Abstract: A process for producing a high density aluminum alloy part from a green part like those produced by binder jet additive manufacturing is described. The process utilizes a build powder that includes a densification aid mixed with the aluminum alloy powder and gets incorporated into the green part during the printing process. In some cases, a continuous high flow of nitrogen gas and controlled heating of the green part and provides a high density aluminum alloy part exhibiting densities of 95% or greater.

Abstract: The present disclosure relates to new metal powders for use in additive manufacturing, and aluminum alloy products made from such metal powders via additive manufacturing. The composition(s) and/or physical properties of the metal powders may be tailored. In turn, additive manufacturing may be used to produce a tailored aluminum alloy product.

Abstract: Tailored metal powder feedstocks for additive manufacturing, and methods of recovering waste streams from the same are disclosed. One or more characteristics of the particles of the feedstock may be preselected, after which the tailored metal powder feedstock is produced. After the tailored metal powder feedstock is used in an additive manufacturing operation, a waste powder may be obtained and subjected to one or more predetermined powder recovery methodologies. At least partially due to the preselected particle characteristic(s), at least some of the first particles preferentially separate from at least some of the second particles during powder recovery.

Abstract: The present disclosure relates to new metal powders for use in additive manufacturing, and aluminum alloy products made from such metal powders via additive manufacturing. The composition(s) and/or physical properties of the metal powders may be tailored. In turn, additive manufacturing may be used to produce a tailored aluminum alloy product.