Aluminum-erbium alloy powder for additive manufacturing and method for preparing same

Abstract

This disclosure describes a high-strength aluminum-erbium alloy for additive manufacturing and its preparation method. The alloy contains 4-20 wt% erbium (Er), 2-10 wt% magnesium (Mg), 1 wt% or less manganese (Mn), optionally 0-1 wt% scandium (Sc), and optionally 0-1 wt% zirconium (Zr). Based on a phase diagram calculation method for supporting alloy composition design, this disclosure aims to simultaneously improve the alloy's formability and mechanical properties. By selecting an Al-Er eutectic system to shorten the solidification interval and form a fine crystalline phase, the present disclosure achieves the technical effects of refined structure, no thermal cracking, and excellent printability. In particular, the introduction of an open-celled FCC AlEr eutectic network structure with a size on the order of 100 nanometers and capable of plastic deformation improves both strength and toughness. This aluminum-erbium alloy combines excellent printability and comprehensive mechanical properties, and its preparation method is mature, low-cost, and highly efficient, making large-scale industrial production possible.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims priority to Chinese Patent Application No. 2023117382286, filed with the China Patent Office on December 15, 2023, entitled "Aluminum-Erbium Alloy Powder for Additive Manufacturing and Preparation Method Thereof," the entire contents of which are incorporated herein by reference.

[0002] The present disclosure is in the field of aluminum alloy smelting and relates to the design and preparation of aluminum alloy powder components, and in particular to high strength aluminum-erbium alloy powders for additive manufacturing and methods for preparing the same. [Background technology]

[0003] Aluminum alloys have advantages such as low density, high specific strength, and excellent corrosion resistance, and are widely used in the aerospace, automotive, and marine industries as ideal structural or functional materials. However, traditional aluminum alloy processing methods (e.g., casting, forging, powder metallurgy, etc.) have limitations in fabricating products and parts with complex geometric shapes. Additive manufacturing, as a layered manufacturing technology, offers a new way to overcome the above dilemma, as it offers high freedom in design and shaping, and low cost. However, additive manufacturing is a non-equilibrium solidification process, and the cooling rate is fast (10 3 ~10 6 K / s), and the temperature gradient is large (~10 -6K / m), are prone to metallurgical defects during the solidification process, such as thermal cracking, spheroidization, and porosity. Only a few alloy systems are suitable for printing parts with low density, specific microstructure, and high mechanical properties. Current aluminum alloy systems suitable for additive manufacturing are primarily Al-Si eutectic systems, which have a narrow solidification temperature range, are less susceptible to cracking, and have good printability. However, they suffer from low strength and elongation, making them uncompetitive in terms of mechanical properties. For example, AlSi10Mg formed by selective laser melting (SLM) has a yield strength of 300 MPa, a tensile strength of 490 MPa, and an elongation of only 4%. On the other hand, conventional high-strength alloys in the 2xxx (Al-Cu-Mg) system, 6xxx (Al-Mg-Si) system, and 7xxx (Al-Zn-Mg-Cu) system are not suitable for additive manufacturing processes because of their high alloying element content, wide solidification temperature interval, and absence of an initial heterogeneous nucleation phase, which leads to severe and periodic grain boundary thermal cracking when coarse columnar crystals grow during printing. Therefore, there is an urgent need to develop easily formable, high-strength, and highly plastic aluminum alloy systems suitable for non-equilibrium rapid solidification processes in additive manufacturing. Summary of the Invention

[0004] Described herein are one or more alloys and additively manufactured parts, as well as methods of making and / or using them. For example, the one or more alloys or compositions thereof can be aluminum alloys. The one or more alloys can be used in three-dimensional (3D) printing and / or additively manufactured parts. Illustratively, an alloy can be a composition comprising multiple materials (e.g., elements, metals, etc.).

[0005] An alloy according to one embodiment of the present disclosure includes aluminum (Al), erbium (Er), magnesium (Mg), and manganese (Mn), and the alloy has a composition including 4-20 wt% erbium (Er), 2-10 wt% magnesium (Mg), and 1 wt% or less manganese (Mn).

[0006] The alloy may have a yield strength of at least 440 megapascals (MPa), a tensile strength of at least 500 MPa, and / or an elongation of at least 4%.

[0007] The alloy may further optionally contain at least one of scandium (Sc) and zirconium (Zr). The alloy may contain 0 to 1 wt% scandium or 0 to 1 wt% zirconium.

[0008] The alloy may be in powder form. The alloy in powder form may further be used in additive manufacturing processes. The alloy may be a hypereutectic alloy.

[0009] Further described herein is a method of producing the aluminum alloy, wherein the aluminum alloy is prepared by a rapid solidification process, such as one or more of atomization powdering, jet deposition, planar flow casting, melt spinning, melt extraction, glaze on a beam, and additive manufacturing.

[0010] Further described herein are components obtained by preparing said alloys and methods for manufacturing the components.

[0011] Compared with the prior art, the present disclosure has the following beneficial effects:

[0012] (1) The high-strength aluminum-erbium alloy powder described in this disclosure has excellent printability. Based on the Al-Er eutectic system, it has a narrow solidification range and a low tendency to thermal cracks. Furthermore, unlike other eutectic aluminum alloy systems, the solidification process additionally forms an AlEr major phase that is coherent with the aluminum matrix, which can play a role in refining the crystals, further improving the solidification behavior and thermal crack sensitivity of the Al-Er system. Comparing the microstructures, it can be seen that the Al-Er alloys of each example of this disclosure have a significantly higher proportion of equiaxed fine crystal zones than Al-Ni-based alloys, demonstrating superior solidification characteristics.

[0013] (2) Block materials formed by selective laser printing of the aluminum-erbium alloy powder described herein have excellent mechanical properties. In the as-formed state, yield strengths can exceed 530 MPa, tensile strengths can exceed 550 MPa, and elongations can exceed 10%. After simple heat treatment, yield strengths can exceed 620 MPa, tensile strengths can exceed 640 MPa, and elongations can exceed 8%. In the as-printed and heat-treated states, yield strengths exceed the levels of all currently commercially available additively manufactured ultra-high strength aluminum alloys.

[0014] (3) The Al3Er eutectic phase inside the block material formed by selective laser printing of the aluminum-erbium alloy powder described in the present disclosure has an alveolar network structure, which has a significant strengthening effect.

[0015] (4) The Al3Er eutectic phase within the block material formed by selective laser printing of the aluminum-erbium alloy powder described in this disclosure contains a large amount of nanotwin crystals and 9R phases, indicating that this eutectic phase (and the alveolar network structure that constitutes it) has the ability to undergo plastic deformation, ensuring high plasticity of the material. The appearance of nanotwin crystals also increases the strength of the eutectic network structure, thereby improving the overall strength level of the material. Meanwhile, the Al3Er eutectic phase, with its FCC crystal structure, is coherent with the aluminum matrix, facilitating cooperative deformation between the two.

[0016] (5) The preparation method and process of high-strength aluminum-erbium alloy powder described in the present disclosure is simple and mature in operation, low-cost and highly efficient, and can be realized in large-scale industrial production.

[0017] (6) The high-strength aluminum-erbium alloy powder described in the present disclosure is highly applicable to additive manufacturing processes such as selective laser melting, enabling large-scale industrial production. [Brief explanation of the drawings]

[0018] Other features, objects and advantages of the present disclosure will become more apparent from the following detailed description taken in conjunction with the accompanying drawings of non-limiting examples.

[0019] [Figure 1] This is a thermodynamic phase diagram of the Al-Er eutectic system. [Figure 2] This is a typical solidification path curve for the Al-Er-Mg-Mn-Zr system. [Figure 3] The thermal crack sensitivity factor of the Al-Er-Mg-Mn system varies with the Mg and Mn contents. [Figure 4] 1 is a typical microstructure of the Al-10.8Er-4.5Mg-0.6Mn-0.7Zr alloy powder prepared in Example 1. [Figure 5] 1 is a typical XRD pattern of the Al-10.8Er-4.5Mg-0.6Mn-0.7Zr alloy powder prepared in Example 1. [Figure 6] 1 is a typical microstructure of the as-printed Al-10.8Er-4.5Mg-0.6Mn-0.7Zr alloy block prepared in Example 1. [Figure 7] 1 is a typical XRD pattern of the as-printed Al-10.8Er-4.5Mg-0.6Mn-0.7Zr alloy block prepared in Example 1. [Figure 8] 1 is a backscattered electron diffraction photograph of the Al-10.8Er-4.5Mg-0.6Mn-0.7Zr as-printed alloy block prepared in Example 1. [Figure 9] 1 shows the structure of a large amount of cellular continuous eutectic network contained in the columnar crystals of the alloy of Example 1. [Figure 10] FIG. 1 is an atomic structure diagram of the Al3Er eutectic phase of the alloy of Example 1. [Figure 11] 1 is a typical tensile curve of the as-printed Al-10.8Er-4.5Mg-0.6Mn-0.7Zr alloy block prepared in Example 1. [Figure 12] 1 is a typical tensile curve of the Al-10.8Er-4.5Mg-0.6Mn-0.7Zr as-printed alloy prepared in Example 1 after heat treatment. [Figure 13]1 shows a typical microstructure of the Al-10.8Er-4.5Mg-0.6Mn-0.5Sc-0.4Zr alloy powder prepared in Example 2. [Figure 14] 1 is a typical microstructure of the as-printed Al-10.8Er-4.5Mg-0.6Mn-0.5Sc-0.4Zr alloy block prepared in Example 2. [Figure 15] 1 is a typical tensile curve of the as-printed Al-10.8Er-4.5Mg-0.6Mn-0.5Sc-0.4Zr alloy block prepared in Example 2. [Figure 16] 1 is a typical tensile curve of the Al-10.8Er-4.5Mg-0.6Mn-0.5Sc-0.4Zr as-printed alloy block prepared in Example 2 after heat treatment. [Figure 17] 1 is a typical tensile curve of the as-printed Al-10.8Er-3.0Mg-0.6Mn-0.7Zr alloy block prepared in Example 3. [Figure 18] 1 is a typical tensile curve of the as-printed Al-10.8Er-3.0Mg-0.6Mn-0.5Sc-0.4Zr alloy block prepared in Example 4. [Figure 19] 1 is a typical tensile curve of the as-printed Al-10.8Er-8.5Mg-0.6Mn-0.7Zr alloy block prepared in Example 5. [Figure 20] 1 is a typical tensile curve of the Al-10.8Er-8.5Mg-0.6Mn-0.5Sc-0.4Zr as-printed alloy block prepared in Example 6. [Figure 21] 1 is a typical tensile curve of the as-printed Al-15.6Er-4.5Mg-0.6Mn-0.7Zr alloy block prepared in Example 7. [Figure 22] 1 is a typical tensile curve of the as-printed Al-15.6Er-4.5Mg-0.6Mn-0.5Sc-0.4Zr alloy block prepared in Example 8. [Figure 23] 10 is a typical tensile curve of the as-printed Al-15.6Er-3.3Mg-0.6Mn-0.7Zr alloy block prepared in Example 9. [Figure 24]1 is a typical tensile curve of the as-printed Al-15.6Er-3.3Mg-0.6Mn-0.5Sc-0.4Zr alloy block prepared in Example 10. [Figure 25] 1 is a typical tensile curve of the as-printed Al-15.6Er-7.8Mg-0.6Mn-0.7Zr alloy block prepared in Example 11. [Figure 26] 1 is a typical tensile curve of the as-printed Al-14.6Er-7.8Mg-0.6Mn-0.5Sc-0.4Zr alloy block prepared in Example 12. [Figure 27] 1 is a typical tensile curve of the as-printed Al-5.0Er-4.5Mg-0.6Mn-0.3Zr alloy block prepared in Example 13. [Figure 28] 1 is a typical tensile curve of the Al-5.5Er-4.5Mg-0.6Mn-0.5Sc-0.4Zr as-printed alloy block prepared in Example 14. [Figure 29] 10 is a typical tensile curve of the as-printed Al-5.0Er-3.0Mg-0.6Mn-0.7Zr alloy block prepared in Example 15. [Figure 30] 10 is a typical tensile curve of the Al-5.0Er-3.0Mg-0.6Mn-0.5Sc-0.4Zr as-printed alloy block prepared in Example 16. [Figure 31] 10 is a typical tensile curve of the as-printed Al-5.2Er-8.5Mg-0.6Mn-0.7Zr alloy block prepared in Example 17. [Figure 32] 10 is a typical tensile curve of the as-printed Al-5.2Er-8.5Mg-0.6Mn-0.5Sc-0.4Zr alloy block prepared in Example 18. [Figure 33] 10 is a typical tensile curve of the as-printed Al-10.8Er-4.5Mg-0.6Mn alloy block prepared in Example 19. [Figure 34] 1 is a typical tensile curve of the Al-5.5Er-4.5Mg-0.6Mn-0.1Zr as-printed alloy block prepared in Example 20. [Figure 35]1 is a typical tensile curve of the Al-7Er-4.5Mg-0.5Mn-0.3Zr as-printed alloy block prepared in Example 21. [Figure 36] 1 is the microstructure of the selective laser printed Al-3Er-4.5Mg-0.5Mn-0.1Zr block of Comparative Example 1. DETAILED DESCRIPTION OF THE INVENTION

[0020] I. Definition In this disclosure, scientific and technical terms used herein have the meanings that are commonly understood by those skilled in the art unless otherwise specified.In addition, the relevant terms and experimental steps used herein are terms and common steps that are widely used in their respective fields.In addition, in order to better understand this disclosure, the definitions and explanations of relevant terms are provided below.

[0021] As used herein, unless otherwise specified, the term "about" or "approximately" means within ±10% of a given value or range. Where an integer is required, the term means within ±10% of a given value or range, rounded up or down to the nearest integer.

[0022] In the description herein, reference is made to "some examples," "some embodiments," or "some implementations," which describe a subset of all possible examples. However, it is understood that "some examples" may be the same or different subsets of all possible examples and may be combined with each other without conflict.

[0023] As used herein, and unless otherwise specified, the terms "comprise," "include," "have," and "contain," including their grammatical equivalents, are to be generally understood as open-ended and non-limiting, e.g., not excluding other unrecited elements or steps.

[0024] As used herein, the term "wt%" refers to weight ratios and percentages of materials in a mixture. For example, 4-20 wt% erbium (Er) indicates that the weight percentage of the element Er is 4-20 wt% of the total weight of the elements in the alloy.

[0025] As used herein, the term "nominal composition" means the weight percentage of each metal element added to a feedstock relative to the total feedstock.

[0026] As used herein, the term "aluminum alloy" means an alloy based on aluminum with certain amounts of other alloying elements added.

[0027] As used herein, the term "9R phase" refers to a long-period dot matrix structure consisting of nine {111} atomic layers, containing three stacking faults, and is typically found only in face-centered cubic (FCC) phases. As used herein, the term "twinning" refers to a mirror-symmetric orientation relationship between two crystals (or two portions of a crystal) along a common crystallographic plane. In this disclosure, twinning in Al-Er alloys modulates plastic deformation and alters grain orientation, thereby improving the alloy's plasticity and ductility. Introducing more twin boundaries in engineering alloys is generally believed to significantly improve alloy life. However, in some alloys, such as polycrystalline nickel-based high-temperature alloys, twin boundaries can easily induce crack initiation and propagation, potentially affecting alloy properties (DOI:10.1038 / s41467-020-18641-z). Controlling and optimizing twinning is an important consideration in alloy design and processing.

[0028] As used herein, the term "additive manufacturing" (AM) refers to any process that involves producing a three-dimensional object and sequentially building up the shape of the object layer at a time. For example, AM processes include three-dimensional printing (3DP) processes, laser direct deposition modeling, direct metal laser sintering (DMLS), direct metal laser melting (DMLM), plasma transferred arc, freeform manufacturing, etc. Non-limiting specific types of AM processes use an energy beam, such as an electron beam or electromagnetic radiation, or a laser beam, to sinter or melt powder material. AM processes can use metal powder material or wire as a feedstock.

[0029] II. Working Examples The alloy elemental analysis in this disclosure was measured using an inductively coupled plasma optical emission spectrometer (ICP-OES), and the weight percentage of the corresponding element was calculated based on the measurement results. Yield strength, tensile strength, and elongation were measured in accordance with ASTM E8 / E8M-2015a Standard Test Methods for Tension Testing of Metallic Materials. To achieve higher phase stability and mechanical properties, a phase diagram calculation method was used to assist in the design of the alloy composition and obtain a thermodynamic equilibrium phase diagram for the Al-Er-Mg-Mn-Zr system. As shown in Figure 1, the eutectic point w(Er) was set to approximately 4%, and a hypereutectic composition was selected to obtain a dissociated eutectic network structure. A high-throughput Scheil solidification path simulation of the Al-Er-Mg-Mn-Zr system was performed using the phase diagram thermodynamic calculation method, and the solid fraction (f) versus temperature T was calculated as shown in Figure 2. s The thermal crack sensitivity factor (CSI) is calculated by |dT / d(f s ) 1 / 2 |of s 1 / 2It is defined as the maximum value within 0.99. The changing trends of the thermal cracking sensitivity factors due to Mg and Mn in the Al-Er-Mg-Mn system are respectively shown in Fig. 3. Currently, the thermal cracking sensitivity factor of the additive manufacturing aluminum alloy for industrial applications is less than 10,000 K. Referring to this, the chemical composition of the optimized designed Al-Er-Mg-Mn-Sc-Zr alloy powder is 4 ≤ w(Er) ≤ 20%, 3 ≤ w(Mg) ≤ 10%, 0 < w(Mn) ≤ 1%, 0 ≤ w(Sc) ≤ 1%, 0 ≤ w(Zr) ≤ 1%, and the remaining amount of Al.

[0030] The present disclosure provides an aluminum- erbium alloy and a preparation method thereof. The additive manufacturing parts manufactured therefrom have low thermal cracking sensitivity, as well as high yield strength and good plasticity.

[0031] In one aspect of the present disclosure, an aluminum alloy is provided that contains 4 to 20 wt% of erbium (Er), 2 to 10 wt% of magnesium (Mg), and 1 wt% or less of manganese (Mn).

[0032] Optionally, the aluminum alloy further contains 0 to 1 wt% of scandium (Sc).

[0033] Optionally, the aluminum alloy further contains 0 to 1 wt% of zirconium (Zr).

[0034] In one embodiment, the aluminum alloy contains 4.0 to 20 wt% Er, for example, 5.0 to 15.6 wt%, 5.0 to 10.8 wt%, 10.8 to 14.6 wt%, 10.8 to 15.6 wt%, or further, 4.5 wt%, 5.0 wt%, 5.2 wt%, 5.3 wt%, 5.5 wt%, 6.0 wt%, 6.5 wt%, 7 wt%, 7.5 wt%, 8.0 wt%, 8.5 wt%, 9.0 wt%, 9.5 wt%, 10.0 wt%, or The Er content may be 10.5 wt%, 10.8 wt%, 11.0 wt%, 11.5 wt%, 12.0 wt%, 12.5 wt%, 13.0 wt%, 13.5 wt%, 14 wt%, 14.5 wt%, 14.6 wt%, 15.0 wt%, 15.6 wt%, 16.0 wt%, 16.5 wt%, 17.0 wt%, 17.5 wt%, 18.0 wt%, 18.5 wt%, 19.0 wt%, 19.5 wt%, 20.0 wt%, or a range between any two of the foregoing. This is useful for producing Er-containing aluminum alloy products with a eutectic structure. When the alloy powder is printed into an alloy block by conventional methods, it is based on the Al-Er eutectic system, and the AlEr phase not only participates in the eutectic reaction to provide excellent solidification properties, but also precipitates as a coherent major phase, playing a role in grain refinement, thereby further improving the thermal crack sensitivity of the alloy. In one embodiment, the aluminum alloy comprises 3.0-10 wt% Mg, such as 3.0-8.5 wt%, 3.0-3.3 wt%, 3.3-4.5 wt%, 4.5-7.8 wt%, 7.8-8.5 wt%, or even 3.0 wt%, 3.3 wt%, 3.5 wt%, 4.5 wt%, 4.0 wt%, 4.5 wt%, 5.0 wt%, 5.5 wt%, 6.0 wt%, 6.5 wt%, 7.0 wt%, 7.5 wt%, 7.8 wt%, 8.0 wt%, 8.5 wt%, 9.0 wt%, 9.5 wt%, 10.0 wt%, or a range between any two of the foregoing.

[0035] In one embodiment, the aluminum alloy contains 1 wt% Mn or less, for example, 0.9 wt% or less, 0.8 wt% or less, 0.7 wt% or less, 0.6 wt% or less, 0.3-0.6 wt%, or 0.3 wt%, 0.4 wt%, 0.5 wt%, 0.6 wt%, 0.7 wt%, or a range between any two thereof.

[0036] The aluminum alloy optionally includes 0-1 wt% Zr, and further includes 0-0.7 wt% Zr, such as 0 wt%, 0.1 wt%, 0.2 wt%, 0.3 wt%, 0.4 wt%, 0.5 wt%, 0.6 wt%, 0.7 wt%, 0.8 wt%, 0.9 wt%, 1.0 wt%, or a range between any two of the foregoing.

[0037] The aluminum alloy optionally includes 0-1 wt% Sc, and further includes 0-0.5 wt% Sc, such as 0 wt%, 0.1 wt%, 0.2 wt%, 0.3 wt%, 0.4 wt%, 0.5 wt%, 0.6 wt%, 0.7 wt%, 0.8 wt%, 0.9 wt%, 1.0 wt%, or a range between any two of the foregoing.

[0038] In one embodiment, the aluminum alloy is 10.8 wt% Er, 4.5 wt% Mg, 0.6 wt% Mn, 0.7 wt% Zr, or 10.8 wt% Er, 4.5 wt% Mg, 0.6 wt% Mn, 0.5 wt% Sc, 0.4 wt% Zr, or 10.8 wt% Er, 3.0 wt% Mg, 0.6 wt% Mn, 0.7 wt% Zr, or 10.8 wt% Er, 3.0 wt% Mg, 0.6 wt% Mn, 0.5 wt% Sc, 0.4 wt% Zr, or 10.8 wt% Er, 8.5 wt% Mg, 0.6 wt% Mn, 0.7 wt% Zr, or 10.8 wt% Er, 8.5 wt% Mg, 0.6 wt% Mn, 0.5 wt% Sc, 0.4 wt% Zr, or 15.6 wt% Er, 4.5 wt% Mg, 0.6 wt% Mn, 0.7 wt% Zr, or 15.6 wt% Er, 4.5 wt% Mg, 0.6 wt% Mn, 0.5 wt% Sc, 0.4 wt% Zr, or 15.6 wt% Er, 3.3 wt% Mg, 0.6 wt% Mn, 0.7 wt% Zr, or 15.6 wt% Er, 3.3 wt% Mg, 0.6 wt% Mn, 0.5 wt% Sc, 0.4 wt% Zr, or 15.6 wt% Er, 7.8 wt% Mg, 0.6 wt% Mn, 0.7 wt% Zr, or 14.6 wt% Er, 7.8 wt% Mg, 0.6 wt% Mn, 0.5 wt% Sc, 0.4 wt% Zr, or 5.0 wt% Er, 4.5 wt% Mg, 0.6 wt% Mn, 0.3 wt% Zr, or 5.5 wt% Er, 4.5 wt% Mg, 0.6 wt% Mn, 0.5 wt% Sc, 0.4 wt% Zr, or 5.0 wt% Er, 3.0 wt% Mg, 0.6 wt% Mn, 0.7 wt% Zr, or 5.0 wt% Er, 3.0 wt% Mg, 0.6 wt% Mn, 0.5 wt% Sc, 0.40 wt% Zr, or 5.2 wt% Er, 8.5 wt% Mg, 0.6 wt% Mn, 0.7 wt% Zr, or 5.2 wt% Er, 8.5 wt% Mg, 0.6 wt% Mn, 0.50 wt% Sc, 0.4 wt% Zr, or 10.8 wt% Er, 4.5 wt% Mg, 0.6 wt% Mn, or 5.5 wt% Er, 4.5 wt% Mg, 0.6 wt% Mn, 0.1 wt% Zr, or Contains 7.0 wt% Er, 4.5 wt% Mg, 0.5 wt% Mn, 0.3 wt% Zr, and 0.1 wt% Sc.

[0039] In one embodiment, the aluminum alloy further comprises residual amounts of aluminum (Al) and unavoidable impurities. In one embodiment, the aluminum alloy is produced in a form selected from powder, slice, strip, wire, sheet, plate, and foil.

[0040] In one embodiment, the alloy is made in powder form, which can be used in additive manufacturing processes.

[0041] 4 and 5 show an exemplary aluminum alloy powder (10.8 wt% Er, 4.5 wt% Mg, 0.6 wt% Mn, 0.7 wt% Zr) of the present disclosure, in which the aluminum alloy powder has an average particle size of about 35 μm, and two phases, α-Al and AlEr, are present in the powder, with an α-Al / AlEr eutectic between the α-Al alveolar crystals. When the aluminum alloy content is less than 4 wt%, e.g., 3 wt%, the resulting alloy microstructure has a discontinuous AlEr network structure, as shown in FIG. 36.

[0042] The atomic structure of the Al3Er eutectic phase further exhibits a continuous alveolar FCC configuration and a 9R phase, as shown in Figure 10. The FCC crystalline Al3Er eutectic phase is coherent with the aluminum matrix, facilitating cooperative deformation between them.

[0043] Figure 6 shows an exemplary as-printed alloy, optionally obtained by conventional selective laser melting (SLM) processing of alloy powder. The alloy is crack-free, and a large amount of Al(Er,Zr) nucleation phase is present at the bottom of the melt pool, which induces the formation of an equiaxed crystal zone with a grain size of approximately 500 nm and a columnar crystal region within the melt pool with a grain size of approximately 2 μm. Figure 9 further illustrates the structure of a large amount of alveolar, continuous AlEr eutectic network contained within the columnar crystals.

[0044] The as-printed alloy has a high yield strength of 440 MPa or more, a tensile strength of 550 or more, and an elongation of greater than 5%. At lower erbium contents, the as-printed alloy has a yield strength of 400 MPa or less and a tensile strength of 470 MPa or less.

[0045] In one embodiment, the alloy exhibits a dual grain morphology in which columnar and equiaxed crystals coexist. The as-printed alloy contains a large amount of Al(Er,Zr) nucleation phase at the bottom of the melt pool, which induces the formation of an equiaxed zone with a grain size of about 500 nm and a columnar region within the melt pool with a grain size of about 2 μm.

[0046] Furthermore, the alloy is rich in fine grain structure. The Al-Er alloy of the present disclosure has significantly more equiaxed fine grain zones than Al-Ni-based alloys, demonstrating superior solidification characteristics. Compared to the Al-Ni-based 3D printing materials reported in the literature (Scripta Materialia 203 (2021): 114034), the Al3Er phase not only participates in the eutectic reaction to provide superior solidification characteristics, but can also precipitate as a coherent major phase, refining grains and further improving resistance to thermal cracking sensitivity. Due to the large difference between the crystal structure of Al-Ni-based Al3Ni and the aluminum matrix, it cannot effectively play a role in heterogeneous nucleation and grain refinement. It can be seen that the Al-Er alloys of the present disclosure have significantly more equiaxed fine grain zones than Al-Ni-based alloys, demonstrating superior solidification characteristics.

[0047] In one embodiment, the alloy has a grain size of 500 nm to about 2 μm.

[0048] In one embodiment, the alloy has a fine grain structure with grain sizes between 500 nm and about 2 μm.

[0049] In one embodiment, the alloy has equiaxed grains with a grain size of about 500 nm and columnar grains with a diameter of 2 μm.

[0050] In one embodiment, the columnar crystals comprise a continuous Al3Er vesicular eutectic network structure.

[0051] In one embodiment, the network cell size of the network structure is 300 to 400 nm. This eutectic phase (and the network structure that constitutes it) has the ability to undergo plastic deformation, which is beneficial for increasing the plasticity of the material.

[0052] In one embodiment, the Al3Er cellular eutectic network structure comprises a twin structure, and the twin structure is a nanotwin.

[0053] In one embodiment, the Al3Er cellular eutectic network structure includes a 9R structure, in which stacking faults occur periodically with a spacing of three closely spaced atomic planes.

[0054] In the present disclosure, the alloy in powder form may be produced by any suitable method.

[0055] In one embodiment, the powder is produced by a melt crushing followed by solidification process.

[0056] In some embodiments, the aluminum alloy powder is produced by a process that has a solidification rate sufficient to promote the formation of a fine eutectic-type structure.

[0057] Another aspect of the present disclosure provides a method for preparing said aluminum alloy, comprising the steps of:

[0058] The method includes preparing the aluminum alloy by a rapid solidification process, the rapid solidification process being preferably one or more selected from gas atomization powdering, jet deposition, planar flow casting, melt spinning, melt extraction, and glaze on a beam.

[0059] In one embodiment, the atomized powdering includes, but is not limited to, gas atomization, rotating electrode atomization, and ultrasonic atomization.

[0060] While the present disclosure generally relates to aluminum alloy products manufactured by powder-based additive manufacturing processes, in some examples, one or more of the aluminum alloy compositions may also be used in wire-based additive manufacturing processes, such as those utilizing electron beam and / or plasma arc.

[0061] In one embodiment, the additive manufacturing includes, but is not limited to, selective laser melting additive manufacturing, laser directed energy deposition additive manufacturing, electron beam selective melting additive manufacturing, and electron beam directed energy deposition additive manufacturing.

[0062] In one embodiment, the method for preparing the aluminum alloy comprises the steps of melting to obtain an aluminum-erbium alloy pre-processed ingot and obtaining an aluminum-erbium alloy powder by gas atomization powdering.

[0063] In one embodiment, the preparation of the aluminum-erbium alloy pre-fabricated ingot comprises the following steps:

[0064] S1: Weigh out pure Al, pure Mg, Al-Er intermediate alloy block, and Al-Mn intermediate alloy block as raw materials according to the weight % of the alloy's chemical composition, and optionally, the raw materials also include Al-Sc intermediate alloy block and / or Al-Zr intermediate alloy block.

[0065] S2: Pure Al and Al-Er intermediate alloy blocks are mixed, heated to melt, and stirred to obtain melt A.

[0066] S3: Add an Al-Mn intermediate alloy block to melt A, heat and melt it, and stir to obtain melt B.

[0067] If the erbium-aluminum alloy contains Sc, an Al-Sc intermediate alloy block is further added to the melt A; If the erbium aluminum alloy contains Zr, an Al-Zr intermediate alloy block is further added to the melt A.

[0068] S4: Pure Mg is injected into melt B to obtain melt C.

[0069] S5: A refining agent and a coating agent are added to the melt obtained in step S4, and the melt is degassed under vacuum to obtain a melt D.

[0070] S6: The melt D is deslag-laden and poured into a preheated mold to obtain a metal ingot.

[0071] In one embodiment, the heating temperature in step S2 is 780 to 800° C., and the stirring time is 1 to 3 minutes.

[0072] In one embodiment, the heating temperature in step S3 is 780 to 800° C., and the stirring time is 1 to 3 minutes.

[0073] In one embodiment, the heating temperature in step S4 is 700 to 740° C., and the stirring time is 1 to 3 minutes.

[0074] In one embodiment, the vacuum oven temperature in step S5 is 740° C., and the degassing time is 5 to 10 minutes.

[0075] In one embodiment, the mold preheating temperature in step S6 is 200 to 250°C.

[0076] In one embodiment, the gas atomization molding comprises the following steps.

[0077] A1: The aluminum-erbium alloy pre-processed ingot is heated and melted in a vacuum environment.

[0078] A2: The molten melt is made to flow under the influence of gravity, and the flowing molten melt is crushed into droplets of various sizes under the impact of atomized nitrogen gas. The droplets solidify as they fall and turn into powder, and this powder is collected to obtain high-strength aluminum-erbium alloy powder.

[0079] In one embodiment, the heating in step A1 is electromagnetic induction heating, the heating temperature is 750 to 800° C., and the temperature is maintained for 0.5 to 0.8 hours.

[0080] In one embodiment, step A1 is specifically as follows.

[0081] a: The aluminum-erbium alloy pre-processed ingot is placed in a graphite crucible in the smelting chamber, the chamber door is closed, and the vacuum level in the smelting chamber is reduced by the vacuum system. Then, nitrogen is passed into the chamber to further replace the air in the chamber and reduce the oxygen content in the chamber.

[0082] b: The chamber is heated by electromagnetic induction to completely melt the ingot.

[0083] In one embodiment, step A2 further comprises the step of vacuum packaging the collected powder after collecting the powder.

[0084] In some specific examples, aluminum-erbium alloy powders for additive manufacturing are prepared using a gas atomization powdering method that includes the following steps:

[0085] (1) Preparation of raw materials

[0086] The raw materials were prepared according to the chemical element composition and mass percentage of the Al-Er-Mg-Mn-Sc-Zr alloy powder for additive manufacturing described above. Pure Al was used as the Al source material, Al-20Er intermediate alloy as the Er source material, pure Mg as the Mg source material, Al-10Mn intermediate alloy as the Mn source material, Al-10Sc intermediate alloy as the Sc source material, and Al-10Zr intermediate alloy as the Zr source material. Pure Al, pure Mg, Al-20Er intermediate alloy block, Al-10Mn intermediate alloy block, Al-10Sc intermediate alloy, and Al-10Zr intermediate alloy block were weighed as raw materials. Furthermore, pure Mg and Al-10Zr intermediate alloy blocks were added to replenish the burned-out raw material portions, based on the criterion that the yield of Mg, Sc, and Zr was 95%.

[0087] (2) Smelting of Al-Er-Mg-Mn-Sc-Zr alloy pre-processed ingots

[0088] a. Pure Al, pure Mg, and Al-20Er intermediate alloy blocks are placed in a graphite crucible, heated to 780-800°C in an electric resistance furnace to melt, and then stirred with a graphite stirring rod for 3 minutes.

[0089] b. Add the Al-10Mn intermediate alloy block and the Al-10Zr intermediate alloy block to the melt and stir with a graphite stir bar for 3 minutes.

[0090] If the aluminum-erbium alloy contains Sc, an Al-10Sc intermediate alloy block is also added to the melt.

[0091] c. Pure Mg is added to the melt and melted by pushing it to the bottom of the melt with a graphite rod.

[0092] d. Add refining agent and refining, then peel off the surface slag, spray coating agent, and vacuum degas for 5 to 10 minutes.

[0093] e. The slag on the surface is peeled off and the mixture is poured into a cylindrical mold preheated to 250°C to obtain a cylindrical ingot.

[0094] f. The oxide film on the surface of the ingot is removed by mechanical treatment.

[0095] (3) Gas atomization molding of Al-Er-Mg-Mn-Sc-Zr alloy powder

[0096] a. The Al-Er-Mg-Mn-Sc-Zr pre-processed ingot is placed in a graphite crucible in the smelting chamber, the chamber door is closed, and the vacuum level in the smelting chamber is reduced by the vacuum system. Then, nitrogen is introduced into the chamber to further replace the air in the chamber and reduce the oxygen content in the chamber.

[0097] b. The chamber is heated to the target temperature of 750-800°C by electromagnetic induction and kept at that temperature for 0.5 hours to completely melt the ingot.

[0098] c. The molten melt flows along the nozzle under the influence of gravity and is broken into droplets of various sizes by collision with fast-moving atomizing nitrogen gas, which solidifies into powder as it falls, and the powder collects at the bottom of the chamber.

[0099] d. The collected powder is vacuum packed to prevent oxidation of the powder.

[0100] Another aspect of the present disclosure provides an additively manufactured part made from gas atomized powder of said alloy.

[0101] In one embodiment, the yield strength of the component is greater than 440 MPa, or even greater than 500 MPa or 550 MPa, or even greater than 600 MPa.

[0102] In one embodiment, the tensile strength of the part is greater than 550 MPa, or even greater than 600 or 650 MPa, or even greater than 700 MPa.

[0103] In one embodiment, the elongation of the part is greater than 4%, even greater than 6%, even greater than 8%, or even greater than 10%, even greater than 12%.

[0104] After production of the final additively manufactured product, it can optionally be subjected to one or more heat treatment steps at one or more temperatures.

[0105] In one embodiment, the part has a yield strength of greater than 580 MPa, a tensile strength of greater than 630 MPa, and an elongation of greater than 8% after being heated at 250-350°C for 5-40 minutes.

[0106] Another aspect of the present disclosure provides a method of manufacturing a part, comprising:

[0107] Producing a powder form of said aluminum alloy.

[0108] The powder form is used in carrying out an additive manufacturing process to manufacture the part. In order to make the objectives, technical solutions, and advantages of the present disclosure clearer, the present disclosure will be described in more detail below, but the described embodiments do not limit the present disclosure, and all other embodiments that can be obtained by a person skilled in the art without any creative effort fall within the protection scope of the present disclosure.

[0109] Before describing the embodiments of the present disclosure in more detail, the terms and terminology associated with the embodiments of the present disclosure will be explained, and the terms and terminology associated with the embodiments of the present disclosure will be applied to the following description.

[0110] The materials and equipment used in specific embodiments of the present disclosure are known products and can be obtained by purchasing them commercially.

[0111] Example Example 1 Within the chemical composition range of Al-Er-Mg-Mn-Sc-Zr alloy, a nominal composition of Al-10.8Er-4.5Mg-0.6Mn-0.7Zr was selected for powder preparation. The weight ratios of each element in the powder alloy product were Er 10.8%, Mg 4.5%, Mn 0.6%, and Zr 0.7%, with the remainder being Al and unavoidable impurities. The preparation steps were as follows:

[0112] (1) Preparation of raw materials

[0113] As raw materials, 14.25 kg of pure Al, 2.25 kg of pure Mg, 27 kg of Al-20Er intermediate alloy blocks, 3 kg of Al-10Mn intermediate alloy blocks, and 3.50 kg of Al-10Zr intermediate alloy blocks were weighed out, and based on the standard that the yield of Mg and Zr was 95%, 0.12 kg of pure Mg and 0.18 kg of Al-10Zr intermediate alloy blocks were additionally weighed out to make up for the raw material loss due to burnout.

[0114] (2) Refining of Al-Er-Mg-Mn-Zr alloy pre-processed ingot

[0115] a. Pure Al, pure Mg, and an Al-20Er intermediate alloy block were mixed in a graphite crucible, heated to 780°C in a resistance furnace to melt, and then stirred with a graphite stir bar for 3 minutes.

[0116] b. An Al-Mn intermediate alloy block and an Al-Zr intermediate alloy block were added to the melt and stirred with a graphite stir bar for 3 minutes.

[0117] c. Pure Mg was added to the melt and melted by pushing it to the bottom of the melt with a graphite rod.

[0118] d. Add refining agent and refining, then peel off the surface slag, spray coating agent, and vacuum degas for 5 to 10 minutes.

[0119] e. The slag on the surface was peeled off, and the mixture was poured into a cylindrical mold preheated to 250°C to obtain a cylindrical ingot.

[0120] f. The oxide film on the surface of the ingot was removed by mechanical treatment.

[0121] (3) Gas atomization molding of Al-Er-Mg-Mn-Zr alloy powder

[0122] a. The Al-Er-Mg-Mn-Zr pre-processed ingot was placed in a graphite crucible in the refining chamber, the door of the refining chamber was closed, and the vacuum level in the refining chamber was reduced by the vacuum system. Nitrogen was then introduced into the chamber to further replace the air in the chamber and reduce the oxygen content in the chamber.

[0123] b. The chamber was heated to the target temperature of 800°C by electromagnetic induction and kept at that temperature for 0.5 hours to completely melt the ingot.

[0124] c. The molten melt was forced to flow along the nozzle under the influence of gravity and was broken into droplets of various sizes by collision with fast-moving atomized nitrogen gas. The droplets solidified into powder as they fell, and the powder was collected at the bottom of the chamber.

[0125] d. The collected powder was vacuum packed to prevent oxidation of the powder.

[0126] The composition of the Al-Er-Mg-Mn-Zr powder produced in this example was determined by inductively coupled plasma optical emission spectroscopy to be Al-10.8Er-4.5Mg-0.6Mn-0.7Zr, which was consistent with the designed nominal composition.

[0127] The typical particle morphology and microstructure of the Al-10.8Er-4.5Mg-0.6Mn-0.7Zr powder produced in this example are shown in Figure 4, and a typical XRD pattern is shown in Figure 5. The powder used for SLM preparation had an average particle size of approximately 35 μm and high sphericity. The powder contained two phases, α-Al and Al3(Er,Zr), and an α-Al / Al3(Er,Zr) eutectic crystal between the α-Al alveolar crystals.

[0128] Using the Al-10.8Er-4.5Mg-0.6Mn-0.7Zr powder prepared in this study, an as-printed Al-10.8Er-4.5Mg-0.6Mn-0.7Zr alloy block was obtained by conventional selective laser melting (SLM) of aluminum alloys. The typical microscopic solidification structure is shown in Figure 6, a typical XRD pattern in Figure 7, and an electron backscattering photograph (EBSC) of the grain structure in Figure 8. The Al-10.8Er-4.5Mg-0.6Mn-0.7Zr alloy prepared by SLM technology showed no cracks or porosity, and the grain structure was fine. A large amount of Al(Er,Zr) nucleation phase was present at the bottom of the melt pool, which induced the formation of an equiaxed crystal zone with a grain size of approximately 500 nm and a columnar crystal region with a grain size of approximately 2 μm within the melt pool. Compared to the Al-Ni-based 3D printing materials reported in the literature (Scripta Materialia 203 (2021): 114034), the Al3Er phase not only participates in the eutectic reaction, providing excellent solidification characteristics, but also precipitates as a coherent major phase, refining grains and further improving resistance to thermal cracking sensitivity. Al3Ni in the Al-Ni-based alloys cannot effectively play a role in heterogeneous nucleation and grain refinement due to the large difference between its crystal structure and the aluminum matrix. Therefore, a comparison of the microstructures revealed that the Al-Er alloys of the examples of the present disclosure have a significantly higher proportion of equiaxed fine grains than Al-Ni-based alloys, demonstrating superior solidification characteristics.

[0129] An important feature of the columnar crystals is the continuous Al3Er vesicular eutectic network structure with a network cell size of 300-400 μm, as shown in Figure 9. The Al3Er eutectic phase that constitutes this network structure contains a large amount of nanotwinning and a 9R structure, as shown in Figure 10, indicating that this eutectic phase (and the network structure that constitutes it) have the ability to undergo plastic deformation, which is beneficial for enhancing the plastic deformability of the material. On the other hand, Al3Er has an FCC structure, which is coherent with the aluminum matrix, favoring cooperative deformation of both. These properties of the Al3Er phase contrast with the brittle eutectic phases with low coherence in eutectic systems such as Al-Si, Al-Fe, Al-Ni, Al-La, and Al-Ce (Si, Al13F4, Al3Ni, Al11La3, and Al11Ce3). The Al-10.8Er-4.5Mg-0.6Mn-0.7Zr alloy block as printed above was subjected to a tensile test according to the ASTM E8 / E8M-2015a standard. The measured yield strength was 540 MPa, the tensile strength was 610 MPa, and the elongation was 11.8%. The tensile curve is shown in Figure 11.

[0130] The printed Al-10.8Er-4.5Mg-0.6Mn-0.7Zr alloy block was heated at 320°C for 25 minutes and then subjected to a tensile test. The measured yield strength was 591 MPa, the tensile strength was 638 MPa, and the elongation was 9.8%. The measured tensile curve is shown in Figure 12. The Al-10.8Er-4.5Mg-0.6Mn-0.7Zr alloy produced in this example has both excellent solidification characteristics and mechanical properties.

[0131] Example 2 Within the chemical composition range of Al-Er-Mg-Mn-Sc-Zr alloy, Al-10.8Er-4.5Mg-0.6Mn-0.5Sc-0.4Zr was selected as the nominal composition and powder preparation was carried out using the following steps.

[0132] (1) Preparation of raw materials

[0133] As raw materials, 13.25 kg of pure Al, 2.25 kg of pure Mg, 27 kg of Al-20Er intermediate alloy blocks, 3 kg of Al-10Mn intermediate alloy blocks, 2.5 kg of Al-10Sc intermediate alloy blocks, and 2 kg of Al-10Zr intermediate alloy blocks were weighed out, and according to the criteria that the yield of Mg, Sc, and Zr is 95%, 0.12 kg of pure Mg, 0.13 kg of Al-10Sc intermediate alloy blocks, and 0.10 kg of Al-10Zr intermediate alloy blocks were additionally weighed out to make up for the raw material portions that had been burned.

[0134] (2) Smelting of Al-Er-Mg-Mn-Zr alloy pre-processed ingots

[0135] a. Pure Al, pure Mg, and an Al-20Er intermediate alloy block were mixed in a graphite crucible, heated to 780°C in a resistance furnace to melt, and then stirred with a graphite stir bar for 3 minutes.

[0136] b. An Al-Mn intermediate alloy block, an Al-Zr intermediate alloy block, and an Al-Sc intermediate alloy block were added to the melt and stirred with a graphite stir bar for 3 minutes.

[0137] c. Pure Mg was added to the melt and melted by pushing it to the bottom of the melt with a graphite rod.

[0138] d. Add refining agent and refining, then peel off the surface slag, spray coating agent, and vacuum degas for 5 to 10 minutes.

[0139] e. The slag on the surface was peeled off, and the mixture was poured into a cylindrical mold preheated to 250°C to obtain a cylindrical ingot.

[0140] f. The oxide film on the surface of the ingot was removed by mechanical treatment.

[0141] (3) The preparation steps were the same as in Example 1.

[0142] The typical particle morphology and microstructure of the Al-10.8Er-4.5Mg-0.6Mn-0.5Sc-0.4Zr powder prepared in this study are shown in Figure 13. The powder used for SLM preparation had an average particle size of approximately 36 μm and high sphericity. Two phases, α-Al and Al3(Er,Zr), were present in the powder.

[0143] Using the Al-10.8Er-4.5Mg-0.6Mn-0.5Sc-0.4Zr powder prepared in this example, an Al-10.8Er-4.5Mg-0.6Mn-0.5Sc-0.4Zr alloy block was obtained by conventional laser selective melting of aluminum alloys, and its typical microstructure is shown in Figure 14. This alloy was free of cracks and numerous pores, and its grain structure was similar to that of the alloy block prepared in Example 1. However, the size of the eutectic alveolar structure and the size of the ultrafine grains in the equiaxed crystal zone were smaller than those in Example 1, suggesting that the addition of Sc element enhanced the grain refinement effect.

[0144] The test results for Example 1 were a yield strength of 553 MPa, a tensile strength of 622 MPa, and an elongation of 12%, and the tensile curve is shown in Figure 15. The printed Al-10.8Er-4.5Mg-0.6Mn-0.5Sc-0.4Zr alloy block was heated at 350°C for 45 minutes and then subjected to a tensile test. The measured yield strength was 591 MPa, the tensile strength was 638 MPa, and the elongation was 8.9%, and the measured tensile curve is shown in Figure 16.

[0145] Example 3 Within the chemical composition range of Al-Er-Mg-Mn-Sc-Zr alloy, Al-10.8Er-3.0Mg-0.6Mn-0.7Zr was selected as the nominal composition and powder preparation was carried out using the following steps.

[0146] (1) Preparation of raw materials

[0147] As raw materials, 15 kg of pure Al, 1.50 kg of pure Mg, 27 kg of Al-20Er intermediate alloy blocks, 3 kg of Al-10Mn intermediate alloy blocks, and 3.50 kg of Al-10Zr intermediate alloy blocks were weighed out, and based on the standard that the yield of Mg and Zr was 95%, 0.10 kg of pure Mg and 0.18 kg of Al-10Zr intermediate alloy blocks were additionally weighed out to make up for the raw material loss due to burnout.

[0148] (2)(3) The preparation steps were the same as in Example 1.

[0149] The yield strength, tensile strength, and elongation measured by the test method of Example 1 were 553 MPa, 602 MPa, and 9.8%, respectively, and the tensile curve is shown in FIG.

[0150] Example 4 Within the chemical composition range of Al-Er-Mg-Mn-Sc-Zr alloy, Al-10.8Er-3.0Mg-0.6Mn-0.5Sc-0.4Zr was selected as the nominal composition and powder preparation was carried out using the following steps.

[0151] (1) Preparation of raw materials

[0152] As raw materials, 14 kg of pure Al, 1.50 kg of pure Mg, 27 kg of Al-20Er intermediate alloy blocks, 3 kg of Al-10Mn intermediate alloy blocks, 2.5 kg of Al-10Sc intermediate alloy blocks, and 2 kg of Al-10Zr intermediate alloy blocks were weighed out, and according to the standard that the yield of Mg, Sc, and Zr is 95%, 0.10 kg of pure Mg, 0.13 kg of Al-10Sc intermediate alloy blocks, and 0.10 kg of Al-10Zr intermediate alloy blocks were additionally weighed out to make up for the portion of raw materials that had been burned out.

[0153] (2)(3) The preparation steps were the same as in Example 2.

[0154] The yield strength, tensile strength, and elongation measured by the test method of Example 1 were 538 MPa, 596 MPa, and 9.6%, respectively, and the tensile curve is shown in FIG.

[0155] Example 5 Within the chemical composition range of Al-Er-Mg-Mn-Sc-Zr alloy, Al-10.8Er-8.5Mg-0.6Mn-0.7Zr was selected as the nominal composition and powder preparation was carried out using the following steps.

[0156] (1) Preparation of raw materials As raw materials, 12.25 kg of pure Al, 4.25 kg of pure Mg, 27 kg of Al-20Er intermediate alloy blocks, 3 kg of Al-10Mn intermediate alloy blocks, and 3.50 kg of Al-10Zr intermediate alloy blocks were weighed out, and based on the standard that the yield of Mg and Zr was 95%, 0.22 kg of pure Mg and 0.18 kg of Al-10Zr intermediate alloy blocks were additionally weighed out to make up for the raw material loss due to burnout.

[0157] (2)(3) The preparation steps were the same as in Example 1.

[0158] The yield strength, tensile strength, and elongation measured by the test method of Example 1 were 505 MPa, 569 MPa, and 12.6%, respectively, and the tensile curve is shown in FIG.

[0159] Example 6 Within the chemical composition range of Al-Er-Mg-Mn-Sc-Zr alloy, Al-10.8Er-8.5Mg-0.6Mn-0.5Sc-0.4Zr was selected as the nominal composition and powder preparation was carried out using the following steps.

[0160] (1) Preparation of raw materials

[0161] As raw materials, 11.25 kg of pure Al, 4.25 kg of pure Mg, 27 kg of Al-20Er intermediate alloy blocks, 3 kg of Al-10Mn intermediate alloy blocks, 2.5 kg of Al-10Sc intermediate alloy blocks, and 2 kg of Al-10Zr intermediate alloy blocks were weighed out, and according to the standard that the yield of Mg, Sc, and Zr is 95%, 0.22 kg of pure Mg, 0.13 kg of Al-10Sc intermediate alloy blocks, and 0.10 kg of Al-10Zr intermediate alloy blocks were additionally weighed out to make up for the portion of raw materials that had been burned out.

[0162] (2)(3) The preparation steps were the same as in Example 2.

[0163] The yield strength, tensile strength, and elongation measured by the test method of Example 1 were 545 MPa, 601 MPa, and 12.6%, respectively, and the tensile curve is shown in FIG.

[0164] Example 7 Within the chemical composition range of Al-Er-Mg-Mn-Sc-Zr alloy, Al-15.6Er-4.5Mg-0.6Mn-0.7Zr was selected as the nominal composition and powder preparation was carried out using the following steps.

[0165] (1) Preparation of raw materials

[0166] As raw materials, 2.25 kg of pure Al, 2.25 kg of pure Mg, 39 kg of Al-20Er intermediate alloy blocks, 3 kg of Al-10Mn intermediate alloy blocks, and 3.5 kg of Al-10Zr intermediate alloy blocks were weighed out, and based on the standard that the yield of Mg and Zr was 95%, 0.12 kg of pure Mg and 0.18 kg of Al-10Zr intermediate alloy blocks were additionally weighed out to make up for the raw material loss due to burnout.

[0167] (2)(3) The preparation steps were the same as in Example 1.

[0168] The yield strength, tensile strength, and elongation measured by the test method of Example 1 were 629 MPa, 637 MPa, and 6.6%, respectively, and the tensile curve is shown in FIG.

[0169] Example 8 Within the chemical composition range of Al-Er-Mg-Mn-Sc-Zr alloy, Al-15.6Er-4.5Mg-0.6Mn-0.5Sc-0.4Zr was selected as the nominal composition and powder preparation was carried out using the following steps.

[0170] (1) Preparation of raw materials

[0171] As raw materials, 1.25 kg of pure Al, 2.25 kg of pure Mg, 39 kg of Al-20Er intermediate alloy blocks, 3 kg of Al-10Mn intermediate alloy blocks, 2.5 kg of Al-10Sc intermediate alloy blocks, and 2 kg of Al-10Zr intermediate alloy blocks were weighed out, and according to the criteria that the yield of Mg, Sc, and Zr is 95%, 0.12 kg of pure Mg, 0.13 kg of Al-10Sc intermediate alloy blocks, and 0.10 kg of Al-10Zr intermediate alloy blocks were additionally weighed out to make up for the raw material portions that had been burned.

[0172] (2)(3) The preparation steps were the same as in Example 2.

[0173] The yield strength, tensile strength, and elongation measured using the test method of Example 1 were 633 MPa, 647 MPa, and 4.5%, respectively, and the tensile curve is shown in FIG.

[0174] Example 9 Within the chemical composition range of Al-Er-Mg-Mn-Sc-Zr alloy, Al-15.6Er-3.3Mg-0.6Mn-0.7Zr was selected as the nominal composition and powder preparation was carried out using the following steps.

[0175] (1) Preparation of raw materials

[0176] As raw materials, 2.85 kg of pure Al, 1.65 kg of pure Mg, 39 kg of Al-20Er intermediate alloy blocks, 3 kg of Al-10Mn intermediate alloy blocks, and 3.5 kg of Al-10Zr intermediate alloy blocks were weighed out, and based on the standard that the yield of Mg and Zr was 95%, 0.10 kg of pure Mg and 0.18 kg of Al-10Zr intermediate alloy blocks were additionally weighed out to make up for the raw material loss due to burnout.

[0177] (2)(3) The preparation steps were the same as in Example 1. The yield strength, tensile strength, and elongation measured by the test method of Example 1 were 568 MPa, 623 MPa, and 9.9%, respectively, and the tensile curve is shown in FIG.

[0178] Example 10 Within the chemical composition range of Al-Er-Mg-Mn-Sc-Zr alloy, Al-15.6Er-3.3Mg-0.6Mn-0.5Sc-0.4Zr was selected as the nominal composition and powder preparation was carried out using the following steps.

[0179] (1) Preparation of raw materials

[0180] As raw materials, 1.85 kg of pure Al, 1.65 kg of pure Mg, 39 kg of Al-20Er intermediate alloy blocks, 3 kg of Al-10Mn intermediate alloy blocks, 2.5 kg of Al-10Sc intermediate alloy blocks, and 2 kg of Al-10Zr intermediate alloy blocks were weighed out, and according to the standard that the yield of Mg, Sc, and Zr is 95%, 0.10 kg of pure Mg, 0.13 kg of Al-10Sc intermediate alloy blocks, and 0.10 kg of Al-10Zr intermediate alloy blocks were additionally weighed out to make up for the raw material portions that had been burned.

[0181] (2)(3) The preparation steps were the same as in Example 2.

[0182] The yield strength, tensile strength, and elongation measured by the test method of Example 1 were 586 MPa, 648 MPa, and 8.6%, respectively, and the tensile curve is shown in FIG.

[0183] Example 11 Within the chemical composition range of Al-Er-Mg-Mn-Sc-Zr alloy, Al-15.6Er-7.8Mg-0.6Mn-0.7Zr was selected as the nominal composition and powder preparation was carried out using the following steps.

[0184] (1) Preparation of raw materials

[0185] As raw materials, 0.60 kg of pure Al, 3.90 kg of pure Mg, 39 kg of Al-20Er intermediate alloy blocks, 3 kg of Al-10Mn intermediate alloy blocks, and 3.5 kg of Al-10Zr intermediate alloy blocks were weighed out, and based on the criterion that the yield of Mg and Zr was 95%, 0.20 kg of pure Mg and 0.18 kg of Al-10Zr intermediate alloy blocks were additionally weighed out to make up for the raw material loss due to burnout.

[0186] (2)(3) The preparation steps were the same as in Example 1.

[0187] The yield strength, tensile strength, and elongation measured by the test method of Example 1 were 670 MPa, 688 MPa, and 4.4%, respectively, and the tensile curve is shown in FIG.

[0188] Example 12 Within the chemical composition range of Al-Er-Mg-Mn-Sc-Zr alloy, Al-14.6Er-7.8Mg-0.6Mn-0.5Sc-0.4Zr was selected as the nominal composition and powder preparation was carried out using the following steps.

[0189] (1) Preparation of raw materials

[0190] As raw materials, 2.10 kg of pure Al, 3.90 kg of pure Mg, 36.50 kg of Al-20Er intermediate alloy blocks, 3 kg of Al-10Mn intermediate alloy blocks, 2.5 kg of Al-10Sc intermediate alloy blocks, and 2 kg of Al-10Zr intermediate alloy blocks were weighed out, and according to the standard that the yield of Mg, Sc, and Zr is 95%, 0.20 kg of pure Mg, 0.13 kg of Al-10Sc intermediate alloy blocks, and 0.10 kg of Al-10Zr intermediate alloy blocks were additionally weighed out to make up for the raw material portions that had been burned.

[0191] (2)(3) The preparation steps were the same as in Example 2.

[0192] The yield strength, tensile strength, and elongation measured by the test method of Example 1 were 668 MPa, 681 MPa, and 5.1%, respectively, and the tensile curve is shown in FIG.

[0193] Example 13 Within the chemical composition range of Al-Er-Mg-Mn-Sc-Zr alloy, Al-5.0Er-4.5Mg-0.6Mn-0.3Zr was selected as the nominal composition and powder preparation was carried out using the following steps.

[0194] (1) Preparation of raw materials

[0195] As raw materials, 27.50 kg of pure Al, 2.25 kg of pure Mg, 12.5 kg of Al-20Er intermediate alloy block, 3 kg of Al-10Mn intermediate alloy block, and 1.5 kg of Al-10Zr intermediate alloy block were weighed out, and based on the standard that the yield of Mg and Zr was 95%, 0.12 kg of pure Mg and 0.08 kg of Al-10Zr intermediate alloy block were additionally weighed out to make up for the raw material portion lost due to burnout.

[0196] (2)(3) The preparation steps were the same as in Example 1.

[0197] The yield strength, tensile strength, and elongation measured using the test method of Example 1 were 443 MPa, 560 MPa, and 11%, respectively, and the tensile curve is shown in FIG.

[0198] Example 14 Within the chemical composition range of Al-Er-Mg-Mn-Sc-Zr alloy, Al-5.5Er-4.5Mg-0.6Mn-0.5Sc-0.4Zr was selected as the nominal composition and powder preparation was carried out using the following steps.

[0199] (1) Preparation of raw materials

[0200] As raw materials, 26.50 kg of pure Al, 2.25 kg of pure Mg, 13.75 kg of Al-20Er intermediate alloy blocks, 3 kg of Al-10Mn intermediate alloy blocks, 2.5 kg of Al-10Sc intermediate alloy blocks, and 2 kg of Al-10Zr intermediate alloy blocks were weighed out, and according to the standard that the yield of Mg, Sc, and Zr is 95%, 0.12 kg of pure Mg, 0.13 kg of Al-10Sc intermediate alloy blocks, and 0.10 kg of Al-10Zr intermediate alloy blocks were additionally weighed out to make up for the raw material portions that had been burned.

[0201] (2)(3) The preparation steps were the same as in Example 2.

[0202] The yield strength, tensile strength, and elongation measured using the test method of Example 1 were 527 MPa, 611 MPa, and 12.3%, respectively, and the tensile curve is shown in FIG.

[0203] Example 15 Within the chemical composition range of Al-Er-Mg-Mn-Sc-Zr alloy, Al-5.0Er-3.0Mg-0.6Mn-0.7Zr was selected as the nominal composition and powder preparation was carried out using the following steps.

[0204] (1) Preparation of raw materials

[0205] As raw materials, 29.50 kg of pure Al, 1.50 kg of pure Mg, 12.50 kg of Al-20Er intermediate alloy block, 3 kg of Al-10Mn intermediate alloy block, and 3.5 kg of Al-10Zr intermediate alloy block were weighed out, and based on the standard that the yield of Mg and Zr is 95%, 0.08 kg of pure Mg and 0.18 kg of Al-10Zr intermediate alloy block were additionally weighed out to make up for the raw material portion lost due to burnout.

[0206] (2)(3) The preparation steps were the same as in Example 1.

[0207] The yield strength, tensile strength, and elongation measured using the test method of Example 1 were 468 MPa, 551 MPa, and 10.7%, respectively, and the tensile curve is shown in FIG.

[0208] Example 16 Within the chemical composition range of Al-Er-Mg-Mn-Sc-Zr alloy, Al-5.0Er-3.0Mg-0.6Mn-0.5Sc-0.4Zr was selected as the nominal composition and powder preparation was carried out using the following steps.

[0209] (1) Preparation of raw materials

[0210] As raw materials, 28.50 kg of pure Al, 1.50 kg of pure Mg, 12.50 kg of Al-20Er intermediate alloy blocks, 3 kg of Al-10Mn intermediate alloy blocks, 2.5 kg of Al-10Sc intermediate alloy blocks, and 2 kg of Al-10Zr intermediate alloy blocks were weighed out, and according to the standard that the yield of Mg, Sc, and Zr is 95%, 0.08 kg of pure Mg, 0.13 kg of Al-10Sc intermediate alloy blocks, and 0.10 kg of Al-10Zr intermediate alloy blocks were additionally weighed out to make up for the raw material portions that had been burned.

[0211] (2)(3) The preparation steps were the same as in Example 2.

[0212] The yield strength, tensile strength, and elongation measured by the test method of Example 1 were 512 MPa, 571 MPa, and 7.0%, respectively, and the tensile curve is shown in FIG.

[0213] Example 17 Within the chemical composition range of Al-Er-Mg-Mn-Sc-Zr alloy, Al-5.2Er-8.5Mg-0.6Mn-0.7Zr was selected as the nominal composition and powder preparation was carried out using the following steps.

[0214] (1) Preparation of raw materials

[0215] As raw materials, 26.25 kg of pure Al, 4.25 kg of pure Mg, 13 kg of Al-20Er intermediate alloy block, 3 kg of Al-10Mn intermediate alloy block, and 3.5 kg of Al-10Zr intermediate alloy block were weighed out, and based on the standard that the yield of Mg and Zr is 95%, 0.22 kg of pure Mg and 0.18 kg of Al-10Zr intermediate alloy block were additionally weighed out to make up for the raw material portion lost due to burnout.

[0216] (2)(3) The preparation steps were the same as in Example 1.

[0217] The yield strength, tensile strength, and elongation measured by the test method of Example 1 were 498 MPa, 564 MPa, and 9.2%, respectively, and the tensile curve is shown in FIG.

[0218] Example 18 Within the chemical composition range of Al-Er-Mg-Mn-Sc-Zr alloy, Al-5.2Er-8.5Mg-0.6Mn-0.5Sc-0.4Zr was selected as the nominal composition and powder preparation was carried out using the following steps.

[0219] (1) Preparation of raw materials

[0220] As raw materials, 26.25 kg of pure Al, 4.25 kg of pure Mg, 13 kg of Al-20Er intermediate alloy blocks, 3 kg of Al-10Mn intermediate alloy blocks, 2.5 kg of Al-10Sc intermediate alloy blocks, and 2 kg of Al-10Zr intermediate alloy blocks were weighed out, and according to the standard that the yield of Mg, Sc, and Zr is 95%, 0.22 kg of pure Mg, 0.13 kg of Al-10Sc intermediate alloy blocks, and 0.10 kg of Al-10Zr intermediate alloy blocks were additionally weighed out to make up for the raw material portions that had been burned.

[0221] (2)(3) The preparation steps were the same as in Example 2.

[0222] The yield strength, tensile strength, and elongation measured using the test method of Example 1 were 512 MPa, 599 MPa, and 10.6%, respectively, and the tensile curve is shown in FIG.

[0223] Example 19 Within the chemical composition range of Al-Er-Mg-Mn-Sc-Zr alloy, Al-10.8Er-4.5Mg-0.6Mn was selected as the nominal composition and powder preparation was carried out using the following steps.

[0224] (1) Preparation of raw materials

[0225] As raw materials, 17.75 kg of pure Al, 2.25 kg of pure Mg, 27 kg of Al-20Er intermediate alloy block, and 3 kg of Al-10Mn intermediate alloy block were weighed out, and based on the standard that the Mg yield was 95%, 0.12 kg of pure Mg was added and weighed out to make up for the raw material portion lost due to burnout.

[0226] (2)(3) The preparation steps were the same as in Example 1.

[0227] The yield strength, tensile strength, and elongation measured by the test method of Example 1 were 507 MPa, 586 MPa, and 8.0%, respectively, and the tensile curve is shown in FIG.

[0228] Example 20 Within the chemical composition range of Al-Er-Mg-Mn-Sc-Zr alloy, Al-5.5Er-4.5Mg-0.6Mn-0.1Zr was selected as the nominal composition and powder preparation was carried out using the following steps.

[0229] (1) Preparation of raw materials

[0230] As raw materials, 30.50 kg of pure Al, 2.25 kg of pure Mg, 13.75 kg of Al-20Er intermediate alloy block, 2.5 kg of Al-10Mn intermediate alloy block, and 0.50 kg of Al-10Zr intermediate alloy block were weighed out, and based on the criterion that the yield of Mg and Zr was 95%, 0.12 kg of pure Mg and 0.03 kg of Al-10Zr intermediate alloy block were additionally weighed out to make up for the raw material portion lost due to burnout.

[0231] (2)(3) The preparation steps were the same as in Example 1.

[0232] The yield strength, tensile strength, and elongation measured using the test method of Example 1 were 504 MPa, 572 MPa, and 8.3%, respectively, and the tensile curve is shown in FIG.

[0233] Example 21 The nominal composition of Al-7Er-4.5Mg-0.5Mn-0.3Zr with a low Er content was selected, and the powder was prepared using the following steps:

[0234] (1) Preparation of raw materials

[0235] As raw materials, 26.25 kg of pure Al, 2.25 kg of pure Mg, 17.50 kg of Al-20Er intermediate alloy blocks, 2.5 kg of Al-10Mn intermediate alloy blocks, 1.5 kg of Al-10Zr intermediate alloy blocks, and 2.5 kg of Al-2Sc intermediate alloy blocks were weighed out, and according to the criteria that the yield of Mg, Sc, and Zr is 95%, 0.12 kg of pure Mg, 0.125 kg of Al-10Zr intermediate alloy blocks, and 0.125 kg of Al-2Sc intermediate alloy blocks were additionally weighed out to make up for the raw material portions that had been burned out.

[0236] (2)(3) The preparation steps were the same as in Example 1.

[0237] The yield strength, tensile strength, and elongation measured by the test method of Example 1 were 525 MPa, 580 MPa, and 12.9%, respectively, and the tensile curve is shown in FIG.

[0238] Examples 1-21 demonstrate that the disclosed high-strength aluminum-erbium alloy powder for additive manufacturing has excellent solidification and forming properties and can be obtained as a complete block. The as-printed alloy has a bimodal grain structure with few defects, consisting of fine equiaxed and columnar crystals. In particular, the micrometer-scale columnar crystal regions form an AlEr eutectic network structure with low stacking fault energy, strengthening the material while providing plasticity through its own deformation. These microstructures enable the disclosed as-printed alloy to have improved yield strength, tensile strength, and elongation, resulting in excellent overall mechanical properties, particularly yield strength, which exceeds that of all conventional additively manufactured aluminum alloy systems.

[0239] Comparative Example 1 As a comparative example, Al-3Er-4.5Mg-0.5Mn-0.1Zr with a low Er content was selected as the nominal composition and powder preparation was carried out using the following preparation steps.

[0240] (1) Preparation of raw materials

[0241] As raw materials, 37.25 kg of pure Al, 2.25 kg of pure Mg, 7.5 kg of Al-20Er intermediate alloy block, 2.5 kg of Al-10Mn intermediate alloy block, and 0.50 kg of Al-10Zr intermediate alloy block were weighed out, and based on the standard that the yield of Mg and Zr is 95%, 0.12 kg of pure Mg and 0.03 kg of Al-10Zr intermediate alloy block were additionally weighed out to make up for the raw material portion lost due to burnout.

[0242] (2)(3) The preparation steps were the same as in Example 1.

[0243] The yield strength measured by the test method of Example 1 was 382 MPa, the tensile strength was 460 MPa, and the elongation was 13.2%.

[0244] The internal Al3Er eutectic network structure of the block material of this comparative example is discontinuous, as shown in Figure 36. This is the main reason for the significantly lower strength than other examples of this disclosure.

[0245] Comparative Example 2 As a comparative example, Al-1Er-4.5Mg-0.5Mn-0.1Zr with a low Er content was selected as the nominal composition and powder preparation was carried out using the following preparation steps.

[0246] (1) Preparation of raw materials

[0247] As raw materials, 42.25 kg of pure Al, 2.25 kg of pure Mg, 2.5 kg of Al-20Er intermediate alloy block, 2.5 kg of Al-10Mn intermediate alloy block, and 0.50 kg of Al-10Zr intermediate alloy block were weighed out, and based on the criterion that the yield of Mg and Zr was 95%, 0.12 kg of pure Mg and 0.03 kg of Al-10Zr intermediate alloy block were additionally weighed out to make up for the raw material portion lost due to burnout.

[0248] (2)(3) The preparation steps were the same as in Example 1.

[0249] The yield strength measured by the test method of Example 1 was 323 MPa, the tensile strength was 415 MPa, and the elongation was 14.3%.

[0250] Test Example The yield strength and tensile strength of the as-printed alloy blocks prepared in the above examples are summarized in Table 1 below. [Table 1]

[0251] The yield strength and tensile strength of the as-printed alloy blocks prepared in the above comparative examples are summarized in Table 2 below. [Table 2]

[0252] The foregoing descriptions of specific exemplary embodiments of the present disclosure have been given for purposes of explanation and illustration. These descriptions are not intended to limit the disclosure to the precise forms disclosed, and it will be apparent that many variations and modifications are possible in light of the above teachings. The purpose of selecting and describing exemplary embodiments is to illustrate certain principles of the present disclosure and their practical applications, thereby enabling those skilled in the art to realize and utilize various different exemplary embodiments of the present disclosure, as well as various different options and modifications. The scope of the present disclosure is intended to be limited by the claims and their equivalents.

Claims

1. 4 to 20 wt % erbium (Er), 2 to 10 wt % magnesium (Mg), 1 wt. % or less of manganese (Mn); optionally, 0-1 wt % scandium (Sc), and An aluminum alloy optionally containing 0-1 wt% zirconium (Zr).

2. 2. Contains 5.0 to 15.6 wt% Er, Preferably, it contains 3.0 to 8.5 wt% Mg, Preferably, it contains 0.5 to 0.6 wt% Mn, Preferably, it contains 0 to 0.7 wt% Zr, 2. An aluminum alloy according to claim 1, preferably containing 0 to 0.5 wt% Sc.

3. 10.8 wt% Er, 4.5 wt% Mg, 0.6 wt% Mn, 0.7 wt% Zr, or 10.8 wt% Er, 4.5 wt% Mg, 0.6 wt% Mn, 0.5 wt% Sc, 0.4 wt% Zr, or 10.8 wt% Er, 3.0 wt% Mg, 0.6 wt% Mn, 0.7 wt% Zr, or 10.8 wt% Er, 3.0 wt% Mg, 0.6 wt% Mn, 0.5 wt% Sc, 0.4 wt% Zr, or 10.8 wt% Er, 8.5 wt% Mg, 0.6 wt% Mn, 0.7 wt% Zr, or 10.8 wt% Er, 8.5 wt% Mg, 0.6 wt% Mn, 0.5 wt% Sc, 0.4 wt% Zr, or 15.6 wt% Er, 4.5 wt% Mg, 0.6 wt% Mn, 0.7 wt% Zr, or 15.6 wt% Er, 4.5 wt% Mg, 0.6 wt% Mn, 0.5 wt% Sc, 0.4 wt% Zr, or 15.6 wt% Er, 3.3 wt% Mg, 0.6 wt% Mn, 0.7 wt% Zr, or 15.6 wt% Er, 3.3 wt% Mg, 0.6 wt% Mn, 0.5 wt% Sc, 0.4 wt% Zr, or 15.6 wt% Er, 7.8 wt% Mg, 0.6 wt% Mn, 0.7 wt% Zr, or 14.6 wt% Er, 7.8 wt% Mg, 0.6 wt% Mn, 0.5 wt% Sc, 0.4 wt% Zr, or 5.0 wt% Er, 4.5 wt% Mg, 0.6 wt% Mn, 0.3 wt% Zr, or 5.5 wt% Er, 4.5 wt% Mg, 0.6 wt% Mn, 0.5 wt% Sc, 0.4 wt% Zr, or 5.0 wt% Er, 3.0 wt% Mg, 0.6 wt% Mn, 0.7 wt% Zr, or 5.0 wt% Er, 3.0 wt% Mg, 0.6 wt% Mn, 0.5 wt% Sc, 0.40 wt% Zr, or 5.2 wt% Er, 8.5 wt% Mg, 0.6 wt% Mn, 0.7 wt% Zr, or 5.2 wt% Er, 8.5 wt% Mg, 0.6 wt% Mn, 0.50 wt% Sc, 0.4 wt% Zr, or 10.8 wt% Er, 4.5 wt% Mg, 0.6 wt% Mn, or 5.5 wt% Er, 4.5 wt% Mg, 0.6 wt% Mn, 0.1 wt% Zr, or 7.0 wt% Er, 4.5 wt% Mg, 0.5 wt% Mn, 0.3 wt% Zr, 0.1 wt% Sc 2. The aluminum alloy of claim 1, comprising:

4. 4. The aluminum alloy according to claim 1, containing residual amounts of aluminum (Al) and unavoidable impurities.

5. 5. An aluminium alloy according to any one of claims 1 to 4, wherein the alloy is produced in powder form, and wherein the powder form is used in an additive manufacturing process.

6. The alloy exhibits a dual grain morphology in which columnar crystals and equiaxed crystals coexist, Preferably, the grain size of the alloy is between 500 nm and about 2 μm. The aluminum alloy according to any one of claims 1 to 5.

7. The columnar crystals are continuous Al ３ containing an Er vesicular eutectic network structure; Preferably, in the network structure, the network cell size is 300 to 400 nm; Preferably, the Al ３ The Er vesicular eutectic network structure includes a twin structure, Preferably, the Al ３ The aluminum alloy of claim 6, wherein the Er alveolar eutectic network structure comprises a 9R structure.

8. A method for preparing an aluminum alloy according to any one of claims 1 to 7, comprising the steps of: preparing the aluminum alloy by a rapid solidification process, the rapid solidification process preferably being one or more selected from gas atomization powdering, jet deposition, planar flow casting, melt spinning, melt extraction and glaze on a beam, and additive manufacturing; Preferably, the atomization powdering is one or more selected from gas atomization, rotating electrode atomization, and ultrasonic atomization; Preferably, the additive manufacturing is one or more selected from selective laser melting additive manufacturing, laser directed energy deposition additive manufacturing, electron beam selective melting additive manufacturing, electron beam directed energy deposition additive manufacturing.

9. The method for preparing the aluminum alloy includes the steps of melting to obtain an aluminum-erbium alloy pre-processed ingot, and obtaining the aluminum-erbium alloy powder by a gas atomization powdering method; Preferably, the preparation of the aluminum-erbium alloy pre-processed ingot comprises: Step S1: weighing out pure Al, pure Mg, Al-Er intermediate alloy block, and Al-Mn intermediate alloy block as raw materials according to the weight percentage of the alloy's chemical composition, and optionally, the raw materials also include Al-Sc intermediate alloy block and / or Al-Zr intermediate alloy block; Step S2: mixing pure Al and Al-Er intermediate alloy blocks, heating and melting them, and stirring them to obtain a melt A; Step S3: Add an Al-Mn intermediate alloy block to the melt A, heat and melt it, and stir it to obtain a melt B; Step S3: if the erbium-aluminum alloy contains Sc, an Al—Sc intermediate alloy block is also added to the melt A, and if the erbium-aluminum alloy contains Zr, an Al—Zr intermediate alloy block is also added to the melt A. Step S4: injecting pure Mg into the melt B to obtain a melt C; Step S5: adding a refining agent and a coating agent to the melt obtained in step S4, and vacuum degassing the melt to obtain melt D; and a step S6 of de-slagging the melt D and pouring it into a preheated mold to obtain a metal ingot.

10. Additively manufactured parts made with gas atomized powder of an aluminum alloy according to any one of claims 1 to 7, Preferably, the part has a yield strength of more than 440 MPa, a tensile strength of more than 550 MPa, and an elongation of more than 58%; Preferably, the part has a yield strength of greater than 580 MPa, a tensile strength of greater than 630 MPa and an elongation of greater than 8% after being incubated at 250-350°C for 5-40 minutes.

11. 1. A method of manufacturing a part, comprising: Producing a powder form of the aluminium alloy according to any one of claims 1 to 7 and using said powder form to produce said part in an additive manufacturing process; A method comprising:

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