive manufacturing system in certain embodiments is shown in FIG. 1. The system 100 includes a feeding unit 110, a spindle 120, and a tool 130. A passageway (throat) 140 for the alloy filler material (feedstock) is shown. The system 100 can include other components, as noted below. A substrate 150 is shown that receives the printed alloy material from the tool 130. The alloy material can be fed from the feeding unit 110 into the throat 140 at a desired rate, as noted below. For example, a piston or rod can be used to push the alloy feedstock toward the surface of the substrate 150. Typically, the spindle 120 is coupled to a motor (not shown) to rotate itself and the tool 130 at a desired rotational speed. The tooling 130 is positioned adjacent to the substrate 150 and deposits the alloy material in the throat in solid form onto the surface of the substrate 150. As discussed in more detail below, the tooling 130 may include surface features and / or certain geometries that aid in the deposition of alloy material onto the surface of the substrate 150. Friction-based fabrication tooling 130 generally includes a non-consumable body formed from a material capable of resisting deformation when subjected to frictional heat and compressive loads at the surface of the substrate 150. As the spindle 120 and tooling 130 rotate, thin layers or tracks of alloy material are deposited onto the surface of the substrate 150. The deposition temperature can be closely controlled to influence the desired microstructure and, correspondingly, to impart desired deposited alloy material properties to the deposited material after heat treatment. As discussed in more detail below, the deposition temperature can be lower during the initial deposition of the alloy material onto the substrate 150 and increased during the addition of subsequent layers / walls / tracks to impart the desired metallurgical bond between the multiple walls / layers / tracks. The exact temperature difference may vary depending on the particular alloy used, and exemplary deposition temperatures are discussed in more detail below.

[0038] In certain embodiments, the system 100 may include a suitable platform, motor, or other components to allow the substrate 150 to move independently of the spindle 120 and the tooling 130. For example, the substrate 150 and the tooling 130 may each move independently in the x, y, and z directions. This independent movement allows for the creation of complex shapes that vary in thickness across the face of the resulting part, as well as a high degree of control over the various components during the deposition of the alloy feedstock material onto the face of the substrate 150.

[0039] In certain configurations, the feeding unit of the system 100 generally includes a reservoir configured to receive the alloy feedstock material. The exact shape and configuration of the reservoir may vary depending on the particular form of the alloy feedstock material used. The alloy feedstock material may be fed in a continuous or discontinuous manner, as desired. A diagram of certain components of a feeding unit configured to feed a continuous solid rod or solid rod-like alloy material is shown in FIG. 2. The feeding unit 211 is positioned in communication with a spindle 212 and a tool 213. A throat or operable passageway 214 capable of receiving the alloy filler material is shown, along with a base plate 250. Other system components are also shown, such as a motor 224, a drive pulley 228 for the spindle 212, the alloy rod filler material 229, a floating (non-driven) secondary spindle 233, a lower spindle 234, a tool holder 235, and a pressure plate 236.

[0040] Another view of the feed unit is shown in FIG. 3. This feed unit, shown in FIG. 3, can be used to feed discontinuous solid alloy filler material, which can be in the form of a rod, beam, or other shape. The view in FIG. 3 shows the spindle 212 and tool 223 along with the working passage 204 and workpiece 250. Other system components are also shown, such as the motor 224, the drive pulley 218 for the spindle 212, the rod filler material 229, the actuator downforce driver 230, the push rod 231, the stand with bearings for the solid feed push rod and actuator 232, the floating (non-driven) secondary spindle 233, the lower spindle 234, the tool holder 235, and the pressure plate 236. In certain embodiments, the feed unit can include and use the actuator 230, the push rod 231, two guide rods, and a cross bar, where the actuator generates a downforce to push the alloy feedstock through the throat 214 and onto the substrate. The guide rods and cross members are optional and may be present to stabilize the push rod 231 .

[0041] Another view of the feed unit is shown in FIG. 4. The feed unit shown in FIG. 4 can be used to feed powder, particle, or pellet-type alloy filler material. Shown in cross section in FIG. 4 are feed unit 211, spindle 212 and tool 213 having working passageway 214, and substrate 250 capable of receiving powder or pellet-type filler alloy material therefrom. Other system components are shown, such as motor 224, drive pulley 228 for spindle 212, floating (non-driven) secondary spindle 233, lower spindle 234, tool holder 235, pressure plate 236, lateral delivery system 237, mixing downtube 238, auger drive mechanism 239, auger assembly 240, and optional injection port for liquid additives (e.g., lubricants, catalysts, etc.) 241. Also shown is tool changer 260, which will be discussed in more detail below.

[0042] 2-4 are configured to deliver various types of alloy filler materials to the underlying substrate, although combinations of various alloy filler materials can be present in the delivery unit and delivered to the tooling for deposition on the substrate. A tool holder 235 having a throat functions to hold and rotate the tool, and the throat allows the alloy feed material to be delivered from the delivery unit to the substrate.

[0043] In certain embodiments, a tool changer 260 may be present to allow for the exchange of one or more different tools. For example, the tool changer 260 may allow for the exchange of one tool with a tool of the same type to replace a worn tool or for the exchange of a different tool to provide a different function in the layer deposited during the deposition process. The tool changer 260 is optional and can be omitted if desired. The tool changer 260 may include various tools positioned in a rest position (e.g., waiting to be used) and may further include a mechanism for automatically or manually placing a selected tool in an utilization position (e.g., where the tool is available for utilization). For example, different tools may be used to deposit a first track and then deposit additional tracks thereon. Alternatively, different tools may be used to deposit different shapes or geometries on the substrate.

[0044] The SSA manufacturing systems described herein advantageously use a tool or tooling configured to non-consumablely deposit alloy feedstock material onto a substrate. The tool or tooling can be configured to exert frictional and other forces on the alloy feedstock material to impart rotation to the alloy feedstock material from the tool body when rotated at a speed sufficient to apply frictional heat of the alloy feedstock material to the substrate. As described in more detail below, the tool generally includes a body having a throat in communication with a feeding unit for receiving material from the feeding unit. The body is designed to deposit the received alloy feedstock material from the throat onto the substrate. The body can be configured with one or more surface features constructed and arranged to capture deposited alloy material onto the substrate within a space or volume between the body and the substrate. Forming and / or shear forces can be applied to the captured material to deposit the alloy material in solid form on the surface of the substrate.

[0045] In certain embodiments, the tool or tooling can be produced using a material that has a higher hardness than the alloy material being deposited and is harder than the substrate. For example, the tool or tooling can include tool steel, copper and its alloy materials, tungsten and its alloy materials, and other metals that, in pure metal or alloy form, have a higher Vickers hardness than the alloy and substrate material being deposited. By selecting a higher hardness for the tooling material, the tooling generally does not wear or deform during the deposition process and can be used to provide multiple tracks on the substrate without having to be replaced.

[0046] Various internal shapes for the tooling are possible. When having a non-circular shape, the consumable filler material can rotate at the same angular velocity as the non-consumable portions of the tool due to the normal force the tool exerts on them at the face of the tool throat. Such shapes include, by way of example, square and elliptical through-holes. In configurations where only a tangential force acting by the inner surface of the tool throat on the face of the alloy filler material is desired, the feedstock can rotate at an angular velocity different from the angular velocity of the tool. The combination of a circular shape for the cross section of the tool and an unattached or loosely attached feedstock can achieve the result of the deposition material and the tool rotating at the same or different speeds. Various tool shapes and surface feature embodiments on the tool are described in more detail below.

[0047] In certain embodiments, the tool may include a shoulder or other feature on its surface that aids in depositing the alloy filler material in solid form onto the surface of the substrate. For example, referring to FIG. 5 , a tool 503 having a throat 504 is shown. A pin 534 having a throat 505 extends from the tool shoulder, and the pin throat 505 is in communication with the tool throat 504. The pin 534 is an optional component of a solid phase additive manufacturing system. The pin 534 may enable better mixing of the surface area of ​​the workpiece and the alloy filler material. The tool shoulder facing the substrate may include at least one protrusion 533 made of the same or a different material as the tool material. The protrusion may be a geometric structure on the tool shoulder having different shapes and located at various positions on the tool shoulder to improve mechanical mixing of the deposited alloy material. If desired, the protrusion 533 may be replaceable by the end user and thus may be replaced without having to replace the entire tool 503. The tool 503 can include one, two, three, four, five, six, or more than six protrusions. The protrusions can be arranged in symmetrical or asymmetrical patterns as desired. The protrusions can be solid or hollow, and different protrusions on the tool can have different shapes, heights, etc. Various tool components are described, for example, in commonly owned U.S. Pat. No. 11,311,959, the entire disclosure of which is incorporated herein by reference.

[0048] In certain embodiments, the throats of the spindles and tools described herein can have various lengths, shapes, and configurations as desired. For example, the cross-sectional shape of the throat can be square, rectangular, circular, elliptical, oval, or other shapes. Furthermore, the cross-sectional shape, diameter, etc. need not be the same from the top edge of the tool to the bottom edge of the tool. The diameter can increase or decrease toward the tool face positioned adjacent the substrate.

[0049] Although not shown, the system may include other suitable components, including, but not limited to, a gas supply, an external energy source, an oven, a thermocouple, a motor, a platform, etc. In certain embodiments, as shown in FIG. 6 , the tool may include or be configured to accept a temperature sensor. The tool 130 may include a temperature sensor 610, which may be integrated into the tool 130 or added separately and may reside on its exterior or interior surface. The sensor 610 may be designed to indirectly monitor the temperature of the surface of the substrate 150 during deposition of the alloy material thereon. Because it is often difficult to directly measure the temperature of the surface of the substrate 150 during deposition, the temperature sensor 610 may be positioned at an appropriate distance above the surface. As discussed in more detail below, a selected temperature window may be used to deposit an alloy material having desirable physical and / or mechanical properties after heat treatment. The temperature sensor 610 may include a thermometer, a thermocouple, a resistance temperature device, an optical device, an infrared sensor, a bimetallic device, a state-change sensor, or any other device capable of measuring or sensing temperature. The sensor 610 can be wired or wirelessly coupled to other components to transmit temperature information to the system. While the exact positioning of the sensor 610 can vary, typically the sensor 610 is positioned about 0.3 mm to about 0.5 mm above the surface of the substrate 150. Temperature values ​​described herein as suitable for producing alloy parts with certain properties refer to temperature values ​​measured using a sensor similar to sensor 610, but not necessarily the actual temperature at the interface between the tool 130 and the surface of the substrate 150. The tool temperature can be monitored and selected based on measurements from the sensor 610 to deposit alloy material at a selected tool temperature range.

[0050] In certain configurations, various components of an SSA manufacturing system are generally under control using a processor and one or more application software programs. For example, referring to FIG. 7, a block diagram of certain components that may be controlled by a processor of a computer system or a dedicated processor is shown. System 700 includes a processor 710 electrically coupled to a feed unit 720, a spindle 730, a temperature control device 740, and a platform 750 configured to receive a substrate. Processor 710 may optionally be coupled to a tool 740 and may further be electrically coupled to a temperature sensor (not shown) associated with tool 740. The processor 710 may control one or more of feeding the alloy material through the feeding unit 720, the rotational speed of the spindle 730 to maintain a temperature setpoint, changing the spindle torque to maintain a temperature setpoint, changing the spindle power to maintain a temperature setpoint, changing the deposition rate to maintain a temperature setpoint, changing the tool traverse speed to maintain a temperature setpoint, changing the alloy filler feed rate to maintain a temperature setpoint, changing the layer height to maintain a temperature setpoint, changing the alloy filler force to maintain a temperature setpoint, changing the pressure under the tool 740 to maintain a temperature setpoint, maintaining a temperature setpoint in, around, or near the tool 740 with an external heating source, maintaining a temperature setpoint under or around the material being deposited and / or under or around the platform 750 with a heat source, and / or maintaining a temperature setpoint by modifying the tool geometry in situ during production. The processor 710 can translate the substrate platform 750 to change its position in the x-, y-, or z-coordinate axes independently of the movements of the spindle 730 and / or the tool 740. In typical use, the substrate platform 750 is moved independently of any movements of the tool 740 during deposition of the alloy filler material thereon.

[0051] An SSA manufacturing system typically also includes a memory unit, storage, or other electrical components. A processor 710 may be used in combination with one or more sensors present in the system to control various components of the system. Such processes may be performed automatically by the processor without user intervention, or the user may input parameters through a user interface. In certain configurations, the processor may reside in one or more computer systems and / or common hardware circuits, including, for example, a microprocessor and / or software suitable for operating the system. The processor may be integrated into the system or may reside on one or more accessory boards, printed circuit ports, or computers electrically coupled to the system components. Typically, the processor is electrically coupled to one or more memory units to accept data from other components of the system to enable adjustment of various system parameters and / or control the system components as needed or desired. The processor may be part of a general-purpose computer such as a Unix-based one, an Intel PENTIUM-type processor, an Intel Core® processor, an Intel Xeon® processor, an AMD Ryzen® processor, an AMD Athlon® processor, an AMD FX® processor, a Motorola PowerPC, a Sun UltraSPARC, a Hewlett-Packard PA-RISC processor, a processor designed by Apple, including an Apple A12 processor, an Apple A11 processor, and others, or any other type of processor. One or more of any type of computer system may be used in accordance with various embodiments of the present technology. Furthermore, the system may be connected to a single computer or distributed among multiple computers attached by a communications network.It should be appreciated that other functions, including network communications, may be performed, and the techniques of the present invention are not limited to having any particular function or set of functions. Various aspects may be implemented as dedicated software running on a general-purpose computer system. A computer system may include a processor connected to one or more memory devices, such as a disk drive, memory, or other device for storing data. Memory is typically used to store programs, user authentication information, and the like during system operation. Components of a computer system may be coupled by an interconnection device, which may include one or more buses (e.g., between components integrated within the same machine) and / or networks (e.g., between components residing on separate, individual machines). The interconnection device allows communication (e.g., signals, data, instructions) to be exchanged between components of the system. Typically, a computer system can receive and / or send commands within processing times, e.g., milliseconds, microseconds, or less, to enable rapid control of the system. For example, computer control may be performed to control temperature during deposition of an alloy material on a surface of a substrate. Typically, the processor is electrically coupled to a power source, which may be, for example, a DC power source, an AC power source, a battery, a fuel cell, or other power source or combination of power sources. The power source may be shared by other components of the system. The system may also include one or more input devices, such as a keyboard, a mouse, a trackball, a microphone, a touch screen, a manual switch (e.g., a disable switch), and one or more output devices, such as a printing device, a display screen, a light, and a speaker. The system may include one or more communication interfaces (in addition to or instead of interconnection devices) that connect the computer system to a communication network. The system may also include suitable circuitry for converting signals received from various electrical devices present therein.Such circuitry may reside on the printed circuit board, or may reside on a separate board or device electrically coupled to the printed circuit board through a suitable interface, such as a Serial ATA interface, an ISA interface, a PCI interface, a USB interface, a Fibre Channel interface, a FireWire interface, an M.2 connector interface, a PCIE interface, or an mSATA interface, or through one or more wireless interfaces, such as Bluetooth, Wi-Fi, near field communication, or other wireless protocols and / or interfaces.

[0052] In certain embodiments, the system generally includes a storage system, which may be removable and / or may include a non-transitory computer-readable medium. The storage system generally includes a computer-readable / writable medium on or within which software code can be stored that can be used by a program executed by a processor or on which information processed by the program can be stored. The medium may be, for example, a hard disk, a solid-state drive, or a flash memory. The program or instructions executed by the processor may be located locally or remotely and may be retrieved by the processor, if desired, using an interconnection mechanism, a communications network, or other means. Generally, in operation, the processor reads data from a non-volatile storage medium into another memory that allows the processor to access the information more quickly than the non-volatile storage medium. Typically, this memory is a volatile random access memory, such as dynamic random access memory (DRAM) or static random access memory (SRAM). This memory may be located within a storage system or a memory system. Typically, the processor manipulates data in the integrated circuit memory and then copies the data to the medium after processing is complete. Various mechanisms for managing data movement between the medium and the integrated circuit memory elements are known, and the present technology is not limited to the mechanisms described above. The inventive technology is not limited to any particular memory or storage system. In certain embodiments, the system may also include specially programmed, dedicated hardware, such as an application specific integrated circuit (ASIC), a microprocessor unit (MPU), or a field programmable gate array (FPGA), or a combination thereof. Aspects of the inventive technology may be implemented in software, hardware, or firmware, or any combination thereof. Furthermore, such methods, operations, systems, system elements, and components thereof may be implemented as part of the systems described above or as separate components.While a particular system has been described as an example of one type of system for implementing various aspects of the present technology, it should be appreciated that aspects are not limited to being implemented on the described system. Various aspects can be implemented using one or more systems having a variety of architectures or components. The system can include a general-purpose computer system programmable using a high-level programming language. The system can be implemented using specially programmed dedicated hardware. The processor in the system is a commercially available processor, such as well-known microprocessors available from Intel, AMD, Apple, and others. Many other processors are also commercially available. Typically, such a processor runs an operating system, which may be, for example, the Windows 7, Windows 8, or Windows 10 operating systems available from Microsoft Corporation; MAC OS X, e.g., Snow Leopard, Lion, Mountain Lion, Mojave, High Sierra, El Capitan, or other versions, available from Apple; the Solaris operating system available from Sun Microsystems; or a UNIX or Linux operating system available from various sources. Many other operating systems can be used, and in certain embodiments, a simple instruction set or command set can act as the operating system. Additionally, the processor may be designed as a quantum processor, designed to perform one or more functions using one or more qubits. In some cases, a simple instruction set may reside on a computer system, tablet, or mobile device that can communicate with the components of the SSA system and that can be updated from time to time using one or more wireless or wired connections between the control device and the SSA system.

[0053] In certain examples, the processor and operating system together may define a platform that enables application programs to be written in a high-level programming language. It should be understood that the techniques of the present invention are not limited to a particular system platform, processor, operating system, or network. Similarly, it will be apparent to those skilled in the art, given the benefit of this disclosure, that the techniques of the present invention are not limited to a particular programming language or computer system. It should further be recognized that other suitable programming languages ​​and other suitable systems could be used. In certain examples, the hardware or software may be configured to execute a recognition architecture, a neural network, or other suitable implementation. If desired, one or more portions of a computer system may be distributed across one or more computer systems coupled to a communications network. These computer systems may be general-purpose computer systems. For example, various aspects may be distributed among one or more computer systems (e.g., servers) configured to provide services to one or more client computers or to perform overall tasks as part of a distributed system. For example, various aspects may be implemented using a client-server system or a multi-tier system that includes components distributed among one or more server systems that perform various functions according to various embodiments. These components may be executable code, intermediate code (e.g., IL), or interpreted code (e.g., Java) that communicate over a communications network (e.g., the Internet) using a communications protocol (e.g., TCP / IP). It should also be appreciated that the inventive technology is not limited to any being run on a particular system or group of systems. Likewise, it should be appreciated that the inventive technology is not limited to any particular distributed architecture, network, or communications protocol.

[0054] In some cases, various embodiments can be programmed using an object-oriented programming language such as, for example, SQL, SmallTalk, Basic, Java, Javascript, PHP, C++, Ada, Python, iOS / Swift, Ruby on Rails, or C# (C Sharp). Other object-oriented programming languages ​​can be used. Alternatively, functional, scripting, and / or logic programming languages ​​can be used. Various configurations can be implemented in non-programming environments (e.g., documents generated in HTML, XML, or other formats that, when displayed in a browser program window, render aspects of a graphical user interface (GUI) or perform other functions). Certain configurations can be implemented as program elements, non-program elements, or any combination thereof. In some cases, the system can include a software interface on the SSA system that can receive user input and parameters from a user based on the particular alloy material to be deposited. Commands and other information and parameters can be entered into the SSA system directly through this user interface or indirectly through an interface with an associated mobile device, e.g., a tablet, phone, or the like, that communicates with the SSA system over a wireless or wired network. The instructions stored in the memory can execute software modules or control routines for the system that can actually provide a controllable model of the system to enable deposition of the alloy material in a desired manner.

[0055] In certain embodiments, the system may include one or more communication interfaces that enable the SSA system to communicate with other systems or components of the SSA system. For example, the system may include an antenna, which may be one or more of a Bluetooth antenna, a cellular antenna, a wireless antenna, other antennas, or a combination thereof.

[0056] In some embodiments, a system may include subtraction components in addition to addition components. For example, with reference to FIG. 8 , a system may include addition system 810 and subtraction system 820. Addition system 810 may be configured to add, for example, an aluminum alloy in solid form to a surface of a substrate, as described herein. The exact nature of the operation performed by subtraction system 820 may vary. For example, subtraction system 820 may be configured to provide one or more of grinding, polishing, milling, etc. to remove a portion of the material added to the substrate using addition system 810. Subtraction system 820 may be used to drill holes or bores or otherwise machine the final product produced using addition system 810 into a final part.

[0057] In a non-limiting example using 7075 alloy material, the exact 7075 alloy used as the raw material can vary. For example, the material temper and shape can vary for various articles and can be round, square, oval, rectangular, etc. In some embodiments, the raw material can be AA7075 having a T6 or T7 temper (or other temper) and a width of 0.30 to 0.7 inches (when the raw material is a square bar). The raw material can be coated with an organic or inorganic lubricant or can be unlubricated during use. If desired, the raw material can be physically or chemically pre-cleaned using solvents, detergents, grinding, etching, abrasive sandblasting, abrasive blasting before use, coated with other materials using, for example, physical vapor deposition, electrodeposition, or other techniques, or subjected to any other physical or chemical process.

[0058] The substrate used with the 7075 alloy feedstock can be the same or a different material than the 7075 alloy feedstock. The substrate can also be physically or chemically pre-cleaned using solvents, detergents, polishing, etching, abrasive sandblasting, or abrasive blasting prior to use; it can be coated with other materials using, for example, physical vapor deposition, electrodeposition, or other techniques; or it can be subjected to any other physical or chemical process. The substrate can be heated or cooled during the deposition of the 7075 alloy thereon. The substrate can also be placed in an environmental chamber with a desired atmospheric composition prior to use. For example, it may be desirable to reduce or limit the amount of oxygen present during deposition to reduce oxide formation.

[0059] The path of the tooling used with 7075 alloy and the substrate can vary. For example, the tool path can be linear, non-linear, or other. In some configurations, the tool path is linear, with the tool first moved in a first direction, followed by an orthogonal movement (up or down), and then another linear movement back toward the initial position of the tooling. This path acts to increase the width of the material deposited on the substrate. In an alternative arrangement, the tool path can be linear, with the tooling being raised after the initial trajectory is deposited to increase the total height of the deposited material. The overall dimension of each trajectory can vary; for example, the layer height for the first layer can vary from about 0.03 inches to about 0.07 inches thick. Additional layers can be added at different heights, from about 0.03 inches to about 0.12 inches thick.

[0060] In certain embodiments, tooling temperature can be used to monitor or estimate the surface temperature. As with indirect measurement methods or temperatures, a thermocouple (or other temperature sensing device) can be positioned within the tool approximately 3-9 mm, 4-8 mm, or 5-7 mm above the tip of the tool and filler material. Generally, deposition temperatures differ for single-track versus dual-track deposition. Single-track deposition typically uses a lower setpoint temperature than that used for dual-track deposition. While the exact temperature difference can vary, the temperature for adding single-track 7075 alloy material can be approximately 5 to 20 degrees Celsius lower than the temperature for dual-track 7075 alloy material. The temperature can be increased or decreased by controlling various parameters mentioned herein, such as traverse speed, material feed rate, etc. As a non-limiting example, the traverse speed (inches per minute) can vary from approximately 1 inch per minute to 5 inches per minute. The material feed rate for single-track deposition can vary from 1 inch per minute to 4 inches per minute. In overlapping track deposition, the material feed rate can vary from 0.5 inches / minute to 4 inches / minute. In overlapping tracks, the stepover distance (the displacement of the tool path centerline between tracks) can vary from about 0.3 inches to about 2 inches. Spindle speed can be used to control the temperature during deposition and can vary from about 50 rpm to about 300 rpm, depending on other parameters used. The temperature used to deposit the second layer (and subsequent layers) on top of the initial layer is typically 5 to 15 degrees Celsius higher than the temperature used to deposit the initial layer on the substrate.

[0061] In certain embodiments, after the material is deposited, the article can be treated, e.g., heat treated, annealed, etc., or can be used as printed. If heat treated, the material is typically left at room temperature for no more than 60 minutes before being heat treated to maintain the temperature of the article above room temperature. Alternatively, the substrate and printed material can be heated to maintain the temperature at a desired set point.

[0062] Processing and Processing Parameters

[0063] As noted herein, SSA manufacturing systems can be used to convert / print alloy material feedstock into larger or different parts. Without wishing to be bound to any one system or configuration, heat is generated by friction between the tool and substrate (in some cases, friction is caused by the pin passing through the substrate surface zone as it extends from the tool shoulder). The generated heat imparts a significant amount of plastic deformation near the rotating tool (and / or rotating pin, if used). The substrate is imparted with significant strain, resulting in refinement of the substrate microstructure. The substrate material adjacent to the tool softens, and the softened material is mechanically agitated and simultaneously mixed and bonded with alloy filler material added through the tool passages using mechanical pressure supplied by the tool shoulder.

[0064] In certain configurations, the process can be controlled by simultaneously controlling key system parameters such as force, pressure, rotation, external heating, external cooling, substrate preheat, gas flow, ambient temperature, traverse speed, and deposition rate to determine the deposition temperature at the interface between the feed alloy and either the substrate or the previously deposited layer. Measuring the exact temperature at the feed tip, which forms the interface with the substrate and / or the previously deposited material, can be difficult. As with indirect measurement methods or temperatures, a thermocouple (or other temperature sensing device) can be positioned within the tool approximately 0.35 mm above the tip of the tool and filler material. Positioning the temperature sensor elsewhere could result in a different bias relative to the actual temperature at the feed tip. For example, a smaller gap between the feed tip and the thermocouple would be expected to result in a higher temperature reading for the same actual deposition temperature. Alternatively, a laser temperature sensing device or other temperature sensing device could be substituted.

[0065] While the exact processing temperature may vary depending on the particular alloy / material used, when 7075-type alloy material is applied to a substrate in a single-wall build, good bonding can be achieved when the 7075 alloy is applied from a tool at a temperature of 360°C to 485°C, more specifically, from about 420°C to about 470°C, e.g., from about 445°C to 470°C. The terms "single wall" or "single track" refer to the initial layer of alloy material deposited on the surface of the substrate. If desired, overlapping tracks of alloy material can be applied to a single-wall build to produce a multi-wall build. Generally, overlapping tracks allow for the creation of thicker walls and bulkier or larger parts. To provide good bonding between the tracks, it may be desirable to increase the temperature setpoint by an additional 10° C. to 30° C., 10° C. to 20° C., or 20° C. to 30° C. during the addition of second and subsequent tracks onto a single wall or track. For example, during the addition of a second 7075 track to an already deposited single track of 7075, the deposition temperature range can be from 370° C. to 520° C., more specifically, from 450° C. to 485° C., e.g., 455° C. to 465° C., which is generally higher than the temperature used to deposit the first track on the substrate.

[0066] In certain configurations, the exact thickness of any one track can vary from about 0.03 inches to about 0.2 inches, more specifically from about 0.04 inches to about 0.18 inches, such as 0.05 inches, 0.06 inches, 0.07 inches, 0.08 inches, 0.09 inches, 0.10 inches, 0.11 inches, 0.12 inches, 0.13 inches, 0.14 inches, 0.15 inches, 0.16 inches, or 0.17 inches. Each of the additional tracks can have the same thickness as the single track. For example, the thickness of each additional track can vary from about 0.03 inches to about 0.2 inches, more specifically from about 0.04 inches to about 0.18 inches, e.g., 0.05 inches, 0.06 inches, 0.07 inches, 0.08 inches, 0.09 inches, 0.10 inches, 0.11 inches, 0.12 inches, 0.13 inches, 0.14 inches, 0.15 inches, 0.16 inches, or 0.17 inches. The percentage of overlap between different tracks can vary from about 5% overlap to about 50% overlap in the x and y directions. For example, adjacent tracks can overlap from about 10% to about 40% in the x and y directions, e.g., 15%, 20%, 25%, 30%, or 35%.

[0067] In certain embodiments, temperature control can be achieved by modifying system parameters. For example, one or more of the following parameters can be modified to control the temperature: modifying spindle speed to maintain a temperature setpoint, modifying spindle torque to maintain a temperature setpoint, modifying spindle power to maintain a temperature setpoint, modifying deposition rate to maintain a temperature setpoint, modifying tool traverse speed to maintain a temperature setpoint, modifying filler material rod feed rate to maintain a temperature setpoint, modifying layer height to maintain a temperature setpoint, modifying filler material rod force to maintain a temperature setpoint, modifying pressure under the tool to maintain a temperature setpoint, maintaining a temperature setpoint with an external heating source in, around, or near the tool, maintaining a temperature setpoint with a heat source under or around the material being deposited, and / or maintaining a temperature setpoint by modifying the tool geometry in situ (during production). Without wishing to be bound by any particular theory, selecting an appropriate temperature range can improve the overall properties of the deposited alloy material. For example, low temperature deposition can result in a lower yield strength, ultimate tensile strength, and percent elongation to break of the deposited alloy, e.g., a yield strength of less than 100 MPa, an ultimate tensile strength of less than 150 MPa, and a percent elongation to break of less than 1%. Increasing the temperature to a higher temperature below the melting point of the alloy raw material can improve the overall physical properties. In some embodiments, the temperature window is selected so that the deposited alloy material has a yield strength of at least 350 MPa, an ultimate tensile strength of at least 400 MPa, and a percent elongation to break of at least 5%. In other configurations, the temperature window is selected so that the deposited alloy material has a yield strength of at least 400 MPa, an ultimate tensile strength of at least 450 MPa, and a percent elongation to break of at least 7%. In some configurations, the temperature window is selected so that the deposited alloy material has a yield strength of at least 450 MPa, an ultimate tensile strength of at least 500 MPa, and a percent elongation to break of at least 8%.In certain configurations, the temperature window is selected so that the deposited alloy material has a yield strength of at least 485 MPa, an ultimate tensile strength of at least 550 MPa, and a percent elongation to break of at least 10%. The physical values ​​in this paragraph refer to values ​​that exist after the deposited material has been subjected to a post-deposition heat treatment to condition the deposited alloy material.

[0068] In some cases, the temperature can be controlled at least in part by selecting or varying the spindle speed during deposition. For example, the spindle can rotate from 150 rpm to about 350 rpm, depending on how fast the tooling is moving in the x and y directions. In some cases, the spindle rotation speed can vary from about 50 rpm to about 600 rpm, more specifically, from about 75 rpm to about 280 rpm, e.g., 100 rpm, 125 rpm, 150 rpm, 175 rpm, 200 rpm, 210 rpm, 220 rpm, 230 rpm, 240 rpm, 250 rpm, 260 rpm, or 270 rpm. The tooling is coupled to the spindle and typically rotates at the same rpm as the spindle. The spindle speed can vary, with the start-up speed typically being higher than the deposition speed. For example, the spindle speed can be 500-600 rpm during start-up to increase the surface temperature, and then reduced to 100-300 rpm during deposition to help maintain a desired deposition temperature.

[0069] In certain embodiments, the exact feed rate of the alloy feedstock can vary from about 1 inch per minute to about 4 inches per minute, more specifically from about 1.5 inches per minute to 3.5 inches per minute, e.g., 1.6 inches per minute, 1.7 inches per minute, 1.8 inches per minute, 1.9 inches per minute, 2.0 inches per minute, 2.1 inches per minute, 2.2 inches per minute, 2.3 inches per minute, 2.4 inches per minute, 2.5 inches per minute, 2.6 inches per minute, 2.7 inches per minute, 2.8 inches per minute, 2.9 inches per minute, or 3.0 inches per minute. The feed rate can be the same or different when depositing a single track or single wall than when depositing overlapping walls. For example, it may be desirable to increase the feed rate during the application of overlapping tracks to increase the surface temperature. The feed rate can be increased or decreased based on temperature measurements to maintain the appropriate temperature range during the application process.

[0070] In some embodiments, the alloy feedstock material can be coated or sprayed with a lubricant or other material suitable for depositing the alloy material onto a substrate. Generally, the lubricant can aid in the movement of the alloy feedstock material through the hollow passages of the tooling. Suitable lubricant materials include, but are not limited to, graphite, carbon black, and other forms of carbon. If desired, metallic lubricants can be used alone or in combination with carbon-based lubricant materials. During application of the alloy feedstock material, the lubricant coating tends to extrude toward the outside of the deposited material and can be later removed during heat treatment of the deposited alloy material.

[0071] In some configurations, the tooling can move horizontally at a desired speed to deposit a desired amount of information on the substrate. The exact horizontal traverse speed can vary from about 2 inches per minute to about 8 inches per minute, more specifically from about 3 inches per minute to about 7 inches per minute, and can be, for example, about 3.5 inches per minute, 4 inches per minute, 4.5 inches per minute, 5 inches per minute, 5.5 inches per minute, inches per minute, or 6.5 inches per minute.

[0072] In certain instances, the substrate may be cleaned or treated prior to deposition of the alloy onto the substrate material, for example, the surface of the substrate may be machined, polished, polished, etched, chemically or physically treated, or otherwise treated to clean or modify the surface of the substrate if desired.

[0073] In certain embodiments, an additively manufactured aluminum alloy is produced by a method including applying an aluminum alloy as a first aluminum alloy layer to a surface of a substrate using an additive manufacturing process including a rotary tool, the aluminum alloy being applied by solid-state application to the surface of the workpiece at a first tool temperature and heat-treating the solid-state applied first aluminum alloy layer to comprise at least 60 volume percent aluminum as equiaxed grains having an aspect ratio of less than 2:1, and after heat-treatment, minimal voids exist between metal atoms in the applied and heat-treated first aluminum alloy layer, and the applied and heat-treated first aluminum alloy layer includes 5-6 weight percent zinc, 2.1-2.9 weight percent magnesium, 1.2-2 weight percent copper, not more than 0.5 weight percent silicon, titanium, chromium, iron, or manganese, with the remainder being aluminum and incidental impurities totaling 100 weight percent. The first tool temperature can be between 360 degrees Celsius and 465 degrees Celsius. The first tool temperature can be maintained by one or more of changing the speed of a spindle coupled to the rotary tool, changing the torque of a spindle coupled to the rotary tool, changing the power of a spindle coupled to the rotary tool, changing the deposition rate of the applied aluminum alloy, changing the traverse speed of the rotary tool, changing the filler feed rate into the rotary tool, changing the layer height, changing the filler force, changing the pressure under the rotary tool, using an external heating / cooling source adjacent to the rotary tool, using an external heating / cooling source adjacent to the face of the substrate, or changing the tool geometry during application.

[0074] In some embodiments, the second aluminum alloy layer can be solid-state applied to the first aluminum alloy layer applied using a rotary tool, where the second aluminum alloy layer is applied using a second tool temperature that is 20 degrees Celsius higher than the first tool temperature. In certain embodiments, after heat treating the applied second aluminum alloy layer, the applied and heat-treated second aluminum alloy layer comprises at least 60 volume percent aluminum as equiaxed grains with an aspect ratio of less than 2:1, minimal voids exist between metal atoms in the applied and heat-treated second aluminum alloy layer, and the applied and heat-treated second aluminum alloy layer comprises 5-6 weight percent zinc, 2.1-2.9 weight percent magnesium, 1.2-2 weight percent copper, not more than 0.5 weight percent silicon, titanium, chromium, iron, or manganese, with the remainder being aluminum and incidental impurities totaling 100 weight percent.

[0075] In certain configurations, one or more subtraction steps can be performed on the alloy product. For example, a subtraction step can be used to remove a portion of an applied first aluminum alloy layer to provide a subtracted first aluminum alloy layer on a substrate. The resulting subtracted first aluminum alloy layer can be subjected to a heat treatment. The subtracted first aluminum alloy layer contains at least 60 volume percent aluminum as equiaxed grains with an aspect ratio of less than 2:1, and after heat treatment, minimal voids exist between metal atoms in the subtracted and heat-treated first aluminum alloy layer. The subtracted and heat-treated first aluminum alloy layer contains 5-6 weight percent zinc, 2.1-2.9 weight percent magnesium, 1.2-2 weight percent copper, not more than 0.5 weight percent silicon, titanium, chromium, iron, or manganese, with the remainder being aluminum and incidental impurities, totaling 100 weight percent. The first tool temperature can be between 360 degrees Celsius and 485 degrees Celsius. In some embodiments, the first tool temperature is maintained by one or more of: changing the speed of a spindle coupled to the rotary tool, changing the torque of a spindle coupled to the rotary tool, changing the power of a spindle coupled to the rotary tool, changing the deposition rate of the aluminum alloy being applied, changing the traverse speed of the rotary tool, changing the filler feed rate into the rotary tool, changing the layer height, changing the filler force, changing the pressure under the rotary tool, using an external heating / cooling source adjacent to the rotary tool, using an external heating / cooling source adjacent to the face of the substrate, or changing the tool geometry during application. A second aluminum alloy layer can be solid-phase applied to the first aluminum alloy layer deposited using the rotary tool, wherein the second aluminum alloy layer is applied using a second tool temperature that is 20 degrees Celsius higher than the first tool temperature.In certain embodiments, after heat treating the applied second aluminum alloy layer, the applied and heat treated second aluminum alloy layer comprises at least 60 volume percent aluminum as equiaxed grains with an aspect ratio of less than 2:1, there is minimal void space between metal atoms in the applied and heat treated second aluminum alloy layer, and the applied and heat treated second aluminum alloy layer comprises 5-6 weight percent zinc, 2.1-2.9 weight percent magnesium, 1.2-2 weight percent copper, not more than 0.5 weight percent silicon, titanium, chromium, iron, or manganese, with the remainder being aluminum and incidental impurities totaling 100 weight percent.

[0076] In some cases, the final formed layer or track may undergo additional post-treatments, including solution treatments or heating. For example, the resulting aluminum alloy may be tempered using methods and processing conditions similar to those commonly used to temper 7075 aluminum alloy. In some embodiments, the formed part may be subjected to a solution heat treatment at a temperature of 430 to 540 degrees Celsius, followed by quenching. Other heat treatment steps may be performed depending on the desired temper or other desired physical properties.

[0077] Products and parts

[0078] In certain embodiments, the systems and methods described herein can be used to produce solid-state additively manufactured products from alloy materials. For example, the alloy products can include at least 60 volume percent of the aluminum in the additively manufactured aluminum alloy as equiaxed grains with an aspect ratio of less than 2:1 after heat treatment of the additively manufactured aluminum alloy. The alloy products, similar to other wrought products such as forgings, contain only minimal voids between the metal atoms of the additively manufactured aluminum alloy. The products are non-extruded, non-rolled, and non-forged products that include the alloy material and can be produced without the use of any forging dies or extrusion tools. As noted herein, the microstructure present in the product is sensitive to the production conditions and may vary depending on the temperature and conditions used during production. In some embodiments, the products have a different microstructure than equivalent alloy products produced using forging or extrusion processes.

[0079] In certain configurations, the alloy product comprises a solid-phase additively manufactured aluminum composition containing 5-6 weight percent zinc, 2.1-2.9 weight percent magnesium, 1.2-2 weight percent copper, not more than 0.5 weight percent silicon, titanium, chromium, iron, or manganese, with the remainder being aluminum and incidental impurities totaling 100 weight percent. The alloy product can be heat treated to impart a desired temper and / or desired mechanical and physical properties. For example, after solution heat treatment and artificial aging to an overaged condition with an A rating for stress corrosion cracking resistance per ASTM 64, an SSA manufactured alloy product can be produced having an ultimate tensile strength (Ftu) of at least 61 ksi (420 MPa), a tensile yield strength (Fty) of at least 51 ksi (352 MPa), and an elongation to fracture or ductility (e) of at least 7% in the longitudinal direction of the main direction of the shape, e.g., the xy plane.

[0080] In certain embodiments, the materials and processes described herein can be used to produce large parts and / or parts with multi-dimensional shapes. The techniques of the present invention can be used to produce high-strength aluminum parts that could otherwise be forged. These types of parts are used in a variety of applications, including aerospace, defense, and similar critical applications. Parts can be deposited, then machined, and heat treated to a temper (such as T6) or even to the more corrosion-resistant T7X temper. Final machining operations can be performed to produce the desired shape, and many, if not most, of the parts will receive some kind of coating to protect their appearance and prevent corrosion. Certain exemplary parts are described below.

[0081] In some configurations, alloy material products produced by deposition using SSA systems can be used in aerospace and vehicle applications. For example, the resulting parts can be used in aircraft, helicopters, missiles, spacecraft, and engines, motors, or other devices capable of flight using any form of propellant or fuel. Alternatively, the resulting parts can be used in vehicle applications, including automobiles, trucks, military vehicles, tanks, submarines, ships, troop carriers, unmanned aerial vehicles, and the like.

[0082] In some embodiments, the resulting part may be a landing gear component 900, as shown in Figure 9. While the exact features and elements of the landing gear component may vary, the landing gear component of Figure 9 includes a retraction actuator 902, a rotation actuator 904, a trunnion 906, a forward trunnion fixture 908, an axle beam folding and compensation actuator 910, a brake assembly 912, a tire and wheel 914, a sensing wheel 916, an axle beam 918, an oleo piston 920, an oleo cylinder 922, an aft fixture 924, a rotation lock pin 926, a metering pin extension 928, and a downlock and leg fixture 930. Any one or more of the components shown in Figure 9, or subassemblies thereof, may be produced using the alloy materials and methods described herein.

[0083] In certain embodiments, the manufactured part may be a rocket nozzle 1000, as shown in FIG. 10 . The rocket nozzle 1000 may be produced as a continuous part using the alloy materials and processes described herein. The rocket nozzle propels the rocket by accepting high-temperature exhaust from the combustion chamber and converting the energy in the high-pressure exhaust into kinetic energy. The detailed rocket nozzle geometry may vary and include, but is not limited to, a bell-shaped nozzle, a de Laval nozzle, an expansion vectoring nozzle, a plug nozzle, an aerospike nozzle, a single expansion ramp nozzle, an extension nozzle, a nozzle with a removable insert, a stepped nozzle, a dual bell nozzle, a dual mode nozzle, a dual expander nozzle, and a dual throat nozzle.

[0084] In other embodiments, the production component can be a nozzle other than a rocket nozzle. For example, the alloy materials and processes described herein can be used to produce a fuel nozzle 1100 (FIG. 11). Typically, the fuel nozzle 1100 is used to supply fuel to turbine engines in aircraft, including passenger aircraft, military aircraft, and other aircraft.

[0085] The product part may be configured as one or more of an aircraft fuselage 1200 or component thereof ( FIG. 12 ), an aircraft floor section or component thereof, an aircraft wing 1300 or component thereof ( FIG. 13 ), an aircraft center wing box or component thereof, an aircraft nose or cockpit 1400 or portion thereof ( FIG. 14 ), an aircraft engine 1500 or component thereof ( FIG. 15 ), a propeller 1600 ( FIG. 16 ), an aircraft tail 1700 ( FIG. 17 ), a helicopter rotor 1800 ( FIG. 18 ), an unmanned aerial vehicle 1900 or component thereof ( FIG. 19 ), or other types of components of an aircraft or aircraft, including components that connect various portions of the structure to one another. Other parts or components that can be produced and / or repaired using the systems and methods described herein include, but are not limited to, ground defense vehicles, pylons, wheels, trusses, cargo and baggage racks, stringers, wing and tail ribs, spars, wing skins, pressure walls, engine surrounds, actuators, stiffeners, missile release ducts, refueling booms, weapons, and launch vehicles. As mentioned herein, any of these articles can be repaired using the 7075 aluminum alloy material described herein.

[0086] In certain embodiments, any of these resulting parts may include an equiaxed grain structure such as that shown in Figure 20. For example, a resulting 7075 aluminum alloy product may include equiaxed grains such as those shown in Figure 20 after heat treatment.

[0087] Certain specific examples are described below to more fully illustrate some of the novel aspects and features described herein. [Example]

[0088] Components were printed using 0.5-inch 7075-T6511 bar stock extruded according to the ANSI H35.2 extrusion standard. The components were printed on 7075-T651 board substrates using individual feeds or by feeding one bar at a time. A modified additive manufacturing system using temperature monitors was used. The system was similar to the commercially available MELD K2 or L3 equipment, but used temperature monitors on the tooling. Components were built under temperature control, with a nominal deposition temperature of 420°C (788°F) for the first layer and 430°C (806°F) for all subsequent layers. Temperature was controlled by parameters such as spindle RPM (revolutions per minute), force, feed rate, and traverse speed. Layer height during deposition was 0.080 inches, except for the first layer, which was 0.055 inches thick. The final dimensions of the build were approximately 1.75 inches wide, 12 inches tall, and 3 inches high. A photograph of the deposited material is shown in FIG. [Example]

[0089] The shaped article of Example 1 was solution heat treated and artificially aged to the 7075-T73 temper using times and temperatures typical for forging to the same temper as described in AMS 2770. The solution heat treatment step was performed at 466°C for 3 hours, followed by a room temperature water quench. The artificial aging step was performed at 121°C for 4.5 hours, followed by a second step at 177°C for 9 hours. The specimens were evaluated for tensile strength, smooth specimen fatigue, and plane strain fracture toughness using the standard NADCAP (Aerospace Specifications) test. All properties met and / or exceeded the minimum and / or typical performance requirements for 7075-T73 die forgings. Tensile testing (Table 1) was performed according to ASTM E8 and exceeded the requirements for 7075-T73 die forgings. The specimens were tested in the z-direction, which corresponds to the transverse direction of conventional forging. YS is yield strength, UTS is ultimate tensile strength, and EI% is elongation at break or ductility, with 7075-T73 values ​​exemplified for comparison purposes. Tensile properties are improved compared to the 7075-T73 tempered material.

[0090] (Table 1) JPEG2025538031000002.jpg47161 [Example]

[0091] The fracture toughness values ​​(Table 2) of the heat treated material of Example 2 were examined and found to be better than expected for comparable orientations compared to hand and die forged 7075-T73, although in this case the XZ orientation of these parts must be compared to the LT orientation (stress applied longitudinally, crack propagating transversely).

[0092] (Table 2) JPEG2025538031000003.jpg48163 [Example]

[0093] The smooth specimen fatigue results (Table 3) for the heat-treated material of Example 2 were examined and found to be comparable or slightly improved compared to 7075-T73 forgings. The specimens were tested in the Z direction, which is equivalent to the ST direction for conventional forgings; therefore, comparisons with the L or T directions are not appropriate, as the L and T directions inherently have better fatigue performance than the ST direction. Testing was conducted in accordance with ASTM E466-21. The specimen diameter for this test was 0.20 inches. Test parameters included Kt=1, R=0.1, f=20 Hz, and runout cycles=107.

[0094] (Table 3) JPEG2025538031000004.jpg10082

[0095] When introducing elements of the examples disclosed herein, the words "a," "an," "the," and "said" are intended to mean that there are one or more of the elements. The terms "comprising," "including," and "having" are intended to be open-ended and mean that there may be additional elements other than the listed elements. It will be recognized by those skilled in the art, given the benefit of this disclosure, that various elements of the examples can be interchanged or substituted for various elements in other examples.

[0096] While certain aspects, examples, and embodiments have been described above, it will be recognized by those skilled in the art, given the benefit of this disclosure, that additions, substitutions, modifications, and variations may be made to the exemplary aspects, examples, and embodiments of the present disclosure.

Claims

1. 1. A solid phase additively manufactured aluminum alloy product, comprising: after heat treatment of the solid phase additively manufactured aluminum alloy product, at least 60 volume percent of the aluminum in the additively manufactured aluminum alloy product is present as equiaxed grains having an aspect ratio of less than 2:1; wherein there is minimal void space between metal atoms in the solid phase additively manufactured aluminum alloy product; the solid state additively manufactured aluminum product comprises 5 to 6 weight percent zinc, 2.1 to 2.9 weight percent magnesium, 1.2 to 2 weight percent copper, not more than 0.5 weight percent silicon, titanium, chromium, iron, or manganese, the balance being aluminum and incidental impurities totaling 100 weight percent; Aluminum alloy products.

2. 10. The solid phase additively manufactured aluminium alloy product of claim 1 having an ultimate tensile strength (Ftu) of at least 420 MPa.

3. 3. The solid phase additively manufactured aluminium alloy product of claim 2, having a tensile yield strength (Fty) of at least 352 MPa.

4. 4. The solid phase additively manufactured aluminum alloy product of claim 3 having an elongation to fracture or ductility (e) of at least 7%.

5. 10. The solid phase additively manufactured aluminum alloy product of claim 1 having a single orbit of deposited solid phase additively manufactured aluminum alloy product.

6. 10. The solid state additively manufactured aluminum alloy product of claim 1, comprising a plurality of overlapping trajectories of deposited solid state additively manufactured aluminum alloy products.

7. 7. The solid phase additively manufactured aluminum alloy product of claim 6, wherein adjacent tracks overlap by at least 10%.

8. 10. The solid state additively manufactured aluminum alloy product of claim 1, further comprising a substrate that receives the solid state additively manufactured aluminum alloy product.

9. 10. The solid state additively manufactured aluminum alloy product of claim 1, wherein at least 75% volume percent of the aluminum within the solid state additively manufactured aluminum alloy product is present as equiaxed grains.

10. 10. The solid state additively manufactured aluminum alloy product of claim 1, wherein at least 90% volume percent of the aluminum within the solid state additively manufactured aluminum alloy product is present as equiaxed grains.

11. 1. A solid-state additively manufactured aluminum alloy produced by adding an aluminum alloy to a surface of a substrate using a solid-state additive manufacturing process, the aluminum alloy is solid-phase applied as a first aluminum alloy layer to the surface of the substrate at a first tool temperature between 360 degrees Celsius and 485 degrees Celsius, followed by a heat treatment; at least 60 volume percent of the aluminum in the applied and heat-treated first aluminum alloy layer is present as equiaxed grains having an aspect ratio of less than 2:1; there is minimal void space between metal atoms in the applied and heat-treated first aluminum alloy layer; the solid state additively manufactured aluminum alloy comprising 5 to 6 weight percent zinc, 2.1 to 2.9 weight percent magnesium, 1.2 to 2 weight percent copper, not more than 0.5 weight percent silicon, titanium, chromium, iron, or manganese, the balance being aluminum and incidental impurities totaling 100 weight percent; Aluminum alloy.

12. 12. The solid phase additively manufactured aluminium alloy of claim 11 having an ultimate tensile strength (Ftu) of at least 420 MPa.

13. 13. The solid phase additively manufactured aluminium alloy of claim 12, having a tensile yield strength (Fty) of at least 352 MPa.

14. 14. The solid phase additively manufactured aluminium alloy of claim 13 having an elongation to fracture or ductility (e) of at least 7%.

15. 12. The solid state additively manufactured aluminum alloy of claim 11 having a single orbit of deposited solid state additively manufactured aluminum alloy.

16. 12. The solid state additively manufactured aluminum alloy of claim 11, comprising a plurality of overlapping orbits of deposited solid state additively manufactured aluminum alloy.

17. 17. The solid phase additively manufactured aluminum alloy of claim 16, wherein adjacent tracks overlap by at least 10%.

18. 12. The solid state additively manufactured aluminum alloy of claim 11, further comprising a substrate for receiving the solid state additively manufactured aluminum alloy.

19. 12. The solid state additively manufactured aluminum alloy of claim 11, wherein at least 75% volume percent of the aluminum within the solid state additively manufactured aluminum alloy is present as equiaxed grains.

20. 12. The solid state additively manufactured aluminum alloy of claim 11, wherein at least 90% volume percent of the aluminum in the solid state additively manufactured aluminum alloy is present as equiaxed grains.

21. 1. An additive manufacturing system for producing an aluminum alloy product, comprising: a feed unit configured to receive an aluminum alloy filler material; a spindle including an internal passage configured to receive the aluminum alloy filler material from the feeding unit; a tool coupled to the spindle, the tool configured to receive the aluminum alloy filler material from the spindle and apply the received aluminum alloy filler material in a solid state to a surface of a substrate as a first aluminum alloy layer; a temperature sensor configured to measure a temperature of the tool during application of the aluminum alloy filler material as the first aluminum alloy layer to a surface of a workpiece; a processor electrically coupled to the temperature sensor and the spindle; a computer readable medium electrically coupled to the processor, the computer readable medium storing instructions that, when executed by the processor, cause the processor to control movement of the spindle to control a first tool temperature of the tool between 360 degrees Celsius and 485 degrees Celsius during application of the first aluminum alloy layer to the side of the substrate, the applied first aluminum alloy layer comprising at least 60 volume percent aluminum as equiaxed grains having an aspect ratio of less than 2:1, and after heat treatment, minimal voids exist between metal atoms in the applied and heat treated first aluminum alloy layer, and the applied and heat treated first aluminum alloy layer comprises 5-6 weight percent zinc, 2.1-2.9 weight percent magnesium, 1.2-2 weight percent copper, not more than 0.5 weight percent silicon, titanium, chromium, iron or manganese, with the remainder being aluminum and incidental impurities totaling 100 weight percent; and Additive manufacturing systems, including:

22. 22. The additive manufacturing system of claim 21, wherein the processor is configured to increase the temperature of the tool from the first tool temperature to a second tool temperature that is about 20 degrees Celsius greater than the first tool temperature to add a vertical layer of the aluminum alloy to the added first aluminum alloy layer.

23. 22. The additive manufacturing system of claim 21, wherein the tool comprises tool steel, copper, a copper alloy, tungsten, or a tungsten alloy.

24. 25. The additive manufacturing system of claim 24, wherein the tool comprises at least one protrusion.

25. 25. The additive manufacturing system of claim 24, wherein the feeding unit includes an actuator that forces the aluminum alloy filler material into the spindle and into the tool.

26. 1. A method of producing an additively manufactured aluminum alloy, comprising: applying an aluminum alloy as a first aluminum alloy layer to a surface of a substrate using an additive manufacturing process including a rotary tool, wherein the aluminum alloy is applied in a solid phase to the surface of a workpiece at a first tool temperature; and heat treating the solid-state applied first aluminum alloy layer, wherein the applied first aluminum alloy layer comprises at least 60% volume percent of aluminum as equiaxed grains having an aspect ratio of less than 2:1, and after heat treating there is minimal void space between metal atoms in the applied and heat treated first aluminum alloy layer, and the applied and heat treated first aluminum alloy layer comprises 5-6 weight percent zinc, 2.1-2.9 weight percent magnesium, 1.2-2 weight percent copper, not more than 0.5 weight percent silicon, titanium, chromium, iron or manganese, the balance being aluminum and incidental impurities totaling 100 weight percent; A method comprising:

27. 27. The method of claim 26, wherein the first tool temperature is between 360 degrees Celsius and 485 degrees Celsius.

28. The first tool temperature is Varying the speed of a spindle coupled to the rotary tool; or Varying the torque of the spindle coupled to the rotary tool; or Varying the power of the spindle coupled to the rotary tool; or Varying the deposition rate of the aluminum alloy being added; or Varying the traverse speed of the rotary tool; or Varying the filler feed rate into the rotary tool; or Changing the layer height, or Modifying the strength of the filler, or Varying the pressure under the rotary tool; or using an external heating / cooling source adjacent to the rotary tool; or using an external heating / cooling source adjacent to the surface of the substrate; or Changing the tool geometry during application; maintained by one or more of 27. The method of claim 26.

29. further comprising solid-state applying a second aluminum alloy layer to the first aluminum alloy layer applied using the rotary tool; the second aluminum alloy layer is applied using a second tool temperature that is 20 degrees Celsius higher than the first tool temperature; 27. The method of claim 26.

30. after heat treatment of the applied second aluminum alloy layer, the applied and heat treated second aluminum alloy layer contains at least 60% volume percent of aluminum as equiaxed grains having an aspect ratio of less than 2:1; there is minimal void space between metal atoms in the applied and heat-treated second aluminum alloy layer; the second aluminum alloy layer applied and heat treated comprises 5 to 6 weight percent zinc, 2.1 to 2.9 weight percent magnesium, 1.2 to 2 weight percent copper, not more than 0.5 weight percent silicon, titanium, chromium, iron, or manganese, the remainder being aluminum and incidental impurities totaling 100 weight percent; 30. The method of claim 29.

31. 1. A subtractive and additive method for producing an aluminum alloy product, comprising: applying an aluminum alloy as a first aluminum alloy layer to a surface of a substrate using an additive manufacturing process including a rotary tool, wherein the aluminum alloy is applied in a solid phase to the surface of a workpiece at a first tool temperature; removing a portion of the applied first aluminum alloy layer using a subtraction process to provide a subtracted first aluminum alloy layer on the substrate; and heat treating the subtracted first aluminum alloy layer, wherein the subtracted first aluminum alloy layer comprises at least 60% volume percent of aluminum as equiaxed grains having an aspect ratio of less than 2:1, and after heat treating there is minimal void space between metal atoms in the subtracted and heat treated first aluminum alloy layer, and the subtracted and heat treated first aluminum alloy layer comprises 5-6 weight percent zinc, 2.1-2.9 weight percent magnesium, 1.2-2 weight percent copper, not more than 0.5 weight percent silicon, titanium, chromium, iron or manganese, with the remainder being aluminum and incidental impurities totaling 100 weight percent; A method comprising:

32. 32. The method of claim 31 , wherein the first tool temperature is between 360 degrees Celsius and 485 degrees Celsius.

33. The first tool temperature is Varying the speed of a spindle coupled to the rotary tool; or Varying the torque of the spindle coupled to the rotary tool; or Varying the power of the spindle coupled to the rotary tool; or Varying the deposition rate of the aluminum alloy being added; or Varying the traverse speed of the rotary tool; or Varying the filler feed rate into the rotary tool; or Changing the layer height, or Modifying the strength of the filler, or Varying the pressure under the rotary tool; or using an external heating / cooling source adjacent to the rotary tool; or using an external heating / cooling source adjacent to the surface of the substrate; or Changing the tool geometry during application; maintained by one or more of 32. The method of claim 31 .

34. further comprising using the rotary tool to solid-state add a second aluminum alloy layer to the added and subtracted aluminum alloy layer; the second aluminum alloy layer is applied using a second tool temperature that is 20 degrees Celsius higher than the first tool temperature; 32. The method of claim 31 .

35. after heat treatment of the applied second aluminum alloy layer, the applied and heat treated second aluminum alloy layer contains at least 60% volume percent of aluminum as equiaxed grains having an aspect ratio of less than 2:1; there is minimal void space between metal atoms in the applied and heat-treated second aluminum alloy layer; the second aluminum alloy layer applied and heat treated comprises 5 to 6 weight percent zinc, 2.1 to 2.9 weight percent magnesium, 1.2 to 2 weight percent copper, not more than 0.5 weight percent silicon, titanium, chromium, iron, or manganese, the remainder being aluminum and incidental impurities totaling 100 weight percent; 35. The method of claim 34.

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