WO2025210613A1

WO2025210613A1 - High strength aluminum alloy for additive manufacturing by laser powder bed fusion (lpbf)

Info

Publication number: WO2025210613A1
Application number: PCT/IB2025/053670
Authority: WO
Inventors: Nikhil DEO; Nithyanand PRABHU; Manish Marotrao Pande; Eric Matthew Johnson
Original assignee: Eaton Intelligent Power Ltd; Indian Institute of Technology Bombay
Current assignee: Eaton Intelligent Power Ltd; Indian Institute of Technology Bombay
Priority date: 2024-04-05
Filing date: 2025-04-07
Publication date: 2025-10-09
Anticipated expiration: 2026-10-05

Abstract

The disclosure provides Si-free aluminum alloys comprising Ce, Zn, and Mg suitable for laser powder bed fusion (LPBF) 3D printing. The printed components can be subjected to hot isostatic pressing and further heat treated to provide 3D printed components exhibiting higher hardness than existing Al-Si based alloys produced under the same conditions. The Si-free aluminum alloy resists coarsening of second phase on HIP, retaining high strength and hardness. The alloy also does not need separate solutionizing and water quenching following HIP, thus saving cost, time and permitting design of more delicate and intricate geometries.

Description

HIGH STRENGTH ALUMINUM ALLOY FOR ADDITIVE MANUFACTURING BY LASER POWDER BED FUSION (LPBF)

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to Indian Provisional Application No. 202411028122 filed April 05, 2024, the disclosure of which is hereby incorporated by reference in its entirety.

BACKGROUND

[0002] Additive manufacturing of aluminum alloy components is used in the aerospace, automotive, and biomedical industries to prepare precise, durable, and lightweight parts. A popular method of additive manufacturing is laser powder bed fusion (LPBF).

[0003] Si-rich aluminum alloys such as AlSilOMg are widely used in LPBF selective laser melting (SLM) and casting processes due to good castability and flowability, satisfactory weldability, reduced shrinkage, and low melting point. Yan et al., 2020, J Mat Sci & Tech 41, 199-208. Al alloy 3D printed components are typically subjected to hot isostatic pressing (HIP) and/or other heat treatments to impart good ductility and high fatigue strength.

[0004] Following laser powder bed fusion (LPBF), the AlSilOMg 3D printed components exhibit good tensile strength as printed, but they tend to lose tensile strength and hardness on hot isostatic pressing (HIP) and T6 heat treatments, as shown in FIG. 2. This is due to coarsening of second phase particles and large Si precipitates that can occur during HIP and solutionizing during heat treatment, as shown in FIG. 3, upper right panel. [0005] U.S. Pat. No. 9,963,770 to Rios et al., UT-Battelle, LLC et al. discloses castable high-temperature Ce-modified cast Al alloys including aluminum and from 5 to 30 wt% of at least one material selected from the group consisting of cerium, lanthanum, and mischmetal.

[0006] U.S. Pat. No. 10,584,403 to Rios et al., UT-Battelle, LLC et al. discloses surface-hardened aluminum-rare earth cast alloys comprising aluminum, and 4 to 60 wt% of a rare earth element selected from cerium, lanthanum, and mischmetal, or a combination thereof. The Al alloy may optionally further comprise 0-15 wt% magnesium, 0-12 wt% silicon, 0-6 wt% iron, 0-5 wt% nickel, and 0-6 wt% zinc. [0007] U.S. Pat. No. 11,185,923 to Karlen et al., Hamilton Sundstrand Corp, discloses a method of manufacturing cast aluminum alloys comprising aluminum, 2-10 wt% cerium, and 0.5 -2.5 wt% titanium.

[0008] U.S. Pub. No. 2006/0289093 Al discloses an Al-Zn-Mg-Ag high strength alloy for aerospace and automotive castings. The aluminum casting alloy includes 4-5 wt% Zn, 1-3 wt% Mg, up to 1% Cu, and less than about 0.3 wt% Si.

[0009] U.S. Pub. No. 2017/0096730 Al to Rios et al., UT-Battelle, LLC et al. discloses a cast alloy including aluminum and from about 5 to about 30 wt percent of at least one of cerium, lanthanum, and mischmetal having a strengthening AI11X3 intermetallic phase, where X is from about 5 to about 30 wt percent of at least one of cerium, lanthanum, and mischmetal.

[0010] U.S. Pub No. 2018/0237893 Al to Rios et al. discloses a rapidly solidified aluminum-rare earth element alloy and method of making. Improved mechanical properties without the need for post-processing heat treatments are said to be exhibited.

[0011] U.S. Pub. No. 2021/0108292 Al to Moore et al. discloses aluminum -rare earth element alloys comprising an alloying element selected from Si, Cu, Mg, Fe, Ti, Zn, Zr, Mn, Ni, Sr, B and Ca.

[0012] U.S. Pub. No. 2021/0130934 Al to Bahl et al. discloses an Al-Ce-Cu alloy comprising 3 to 35 wt% Cu for use in additive manufacturing.

[0013] CN 105803235B to Grirem Advanced Materials provides an aluminumscandium master alloy comprising scandium at 1-10 wt%.

[0014] CN114951666A to Hunan Jinkun New Materials provides an aluminum scandium target material comprising a scandium content of 2 to 43 at%.

[0015] CN112063866B to Hunan Rare Earth Metals Research Institute provides an aluminum alloy with high scandium content greater than 30 wt%.

[0016] U.S. Pat. No. 3,619,181A to Alcoa discloses an aluminum alloy comprising at least 85% aluminum and from 0.01 to 5 wt % scandium.

[0017] U.S. Pat. No. 12,116,652 to Elementum 3D, Inc. discloses an additive manufacturing method of producing a metal alloy article.

[0018] There is a need for new Al alloys that enable heat treating after laser powder bed fusion to improve physical properties of 3D printed components including good hardness and tensile strength after HIP and/or other heat treatments. SUMMARY

[0019] The disclosure provides aluminum alloy compositions comprising Ce, Zn, and Mg (Al-Ce-Zn-Mg-X) suitable for laser powder bed fusion (LPBF). The inventive aluminum alloy eliminates the need for elements such as Si which may coarsen during HIP after printing.

[0020] Uses for the new Al alloy may include various Al alloy parts produced by LPBF. For example, the new Al alloy may be used for LPBF production of parts for aerospace, automotive, or biomedical use.

[0021] An inventive aluminum alloy is provided comprising 75 to 92 wt% Al, 3.0 to 12.0 wt% Ce or La, 3.0 to 10.5 wt% Zn, and 0.5 to 5.0 wt % Mg, and optionally 0-1.0 wt% Sc and/or Zr. In some cases, the aluminum alloy comprises 78 to 92 wt% Al, 3.0 to 11.0 wt% Ce, 4.0 to 9.0 wt% Zn, and 1.0 to 4.0 wt % Mg, and optionally 0-1.0 wt% Sc and/or Zr. In some cases, the aluminum alloy comprises 80 to 90 wt% Al, 5.0 to 10.0 wt% Ce, 5.0 to 8.5 wt% Zn, 1.5 to 3.0 wt% Mg, and optionally 0-0.5 wt% Sc and/or Zr. In some cases, the aluminum alloy comprises 3.0 to 12.0 wt% Ce, 3.0 to 10.5 wt% Zn, 0.5 to 5.0 wt% Mg, and a balance of aluminum. In some cases, the aluminum alloy comprises 3.0 to 11.0 wt% Ce, about 4.0 to 9.0 wt% Zn, and 1.0 to 4.0 wt% Mg, and a balance of aluminum. In some cases, the aluminum alloy comprises about 6.0 to 10.0 wt% Ce, about 5.0 to 8.5 wt% Zn, about 1.5 to 3.0 wt% Mg, and a balance of aluminum. In some cases, the alloy composition does not include Cu. In some cases, the alloy composition does not include added Si. In some cases, the alloy composition does not include added Cu or Si. In some cases, the amount of cerium and zinc in the alloy composition are sufficient to cause formation of a ternary intermetallic phase of Al-Ce-Zn. In some cases, the aluminum alloy comprises one or more of scandium, iron, titanium, zirconium, manganese, chromium, tin, boron, or vanadium in an amount less than 1 wt%, less than 0.5 wt%, or less than 0.1 wt% for each element taken individually. In some cases, an aluminum alloy powder is provided comprising Al-Ce-Zn-Mg-X. In some cases, X is Zr or Sc. In some cases, X is Sc. In some cases, X is Zr.

[0022] A method of making a three-dimensional aluminum alloy component is provided, comprising: providing an aluminum alloy powder comprising from 75 to 92 wt% Al, from 3.0 to 12.0 wt% Ce or La, 3.0 to 10.5 wt% Zn, and 0.5 to 5.0 wt % Mg, and optionally 0-1.0 wt% Sc and/or Zr; from 78 to 92 wt% Al, from 3.0 to 11.0 wt% Ce, 4.0 to 9.0 wt% Zn, and 1.0 to 4.0 wt % Mg; or 80 to 90 wt% Al, 5.0 to 10.0 wt% Ce, 5.0 to 8.5 wt% Zn, and 1.5 to 3.0 wt % Mg; depositing a first layer of the powder on a build platform; and irradiating the first powder layer to at least partially fuse or melt the powder into a first layer. The irradiating may comprise any appropriate energy source. The irradiating may comprise a laser or an electron beam. The method may further comprise lowering the platform. The platform may be lowered the width of the first layer or about 10 to about 200 microns, about 20 to 100 microns, 25 to 75 microns, or about 30 to 40 microns. The method may comprise depositing a second layer of the powder onto the first layer and irradiating the second powder layer to at least partially fuse or melt the powder into a second layer. The method may be repeated to form the 3D printed component. [0023] In some cases, the method comprises laser powder bed fusion (LPBF). [0024] A method of making a three-dimensional aluminum alloy component is provided, comprising: providing an aluminum alloy powder comprising from 75 to 92 wt% Al, from 3.0 to 12.0 wt% Ce or La, 3.0 to 10.5 wt% Zn, and 0.5 to 5.0 wt % Mg, and optionally 0-1.0 wt% Sc and/or Zr; from 78 to 92 wt% Al, from 3.0 to 11.0 wt% Ce, 4.0 to 9.0 wt% Zn, and 1.0 to 4.0 wt % Mg; or 80 to 90 wt% Al, 6.0 to 10.0 wt% Ce, 5.0 to 8.5 wt% Zn, and 1.5 to 3.0 wt % Mg; depositing the powder on a build platform; and simultaneously irradiating the first powder layer to at least partially fuse or melt the powder into the 3D aluminum alloy component. The irradiating may comprise any appropriate energy source. The irradiating may comprise a laser, electron beam, or electric arc.

[0025] In some cases, the method comprises directed energy deposition (DED).

[0026] In some cases, the method further comprises hot isostatic pressing (HIP) of the

3D printed component.

[0027] In some cases, the method further comprises heat treating the 3D printed component. In some cases, the method comprises heat treating the 3D printed component without solutionizing. In some cases, the heat treating comprises quenching, and artificially ageing the 3D printed component to create a heat-treated 3D printed component. In some cases, the heat treating comprises quenching, and artificially ageing the 3D printed component to create a heat-treated 3D printed component without solutionizing. In some cases, the heat treating comprises artificially ageing the 3D printed component. In some cases, the heat treating comprises artificially ageing the 3D printed component without solutionizing. In some cases, the method does not include quenching. [0028] In some cases, the heat treating comprises artificially ageing the 3D printed component by holding at one or more temperatures in a range between 120 deg C to 200 deg C for from 2 to 24 hours to provide an artificially aged 3D printed component. In some cases, the artificially aged 3D printed component exhibits a hardness of at least 118 HV, at least 140 HV, 118-190 HV, or 140-185 HV when measured by ASTM E384-22 at 1,000 gf. In some cases, the artificially aged 3D printed component exhibits tensile strength of at least about 400 MPa when measured by ASTM E8/E8M. In some cases, a 3D printed component is provided that exhibits a hardness of at least 103 HV, at least 110 HV, at least 130 HV, at least 140 HV, at least 150 HV, at least 155 HV, at least 160 HV, at least 170 HV, or at least 180 HV when measured by ASTM E384-22 at 1,000 gf. In some cases, the 3D printed component exhibits a hardness of at least 140 HV when measured by ASTM E384-22 at 1,000 gf.

[0029] A 3D printed component is provided comprising an aluminum alloy comprising 75-92 wt% Al, 3.0 to 12.0 wt% Ce or La, 3.0 to 10.5 wt% Zn, 0.5 to 5.0 wt % Mg, and 0 to 1.0 wt% Sc or Zr. In some cases, the 3D printed component comprises an Al alloy comprising 78 to 92 wt% Al, 3.0 to 11.0 wt% Ce, 4.0 to 9.0 wt% Zn, 1.0 to 4.0 wt % Mg. In some cases, the 3D printed component comprises an Al alloy comprising 80.0-90.0 Al, 6.0 to 10.0 wt% Ce, 5.0 to 8.5 wt% Zn, and 1.5 to 3.0 wt % Mg. In some cases, the 3D printed component comprises an Al alloy comprising 6.0 to 10.0 wt% Ce, 5.0 to 8.5 wt% Zn, and 1.5 to 3.0 wt % Mg, and a balance of aluminum. In some cases, the 3D printed component comprises an aluminum alloy that contains <0.1 wt% each of Cu or Si.

[0030] In some cases, the 3D printed component is subjected to HIP and heat treatment. In some cases, the 3D printed component does not require quenching after solutionizing. In some cases, the 3D printed component is air cooled after solutionizing. In some cases, the 3D printed component is subjected to HIP and heat treated without solutionizing. In some cases, the 3D printed component is subjected to HIP and artificial ageing without solutionizing. In some cases, the 3D printed component after HIP exhibits submicron particles of Aln-xCe3Zn_xand or AhCeZm in the microstructure.

[0031] In some cases, the 3D printed component exhibits minimal coarsening of second phase particles after HIP. In some cases, following the HIP the 3D printed component exhibits minimal coarsening such that no second phase particles exhibit a diameter of greater than 5 microns, greater than 4 microns, or greater than 3 microns. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] FIG. 1 shows a table of tensile strength (MPa) of as cast and selective laser melting (SLM) of prior art AlSilOMg alloy. The tensile strength of the as printed SLM AlSilOMg alloy is higher than the as cast AlSilOMg alloy.

[0033] FIG. 2 shows a bar graph of mechanical properties of a prior art AlSilOMg aluminum alloy as cast, and as printed before and after HIP and T6 heat treatment. The hardness (BHN) and the tensile strength (MPa) are increased in the as printed Al alloy part compared to the as cast Al alloy part. Following HIP and T6 heat treatment the hardness and tensile strength are each substantially reduced compared to the as printed AlSilOMg alloy part.

[0034] FIG. 3 A shows photomicrographs of prior art AlSilOMg aluminum alloy after 3D printing (left panel) and after 3D printing + HIP (right panel) T-t cycle only. After 3D printing + HIP of the prior art AlSilOMg alloy, large, multi -micron sized particles of Si having a diameter of up to 6-7 microns or greater are apparent, as shown in right panel. The white bar in left panel is 0.5 micron. The white bar in the right panel is 1 micron.

[0035] FIG. 3B shows photomicrographs of the inventive high strength Al-Ce-Zn-Mg- X aluminum alloy after 3D printing (left panel) and after 3D printing + HIP (right panel). The white bar in left panel is 0.5 micron. The white bar in the right panel is 1 micron. Submicron particles of ternary second phases such as, e.g., Aln-xCesZnx, where 0<x<l 1, or AhCeZm are apparent in the grains. Drastically different coarsening behavior of prior art AlSilOMg and inventive Al alloys are observed after 3D printing and HIP.

[0036] FIG. 4 shows a graph reproduced from Czerwinski, 2020, Materials, 13, 3441, showing diffusion coefficient (m²/s) vs reciprocal temperature for alloying elements in Al for various elements.

[0037] FIG. 5 shows a bar graph of the hardness (HV) of inventive Al-Ce-Zn-Mg-X alloy after heat treating under various conditions and either air cooling or water quenching. The inventive alloy exhibits very similar hardness after either air cooling or water quenching when heat treated under otherwise similar conditions.

[0038] FIG. 6 shows a bar graph of hardness (HV) at different conditions comparing prior art AlSilOMg and inventive high strength Al alloy as printed + aged (A), after HIP (B), and after HIP + HT (C). The inventive Al alloy exhibits somewhat higher hardness (-160 HV) compared to prior art alloy after printing + ageing (-155 HV). After HIP, inventive Al alloy exhibits hardness of about 100 HV, compared to prior art Al alloy exhibits ~60 HV hardness. In some cases, after HIP + HT, inventive Al alloy exhibits hardness of -158 HV, compared to prior art Al alloy exhibiting hardness of -110 HV The inventive Al alloy exhibits superior hardness compared to prior art Al alloy in all three conditions: as printed +aged, after HIP, and after HIP + HT.

[0039] FIG. 7 shows a schematic of a typical prior art T6 heat treatment (HT) process following HIP. The HT cycle includes solutionizing at about 530 deg C, water quenching to rapidly decrease temperature, and artificial ageing at a temperature of about 160 deg C.

[0040] FIG. 8 shows a schematic of an artificial ageing (HT) process without a solutionizing heat treatment. In this case, the part is subjected to artificial ageing at 120 deg C for about 4 h, then at about 160 deg C for about 4 h. In the present disclosure, the solutionizing and quenching steps can be eliminated.

DETAILED DESCRIPTION OF THE INVENTION

[0041] The present disclosure provides new aluminum alloy compositions that enable HIP and/or other heat treatments after powder bed fusion manufacturing of 3D printed components to obtain significantly higher hardness and tensile strength as compared to prior art Si-rich prior art aluminum alloys.

[0042] Aluminum alloys are provided including other alloying elements which increase strength by precipitation hardening also known as age hardening. Age hardening is ensured by addition of elements such as Zn and Mg, which come out of solution much more slowly. With absence of Si, alternative alloying elements are employed that enable a narrow freezing range and render enough fluidity to the alloy. This can be achieved by adding alloying element cerium (Ce) or lanthanum (La) among others. By selecting a composition near eutectic composition, a narrow freezing range can be ensured. At the same time the right stoichiometry of Zn and Mg can ensure high strength.

[0043] Definitions

[0044] The singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0045] The term "and/or" refers to and encompasses any and all possible combinations of one or more of the associated listed items.

[0046] The term "about," when referring to a measurable value such as an amount of a compound, dose, time, temperature, and the like, is meant to encompass variations of +/- 10%, 5%, 1%, 0.5%, or even 0.1% of the specified amount. [0047] The terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Unless otherwise defined, all terms, including technical and scientific terms used in the description, have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. In the event of conflicting terminology, the present specification is controlling.

[0048] All patents, patent applications and publications referred to herein are incorporated by reference in their entirety.

[0049] The term “room temperature” refers to the temperature of the surrounding air. In some cases, the term “room temperature” refers to a temperature in a range of 20 to 30 deg C (68 to 86 deg F). In some cases, ambient room temperature is 23 deg C ± 2.0 deg C (73.4 deg F ± 3.6 deg F).

[0050] The term “hot isostatic pressing” (HIP) refers to a form of heat treatment that uses high uniform pressure at high temperature to improve material properties. The pressure may be applied by an inert gas, such as argon. A preprinted or cast shape is simultaneously subjected to both high pressure and high temperatures. The variables of pressure, temperature, and time are controlled. The term “T-t cycle” refers to the Temperature (T) and time (t) parameters used during an HIP process. In some cases, a 3D printed component is subjected to a temperature between 500 to 550 deg C, 510 to 540 deg C, 520 to 540 deg C, or about 530 deg C for 1 to 12 hours, 2 to 10 hrs, 4 to 10 hours, 5 to 7 hours, or about 2 hours, about 4 hours, or about 6 hours under a pressure of 75 to 200 MPa, or about 100 MPa.

[0051] The term “additive manufacturing” (AM) refers to a technology that allows physical components to be made from virtual three-dimensional (3D) computer models by building the component layer-by-layer until the part is complete. Additive manufacturing builds the part one layer at a time by “printing” each new layer on top of the previous one until the part is complete. Depending on the technology, the layer thicknesses may vary from a few microns up to around 50 or more microns, or around 70 or more microns. In some cases, the layer may be 10-50 microns, 20-40 microns, 25-35 microns, or 30 microns ± 2 microns. [0052] The term “powder bed fusion” (PBF) refers to a process in which thermal energy selectively fuses regions of a powder bed. PBF is a method of additive manufacturing. In one method, PBF comprises depositing a layer of powder on a build platform or on a previous layer, irradiating the powder by laser or electron beam, and lowering of the build platform. The platform may be lowered by a predetermined powder layer thickness. Selective melting of one powder layer in laser powder bed fusion (LPBF) may be, for example, 10-200 microns, or 20-100 microns thick. Selective melting of one powder layer in electron beam powder bed fusion (EPDF) may be, for example, 25-250 microns, or 50-150 microns thick. The process is repeated with successive powder layers until the required part is completely built. LPBF may use a fiber laser as the energy source. The electron beam powder bed fusion may be performed under a vacuum. The LPBF process may be carried out in an inert gas (e.g., argon or nitrogen)-filled chamber to minimize oxygen and reduce risk of hydrogen pickup. In some cases, the laser in the LPBF system can operate up to 1 kW or higher with various spot diameter. In some cases, LPBF systems the layer may be melted in two steps comprising contouring wherein the outer boundary is irradiated by the laser and built first, then the powder within the contour/perimeter is melted subsequently. After two steps of the melting process, another powder layer is deposited. The process is repeated until the 3D part is completed.

[0053] Different types of powder bed fusion (PBF) methods include direct laser sintering method (DLSM), selective laser melting (SLM), selective heat sintering (SHS), electron beam melting (EBM), and selective laser sintering (SLS).

[0054] The term “laser powder bed fusion” (LPBF) as used herein refers to an additive manufacturing technique comprising a laser to provide a 3D printed component. First, a powder material is evenly applied to a build platform to create a thin layer of powder, for example, from about 10 to about 200 microns. The powder may be spread comprising, e.g., a roller or a blade. The material is selectively fused, melted, or sintered with a directed laser beam. The build platform is lowered and a second layer of powder is applied. The process is repeated. Individual melt tracks are created next to each other, which together form a layer. Several layers on top of each other form a component. The thin layer thickness enables high detail resolution of the components. See, for example, www.ipt.fraunhofer.de/en/technologies/additive-manufacturing/laser-powder-bed-fusion- download-03 -24-2024. [0055] The term “selective laser melting” (SLM) refers to an additive manufacturing technique comprising use of a high-powered laser beam to form three-dimensional parts. During the printing process, the laser beam melts and fuses various metal powders together. As the laser beam hits a thin layer of the material, it selectively joins or welds the particles together. After one complete print cycle, the printer adds a new layer of powdered material to the previous one. One difference between SLM and SLS is that SLM completely melts the powder whereas SLS only partially melted or sintered powder is used. SLM products may have fewer or no voids.

[0056] The term “selective laser sintering” (SLS) refers to a powder-based additive manufacturing technique that uses energy provided by a laser to at least partially melt or sinter and fuse metal powders then stack layer by layer to form a printed 3D part. The metal powder quality significantly affects the performance of SLS sintered parts.

[0057] The term “sinter” refers to a method of making a powdered material coalesce into a solid or porous mass comprising heating without liquefaction.

[0058] The term “direct metal laser sintering” (DMLS), sometimes referred to as direct laser metal forming (DMLF), is a method of additive manufacturing comprising a highly intensive laser beam directed onto a metal powder bed to fuse metal particles according to a computer-aided design file.

[0059] Unless otherwise specified, the term “percent,” or “%,” refers to weight percent.

[0060] The embodiments described in one aspect of the present disclosure are not limited to the aspect described. The embodiments may also be applied to a different aspect of the disclosure as long as the embodiments do not prevent these aspects of the disclosure from operating for its intended purpose.

[0061] The term “alloy” refers to a solid or liquid mixture of two or more metals or of one or more metals with certain metalloid elements.

[0062] The term “master alloy” refers to a pre-alloyed concentrate of mixture of alloying elements. A master alloy can be used to add major alloying elements in one form to the base metal. A master alloy may be a semi-finished product that is commercially available for use as a raw material by the metals industry.

[0063] The term “eutectic composition” or structure refers to a homogenous solid mix of atomic and/or chemical species forming a super lattice having a unique molar ratio between the components. At this molar ratio, the mixtures melt as a whole (i.e., all components of the mixture melt simultaneously) at a specific temperature or narrow temperature range (e.g., 1-2 deg) -the eutectic temperature. At other ratios, one component of the mixture will melt at a first temperature and remaining material with eutectic composition will melt at other temperatures.

[0064] The term “castability” refers to a feasibility of an alloy for casting into complex shapes and can be rated in a system of poor (0) to excellent (5). “0” refers to incomplete filling with frequent hot tearing and macro-voids resulting in multiple breaks in casting. “1” refers to incomplete filling of casting mold with hot-tearing and cracking present with abundant micro-voids and moderate number of macro-voids. “2” refers to complete filling of mold with moderate hot-tearing and cracking or complete fill with little hot-tearing or cracking and moderately numerous micro- and macro-voids. “3” refers to complete filling of mold with little hot-tearing or cracking or complete filling with moderate frequency of micro-voids and few macro-voids. “4” refers to complete filling of casting mold with no hot-tearing or cracking, very few macro-voids in combination with very few-micro-voids; or a low/med presence of micro-voids. “5” refers to complete filling of the casting mold with no hot-tearing or cracking, no macro-voids and very few micro-voids.

[0065] The term “hardness” refers to the mechanical resistance of a material (test specimen) to mechanical indentation by another harder body (indenter).

[0066] The term “Vickers hardness” refers to a hardness measurement determined by indenting the test material with an indenter subjected to a load of 0.1 to 100 kgf for a period of time. The hardness test method according to Vickers is described in ISO 6507 (Metallic materials- Vickers hardness test-Part 1 : Test method), ASTM E92, or ASTM E384 (Standard Test Method for Microindentation Hardness of Materials to Vickers and Knoop). Vickers hardness may be expressed in units of HV. A Vickers Hardness Testing Machine may be employed. Unless otherwise specified, Vickers hardness is measured under Micro-Vicker’s hardness test ASTM E384-22 Standard Test Method for Microindentation Hardness of Materials using a square-based pyramidal shaped diamond indenter with face angles of 136 degrees and test forces in the range of 9.8 x 10-3 to 9.8 N (1 to 1000 gf). In some cases, the indenter for aluminum is Vickers diamond and force load is 1000 gf (1 kg). In some cases, the indenter for aluminum is Vickers diamond and force load is 100 gf.

[0067] The term “Brinell hardness” refers to a hardness measurement Brinnell Hardness Number (BHN) determined by ISO 6506 or ASTM E10. In some cases, the term “Brinell hardness” expressed in units of HBS refers to indenter steel 10mm ball and 500- kgf force, e.g., for aluminum products.

[0068] The term “Rockwell hardness” refers to a hardness measurement made by a differential-depth method where the residual depth of the indent made by the indenter is measured. The deeper a defined indenter penetrates the surface of a test specimen, the softer the material being tested. Rockwell hardness may be determined by standardized test methods such as ISO 6508 or ASTM El 8. The Rockwell hardness (HR) is determined from the residual indentation depth. Th indenter and test force must be specified. For example, under ISO 6508, method HRHW employs a tungsten carbide 1/8” metal ball and 60 kgf force, e.g., for aluminum materials. Method HRB refers to a 1/16” ball indenter and 100 kg test force.

[0069] The requirement to convert from one hardness test scale to another is covered by various International Standards (ASTM El 40 or ISO 18265). Conversion charts are available according to hardness test scale conversion algorithms provided within ASTM E140.

[0070] Standard test methods for tension testing of metallic materials including the aluminum alloys disclosed herein may be performed at room temperature including methods of determining yield strength, yield point elongation, tensile strength, elongation, and reduction of area may be determined by standardized test ASTM E8ZE8M. Unless otherwise specified, ASTM E8ZE8M-13a test version may be employed.

[0071] The term “tensile strength” refers to the maximum tensile stress that a material is capable of sustaining. Tensile strength for aluminum alloys may be determined by standardized test ASTM E8ZE8M. Unless otherwise specified, ASTM E8ZE8M-13a test version may be employed.

[0072] The term “yield strength” or “yield stress” refers to the engineering stress at which, by convention, it is considered that plastic elongation of the material has commenced, i.e., the stress a material can withstand without permanent deformation; the stress at which a material begins to deform plastically. Yield strength for aluminum alloys may be determined by standardized test ASTM E8ZE8M. Unless otherwise specified, ASTM E8ZE8M-13a test version may be employed.

[0073] The term “T6” heat treatment refers to a prior art heat treatment comprising solutionizing, water quenching, and then artificially aged heat treatment. Such a heat treatment is represented schematically in FIG. 7 comprising solution treatment, quenching and artificial ageing. In some cases, a representative T6 heat treatment may include solutionizing, e.g., at 516-579 deg C for one to several hours, rapidly quenching, then artificial ageing at about 120-180 deg C for several hours. The term “T5” heat treatment refers to a heat treatment comprising artificial ageing only. The term “T4” heat treatment refers to only solution heat treatment.

[0074] Alloy Compositions

[0075] Aluminum alloys frequently include silicon which renders fluidity to Al alloys. Fluidity and casting characteristics are typically poor without silicon (e.g., A513).

[0076] Conventional Si-rich aluminum alloys for laser powder bed fusion (LPBF) have good strength in as printed condition but lose strength on hot isostatic pressing (HIP) and T6 heat treatment. This is due to coarsening of second phase (Si) particles during HIP and solutionizing during heat treatment. One problem may be the high diffusivity of Si. A possible solution may include eliminating Si from aluminum alloy compositions and adding another suitable element. This should have the effect of making the alloy fluid and narrowing down the freezing range by addition of other alloying elements having lower diffusivity in Al than Si.

[0077] Criteria for a suitable replacement element for Si included having a eutectic reaction between Al and the element or an intermetallic if formed, having a lower diffusivity in Al than Si. Several candidate replacement elements were considered including Sc, Ce, La, Mn, Zr, Cr, and V. The candidate replacement elements each exhibit a lower diffusivity in Al than Si. FIG. 4 shows a graph of diffusion coefficient (m²/s) vs reciprocal temperature for alloying elements in Al for various transition metals and rare earth metals, as reproduced from Czerwinski, 2020, Materials, 13, 3441. Among candidate elements, Sc and Zr are fairly expensive.

[0078] Several aluminum alloys are known in the art.

[0079] The term “A356.0” refers to a known prior art aluminum alloy including 7% silicon, 0.3 % magnesium, no more than 0.2 % copper, no more than 0.2 % manganese, no more than 0.1% zinc, and no more than 0.2% iron.

[0080] The term “A357” refers to a known prior art aluminum alloy including 6.5-7.5 % silicon, 0.04-0.07% beryllium, 0.2% iron, 0.2% copper, 0.4-0.7% magnesium, 0.04- 0.2% titanium, 0.1% zinc, 0.1% manganese.

[0081] The term “A380” refers to a known prior art aluminum alloy including 7.5-9.5 % silicon, 1.3% iron, 3.0-4.0 % copper, 0.3% magnesium, 0.5% manganese, 0.5% nickel, 3.0% zinc, and 0.35% tin. See, for example, NADCA Alloy Data-Aluminum Castings- 2021.

[0082] The term “A383” (ADC12) refers to a known prior art aluminum alloy including 2.0-3.0 % copper, 0.1 % magnesium, a maximum of 1.3% iron, a maximum of 0.15 % tin, a maximum of 0.3% nickel, 3.0% zinc, 0.5% manganese, 9.5-11.5% silicon, and up to 0.5% other metallic elements. A383 (ADC12) aluminum alloy may be used in cold chamber die casting process.

[0083] The term “AlSilOMg” refers to a known prior art aluminum alloy comprising about 9 to about 11 wt% Si, about 0.2 to about 0.45 wt% Mg, less than about 1 wt% other elements, such as Fe and/or Ca, and the balance aluminum. Prealloyed AlSilOMg powders are commercially available, e.g., EOS Aluminum AlSilOMg, EOS GmbH, or MSE PRO AlSilOMg aluminum based metal powder, MSE Supplies LLC. Various powder sizes such as 0-45 micron, 15-45 micron, 45-105 micron, or 75-180 micron are available.

[0084] The disclosure provides a new aluminum alloy comprising Al, Ce and/or La Zn, and Mg and a method for providing a 3D printed component comprising additive manufacturing, in some cases, by LPBF. In some cases, the new aluminum alloy comprises Al, Ce, Zn, and Mg. In some cases, the new aluminum alloy comprises Al, La, Zn, and Mg. In some cases, a 3D printed component is provided as printed. In some cases, the 3D printed component is heat treated. In some cases, the 3D printed component is subjected to HIP. In some cases, the 3D printed component is subjected to HIP and a further heat treatment. In some cases, the 3D printed component is subjected to HIP and artificial ageing. In some cases, the 3D printed component is subjected to HIP and T6 heat treatment.

[0085] A new aluminum alloy has been developed that is amenable to 3D printing by LPBF followed by HIP and/or other heat treatment to provide a 3D printed component without significant loss of tensile strength and hardness compared to as printed condition. In the new aluminum alloy, cerium is used to ensure good fluidity, narrow freezing range, with retention of precipitation hardening elements Zn and Mg in solution after LPBF. In some cases, the alloy comprises < 0.1 wt% Si. In some cases, the alloy does not include Si. In some cases, the alloy comprises < 0.1 wt% Cu. In some cases, the alloy does not include copper. The inventive alloy compositions are shown in Table 1. In some cases, the inventive alloy is an Al-Ce-Zn-Mg-X alloy according to Table 1, wherein optional X is Sc or Zr.

[0086] Table 1. Inventive Aluminum Alloy Compositions

[0087] An inventive aluminum alloy is provided comprising 75 to 92 wt% Al, 3.0 to 12.0 wt% Ce or La, 3.0 to 10.5 wt% Zn, 0.5 to 5.0 wt % Mg, and 0 to 1.0 wt% Zr or Sc. An inventive aluminum alloy is provided comprising 75 to 92 wt% Al, 3.0 to 12.0 wt% Ce, 3.0 to 10.5 wt% Zn, 0.5 to 5.0 wt % Mg, and 0 to 1.0 wt% Zr or Sc. An inventive aluminum alloy is provided comprising 78 to 92 wt% Al, 3.0 to 11.0 wt% Ce, 4.0 to 9.0 wt% Zn, 1.0 to 4.0 wt % Mg, and 0 to 1.0 wt% Zr or Sc. An inventive aluminum alloy is provided comprising 80.0 to 90.0 wt% Al, 5.0 to 10.0 wt% Ce, 5.0 to 8.5 wt% Zn, and 1.5 to 3.0 wt % Mg. In some cases, the alloy composition includes less than 0.1 wt% Si. In some cases, the alloy composition does not include Si. In some cases, the inventive Al alloy does not include added Si. In some cases, the alloy composition includes less than 0.1 wt% Cu. In some cases, the inventive Al alloy does not include added Cu. In some cases, the inventive Al alloy composition includes no more than 0.1 wt% Cu and no more than 0.1 wt% Si. In some cases, the inventive Al alloy does not include Cu or Si. In some cases, the inventive Al alloy does not include added Cu or Si.

[0088] The aluminum alloy composition of the disclosure may comprise one or more elements such as iron, calcium, titanium, zirconium, scandium, manganese, chromium, tin, boron, or vanadium in an amount 1 wt% or less, less than 0.5 wt%, or less than 0.1 wt% for each element taken individually. In some cases, the inventive aluminum alloy composition does not include any detectable iron, calcium, titanium, zirconium, manganese, chromium, tin, boron, or vanadium. Chemical composition of the alloys may be tested by any appropriate technique known in the art, for example, electron probe micro-analyzer or Inductively Coupled Plasma Optical Emission Spectroscopy (ICP- OES). ICP-OES is an analytical technique used to determine how much of certain elements are in a sample. ICP-OES instruments are commercially available, for example, Agilent 5800 IVP-OES, or Agilent 5900 ICP-OES, from Agilent Technologies, Inc., Santa Clara CA, US; or Avio 560 Max ICP Optical Emission Spectrometer, or Avio 550 Max ICP-OES, PerkinElmer® ICP-OES; or iCAP PRO Series ICP-OES systems from ThermoFisher Scientific Inc.

[0089] Additive Manufacturing Methods

[0090] Many advantages of additive manufacturing with aluminum alloys include the ability to process metal parts with complex shapes and fine structures including thin walled structures and internal cavities. Additive manufacturing offers high utilization of raw materials, and short process cycles. The strength of the additive manufactured alloys can be increased by in-situ forming amorphous, nanocrystalline, or ultrafine grained structures compared to traditional methods. For example, Si-rich aluminum alloys have been widely used in SLM process due to favorable castability and flowability, satisfactory weldability, reduced shrinkage, and low melting point. Yan et al., 2020, J Mat Sci & Tech 41, 199-208.

[0091] Unfortunately, when a printed AlSilOMg part is subjected to certain heat treatment methods (e.g., HIP + T6) a reduction in hardness and tensile strength is exhibited.

[0092] In particular, laser powder bed fusion (LPBF) 3D printed prior art AlSilOMg alloy exhibits good strength in as printed condition of about 460 MPa as shown in FIG. 2. However, components manufactured by LPBF need HIP to impart good ductility and high fatigue strength. Following HIP, the components are heat treated by T6 (solution treatment followed by artificial ageing). Both HIP and solutionizing heat treatments are carried out at 500 deg C or higher. This causes drastic reduction in tensile strength (TS) of the alloy from 460 MPa to 310 MPa as shown in FIG. 2 (data published by EOS manufacturer of LPBF machines). This happens due to coarsening of second phase particles, which is due to high diffusivity of elements like Si.

[0093] FIG. 2 shows a bar graph of mechanical properties of a prior art AlSilOMg aluminum alloy as cast, and as printed before and after HIP and T6 heat treatment. The hardness (BHN) and the tensile strength (MPa) are increased in the as printed Al alloy part compared to the as cast Al alloy part. Following HIP and T6 heat treatment the hardness and tensile strength are each substantially reduced compared to the as printed AlSilOMg alloy part. [0094] Loss of hardness and tensile strength following heat treatment of the AlSilOMg alloy is due to coarsening of second phase particles and precipitates that occur during HIP and solutionizing during heat treatment, as illustrated in FIG. 3 A. FIG. 3 A shows photomicrographs of prior art AlSilOMg aluminum alloy after 3D printing (left panel) and after 3D printing + HIP (right panel). After 3D printing + HIP of the prior art AlSilOMg alloy, large, multi-micron sized particles of Si are apparent as shown in FIG. 3 A (right panel). One problem with the prior art Si-rich Al alloys is the high diffusivity of Si which is used to render fluidity and narrow freezing range of the alloy.

[0095] The problem has been solved by eliminating Si from the Al alloy composition. Fluidity was rendered by adding elements having low diffusivity and a eutectic reaction with Al. Candidate replacement elements having low diffusivity in Al as shown in FIG. 4 included Ce, La, Sc, Mn, Zr, V. Among the candidate elements, Sc and Zr are fairly expensive, Mn and Zr have a eutectic point at a very low Al content limiting amount of eutectic phase formed and a steep liquidus line in hyper-eutectic portion. Rare earth elements cerium Ce and lanthanum La were selected for further study. Ce was selected as having a fairly low price. Ce has a eutectic reaction at about 10.6 % Ce and a very low diffusivity, as shown in FIG. 4. Prior art Al alloys use a combination of Si and Mg to enable precipitation hardening. In the inventive Al alloy, precipitation hardening is enabled by a combination of Zn and Mg which can deliver significantly higher strength. [0096] The present disclosure provides an Al-Ce-Zn-Mg-X alloy printed component that resists this coarsening of second phase particles and thereby maintains good strength even after HIP and HT. In contrast to prior art AlSilOMg, inventive high strength Al-Ce- Zn-Mg-X aluminum alloy after 3D printing + HIP exhibits generally sub-micron particles of a ternary second phase such as Aln-xCesZnx and / or AhCeZm, as shown in FIG. 3B, right panel. Thus, drastically different coarsening behavior of prior art AlSilOMg and inventive Al alloys are observed after 3D printing and HIP.

[0097] Any appropriate additive manufacturing technique may be employed. Any melting based additive manufacturing technique may be employed. The additive manufacturing technique may comprise laser powder bed fusion, electron beam powder bed fusion, or directed energy deposition.

[0098] Any appropriate laser powder bed fusion 3D metal printer can be employed. For example, Renishaw from the UK, EOS (EOSINT M Series) from Germany, Concept Laser, 3D Systems, US, or any other appropriate 3D printer may be employed. In some cases, a commercially available EOS M280 DMLS (direct metal laser sintering) metal 3D printer is employed, e.g., equipped with a 200 W or 400 W Yb-fiber laser. The operation may be based directly on three-dimensional computer-aided design (CAD) data.

[0099] In some cases, directed energy deposition (DED) 3D printing may be employed. Directed energy deposition metal printing is a metal additive manufacturing process that adds material alongside the heat input simultaneously. An energy source, such as an electron beam, laser, or arc, such as plasma arc welding (PAW), or gas tungsten arc welding (GTAW), or tungsten inert gas welding (TIG), is used to melt a material which is simultaneously deposited by a nozzle on build platform. The material may be a metal powder or wire material which is deposited after melting. The continuous supply of metal powder during the DED process differentiates from PBF process. Powder DED machines often have inert gases blown together with the powder from the nozzles. In some cases, the Al alloy particle size may be within a range of from 50 to 150 microns.

[00100] A method of making a three-dimensional (3D) printed Al alloy component is provided comprising (i) obtaining a fine powder of an Al alloy according to the present disclosure, (ii) depositing a layer of the Al alloy powder on a build platform, (iii) irradiating the Al alloy powder comprising a laser or electron beam to at least partially melt or fuse the powder, (iv) lowering the build platform, and (v) repeating steps (ii) -(iv) to provide the printed component. The printed component is removed from the powder bed and optionally subjected to post-processing. The post-processing may include heat treating, for example, HIP, solutionizing, quenching, artificial ageing; and/or surface treating of the printed component, for example, machining, shot peening, vibratory peening, electro-chemical polishing, and ultrasonic nanocrystalline surface modification, for example, to improve microstructure, surface, and mechanical properties.

[00101] The fine powder of an Al alloy may be obtained by any appropriate technique known in the art. The fine powder may be produced by atomization of an Al alloy according to the disclosure to provide a pre-alloyed powder suitable for powder bed fusion such as laser powder bed fusion (LBPF). For example, a spherical metal powder may be produced by water, plasma, or gas atomization. Stegman et al., 2023, Metals, 13, 1384. Doi.org/10.3390/metl3081384. The powder may be a gas atomized powder. The powder may be a plasma atomized powder. The powder may be a water atomized powder. The powder may be produced by vacuum induction atomization. In some cases, the powder can be produced by machining rods of desired composition to produce particles suitable for additive manufacturing. In gas atomization (GA), Ar or N may be used as a high- velocity jet that interacts with the molten metal. Lower thermal energy from the gaseous jet allows sufficient time for the surface tension to spheroidize the metal particle, producing highly spherical particles. Water atomization (WA) is economical because water is an effective and inexpensive cooling agent. But WA can create powders with irregular shapes and porosity due to higher thermal transport capabilities. Plasma-based processing techniques produce the powder from a solid source material without contamination brought by the refractory nozzle and superheating, allowing time for trapped gases to escape, and for surface tension to create an ideal sphere. WA and GA provide a broader particle size distribution from 1 to 500 microns, and plasma-based technology produces a PSD from 1 to 200 microns.

[00102] Particle size and particle size distribution of the Al alloy powder may be determined by any appropriate technique known in the art. For example, particle size distribution may be determined by laser diffraction (LD) (volume-based particle size distribution), dynamic light scattering (DLS), dynamic image analysis (DIA) (numberbased particle size distribution), photoanalysis, e.g., comprising scanning electron microscope (area-based), or sieve analysis (mass-based particle size distribution). In some cases, the particle size distribution may be determined by ASTM B822-20 by light scattering, reported as volume percent. The D50, D-50 is the mean particle size where D is the diameter of powder particles. Dx50 or DV(0.5) is the median for a volume distribution. Dn50 is used for number distributions. In some cases, the Al alloy powder may have a particle size distribution comprising a D50 in a range of 15-65 microns, or 20- 45 microns. In some cases, suitable Al alloy particle size for laser powder bed fusion may have D50, for example, in a range of 5-70 microns, 10-65 microns, 15-65 microns, or 20- 45 microns. In some cases, the Al alloy powder suitable for LPBF may have D10 of 5-15 microns, and a D90 of 40-80 microns. In some cases, the particle total size is within a range of from 15 to 63 microns. In some cases, the Al alloy powder suitable for electronbeam powder bed fusion may have a D50 in a range of 45-100 microns, or 50 to 80 microns. In some cases, no flux is included in the Al alloy powder. In some cases, no flow agent is included in the Al alloy powder. For LPBF, good flowability of the powder is desirable to enable spreading the powder across the plate evenly and without agglomerations. Flowability may be tested by a Hall Flow test, fluid bed permeability tests, or FT4 shear under consolidation tests. [00103] The build platform may reside in a chamber filled with an inert gas. The inert gas nay be argon or nitrogen.

[00104] The build platform may be pre-heated to reduce internal stress and deformation during a rapid cooling process. In some cases, the build platform may be pre-heated to a temperature of 75-125 deg C, or about 100 deg C.

[00105] Depositing the layer of the Al alloy powder on a build platform may comprise adding the Al alloy powder to the build platform, and smoothing the added powder with a roller, blade, or recoater arm to achieve a uniform powder layer in a predetermined powder layer thickness. The adding may include moving the Al alloy powder from a powder reservoir to the build platform comprising a dispensing device and optionally a powder dispenser platform. The predetermined powder lay thickness may be, for example, 10-200 microns, 20-100 microns, 20-75 microns, 20-60 microns, or 30-40 microns thick.

[00106] The powder layer is irradiated to at least partially fuse, melt, or sinter the powder layer. The irradiating may comprise a laser beam or an electron beam. The laser beam may be any appropriate laser. The laser may be a Yb-laser.

[00107] The platform may be lowered by a predetermined powder layer thickness, for example, lowering the platform by 10-200 microns, 20-100 microns, 25-75 microns, or 30-40 microns.

[00108] There may be a hold period between one or more steps to allow the layer(s) to at least partially cool prior to the next step.

[00109] The process is repeated with successive powder layers until the required part is completely built. LPBF may use a fiber laser as the energy source. The process may be carried out in an inert gas (e.g., argon or nitrogen)-filled chamber to minimize oxygen and reduce risk of hydrogen pickup. In some cases, the laser in the LPBF system can operate up to 1 kW or higher with various spot diameter. In some cases, LPBF systems the layer may be melted in two steps comprising contouring wherein the outer boundary is irradiated by the laser and built first, then the powder within the contour/perimeter is melted subsequently. After two steps of the melting process, another powder layer is deposited. The process is repeated until the 3D part is completed.

[00110] After printing, the 3D printed component may be removed from the build platform and optionally cleaned. The cleaning may comprise compressed air or sandblasting. The 3D printed component may be subjected to post processing such as heat treatment, CNC machining, or polishing to improve surface quality.

[00111] Hot Isostatic Pressing

[00112] Hot isostatic pressing (HIP) is an established treatment of cast components and 3D printed components to increase their density and decrease casting porosity under a prespecified pressure, temperature, and time. Hafenstein et al., 2020 Technologies, 8, 48; doi: 10.3390/technologies8030048. In some cases, the HIP is carried under pressure applied by an inert gas, such as argon or nitrogen. A 3D printed component is simultaneously subjected to both high pressure and high temperatures. In some cases, a 3D printed component is subjected to a temperature between 500 to 550 deg C, 510 to 540 deg C, 520 to 540 deg C, or about 530 deg C, for example, for 2-12 hours, 4-10 hours, 5 to 7 hours, or about 6 hours under a pressure of 70 to 200 MPa, 75 to 150 MPa, or about 100 MPa. In some cases, HIP is performed at a pressure of 75 MPa, a temperature of 510 deg C, and a duration of 120 min. For example, in some cases, HIP may be performed at 100 MPa at 530 deg C for 6 h.

[00113] In some cases, one or more heat treatment, e.g., comprising artificial ageing or T6 heat treatment may be performed separately after HIP densification of the 3D printed component to achieve high material strength.

[00114] Heat Treatment

[00115] The term “heat treatment” or “heat treating” refers to heat treating a 3D printed aluminum alloy part. After the 3D printed aluminum part cools, it exhibits certain “as printed” strength characteristics. Many applications require aluminum 3D printed components to have different mechanical properties, metallurgical structure, or tensile strength than an aluminum part will have “as printed.” Heat treatment can be used to strengthen and improve the structure of as printed shaped aluminum parts.

[00116] Various standard heat treatments are known including F condition (none-as cast), TB condition (solution treated and naturally aged, e.g., T4), TE condition (artificially aged, e.g., T5 or T51), TB7 condition (solution treated and stabilized), TF condition (solution heat treated and fully artificially aged, e.g., T6), TF7 condition (solution treated and artificially aged and stabilized, e.g., T7 or T71 tempers), and TS condition (stress relieved and annealed). See, for example, Kaufman, JG 2000 Introduction to aluminum alloys and tempers, 2000, astmintemational.org, pp. 9-22; and Birdsall 1958, Aluminum Heat Treating, Reynolds Metals Company, Richmond, VA. [00117] The term “precipitation hardening,” or “precipitation-hardening,” or “artificial ageing,” or “age hardening” is a widely used mechanism for strengthening of aluminum alloys. In general, there are three groups of aluminum alloys that are typically produced by age hardening and can be thermally strengthened: aluminum alloys in the 2000 series, 6000 series, and the 7000 series. The term “precipitation-hardening process” is a three- step process comprising solutionizing (i.e., solid solution treatment), quenching, and artificial aging. For example, in a T6 heat treatment condition the sample is solution treated, quenched, then artificially aged, as shown in FIG. 7.

[00118] The term “solutionizing” or “solid solution treatment” or “solution treatment” refers to where the alloy is heated above the solvus temperature and soaked (held) there until a homogenous solid solution (alpha, a) is produced. Certain alloying elements are dissolved in this step and any segregation present in the original alloy is reduced. Solutionizing is the first step in the precipitation-hardening process. The first step in the precipitation-hardening heat treatment is solutionizing the casting by heating to a very high temperature above the solvus temperature but just below the alloy melting point, e.g., > 500 deg C to about 580 deg C, or about 516 deg C to about 579 deg C, e.g., -538 deg C (-1,000 F) for several hours, e.g., about 1 to about 24 hours, about 2 to about 18 hours, or -12 hours.

[00119] In certain heat treatments, solutionizing is followed by quenching, then artificial ageing. For example, T6 heat treatment includes solutionizing, quenching, and artificial ageing. FIG. 7 shows a representative example of a heat treating process comprising solutionizing at about 530 deg C, water quenching, and artificial ageing at about 160 deg C. FIG. 7 shows a schematic of a typical prior art T6 heat treatment (HT) process following HIP. When using Al alloys according to the present disclosure, the solutionizing and quenching steps can be eliminated.

[00120] The term “quenching” refers to rapid cooling of the metal sample. The rapid cooling may comprise lowering the sample into a liquid solution bath, such as water or ethylene glycol at a specific temperature. For example, in some cases, the quench temperature may be at a specific temperature. In some cases, the quench temperature may be, e.g., 20-80 deg C, or 66-100 deg C (150-214 deg F). In the case of an Al alloy with a precipitation hardening agent or solute such as Cu, the solid solution alpha (a) is rapidly cooled forming a supersaturated solid solution of alphass (ass) which may contain excess copper and is not an equilibrium structure. The atoms do not have time to diffuse to potential nucleation sites and thus theta (0) precipitates do not form. Quenching is the second step in the precipitation-hardening process.

[00121] The third step is artificially ageing the castings in a furnace heated to a temperature below the solvus temperature, e.g., 120 - 180 deg C for several hours, e.g., about 3-5 hours and allowed to cool naturally. In some cases, quenching can cause distortion and stress in parts due to extreme temperature differentials.

[00122] The term “precipitation ageing,” “aging,” “ageing” or “artificial ageing” is a heat treatment carried out at a temperature above ambient and below the solvus temperature for several hours to produce finely dispersed precipitates. Artificial ageing produces a finely dispersed precipitate, for example, in an Al alloy with certain combinations of solute elements such as, e.g., Mg and Si, or Zn and Mg, etc. The artificial ageing temperature may be in a range of, for example, from about 120 deg C to about 200 deg C (300 to 400 deg F), or about 120 deg C to about 180 deg C, or about 150 deg C to about 180 deg C. The soak (hold) times may be in a range of, for example, from about 2 to about 24 hours, about 4 to about 18 hours, or about 6 to about 12 hours. The supersaturated alpha, ass, is heated below the solvus temperature to produce a finely dispersed precipitate. Atoms diffuse only short distances at this aging temperature. For example, when an Al alloy includes a solute element, because the supersaturated alpha, ass, is not stable, the solute element atoms can diffuse to numerous nucleation sites and precipitates grow. The formation of finely dispersed precipitate in the alloy may be one objective of the precipitation-hardening process. The fine precipitates in the alloy may impede dislocation movement by forcing the dislocations to either cut through the precipitated particles or go around them. By restricting dislocation movement during deformation, the alloy is strengthened. In the precipitation-hardening process, ageing is the third step. Precipitation ageing may be performed under TE condition (T5 or T51). Under T5 conditions, a sample is cooled from an elevated temperature shaping process and artificially aged. A T51 heat treatment bakes the casting at a low temperature to artificially age it. For example, the printed component may be heated 3-5 hours at 227 deg C (440 deg F) then allowed to cool naturally.

[00123] The term “solution treated and stabilized” refers to a TF7 condition (T7 or T71) where a cast alloy is solution heat treated then stabilized (overaged). The stabilization occurs at a temperature in a range of 200 to 250 deg C (400-480 deg F) in order to stabilize mechanical properties and can result in slightly lower tensile strength and yield strength but increased elongation value compared to T6 series of heat treatments.

[00124] The term “solvus temperature” refers to the temperature at which a solid solution becomes unstable and separates into different phases. It is a function of the composition of the system and can be represented by a curve or a surface on a phase diagram. Solvus temperature is different from the solidus temperature, which is the temperature at which an alloy starts to melt.

[00125] The term “solution treated and stabilized” refers to a heat treatment such as a T7 or T71 heat treatment is similar to T6 except the temperature of the ageing after quench. For T7 castings are aged at 440 deg F (227 deg C) for 7-9 hours. For T71, castings are aged at 475 deg F (204 deg C) for 3-6 hours.

[00126] The method may further comprise heat treating the 3D printed component. In some cases, the heat treating comprises artificially ageing the 3D printed component by holding at one or more temperatures in a range between 120 deg C to 200 deg C for from 2 to 24 hours. The method may include air cooling the artificially aged 3D printed component. In some cases, the artificially aged 3D printed component exhibits a hardness of at least 150 HV when measured by ASTM E384-22 at 1,000 gf.

[00127] In some cases, the heat treating of the 3D printed component comprises solutionizing, quenching, and artificially ageing the 3D printed component to create a heat-treated 3D printed component. In some cases, the solutionizing comprises heating the 3D printed component to a solutionizing temperature above the solvus temperature and below the solidus temperature. In some cases, the solutionizing temperature is in a range from about 500 deg C and about 550 deg C. In some cases, the solutionizing is performed for from about 1 to about 12 hours, or about 2 to about 6 hours, or no more than 4 hours. In some cases, the heat-treated 3D printed component exhibits a hardness of at least 150 HV when measured by ASTM E384-22 at 1,000 gf.

[00128] A 3D printed component is provided comprising an Al alloy comprising 75-92 wt% Al, 3.0 to 12.0 wt% Ce or La, 3.0 to 10.5 wt% Zn, 0.5 to 5.0 wt % Mg, and 0-1.0 wt% Zr or Sc. The 3D printed component can comprise an Al alloy comprising 75-92 wt% Al, 3.0 to 12.0 wt% Ce, 3.0 to 10.5 wt% Zn, 0.5 to 5.0 wt % Mg, and 0-1.0 wt% Zr or Sc. The 3D printed component may comprise an Al alloy comprising 78-92 wt% Al, 3.0 to 11.0 wt% Ce, 4.0 to 9.0 wt% Zn, 1.0 to 3.0 wt % Mg, and 0-1.0 wt% Zr or Sc. The 3D printed aluminum alloy may comprise an Al alloy comprising 80.0-90.0 wt% Al, 5.0-10.0 wt% Ce, 5.0 to 8.5 wt% Zn, and 1.5 to 3.0 wt % Mg. In some cases, the 3D printed component may comprise 6.0 to 10.0 wt% Ce, 5.0 to 8.5 wt% Zn, and 1.5 to 3.0 wt% Mg, and a balance of Al. In some cases, the 3D printed component includes less than 0.1 wt% Cu. In some cases, the 3D printed component does not include added Cu. In some cases, the 3D printed component does not include added Cu. In some cases, the 3D printed component includes less than 0.1 wt% Si. In some cases, the 3D printed component does not include Si. In some cases, the 3D printed component does not include added Si. In some cases, the 3D printed component includes no more than 0.1 wt% Cu and no more than 0.1 wt% Si. In some cases, the 3D printed component does not include Cu or Si. In some cases, the 3D printed component does not include added Cu or Si.

[00129] The 3D printed component may be designed for the aerospace, automotive, or biomedical industries. For example, LPBF of the present Al alloy is suitable for the production of jet engines, automotive calipers and pistons, or orthopedic implants, some cases, the 3D printed component may be an aerospace component. In some cases, the 3D printed component may be an automotive component. In some cases, the 3D printed component may be a biomedical component.

EXAMPLES

Example 1. Alloy Preparation and Comparative Casting Method

[00130] The inventive aluminum alloys were prepared as follows. Proportions of Al, Ce, Mg and Zn were employed as found in Table 1. Commercially pure Al and Al-Ce master alloy were melted in an Induction furnace. Al-Zn and then Al-Mg master alloys were added to the melt in pre-determined proportions to produce an aluminum alloy. [00131] The alloy was made and then cast into ingots suitable for atomization.

[00132] For casting, a casting mold was heated to 500 deg C in a separate oven. The metal was held at 760 deg C and stirred for homogenization. After removal of slag, the metal was poured into casting mold. After the samples were cooled, removed from the mold, and prepared by standard metallographic practices, the ‘as cast’ hardness of the samples was measured by ASTM E384 method. As cast samples exhibited hardness of 103-116 HV1 when tested under ASTM E384-22 under 1000 gf.

Example 2. Laser Powder Bed Fusion

[00133] A fine powder was produced from the aluminum alloy of example 1 by atomization. The fine Al alloy powder was employed using a commercial LPBF printer. The Al alloy powder was spread on the build platform of the printer to a thickness of 30 microns, the powder bed as subjected to laser shining to fuse the powder layer, the build platform was lowered, and a new layer of Al alloy powder was spread to create an “as printed” 3D printed component.

Example 3. Hot Isostatic Pressing

[00134] The 3D printed component of example 2 is subjected to HIP process comprising heating to 530 deg C under argon under 100 MPa pressure for about 2 to about 6 hours. Hardness is measured by ASTM E384 method after the samples are prepared by standard metallographic practices. FIG. 6 shows hardness of inventive alloy at different conditions compared to prior art AlSilOMg alloy when tested under same conditions.

Example 4. Artificial Ageing of Printed Samples without Solutioning

[00135] The as printed 3D printed components of example 2 or 3D printed + HIP treated components of example 3 were subjected to artificial ageing as follows. The samples were soaked first at 120 deg C for 4 hrs followed by 160 deg C for 4 hrs. Hardness was measured by ASTM E384 method after the samples were prepared by standard metallographic practices. After 3D printing and artificial ageing, the inventive alloy 3D printed samples exhibited hardness of about 160 HV1 when tested under ASTM E384-22 under 1000 gf. Air cooling directly after HIP followed by artificial ageing treatment was found to be adequate to develop desirable high hardness in samples as shown in FIG. 6.

Example 5. Solutionizing and Artificial Ageing of 3D Printed Samples

[00136] Sample pieces of a 3D printed sample of the inventive Al alloy of example 3 were heat treated (HT) after HIP. The HT included solutionizing by heating to 500 deg C in a muffle furnace and soaked for 2 hrs. The pieces were then removed from the furnace, air cooled without water quenching, and artificially aged at 120 deg C for 4 hrs followed by 160 deg C for 4hrs and air cooled at the end of the cycle. Hardness of the samples was measured after the samples were prepared by standard metallographic practices. After HIP and heat treatment, the 3D printed samples of the inventive alloy exhibited hardness of about 157 HV1 when tested under ASTM E384-22 under 1000 gf, compared to a 3D printed sample of prior art alloy AlSilOMG which exhibited hardness of only about 108 after HIP and HT under same conditions, as shown in FIG. 6.

[00137] Clauses

[00138] Clause 1. A method of making a 3D printed aluminum alloy component, comprising: providing an aluminum alloy powder comprising from 75 to 92 wt% Al, from 3.0 to 12.0 wt% Ce or La or a combination of both, 3.0 to 10.5 wt% Zn, and 0.5 to 5.0 wt % Mg; depositing the aluminum alloy powder on a build platform; and irradiating the aluminum alloy powder to at least partially fuse or melt the powder to form the 3D printed aluminum alloy component.

[00139] Clause 2. The method of clause 1, wherein the aluminum alloy powder comprises from 75 to 92 wt% Al, from 3.0 to 12.0 wt% Ce, 3.0 to 10.5 wt% Zn, and 0.5 to 5.0 wt % Mg.

[00140] Clause 3. The method of clause 1, wherein the aluminum alloy powder comprises from 75 to 92 wt% Al, from 3.0 to 12.0 wt% La, 3.0 to 10.5 wt% Zn, and 0.5 to 5.0 wt % Mg.

[00141] Clause 4. The method of any one of clauses 1 to 3, wherein the depositing comprises depositing a first layer of the aluminum powder on the build platform; and the irradiating comprises irradiating the first layer of powder to at least partially fuse or melt the powder into a first layer, the method further comprising lowering the build platform; depositing a second layer of the powder onto the first layer; and irradiating the second powder layer to at least partially fuse the powder into a second layer, and optionally repeating the lowering, depositing, and irradiating to form the 3D printed component.

[00142] Clause 5. The method of any one of clauses 1 to 4, wherein the depositing comprises depositing the aluminum alloy powder on the build platform in a continuous fashion and simultaneously irradiating the aluminum alloy powder.

[00143] Clause 6. The method of any one of clauses 1 to 5, wherein the irradiating comprises a laser, electron beam, or electrical arc.

[00144] Clause 7. The method of any one of clauses 4 to 6, wherein the first layer of the aluminum alloy powder is from 10 to 200 microns, 20 to 100 microns, 25 to 75 microns, or 30 to 40 microns thick.

[00145] Clause 8. The method of any one of clauses 1 to 7, wherein the aluminum alloy powder comprises 78.0 to 92.0 wt% Al; 3.0 to 11.0 wt% Ce, 4.0 to 10.5 wt% Zn, and 1.0 to 4.0 wt% Mg. [00146] Clause 9. The method of any one of clauses 1 to 8, wherein the aluminum alloy powder comprises 80.0 to 90.0 wt% Al; 5.0 to 10.0 wt% Ce, 4.0 to 9.0 wt% Zn, and 1.5 to 3.0 wt% Mg.

[00147] Clause 10. The method of any one of clauses 1 to 9, wherein the aluminum alloy powder comprises < 0.1 wt% Cu.

[00148] Clause 11. The method of any one of clauses 1 to 10, wherein the aluminum alloy powder comprises < 0.1 wt% Si.

[00149] Clause 12. The method o any one of clauses 1 to 11, wherein the aluminum alloy powder does not include added Cu or Si.

[00150] Clause 13. The method of any one of clauses 1 to 12, wherein the amount of cerium and zinc in the aluminum alloy powder are sufficient to cause formation of a ternary intermetallic phase.

[00151] Clause 14. The method of clause 13, wherein the ternary intermetallic phase comprises AhCeZm and/or Aln-xCesZnx.

[00152] Clause 15. The method of any one of clauses 1 to 14, wherein the aluminum alloy powder further comprises one or more of iron, titanium, zirconium, scandium, manganese, chromium, tin, boron, or vanadium in an amount less than 1 wt% for each element taken individually.

[00153] Clause 16. The method of any one of clauses 1 to 15, wherein the aluminum alloy powder further comprises 0.01 to 1 wt%, or 0.1 to 0.5 wt% of Zr and/or Sc.

[00154] Clause 17. The method of any one of clauses 1 to 16, wherein the 3D printed component as printed exhibits a hardness of at least 110 HV when measured by ASTM E384-22 at 1,000 gf.

[00155] Clause 18. The method of any one of clauses 1 to 17, further comprising hot isostatic pressing (HIP) of the 3D printed component.

[00156] Clause 19. The method of clause 18, wherein the HIP comprises subjecting the 3D printed component to a pressure of 75 -150 MPa 80-120 MPa, or 90-110 MPa under an inert gas.

[00157] Clause 20. The method of clause 18 or 19, wherein the HIP is performed at a temperature in a range of 510 -540 deg C, 520 -540 deg C, or 525-535 deg C.

[00158] Clause 21. The method of any one of clauses 18 to 20, wherein the HIP is performed for a first period of time in a range of 2-12 hours, 4-10 hours, or 5 -7 hours. [00159] Clause 22. The method of any one of clauses 18 to 21, wherein following the HIP the 3D printed component exhibits minimal coarsening such that no second phase particles exhibit a diameter of greater than 5 microns, greater than 4 microns, or greater than 3 microns.

[00160] Clause 23. The method of any one of clauses 1 to 22, further comprising further heat treating the 3D printed component.

[00161] Clause 24. The method of clause 23, wherein the further heat treating comprises artificial ageing the 3D printed component.

[00162] Clause 25. The method of clause 24, wherein the further heat treating comprises holding at one or more temperatures in a range of 120 - 200 deg C for a second period of time in a range of 2 to 24 hours, optionally comprising steps at different temperatures, to provide an artificially aged 3D printed component.

[00163] Clause 26. The method of any one of clauses 23 to 25, wherein the further heat treating comprises solutionizing, air cooling without quenching, and artificially ageing the 3D printed component to create a heat-treated 3D printed component.

[00164] Clause 27. The method of any one of clauses 23 to 26, wherein the further heat treating does not include separate solutionizing and water quenching of the 3D printed component.

[00165] Clause 28. The method of any one of clauses 23 to 25, wherein the further heat treating comprises solutionizing, quenching, and artificially ageing the 3D printed component to create a heat-treated 3D printed component.

[00166] Clause 29. The method of any one of clauses 23 to 28, wherein the heat-treated 3D printed component exhibits a hardness of at least 130 HV, at least 140 HV, at least 150 HV, at least 160 HV, at least 170 HV, or at least 180 HV when measured by ASTM E384- 22 at 1,000 gf.

[00167] Clause 30. A method of making a three-dimensional (3D) printed Al alloy component comprising

(i) obtaining a fine powder of an Al alloy comprising 75 to 92 wt % Al, 3.0 to 12.0 wt% Ce, 3.0 to 10.5 wt% Zn, and 0.5 to 5.0 wt % Mg;

(ii) depositing the Al alloy powder on a build platform;

(iii) irradiating the Al alloy powder comprising a laser or electron beam to at least partially melt or fuse the powder; and

(iv) optionally repeating steps (ii) — (iiii) to provide the printed component. [00168] Clause 31. The method of clause 30, further comprising heat treating the printed component, wherein the heat treating comprises HIP and artificial ageing of the printed component, wherein the heat-treated 3D printed component exhibits a hardness of at least 130 HV, at least 150 HV, at least 160 HV, at least 170 HV, or at least 180 HV when measured by ASTM E384-22 at 1,000 gf.

[00169] Clause 32. A 3D printed component comprising an aluminum alloy comprising

75 to 92 wt % Al, 3.0 to 12.0 wt% Ce or La, 3.0 to 10.5 wt% Zn, and 0.5 to 5.0 wt % Mg; 75 to 92 wt % Al, 3.0 to 12.0 wt% Ce, 3.0 to 10.5 wt% Zn, and 0.5 to 5.0 wt % Mg; 78.0 to 92.0 wt % Al, 3.0 to 11.0 wt% Ce, 4.0 to 9.0 wt% Zn, and 1.5 to 4.0 wt % Mg; or

80.0 to 90.0 wt % Al, 5.0 to 10.0 wt% Ce, 5.0 to 8.5 wt% Zn, and 1.5 to 3.0 wt% Mg, and wherein the aluminum alloy comprises less than 0.1 wt% Si and less than 0.1 wt% Cu. [00170] Clause 33. The 3D printed component of clause 31, wherein the printed aluminum alloy further comprises 0.01-1 wt%, or 0.1-0.5 wt% of Zr and/or Sc. [00171] The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter append.

Claims

WHAT IS CLAIMED IS:

1. A method of making a 3D printed aluminum alloy component, comprising: providing an aluminum alloy powder comprising from 75 to 92 wt% Al, from 3.0 to 12.0 wt% Ce or La or a combination of both, 3.0 to 10.5 wt% Zn, and 0.5 to 5.0 wt % Mg; depositing the aluminum alloy powder on a build platform; and irradiating the aluminum alloy powder to at least partially fuse or melt the powder to form the 3D printed aluminum alloy component.

2. The method of claim 1, wherein the depositing comprises depositing a first layer of the aluminum powder on the build platform; and the irradiating comprises irradiating the first layer of powder to at least partially fuse or melt the powder into a first layer, the method further comprising lowering the build platform; depositing a second layer of the powder onto the first layer; and irradiating the second powder layer to at least partially fuse the powder into a second layer, and optionally repeating the lowering, depositing, and irradiating to form the 3D printed component.

3. The method of claim 1, wherein the depositing comprises depositing the aluminum alloy powder on the build platform in a continuous fashion and simultaneously irradiating the aluminum alloy powder.

4. The method of claim 1, wherein the irradiating comprises a laser, electron beam, or electrical arc.

5. The method of claim 2, wherein the first layer of the aluminum alloy powder is from 10 to 200 microns, 20 to 100 microns, 25 to 75 microns, or 30 to 40 microns thick.

6. The method of claim 1, wherein the aluminum alloy powder comprises 78.0 to 92.0 wt% Al; 3.0 to 11.0 wt% Ce, 4.0 to 9.0 wt% Zn, and 1.0 to 4.0 wt% Mg, optionally wherein the aluminum alloy powder comprises 80.0 to 90.0 wt% Al; 5.0 to 10.0 wt% Ce, 5.0 to 8.5 wt% Zn, and 1.5 to 3.0 wt% Mg.

7. The method of claim 1, wherein the aluminum alloy powder comprises < 0.1 wt% Cu; the aluminum alloy powder comprises < 0.1 wt% Si; and/or the aluminum alloy powder does not include added Cu or Si.

8. The method of claim 1, wherein the amount of cerium and zinc in the aluminum alloy powder are sufficient to cause formation of a ternary intermetallic phase of AhCeZm and/or Aln-xCesZnx.

9. The method of claim 1, wherein the aluminum alloy powder further comprises one or more of iron, titanium, zirconium, scandium, manganese, chromium, tin, boron, or vanadium in an amount less than 1 wt% for each element taken individually, optionally wherein the aluminum alloy powder further comprises 0.01 to 1 wt%, or 0.1 to 0.5 wt% of Zr and/or Sc.

10. The method of claim 1, wherein the 3D printed component as printed exhibits a hardness of at least 110 HV when measured by ASTM E384-22 at 1,000 gf.

11. The method of claim 10, further comprising hot isostatic pressing (HIP) of the 3D printed component, optionally wherein the HIP comprises subjecting the 3D printed component to a pressure of 75 -150 MPa 80-120 MPa, or 90-110 MPa under an inert gas; at a temperature in a range of 510 -540 deg C, 520 -540 deg C, or 525-535 deg C; for a first period of time in a range of 2-12 hours, 4-10 hours, or 5 -7 hours.

12. The method of claim 11, wherein following the HIP the 3D printed component exhibits minimal coarsening such that no second phase particles exhibit a diameter of greater than 5 microns, greater than 4 microns, or greater than 3 microns.

13. The method of claim 11, comprising further heat treating the 3D printed component, wherein the further heat treating comprises artificial ageing the 3D printed component, optionally comprising holding at one or more temperatures in a range of 120 - 200 deg C for a second period of time in a range of 2 to 24 hours, optionally comprising steps at different temperatures, to provide an artificially aged 3D printed component.

14. The method of claim 13, wherein the further heat treating does not include solutionizing and water quenching of the 3D printed component.

15. The method of claim 13, wherein the further heat treating comprises solutionizing, air cooling without quenching, and artificially ageing the 3D printed component to create a heat- treated 3D printed component.

16. The method of claim 13, wherein the further heat treating comprises solutionizing, quenching, and artificially ageing the 3D printed component to create a heat-treated 3D printed component.

17. The method of claim 13, wherein the heat-treated 3D printed component exhibits a hardness of at least 130 HV, at least 140 HV, at least 150 HV, at least 160 HV, at least 170 HV, or at least 180 HV when measured by ASTM E384-22 at 1,000 gf.

18. A method of making a three-dimensional (3D) printed Al alloy component comprising

(ii) depositing the Al alloy powder on a build platform;

(iv) optionally repeating steps (ii) — (iiii) to provide the printed component, and optionally further comprising

(v) heat treating the printed component, wherein the heat treating comprises HIP and artificial ageing of the printed component, wherein the heat-treated 3D printed component exhibits a hardness of at least 130 HV, at least 150 HV, at least 160 HV, at least 170 HV, or at least 180 HV when measured by ASTM E384-22 at 1,000 gf, optionally wherein the heat treating does not include solutionizing and/or quenching.

19. A 3D printed component comprising an aluminum alloy comprising

75 to 92 wt % Al, 3.0 to 12.0 wt% Ce or La, 3.0 to 10.5 wt% Zn, and 0.5 to 5.0 wt % Mg;

75 to 92 wt % Al, 3.0 to 12.0 wt% Ce, 3.0 to 10.5 wt% Zn, and 0.5 to 5.0 wt % Mg;

78.0 to 92.0 wt % Al, 3.0 to 11.0 wt% Ce, 4.0 to 9.0 wt% Zn, and 1.5 to 4.0 wt % Mg; or

80.0 to 90.0 wt % Al, 5.0 to 10.0 wt% Ce, 5.0 to 8.5 wt% Zn, and 1.5 to 3.0 wt% Mg, and wherein the aluminum alloy comprises less than 0.1 wt% Si and less than 0.1 wt% Cu.

20. The 3D printed component of claim 19, wherein the printed aluminum alloy further comprises 0.01-1 wt%, or 0.1-0.5 wt% of Zr and/or Sc.