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

Abstract: A method comprises fusion welding a filler metal to a first aluminum component; wherein the first aluminum component comprises a 7xxx series aluminum alloy; and wherein the filler metal comprises an aluminum alloy, in weight percent: up to 0.15 Fe; up to 0.15 Si; from 2.3 to 2.7 Mg; from 1.4 to 1.8 Cu; from 6.0 to 9.0 Zn; and from 0.06 to 0.14 Zr. In some embodiments, the 7xxx series aluminum alloy comprises 0.5-2.6 wt. % Cu. In some embodiments, the filler metal comprises, in weight percent, up to 0.45 Sc.

Abstract: Al—Mg and Al—Mg—Zn weld filler alloy compositions for use with fusion weldable 7xxx, 6xxx, 5xxx and 2xxx series aluminum alloy base metals are disclosed. The weld filler alloys may be used for joining a first aluminum base metal segment to a second aluminum base metal segment, where the base metal segments is at least one of 7xxx, 6xxx, 5xxx and 2xxx series aluminum alloy. The weld filler alloys, in wire or rod form, may also be used to repair a defective weld.

Abstract: 7xxx aluminum alloy weld filler alloys and methods of using the same are described. The 7xxx aluminum alloy weld filler alloys may be used to repair 7xxx alloy products. The repaired volume of the 7xxx alloy products may be substantially crack-free, and may facilitate reuse of the repaired 7xxx alloy products.

Abstract: A method of welding continuous or intermittent lap-penetration joints using a gas metal buried arc (GMBA) welding process. A first component is GMBA welded to an underlying second metal component, by forming an arc between a consumable metal electrode and a surface of the first component, depositing metal from the electrode to the first component and producing a pool of molten metal which extends through the first component and into the second component. The molten pool metal solidifies into a weld that extends into the second component wherein the weld width at the interface between the components is at least equal to the thickness of the thinner of the first component and the second component. The arc is at least partially buried within the thickness of the first component and is moved in the direction of the desired joint location to produce a joint.

Abstract: A method of welding continuous or intermittent lap-penetration joints using a gas metal buried arc (GMBA) welding process. A first component is GMBA welded to an underlying second metal component, by forming an arc between a consumable metal electrode and a surface of the first component, depositing metal from the electrode to the first component and producing a pool of molten metal which extends through the first component and into the second component. The molten pool metal solidifies into a weld that extends into the second component wherein the weld width at the interface between the components is at least equal to the thickness of the thinner of the first component and the second component. The arc is at least partially buried within the thickness of the first component and is moved in the direction of the desired joint location to produce a joint.