Patent ID: 7032644

Claim:
A method of forming an aluminum alloy, comprising: (a) providing a heat source and a nozzle; (b) delivering a feedstock through the nozzle, the feedstock comprising aluminum and at least one alloy element in a quantity that is greater than an equilibrium solute level for the alloy element in aluminum; (c) directing the feedstock through the nozzle to a point where the feedstock converges with the heat source; (d) melting the feedstock with the heat source to form a molten pool on a substrate; and (e) moving the heat source and the nozzle away from the molten pool, such that the molten pool rapidly cools and solidifies to form a continuous line of deposited alloy to form a part, the rapid cooling causing the alloy element to alloy within the aluminum of the part at a level greater than the equilibrium solute of the alloy element within the aluminum.