AU2019261124A1 - Hot-stamping forming method for lightweight aluminum alloy vehicle body component - Google Patents

Hot-stamping forming method for lightweight aluminum alloy vehicle body component Download PDF

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AU2019261124A1
AU2019261124A1 AU2019261124A AU2019261124A AU2019261124A1 AU 2019261124 A1 AU2019261124 A1 AU 2019261124A1 AU 2019261124 A AU2019261124 A AU 2019261124A AU 2019261124 A AU2019261124 A AU 2019261124A AU 2019261124 A1 AU2019261124 A1 AU 2019261124A1
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aluminum alloy
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heating
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Zhili HU
Lin Hua
Huanhuan LI
Wenpei ZHANG
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Wuhan University of Technology WUT
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Wuhan University of Technology WUT
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21DWORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/02Stamping using rigid devices or tools
    • B21D22/022Stamping using rigid devices or tools by heating the blank or stamping associated with heat treatment

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  • Thermal Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)

Abstract

A hot-stamping forming method for a lightweight aluminum alloy vehicle body component, comprising: placing an original T6-state aluminum alloy sheet blank in a heating device for quick heating, the heating rate being 1-10 °C/s and the heating temperature being 50-300°C lower than the solution temperature of the alloy, and then maintaining the temperature for 10-300 s; then, quickly transferring the blank to a water-cooling mold for hot-stamping forming, and performing pressure holding and quenching in the mold at a cooling rate of not less than 30 °C/s to obtain a formed part. The blank used is a T6-state aluminum alloy, a T4-state vehicle body part can be obtained without performing subsequent solution and aging heat treatment that is necessarily used in a conventional stamping process for strengthening, and the part is further strengthened in a subsequent paint baking procedure to obtain T8-state mechanical properties. The method shortens the production period of hot forming, greatly improves the production efficiency, and can also ensure the usage performance of products.

Description

HOT STAMPING FORMING METHOD OF LIGHTWEIGHT ALUMINUM ALLOY BODY COMPONENT
Field
[0001] The present invention relates to the field of metal sheet forming and processing, in particular to a hot stamping forming method of a lightweight aluminum alloy body component.
Background
[0002] Nowadays, the world is facing great pressure from resources and environment. Energy conservation and emission reduction have become the common goal of global automobile manufacturers. Under such environment, lightweight has become an inevitable trend in the automobile industry. As an important lightweight material, aluminum alloy has become the second largest automobile material after steel due to its unique advantages. However, under cold forming conditions, aluminum alloy has poor formability and is prone to wrinkling, cracking, springback and other defects. However, the formability of aluminum alloy will be effectively improved at high temperature, so hot stamping process is an effective method to solve this problem and has been widely used.
[0003] In the traditional hot forming method, after the sheet metal is hot formed at the forming temperature, solid solution and aging treatment is usually carried out to improve the !0 strength (as shown in Fig. 2). This method is prone to thermal distortion during rapid quenching, and the forming accuracy is difficult to ensure. On this basis, the integrated process of solution heat treatment, forming and cold-die quenching (HFQ*) is proposed. This process is a composite process combining hot forming and heat treatment of the aluminum alloy, i.e., the aluminum alloy sheet after complete solid solution is quickly transferred to a pair of !5 water-cooled dies, then the dies are quickly closed for forming, and the dies are kept closed after the forming is completed, so that the part is quenched in the dies, and finally artificial aging treatment is carried out to improve its strength (as shown in Fig. 3). In-die quenching is beneficial to the strength and dimensional accuracy, but there are still prolonged processes in this method and the production cycle has not been significantly shortened.
[0004] The Patent Document W02015112799(A1) discloses a method of producing aluminum alloy body parts, which includes the following steps:
[0005] a) providing a blank of an aluminum alloy, with any size and shape, selected from the group consisting of a 2000, 6000, 7000, 8000 and 9000 series aluminum alloy, wherein the blank of the aluminum alloy is subjected to solid solution and aging heat treatment, thus having a T4 state or a state close to T4;
[0006] b) heating the blank to form at a temperature of at least 150°C, wherein the blank is heated to a temperature range of 150-350°C, preferably 190-225°C; and holding the heated blank at the heating temperature for 2-6 minutes;
[0007] (c) rapidly transferring the blank to a die for stamping and forming to a complex three-dimensional shape, and cooling the workpiece after the stamping process is completed, wherein the properties of the aluminum alloy part are unchanged during the cooling process; and
[0008] d) after completing the stamping process, the formed part being in a state close to T6 but not exceeding T6, without any other heat treatment or mechanical processing for use in an automobile body.
[0009] The blank used in this patent document is an aluminum alloy sheet with a state close to T4, and the heating temperature is controlled at 150-350°C (preferably 190-225°C), so that the formed part has a state close to T6. After the forming process is completed, the part is cooled by water quenching or air cooling. The blank adopted by the present invention is a T6 strengthened state aluminum alloy sheet, the heating temperature is 50-300°C lower than the solid solution temperature, which makes the precipitated phase of the blank redissolve to improve its plasticity. The work hardening effect in the hot forming process produces the strengthening effect, and at the same time, it also promotes the natural precipitation of the strengthening phase. The strength of the stamped part can reach a further developed T4 state, and T8-state mechanical properties can be further obtained after strengthening by short-term paint baking treatment. After stamping, keeping the dies closed for in-die pressure-keeping quenching is beneficial to the dimensional accuracy of the part.
[0010] The Patent Document W02015123663(A1) discloses a warm forming method of a work-hardened alloy sheet, which mainly includes the following steps: !5 [0011] a) providing a blank of lightweight alloy sheet, the blank being work-hardened to achieve the desired yield strength;
[0012] b) heating the blank to a forming temperature, greater than the ambient temperature, which is sufficient to form all the three-dimensional features without fracturing;
[0013] (c) maintaining the blank at the forming temperature for a time (5-15 minutes) at least sufficient to establish a uniform temperature in the blank, the forming temperature being less than the process recrystallization temperature to avoid strength reduction caused by recrystallization;
[0014] (d) transferring the heated blank to a cold die, closing the die to form a desired part, and then cooling the stamping part to an ambient temperature; and
[0015] e) the work-hardening of the blank being selected to develop the desired strength, after stamping, the desired strength being greater than that of a part obtained by cold forming from the annealed blank.
[0016] The object of the method provided in this patent document is a work-hardened sheet blank, and the blank is heated to a uniform temperature. The recrystallization of the material is limited by work-hardening and by selecting a suitable alloy blank and forming temperature, so as to avoid a decrease in strength, and forced air cooling or liquid spray cooling is used. The processing object of the present invention is a T6 strengthened state aluminum alloy sheet, the blank does not need to undergo work-hardening and recrystallization is not limited. The work-hardening effect caused in the hot forming process not only produces the strengthening effect, but also promotes the subsequent natural precipitation of the strengthening phase. The strength of the part after stamping can exceed the T4 state, and T8-state mechanical properties can be further obtained after strengthening by short-term paint baking treatment. Adopting pressure-keeping quenching in the cold dies is beneficial to the dimensional accuracy of the part. In addition, it is not necessary to maintain a uniform heating temperature in the blank of the present invention.
Summary
[0017] The present invention provides a hot stamping forming method of an automobile component having a complex three-dimensional shape by using a high-strength aluminum alloy !0 sheet, which saves cost and has high production efficiency. The method includes the step of providing an aluminum alloy sheet blank, the alloy is heat-treatable and equipped with T6 temper. The method further includes the steps of heating the aluminum alloy sheet to a temperature which is 50-300°C lower than the solid solution temperature of the aluminum alloy and performing heat preservation, wherein the heat preservation time is controlled at 10-300s; !5 then quickly transferring the heated sheet metal to a water-cooled die for die closing and pressure-keeping quenching. After stamping, the part can be applied to the automobile body without subsequent artificial aging heat treatment strengthening.
[0018] In the process of the present invention, the precipitated phase of the T6-state blank is redissolved by short-term heating, thus improving the plasticity of the alloy and enabling the alloy to form a required complex three-dimensional shape. The work hardening effect in the hot forming process not only produces the strengthening effect, but also promotes the generation and proliferation of a large number of dislocations, hence, vacancies for precipitation of a strengthening phase are effectively provided, and the strengthening phase can be naturally and efficiently precipitated in large quantities, so that the further developed T4-state body part is obtained. In the subsequent paint baking treatment process, the part will be further strengthened to obtain T8-state mechanical properties. Therefore, the formed part can be used in the automobile body without artificial aging heat treatment. Further, subsequent machining processes such as trimming and punching can be considered. Since no further heat treatment operation is required after stamping, the production efficiency can be greatly improved and a large amount of manpower and economic cost can be saved.
Brief Description of the Drawings
[0019] Fig. 1 describes a technical route for forming a body component by using a T6-state aluminum alloy sheet of the present invention; wherein,
[0020] 20-heating equipment, 22-blank, 24-transfer device, 26-stamping equipment, 28-upper die, 30-lower die, 32-cooling system in die, 34-formed part;
[0021] Fig. 2 describes a technical route of a conventional aluminum alloy sheet hot forming process; and
[0022] Fig. 3 describes a technical route of the solution heat treatment, forming and cold-die quenching, (HFQ*) process of aluminum alloy.
Detailed Description of the Embodiments
[0023] The present invention provides a hot stamping method of producing a lightweight high-strength aluminum alloy automobile component with a complex three-dimensional shape. !0 The blank used for forming the component is an aluminum alloy sheet with T6 temper. According to different shapes and sizes of the required forming components, the aluminum alloy blank can be cut into any size and shape for use in subsequent processes.
[0024] As the blank used in the present invention is the T6 strengthened state aluminum alloy, an aluminum alloy material suitable for heat treatment strengthening is selected for the present !5 invention. As shown in Fig. 1, the next step of the present invention is to place the selected aluminum alloy blank 22 in the heating equipment 20 for heating and heat preservation. The heating method can be resistance heating, induction heating, etc. The selected heating temperature is 50-300°C lower than the solid solution temperature of the material, the heating rate is controlled at 1-10°C/s, and the heat preservation time is controlled at 10-300s. Short-term heating makes the precipitated phase of the alloy redissolve, thus greatly improving the plasticity of the alloy and enabling it to form the required complex three-dimensional shape. Further, different temperatures can be set in different regions of the heating equipment, thus forming temperature gradients in different parts of the blank.
[0025] After the heating process is completed, the heated blank is quickly transferred to the stamping equipment 26 by the automatic transfer device 24. The equipment has a pair of stamping dies with complementary shapes and is installed on a press. The blank 22 is placed between the upper die 28 and the lower die 30 and is placed in the correct position by means of a positioning device. The transfer process should take as short a time as possible, generally within 7s, so as to minimize the drop in blank temperature. Immediately after the blank 22 is transferred to the stamping equipment 26, the dies are closed, and the blank 22 is formed to the desired complex three-dimensional shape. After closing, the dies are kept closed, and the workpiece is kept under pressure and quenched in the dies at a cooling rate of not less than 30°C/s. The cooling system 32 is provided in the dies, which, on one hand, can ensure the quenching rate, and on the other hand, effectively prevent the temperature of the die from rising due to frequent heat exchange with the blank in mass production of parts. The quenching process under the pressure is conducive to ensuring the dimensional accuracy of the part. Further, subsequent machining processes such as trimming and punching can be considered.
[0026] While the work hardening effect in the hot forming process produces the strengthening effect, it also promotes the generation and proliferation of a large number of dislocations and effectively provides vacancies for the precipitation of the strengthening phase, hence, the strengthening phase can be naturally and efficiently precipitated in large quantities, so that the formed component can obtain the mechanical properties of further developed T4-state without subsequent artificial aging heat treatment, and can be directly applied to the automobile body. Furthermore, in combination with the automobile body manufacturing process, the body needs !0 to be treated with short-term paint baking after assembly. During the short-term paint baking process, the strengthening phase of the formed component will be further precipitated, and the component can quickly reach the peak strength and obtain the mechanical properties of T8-state. In addition, the heating temperatures of different parts of the aluminum alloy blank can be different, so that the component with gradient mechanical properties can be formed. The !5 so-called gradient mechanical properties refer to the gradient change of mechanical properties along the dimensional direction, thus realizing the multi-performance requirements of a single part.
[0027] The present invention provides a hot stamping method of an aluminum alloy body component, which forms a body component with a complex three-dimensional shape. In this method, a T6-state aluminum alloy sheet is used as a forming blank with high strength. The method includes the step of heating the T6-state blank to a temperature which is 50-300°C lower than the solid solution temperature and performing short-term heat preservation. On the one hand, the short-term heating treatment makes the precipitated phase of the material redissolve, thus greatly improving the plasticity of the alloy. The experimental data show that when the alloy blank is heated to this temperature and kept for 10-300s, the elongation can reach 20% or above, thus the required complex three-dimensional shape can be formed without cracking. On the other hand, the work hardening effect in the hot forming process not only produces the strengthening effect, but also promotes the generation and proliferation of a large number of dislocations, hence, vacancies for the precipitation of the strengthening phase are effectively provided, and the strengthening phase can be naturally and efficiently precipitated in large quantities, so that the further developed T4-state body part is obtained. In consideration of the automobile body manufacturing process, the body needs to be treated with short-term paint baking after assembly. During the short-term paint baking process, the strengthening phase of the formed component of this process will be further precipitated, so that the component can quickly reach the peak strength and reach the T8-state mechanical properties. Therefore, after stamping, the component can be used for the automobile body without subsequent artificial aging heat treatment strengthening. After the forming process is completed, in-die pressure-keeping quenching is carried out to ensure the dimensional accuracy of the part. Compared with the traditional aluminum alloy hot forming technology and the solution heat treatment, forming and cold-die quenching (HFQ*), the process method has fewer forming procedures, shortens the production cycle from more than 12 hours to less than 10 minutes, and finally can obtain the body part with the T8-state mechanical properties. The formed part does not need additional heat treatment strengthening, thus saving a lot of human resources and mechanical equipment. Although the aging strengthening blank has no advantage in raw !0 material price, the benefits brought by the reduction of labor cost and production equipment cost and the improvement of production efficiency are obvious.
[0028] In order to make the present invention more understandable, the present invention will be further explained with reference to the embodiments.
[0029] Embodiment 1 !5 [0030] The embodiment of the present invention will now be described in detail by taking a 7075 aluminum alloy sheet as an example. According to the national standard GB/T 228.1-2010 "Metal materials-Tensile testing-Part I: Method of test at room temperature", the tensile test of the aluminum alloy sheet blank was carried out, and the tensile strength was 565MPa.
[0031] According to the traditional hot stamping method, the blank is generally heated to the required forming temperature for hot forming, and after the hot forming is completed, the blank is subjected to solid solution + artificial aging treatment, i.e., the blank is heated to 460-499°C and kept for 30-40 minutes, and heated to 115-125°C and kept for 24 hours after quenching to obtain the part with the strength meeting the use requirements. However, according to the HFQ* process, the blank should undergo solid solution treatment first, i.e., the blank is heated to 460-499°C and kept for 30-40 minutes, then the temperature is reduced to the required forming temperature for hot forming, and the workpiece is aged after quenching in the dies, i.e., the blank is heated to 115-125°C and kept for 24 hours. However, the heating temperature of the present invention is 50-300°C lower than the solid solution temperature, i.e., 200-450°C, no solid solution aging is required to improve the strength of the part after hot forming, the total time required in the whole forming process can be controlled within 10 minutes, and a large amount of production time is saved.
[0032] The hot stamping forming method of a lightweight aluminum alloy body component mainly includes the following steps:
[0033] (1) the T6-state 7075 aluminum alloy blank is placed in a resistance furnace for heating and heat preservation for 3 minutes, wherein the heating temperature is lower than the solid solution temperature, which can be set to be 300°C, 350°C and 400°C respectively;
[0034] (2) the blank is taken out and rapidly transferred to a stamping die for hot forming, wherein the transfer time is controlled to be within 7s, and pressure-keeping quenching is performed in the die after stamping is completed;
[0035] (3) the final part can be obtained without subsequent heat treatment strengthening.
[0036] The blank used in the step (1) is an aging strengthening T6-state blank, and can be used for an automobile body without subsequent artificial aging heat treatment strengthening after hot forming.
[0037] After the stamping process in the step (2) is completed, the die is kept closed to !0 maintain pressure in the die, which is beneficial to the accuracy of the part. A cooling system is arranged in the die to prevent the temperature of the die from rising in the continuous production process and ensure the quenching efficiency in the die.
[0038] In step (3), it can be considered that the formed part is subjected to necessary subsequent machining processes such as trimming, punching, etc. !5 [0039] Finally, the mechanical properties of the formed part are tested. The results show that when the heating temperature is 350°C, the strength can reach 80% or above of the original blank, which meets the use requirements of the part.
[0040] Embodiment 2
[0041] The embodiment of the present invention will be described in detail by taking a 7075 aluminum alloy sheet as an example. According to the national standard GB/T 228.1-2010 "Metal materials-Tensile testing-Part I: Method of test at room temperature", the tensile test of the aluminum alloy sheet blank was carried out, and the tensile strength was 565MPa.
[0042] According to the traditional hot stamping method, as shown in Fig. 2, the blank is generally heated to the required forming temperature (generally 450-500°C) for hot forming, and after the hot forming is completed, solid solution + artificial aging treatment is carried out, i.e., the blank is heated to 460-499°C and kept for 30-40 minutes, and then is heated to 115-125°C and kept for 24 hours after quenching to obtain the final part. However, according to the HFQ© process, as shown in Fig. 3, the blank should undergo solid solution treatment first, i.e., the blank is heated to 460-499°C and kept for 30-40 minutes, then is quickly transferred to a water-cooled die for hot forming, and the workpiece is aged after pressure-keeping quenching in the cold die, i.e., the workpiece is heated to 115-125°C and kept for 24 hours. However, the heating temperature of the present invention is 50-300°C lower than the solid solution temperature, i.e., 200-450°C, no solid solution aging is required to improve the strength of the part after hot forming, the total time required in the whole forming process can be controlled within 10 minutes, and a large amount of production time is saved. The comparison of the three different processes is shown in the following table.
[0043] Forming process Used blank Heating temperature Subsequent heat treatment Traditional hot No limit 450-500 0 C Solid solution + aging forming (>24hours) HFQ process No limit 460-499 0 C Artificial aging (24hours) (heat preservation for 30-40 minutes) The present T6-state blank 200-450 0 C None invention (heat preservation for 10-300 seconds)
[0044] The hot stamping forming method of a lightweight aluminum alloy body component mainly includes the following steps:
[0045] (1) the T6-state 7075 aluminum alloy blank is placed in a resistance furnace for heating and heat preservation for 1 minute, wherein the heating rate is 1°C/s, and the heating temperature is set to be 350°C;
[0046] (2) the blank is taken out and rapidly transferred to a water-cooled die for hot forming, wherein the transfer time is controlled to be within 7s, and pressure-keeping quenching is !0 performed in the die after stamping is completed, and the cooling rate is 50°C/s;
[0047] (3) the further developed T4-state body part can be obtained without subsequent heat treatment strengthening; and
[0048] (4) in consideration of the automobile body manufacturing process, the body needs to be treated with short-term paint baking after assembly, and after the paint baking process, the !5 part can obtain the T8-state mechanical properties finally.
[0049] The blank used in the step (1) is an aging strengthening T6-state blank, and can be used for an automobile body without subsequent artificial aging heat treatment strengthening after hot forming.
[0050] After the stamping process in the step (2) is completed, the die is kept closed to maintain pressure in the die, which is beneficial to the accuracy of the part. A cooling system is arranged in the die to prevent the temperature of the die from rising in the continuous production process and ensure the quenching efficiency in the die.
[0051] In step (3), it can be considered that the formed part is subjected to necessary subsequent machining processes such as trimming, punching, etc.
[0052] Finally, the mechanical properties of the formed part are tested. The results show that the strength can reach 80% or above of the original blank, which meets the use requirements of the part.
[0053] Embodiment 3
[0054] The embodiment of the present invention will be described in detail by taking a 7075 aluminum alloy sheet as an example. According to the national standard GB/T 228.1-2010 "Metal materials-Tensile testing-Part I: Method of test at room temperature", the tensile test of the aluminum alloy sheet blank was carried out, and the tensile strength was 565MPa. The sheet is cut into a formed blank of an automobile B pillar by a laser cutting method.
[0055] The hot stamping forming method of a lightweight aluminum alloy body component !0 mainly includes the following steps:
[0056] (1) the T6-state 7075 aluminum alloy blank is placed in a resistance furnace for heating and heat preservation for 1 minute, wherein the heating rate is 1°C/s, and the upper area of the blank is heated to 350°C and the lower area of the blank is heated to 400°C by using a gradient heating method;
[0057] (2) the blank is taken out and rapidly transferred to a water-cooled die for hot forming, wherein the transfer time is controlled to be within 7s, and pressure-keeping quenching is performed in the die after stamping is completed, and the cooling rate is 50°C/s;
[0058] (3) the final part can be obtained without subsequent heat treatment strengthening.
[0059] The blank used in the step (1) is an aging strengthening T6-state blank, and can be used for an automobile body without subsequent artificial aging heat treatment strengthening after hot forming.
[0060] The heating furnace used in the step (1) carries out gradient heating on the aluminum alloy blank, the temperature in the upper area of the blank is lower than the temperature in the lower area. The high temperature has a relatively significant influence on the precipitated phase in the lower area. The finally formed B-pillar part has gradient mechanical properties, thus realizing the multi-performance requirements of a single part and meeting crush safety performance under different requirements.
[0061] After the stamping process in the step (2) is completed, the die is kept closed to maintain pressure in the die, which is beneficial to the accuracy of the part. A cooling system is arranged in the die to prevent the temperature of the die from rising in the continuous production process and ensure the quenching efficiency in the die.
[0062] In step (3), it can be considered that the formed part is subjected to necessary subsequent machining processes such as trimming, punching, etc.
[0063] Finally, the mechanical properties of the formed part are tested. The results show that the strength of the lower area of the B-pillar part can reach 80% or above of the original blank, which meets the use requirements of the part.

Claims (2)

1. A hot stamping forming method of a lightweight aluminum alloy body component, characterized by comprising the following steps:
Si) placing a T6-state aluminum alloy blank in heating equipment for rapid heating, wherein a heating rate is 1-10°C/s, and a heating temperature is 50-300°C lower than a solid solution temperature of the alloy; then performing heat preservation, wherein a heat preservation time is 10-300s, so that a precipitated phase of the T6-state aluminum alloy blank is redissolved, a strength of the blank is obviously reduced, and a plasticity is improved;
S2) taking out the blank, rapidly transferring (transfer time<7s) the blank to a water-cooled die for hot forming, and performing in-die pressure-keeping quenching after stamping, wherein a cooling rate is not lower than 30°C/s;
S3) a work hardening effect in the hot forming process not only producing a strengthening effect, but also promoting generation and proliferation of a large number of dislocations, vacancies for precipitation of a strengthening phase being effectively provided, and the strengthening phase being naturally and efficiently precipitated in large quantities, so that a further developed T4-state body part is obtained from the formed component without subsequent artificial aging heat treatment; and
S4) in combination with an automobile body manufacturing process, a body needing to be !0 subjected to short-term paint baking treatment after assembly, and for the formed component of the process, the strengthening phase being further precipitated during the short-term paint baking process, so that the formed component quickly reaches a peak strength and obtains T8-state mechanical properties.
2. The hot stamping forming method of the lightweight aluminum alloy body component according to claim 1, characterized in that a heating temperature of each part of the T6-state aluminum alloy blank in the step Si) is identical or different.
AU2019261124A 2018-04-27 2019-01-31 Hot-stamping forming method for lightweight aluminum alloy vehicle body component Abandoned AU2019261124A1 (en)

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CN201810394967.0A CN108380722A (en) 2018-04-27 2018-04-27 A kind of hot press-formed method of lightweight car body of aluminum alloy component
CN201810394967.0 2018-04-27
PCT/CN2019/074150 WO2019205768A1 (en) 2018-04-27 2019-01-31 Hot-stamping forming method for lightweight aluminum alloy vehicle body component

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