Abstract: A component for an electronic device can include a pre-formed substrate comprising a first metal and an additively manufactured portion bonded to the pre-formed substrate. The additively manufactured portion can include a first portion comprising a second metal and defining a volume, the first portion having a first value of a material property, and a second portion disposed in the volume, the second portion having a second value of the material property that is different from the first value.

Abstract: The disclosure provides an aluminized composite including a base material. The aluminized composite may also include a diffusion layer disposed over the base material. The aluminized composite may further include an aluminum material disposed over the diffusion layer.

Abstract: The disclosure provides an aluminum alloy may include iron (Fe) of at least 0.10 wt %, silicon (Si) of at least 0.35 wt %, and magnesium (Mg) of at least 0.45 wt %, manganese (Mn) in amount of at least 0.005 wt %, and additional elements, the remaining wt % being Al and incidental impurities.

Abstract: A method of forming a part can include selectively activating one or more lasers of a laser array comprising at least 100 lasers based at least partially on a geometry of the part being formed. The method can further include scanning laser spots over a powder bed, the laser sports generated by the activated lasers, and selectively sintering a powder contained in the powder bed with the laser spots to form the part.

Abstract: This application relates to a composite part that can include a non-metal layer having attachment features, and a metal part that is joined with the non-metal layer. The metal part can include a plurality of interlocking structures that are disposed at an external surface of the metal part, where each of the interlocking structures can include an opening characterized as having a first width, and an undercut region, where the opening leads into the undercut region, and the undercut region is characterized as having a second width that is greater than the first width such that the undercut region captures and retains one of the attachment features of the non-metal layer.

Abstract: Anodic oxide coatings and methods for forming anodic oxide coatings on metal alloy substrates are disclosed. Methods involve post-anodizing processes that improve the appearance of the anodic oxide coating or increase the strength of the underlying metal alloy substrates. In some embodiments, a diffusion promoting process is used to promote diffusion of one or more types of alloying elements enriched at an interface between the anodic oxide coating and the metal alloy substrate away from the interface. The diffusion promoting process can increase an adhesion strength of the anodic oxide film to the metal alloy substrate and reduce an amount of discoloration due to the enriched alloying elements. In some embodiments, a post-anodizing age hardening process is used to increase the strength of the metal alloy substrate and to improve cosmetics of the anodic oxide coatings.

Abstract: An aluminum alloy that may include 0.45 to 0.85 wt % Si, 0.15 to 0.25 wt % Cu, 0.40 to 0.80 wt % Fe, 1.20 to 1.65 wt % Mg, and 0.80 to 1.10 wt % Mn, where the balance is aluminum and incidental impurities. The alloy can include used beverage can (UBC) scrap.

Abstract: Sealed anodic coatings that are resistant to leaching of nickel and nickel-containing products and methods for forming the same are described. Methods involve post-sealing thermal processes to remove at least some of the leachable nickel from the sealed anodic coatings. In some embodiments, the post-sealing thermal processes involve immersing the sealed anodic coating within a heated solution so as to promote diffusion of the leachable nickel out of the sealed anodic coatings and into the heated solution. The resultant sealed anodic coating is pre-leached of nickel and is therefore well suited for many consumer product applications. In some embodiments, a post-sealing thermal process is used to further hydrate and seal the sealed anodic coating, thereby repairing structural defects within the sealed anodic coating.

Abstract: The disclosure provides an aluminum alloy may include iron (Fe) of at least 0.10 wt %, silicon (Si) of at least 0.35 wt %, and magnesium (Mg) of at least 0.45 wt %, manganese (Mn) in amount of at least 0.005 wt %, and additional elements, the remaining wt % being Al and incidental impurities.

Abstract: This application relates to a composite part that can include a non-metal layer having attachment features, and a metal part that is joined with the non-metal layer. The metal part can include a plurality of interlocking structures that are disposed at an external surface of the metal part, where each of the interlocking structures can include an opening characterized as having a first width, and an undercut region, where the opening leads into the undercut region, and the undercut region is characterized as having a second width that is greater than the first width such that the undercut region captures and retains one of the attachment features of the non-metal layer.

Abstract: This disclosure relates to rapid and repeatable tests that can be used to evaluate the interfacial adhesion of coatings to substrates. In particular embodiments, tests are used to assess the resistance of anodic oxides to delamination from aluminum substrates. The tests can be conducted using standard hardness test equipment such as a Vickers indenter, and yield more controlled, repeatable results than a large sample of life-cycle tests such as rock tumble tests. In particular embodiments, the tests involve forming an array of multiple indentations within the substrate such that stressed regions where the coating will likely delaminate are formed and evaluated.

Abstract: Sealed anodic coatings that are resistant to leaching of nickel and nickel-containing products and methods for forming the same are described. Methods involve post-sealing thermal processes to remove at least some of the leachable nickel from the sealed anodic coatings. In some embodiments, the post-sealing thermal processes involve immersing the sealed anodic coating within a heated solution so as to promote diffusion of the leachable nickel out of the sealed anodic coatings and into the heated solution. The resultant sealed anodic coating is pre-leached of nickel and is therefore well suited for many consumer product applications. In some embodiments, a post-sealing thermal process is used to further hydrate and seal the sealed anodic coating, thereby repairing structural defects within the sealed anodic coating.

Abstract: This disclosure relates to rapid and repeatable tests that can be used to evaluate the interfacial adhesion of coatings to substrates. In particular embodiments, tests are used to assess the resistance of anodic oxides to delamination from aluminum substrates. The tests can be conducted using standard hardness test equipment such as a Vickers indenter, and yield more controlled, repeatable results than a large sample of life-cycle tests such as rock tumble tests. In particular embodiments, the tests involve forming an array of multiple indentations within the substrate such that stressed regions where the coating will likely delaminate are formed and evaluated.

Abstract: Anodic oxide coatings and methods for forming anodic oxide coatings on metal alloy substrates are disclosed. Methods involve post-anodizing processes that improve the appearance of the anodic oxide coating or increase the strength of the underlying metal alloy substrates. In some embodiments, a diffusion promoting process is used to promote diffusion of one or more types of alloying elements enriched at an interface between the anodic oxide coating and the metal alloy substrate away from the interface. The diffusion promoting process can increase an adhesion strength of the anodic oxide film to the metal alloy substrate and reduce an amount of discoloration due to the enriched alloying elements. In some embodiments, a post-anodizing age hardening process is used to increase the strength of the metal alloy substrate and to improve cosmetics of the anodic oxide coatings.

Abstract: Anodic oxide coatings and methods for forming anodic oxide coatings on metal alloy substrates are disclosed. Methods involve post-anodizing processes that improve the appearance of the anodic oxide coating or increase the strength of the underlying metal alloy substrates. In some embodiments, a diffusion promoting process is used to promote diffusion of one or more types of alloying elements enriched at an interface between the anodic oxide coating and the metal alloy substrate away from the interface. The diffusion promoting process can increase an adhesion strength of the anodic oxide film to the metal alloy substrate and reduce an amount of discoloration due to the enriched alloying elements. In some embodiments, a post-anodizing age hardening process is used to increase the strength of the metal alloy substrate and to improve cosmetics of the anodic oxide coatings.