Aluminum-lithium alloy parts and aluminum-copper alloy parts produced using solid-state manufacturing

Abstract

Solid-state additively manufactured aluminum-lithium and aluminum-copper alloy products and methods for producing them are described. Various components including the aluminum-lithium and aluminum-copper alloy products are described.

Description

[Technical Field]

[0001] [Priority application] This application is related to and claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 421,530, filed November 1, 2022, the entire disclosure of which is hereby incorporated by reference herein for all purposes.

[0002] Certain embodiments described herein relate to aluminum alloy products. More specifically, certain configurations described relate to aluminum-lithium alloy products or aluminum-copper alloy products produced using 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-lithium alloy or aluminum-copper 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 embodiments, a solid state additively manufactured aluminum alloy product is described, wherein, in certain configurations, at least 60 volume percent of the aluminum in the additively manufactured aluminum alloy product is present as equiaxed grains with an aspect ratio of less than 2:1 after heat treatment of the solid state additively manufactured aluminum alloy product, minimal voids exist between metal atoms in the solid state additively manufactured aluminum alloy product, and the solid state additively manufactured aluminum product comprises an aluminum lithium alloy, or an aluminum copper alloy, or an aluminum lithium copper alloy.

[0007] In certain embodiments, the solid state additively manufactured aluminum product comprises a 1000 series aluminum alloy, such as alloy 1230, alloy 1430, alloy 1420, and alloy 1421. In other embodiments, the solid state additively manufactured aluminum product comprises a 2000 series aluminum alloy, such as alloys 2050, 2055, 2060, 2x95, 2x96, 2x97, 2x98, and 2x99, where x is 0, 1, or 2.

[0008] In some embodiments, the solid phase additively manufactured aluminum alloy product comprises a single track of deposited solid phase additively manufactured aluminum lithium alloy product. In other embodiments, the solid phase additively manufactured aluminum alloy product comprises multiple overlapping tracks of deposited solid phase additively manufactured aluminum alloy product. In some configurations, adjacent tracks overlap by at least 10%.

[0009] In other configurations, the solid state additively manufactured aluminum alloy product further comprises a substrate that receives the solid state additively manufactured aluminum alloy product.

[0010] In some embodiments, at least 90% volume percent of the aluminum in the solid phase additively manufactured aluminum alloy product is present as equiaxed grains.

[0011] In another aspect, there is provided 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, wherein the aluminum alloy is solid state added to the surface of the substrate as a first aluminum alloy layer at a first tool temperature between 330 degrees Celsius and 560 degrees Celsius, and the aluminum alloy comprises an aluminum lithium alloy, or an aluminum copper alloy, or an aluminum lithium copper alloy.

[0012] In certain embodiments, solid state additively manufactured aluminum alloys include 1000 series aluminum alloys, such as, for example, 1230, 1430, 1420, and 1421. In other embodiments, solid state additively manufactured aluminum includes 2000 series aluminum alloys, such as, for example, 2050, 2055, 2060, 2x95, 2x96, 2x97, 2x98, and 2x99 alloys, where x is 0, 1, or 2.

[0013] In some configurations, the solid phase additively manufactured aluminum alloy comprises a single track of deposited solid phase additively manufactured aluminum alloy, while in other embodiments, the solid phase additively manufactured aluminum alloy comprises multiple overlapping tracks of deposited solid phase additively manufactured aluminum alloy, for example, adjacent tracks can overlap by at least 10%.

[0014] In certain embodiments, the solid state additively manufactured aluminum alloy further comprises a substrate that receives the solid state additively manufactured aluminum alloy.

[0015] In other embodiments, at least 90% volume percent of the aluminum in the solid phase additively manufactured aluminum alloy is present as equiaxed grains.

[0016] In another aspect, an additive manufacturing system for producing an aluminum alloy product is described. In certain embodiments, the system includes a feeding unit configured to receive an aluminum alloy filler material including one or more of an aluminum-lithium alloy, an aluminum-copper alloy, or an aluminum-lithium-copper alloy. The system can also include a spindle including an internal passage configured to receive the aluminum alloy filler material from the feeding unit. The system can also include a tool coupled to the spindle, the tool configured to receive the aluminum alloy filler material from the spindle and to apply the received aluminum alloy filler material in a solid state as a first aluminum alloy layer to a surface of a substrate. The system can also include 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 the surface of the workpiece. The system can also include a processor electrically coupled to the temperature sensor and the spindle. The system may also include a computer-readable medium electrically coupled to the processor, the computer-readable medium having instructions stored thereon 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 330 degrees Celsius and 560 degrees Celsius during application of the first aluminum alloy layer to the side of the substrate.

[0017] In certain embodiments, the processor is configured to increase the temperature of the tool from a first tool temperature to a second tool temperature that is about 20 degrees Celsius greater than the first tool temperature to apply a vertical layer of aluminum alloy to the applied first aluminum alloy layer. In other embodiments, the tool comprises tool steel, copper, a copper alloy, tungsten, or a tungsten alloy. In some embodiments, the tool comprises at least one protrusion. In certain examples, the feeding unit includes an actuator that forces the aluminum alloy filler material into the spindle and the tool.

[0018] In another aspect, a method of producing an additively manufactured aluminum alloy includes applying an aluminum alloy as a first aluminum lithium alloy layer to a surface of a substrate using an additive manufacturing process including a rotary tool, wherein the aluminum alloy is applied in solid phase to the surface of the workpiece at a first tool temperature, and the aluminum alloy comprises one or more of an aluminum lithium alloy, or an aluminum copper alloy, or an aluminum lithium copper alloy.

[0019] In certain embodiments, the first tool temperature is between 330 degrees Celsius and 560 degrees Celsius. 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, 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 lithium 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.

[0020] In another embodiment, 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.

[0021] In some 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, with minimal voids between metal atoms in the applied and heat treated second aluminum alloy layer.

[0022] In another aspect, a subtractive and additive method for producing an aluminum alloy product includes adding an aluminum alloy as a first aluminum-lithium alloy layer to a surface of a substrate using an additive manufacturing process including a rotary tool, where the aluminum alloy is added in solid phase to the surface of the workpiece at a first tool temperature, and the aluminum alloy includes one or more of an aluminum-lithium alloy, an aluminum-copper alloy, or an aluminum-lithium-copper alloy. The method also includes removing a portion of the first aluminum alloy layer applied using the subtractive process to provide a subtractive first aluminum alloy layer on the substrate.

[0023] In some embodiments, the first tool temperature is between 330 degrees Celsius and 560 degrees Celsius. 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, or changing the torque of a spindle coupled to the rotary tool, or changing the power of a spindle coupled to the rotary tool, changing the deposition rate of the aluminum lithium 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.

[0024] In some embodiments, the method includes solid-state adding a second aluminum alloy layer to the added and 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.

[0025] Additional aspects, embodiments, configurations, and features are described in more detail below.

[0026] Certain aspects are described in more detail below with reference to the accompanying drawings. [Brief explanation of the drawings]

[0027] [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 in 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 by depositing an aluminum alloy using a solid state additive manufacturing system. [Figure 21] 1 is a photograph showing a part built using an aluminum copper alloy material according to certain embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0028] Additional aspects, examples, embodiments, and features are described below.

[0029] Certain embodiments described herein use aluminum-lithium alloys or aluminum-copper alloys in combination with solid-state additive (SSA) manufacturing to produce products and articles comprising the aluminum alloy. The exact composition of the aluminum alloy can vary and includes, but is not limited to, 1230, 1430, 1421, and 2020 aluminum-lithium alloys. In some embodiments, the aluminum alloy can be an aluminum-copper alloy that can be deposited using a solid-state process, such as 2050, 2195, 2099, 2055, 2196, 2x97, and 2060 Al-Cu alloys.

[0030] In certain embodiments, the aluminum alloy can be a 1000 series alloy, such as 1230, 1430, 1420, 1421, and other aluminum and lithium alloys. For example, the aluminum alloy can be a 1230 alloy containing Si0.3, Fe0.3, Cu4.8-5.8, Mn0.4-0.8, Mg0.05, Zn0.1, Ti0.15, Li0.9-1.4, Cd0.1-0.25, with the balance being aluminum and trace impurities. The values ​​following the elements refer to the weight percentages in the alloy unless otherwise specified. In another example, the aluminum alloy may be a 1430 alloy containing 0.1% Si, 0.15% Fe, 1.4-1.8% Cu, 0.3-0.5% Mn, 2.3-3.0% Mg, 0.5-0.7% Zn, 0.01-0.1% Ti, 1.5-1.9% Li, 0.08-0.14% Zr, 0.02-0.1% Be, 0.01-0.1% Sc, 0.003% Na, 0.2-0.4% Ce, 0.05-0.1% Y, with the balance being aluminum and trace impurities. In certain embodiments, the aluminum alloy may be a 1420 alloy containing 5.0% Mg, 2.0% Li, and 0.1% Zr, with the balance being aluminum and trace impurities. In some embodiments, the aluminum alloy may be 1421 alloy, which includes Mg5.0, Li2.0, Mn0.2, Sc0.2, Zr0.1, with the balance being aluminum and trace impurities.

[0031] In some embodiments, the aluminum alloy may include copper in combination with other metals. For example, the aluminum alloy may be a 2050 alloy containing Cu3.5, Li1.0, Ag0.45, Mn0.35, Zr0.12, and Mg0.04, with the balance being aluminum and trace impurities. The value following the element refers to the weight percentage in the alloy unless otherwise specified. In some embodiments, the aluminum alloy may be a 2x95 alloy, where x is 0, 1, 2, or 3. For example, the aluminum alloy may be a 2195 alloy containing Cu4.0, Mn0.5, Mg0.45, Li1.0, Ag0.4, and Zr0.12, with the balance being aluminum and trace impurities. In certain embodiments, the aluminum alloy may be a 2x96 alloy, where x is 0, 1, 2, or 3. For example, the aluminum alloy may be a 2196 alloy containing Si0.12, Fe0.15, Cu2.5-3.3, Mn0.35, Mg0.25-0.8, Zn0.35, Ti0.10, Ag0.25-0.6, Li1.4-2.1, Zr0.08-0.16, with the balance being aluminum and trace impurities. In another configuration, the aluminum alloy may be a 2x97 alloy, where x is 0, 1, 2, or 3. For example, a 2097 aluminum alloy may contain Si0.12, Fe0.15, Cu2.5-3.1, Mn0.10-0.6, Mg0.35, Zn0.35, Ti0.15, Li1.2-1.8, Zr0.08-0.15, with the balance being aluminum and trace impurities. 2197 aluminum alloy contains Si0.10, Fe0.10, Cu2.5-3.1, Mn0.10-0.50, Mg0.25, Zn0.05, Ti0.12, Li1.3-1.7, Zr0.08-0.15, and the remainder is aluminum and trace impurities. 2297 aluminum alloy contains Si0.10, Fe0.10, Cu2.5-3.1, Mn0.10-0.50, Mg0.25, Zn0.05, Ti0.12, Li1.1-1.7, Zr0.08-0.15, and the remainder is aluminum and trace impurities.The 2397 aluminum alloy contains Si0.10, Fe0.10, Cu2.5-3.1, Mn0.10-0.50, Mg0.25, Zn0.05-0.15, Ti0.12, Li1.1-1.7, and Zr0.08-0.15, with the balance being aluminum and trace impurities. In other embodiments, the aluminum alloy can be a 2x98 alloy, where x is 0, 1, 2, or 3. For example, the aluminum alloy can be a 2098 alloy containing Si0.12, Fe0.15, Cu2.3-3.8, Mn0.35, Mg0.25-0.8, Zn0.35, Ti0.10, Ag0.25-0.6, Li2.4-2.8, and Zr0.04-0.18, with the balance being aluminum and trace impurities. In other embodiments, the aluminum alloy can be a 2x99 alloy, where x is 0, 1, 2, or 3. For example, the aluminum alloy can be a 2099 alloy containing Cu2.53, Mn0.3, Mg0.25, Li1.75, Zn0.75, Zr0.09, with the balance being aluminum and trace impurities. In certain embodiments, the aluminum alloy can be a 2055 alloy containing Cu3.7, Zn0.5, Li1.1, Ag0.4, Mn0.2, Mg0.3, Zr0.1, with the balance being aluminum and trace impurities. In other embodiments, the aluminum alloy can be a 2060 aluminum alloy containing copper, iron, lithium, magnesium, manganese, silicon, silver, titanium, zinc, zirconium, and aluminum.

[0032] In certain configurations, 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 alloys using solid phase additive manufacturing. For example, alloy bars can be added to a solid phase additive (SSA) manufacturing system to provide large articles containing the alloys. Generally, solid phase 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 can often be as much as $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. The embodiments described herein are capable of producing high strength aluminum alloy parts from a variety of Al-Li or Al-Cu alloys via additive manufacturing processes.

[0033] Al-Li alloys are increasingly being used in applications requiring high strength, high hardness, and excellent corrosion and fatigue resistance. These alloys are produced by wrought processes, including rolling, extrusion, and forging, or a combination of these. However, thick Al-Li products present strength, cost, and lead-time challenges. Producing thick, three-dimensional shapes from Al-Li is typically accomplished by one of two process routes: 1) machining from plate or hand forgings, which is hindered by the low strength of thick Al-Li due to its quench sensitivity and limited rolling thickness; or 2) forging in a forming die, which helps overcome the limitations of plate but requires uneconomical setup operations with long lead times. The addition of Li, along with Ag, which is often added to provide additional benefits, significantly increases the raw material costs of these alloys. Therefore, additive manufacturing processes can enable critical cost savings by reducing the amount of raw material required, increasing cost recovery.

[0034] In certain embodiments, Al-Li or Al-Cu alloys can be used in SSA processes with substrates, typically plates but also other product forms such as extrusions and forgings. The SSA process involves building parts layer-by-layer, either single-wall for thin sections or multiple overlapping walls for thick sections. 3D parts with various geometries are built by moving the deposition spindle relative to a reference point. The process controls deposition by monitoring temperature within careful parameters, including external heating / cooling, deposition rate, rotational speed, and spindle travel, and uses temperature feedback to influence other parameters to achieve excellent adhesion and metallurgical bonding between each layer and overlapping layers. The composition used is a commercially available Al-Li alloy. The addition of lithium reduces the density of aluminum, increases its elastic modulus, and improves corrosion and fatigue resistance. These alloys are increasingly being used in aerospace applications and other demanding applications such as space and Formula 1 racing. The substrate is typically a plate, and the raw material is typically an extruded bar, but can be other extruded shapes, other product forms such as drawn bars and rods, or cut-to-size plates. Substrate materials other than Al-Li can be used, and indeed this may offer advantages for certain parts by optimizing design properties within different portions of the same component. For example, one area may require the highest modulus, while the bulk may require high strength.

[0035] In certain embodiments, a part begins with a substrate as a base, and then material is added layer by layer to build the detailed design. Before deposition begins, the part is modeled based on the desired final part, and a deposition plan is developed to build a high-quality Al-Li or Al-Cu part. After deposition, the part can be used in the as-deposited state, or it can be solution heat treated and artificially aged to a desired temper such as T6 or one of many -T8X variants to achieve higher strength, better fatigue resistance, and to optimize other attributes.

[0036] SSA System Components

[0037] 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 geometry, 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 closed cone shapes. The resulting articles can have properties similar to plate and forgings.

[0038] 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.

[0039] 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.

[0040] In certain embodiments, system 100 may include suitable platforms, motors, or other components to enable substrate 150 to move independently of spindle 120 and tooling 130. For example, substrate 150 and tooling 130 may each move independently in the x, y, and z directions. This independent movement enables the creation of complex shapes that vary in thickness across the surface of the generated part, as well as a high degree of control over the various components during deposition of the alloy feedstock material onto the surface of substrate 150.

[0041] 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.

[0042] 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 feed material 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 .

[0043] 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.

[0044] 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.

[0045] 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.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 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 a material that is the same as or different from 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.

[0050] 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.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] 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.

[0057] 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.

[0058] In some embodiments, a system can include subtraction components in addition to addition components. For example, with reference to FIG. 8 , a system can include addition system 810 and subtraction system 820. Addition system 810 can be configured to add, for example, an aluminum-lithium alloy in solid form to a surface of a substrate, as described herein. The exact nature of the action performed by subtraction system 820 can vary. For example, subtraction system 820 can 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 can be used to drill holes or openings or otherwise machine the final product produced using addition system 810 into a final part.

[0059] Processing and Processing Parameters

[0060] 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.

[0061] 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.

[0062] The exact tool temperature range used for various alloys can vary. For example, 2055 and 2x95 alloys can use a tool temperature range of 330°C to 530°C, e.g., 370°C to 510°C or 440°C to 490°C. 2050, 2060, and 2x98 alloys can use a tool temperature range of 330°C to 540°C, e.g., 370°C to 540°C or 450°C to 510°C. 2x96, 2x97, and 2x98 alloys can use a tool temperature range of 330°C to 560°C, e.g., 370°C to 530°C or 440°C to 510°C. High copper alloys with silver can use a tool temperature range of 330°C to 530°C, e.g., 370°C to 510°C or 440°C to 490°C. Medium copper alloys with silver can use a tool temperature range of 330°C to 540°C, e.g., 370°C to 530°C or 450°C to 510°C. Alloys without silver can use a tool temperature range of 330°C to 560°C, e.g., 370°C to 540°C or 460°C to 530°C.

[0063] The final part size is not limited by the processes mentioned above; limitations may be based on the deposition equipment, e.g., deposition bed size and vertical height that can be reached by increasing the spindle. There may also be limitations based on post-deposition processes such as machining and heat treatment.

[0064] 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 approximately 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 approximately 180 rpm to approximately 600 rpm, more specifically, from approximately 200 rpm to approximately 280 rpm, e.g., 210 rpm, 220 rpm, 230 rpm, 240 rpm, 250 rpm, 260 rpm, or 270 rpm. The tooling is coupled to the spindle and generally 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 to increase the surface temperature during start-up, and then reduced to 180-300 rpm to assist in maintaining the desired deposition temperature during deposition.

[0065] 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.

[0066] 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.

[0067] 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.

[0068] 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.

[0069] 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, wherein the aluminum-lithium alloy is applied in a solid phase to the surface of the workpiece at a first tool temperature, and 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 after heat-treating, minimal voids exist between metal atoms in the applied and heat-treated first aluminum-lithium alloy layer, and the applied and heat-treated first aluminum alloy layer comprises an aluminum alloy. As referred to herein, the aluminum alloy can be an aluminum-lithium alloy or an aluminum-copper alloy, or both. The first tool temperature can be between 290 degrees Celsius and 500 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, 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.

[0070] In some embodiments, the second aluminum alloy layer can be solid-state applied to the first aluminum alloy layer applied using a rotary tool, and the second aluminum lithium 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 2.0 to 2.6 weight percent copper, 1.9 to 2.6 weight percent magnesium, 5.7 to 6.7 weight percent zinc, 0.08 to 0.15 weight percent zirconium, not more than 0.7 weight percent silicon, titanium, chromium, iron, or manganese, with the remainder being aluminum and incidental impurities totaling 100 weight percent.

[0071] 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 comprises 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, and the subtracted and heat-treated first aluminum alloy layer comprises an aluminum-lithium alloy or an aluminum-copper alloy described herein. The first tool temperature can be between 290 degrees Celsius and 500 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 the face of the substrate, or changing the tool geometry during application. A second aluminum alloy layer can be solid-phase applied to the subtracted first 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 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 an aluminum lithium alloy or an aluminum copper alloy described herein.

[0072] In some instances, the final formed layer or track may be subjected to additional post-treatments, including solution treatment or heating. For example, the resulting aluminum alloy product may be tempered using methods and process conditions similar to those commonly used to temper other metal alloys. In some embodiments, the formed part may be subjected to a solution heat treatment at a temperature of 430°C to 540°C, followed by quenching.

[0073] In certain embodiments, changing or resetting process parameters that can be used to control deposition temperature and other important characteristics include, but are not limited to, changing spindle speed to maintain a temperature setpoint, changing spindle torque to maintain a temperature setpoint, changing spindle power to maintain a temperature setpoint, changing deposition rate to maintain a temperature setpoint, changing tool traverse speed to maintain a temperature setpoint, changing filler bar feed rate to maintain a temperature setpoint, changing layer height to maintain a temperature setpoint, changing filler bar force to maintain a temperature setpoint, changing pressure under the tool to maintain a temperature setpoint, maintaining a temperature setpoint through an external heating source in, around, or near the tool, maintaining a temperature setpoint with a source of heat under or around the material being deposited, and maintaining a temperature setpoint by changing tool geometry in situ (during printing).

[0074] Products and parts

[0075] 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.

[0076] In certain embodiments, alloy products comprise solid phase additively manufactured aluminum compositions comprising the aluminum alloys described herein. The alloy products can be heat treated to achieve a desired temper and / or to impart 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, the SSA manufactured alloy product, in the longitudinal direction of the primary direction of the shape, e.g., the xy plane, has the ultimate tensile strength, tensile yield strength, and elongation to break described herein for various aluminum alloys.

[0077] 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 alloy parts that would otherwise be forged. These types of parts are used in a variety of applications, including aerospace, defense, and similar critical applications. The parts can be deposited and then machined and heat treated to a certain temper. There may be a final machining operation to produce the desired shape, and many, if not most, parts will receive some kind of coating to protect their appearance and prevent corrosion. Certain exemplary parts are described below.

[0078] The alloy materials described herein can be used to produce, for example, aircraft component forgings for bodies, wings, tails, and landing gear, helicopter components, land defense vehicles, pylons, trusses, cargo and baggage racks, stringers, wing and tail ribs, wing spars, wing outer plates, pressure walls, engine surrounds, actuators, stiffeners, missile tubes, refueling booms, weapons, launch vehicles, brake calipers, turbocharger wheels, and other components.

[0079] In some embodiments, the produced 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.

[0080] In certain embodiments, the produced 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 hot exhaust from the combustion chamber and converting the energy in the high-pressure exhaust into kinetic energy. The exact rocket nozzle shape 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.

[0081] In other embodiments, the produced component may be a nozzle other than a rocket nozzle. For example, the alloy materials and processes described herein may 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.

[0082] The generated part may also be configured as one or more of an aircraft fuselage 1200 or component thereof ( FIG. 12 ), an airplane floor section or component thereof, an airplane wing 1300 or component thereof ( FIG. 13 ), an airplane center wing box or component thereof, an airplane nose or cockpit 1400 or portion thereof ( FIG. 14 ), an airplane engine 1500 or component thereof ( FIG. 15 ), a propeller 1600 ( FIG. 16 ), an airplane tail 1700 ( FIG. 17 ), a helicopter rotor 1800 ( FIG. 18 ), an unmanned aerial vehicle 1900 or component thereof ( FIG. 19 ), or other components of an aircraft or type of aircraft, including components that connect various portions of the structure to one another.

[0083] In certain embodiments, any of these produced parts may include an equiaxed grain structure such as that shown in Figure 20. For example, the produced aluminum alloy product may include equiaxed grains such as those shown in Figure 20 after heat treatment.

[0084] To further illustrate some of the aspects and features of the technology described herein, certain specific examples are described below. [Example]

[0085] Components were printed using 0.5 inch 2195-T8511 bars extruded according to extrusion standard ANSI H35.2. The components were printed on 2195-T8511 plate 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 a commercially available MELD K2 or L3 machine, but used temperature monitors on the tooling.

[0086] Single orbital components were built under temperature control, with a nominal deposition temperature of 390°C (734°F) using a range of 380°C to 400°C (716°F to 752°F). These values ​​correspond to measured tool temperatures. To maintain the tool temperature within the selected range, the tool temperature was controlled through parameters such as spindle RPM (revolutions per minute), force, feed rate, and traverse speed. The 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 2 inches wide, 6 inches long, and 3 inches high. A photograph of the 2195 alloy build is shown in Figure 21.

[0087] 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.

[0088] 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. [Explanation of symbols]

[0089] 100 Solid-phase additive manufacturing system 110 Feeding unit 120 spindle 130 Tools 150 boards

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 an aluminum lithium alloy, an aluminum copper alloy, or an aluminum lithium copper alloy. Aluminum alloy products.

2. 10. The solid state additively manufactured aluminum alloy product of claim 1, wherein the solid state additively manufactured aluminum product comprises a 1000 series aluminum alloy.

3. 3. The solid state additively manufactured aluminum alloy product of claim 2, wherein the 1000 series aluminum alloy is selected from the group consisting of 1230 alloy, 1430 alloy, 1420 alloy, and 1421 alloy.

4. 10. The solid state additively manufactured aluminum alloy product of claim 1, wherein the solid state additively manufactured aluminum product comprises a 2000 series aluminum alloy.

5. the 2000 series aluminum alloy is selected from the group consisting of 2050, 2055, 2060, 2x95, 2x96, 2x97, 2x98, and 2x99 alloys; x is 0, 1, or 2; 5. The solid state additively manufactured aluminum alloy product of claim 4.

6. 10. The solid state additively manufactured aluminum alloy product of claim 1 having a single track of deposited solid state additively manufactured aluminum lithium alloy product.

7. 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.

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

9. 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.

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, applied in a solid phase as a first aluminum alloy layer to the surface of the substrate at a first tool temperature between 330 degrees Celsius and 560 degrees Celsius; aluminum lithium alloy or aluminum copper alloy or aluminum lithium copper alloy, Aluminum alloy.

12. 12. The solid state additively manufactured aluminum alloy of claim 11, comprising a 1000 series aluminum alloy.

13. 13. The solid state additively manufactured aluminum alloy of claim 12, wherein the 1000 series aluminum alloy is selected from the group consisting of 1230 alloy, 1430 alloy, 1420 alloy, and 1421 alloy.

14. 12. The solid state additively manufactured aluminum alloy of claim 11, comprising a 2000 series aluminum alloy.

15. the 2000 series aluminum alloy is selected from the group consisting of 2050, 2055, 2060, 2x95, 2x96, 2x97, 2x98, and 2x99 alloys; x is 0, 1, or 2; 15. The solid state additively manufactured aluminum alloy of claim 14.

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

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

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

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

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 comprising one or more of an aluminum lithium alloy, an aluminum copper alloy, or an aluminum lithium copper alloy; 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 330 degrees Celsius and 560 degrees Celsius during application of the first aluminum alloy layer to the surface of the substrate; 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 lithium 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 the aluminum alloy comprises one or more of an aluminum lithium alloy, an aluminum copper alloy, or an aluminum lithium copper alloy; A method comprising:

27. 27. The method of claim 26, wherein the first tool temperature is between 330 degrees Celsius and 560 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 lithium 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 applied first aluminum alloy layer 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; 30. The method of claim 29.

31. 1. A subtraction and addition method for producing an aluminum alloy product, comprising: applying an aluminum alloy as a first aluminum lithium 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 the aluminum alloy comprises one or more of an aluminum lithium alloy, an aluminum copper alloy, or an aluminum lithium copper alloy; and 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; Deduction and addition methods, including:

32. 32. The method of claim 31 , wherein the first tool temperature is between 330 degrees Celsius and 560 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 lithium 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 solid-state adding a second aluminum alloy layer to the added and subtracted aluminum alloy layer 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; 32. The method of claim 31 .

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