Wire-arc additive manufacturing (WAAM) is a feasible technology for manufacturing of metallic components of medium complexity with a high deposition rate. Manufacturing of aluminum alloys for e.g. structural components of the aero plane fuselage by this technology has been impeded by the unavailability of high-performance alloys with good processability and low susceptibility to hot cracking. Therefore, a novel alloy system has been developed based on the Al-Zn-Mg-Cu system and successfully processed by WAAM without the occurrence of any hot cracks. Heat treatment strategies were developed allowing for optimum mechanical properties. A homogeneous grain structure was observed with few elongated grains. Upon heat treatment, the formation of T phases was verified with a precipitate size in the range of ~ 10 nm. These are responsible for the observed pronounced age-hardening response of this alloy. An isotropic proof stress of up to ~ 340 MPa and a fracture strain of up to ~ 11% are evidence of the high quality of the WAAM deposited material allowing for an extended use of these alloys for advanced applications. Finally, the applicability and processability of the alloy was proven by fabrication of a motorcycle piston.

线弧增材制造（WAAM）是一种可行的技术，用于制造具有高沉积速率的中等复杂度的金属部件。由于无法获得具有良好加工性和低热裂敏感性的高性能合金，因此阻碍了通过该技术来制造用于例如飞机机身的结构部件的铝合金。因此，已经开发了基于Al-Zn-Mg-Cu体系的新型合金体系，并且通过WAAM成功地对其进行了处理，而没有出现任何热裂纹。开发了热处理策略以实现最佳的机械性能。观察到均匀的晶粒结构，几乎没有拉长的晶粒。热处理后，以约10 nm的沉淀尺寸验证了T相的形成。这些是造成这种合金明显的时效硬化反应的原因。高达〜340 MPa的各向同性屈服应力和高达〜11％的断裂应变证明了WAAM沉积材料的高品质，可将这些合金广泛用于先进应用。最后，通过摩托车活塞的制造证明了该合金的适用性和可加工性。