CA1284896C - Method for producing dispersion strengthened aluminum alloys - Google Patents

Abstract

AN IMPROVED METHOD FOR PRODUCING
DISPERSION STRENGTHENED ALUMINUM ALLOYS
ABSTRACT

A process is provided for obtaining low density aluminum-base alloys having high strength in the forged condition comprising an interrelated control of the extrusion and forging conditions. Dispersion strengthened mechanically alloyed aluminum-base alloys containing magnesium and lithium which benefit from such process are disclosed. The alloys may contain silicon.

Description

12~34~3~36 AN IMPROVED METHOD FOR PRODUCING
DISPERSION STRENGTHENED ALUMINUM ALLOYS
TECHNICAL FIELD

The present inventlon relates to di~pers10n strqngthened aluminum-base~alloys, and more particularly to a me~hod of producing forged "mechanically alloyed" aluminum alloy systems having improved mechanical properties.

BACKGROUND OF THE INVENTION

In recent years there has been an intensive search for hlgh strength aluminum which wauld ~atisfy the demands of advanced design ln aircraft, automotive, naval and electrical industries. While high strength is a key characteristic of the materials sought, to meet the qualifications for certain advanced tesign applications the alloys must meet a combination of property requirements such as density, strength, ductillty, toughness, fatigue and corrosion resistance, depending on the ultimate end use of the materials. The complexity of the problem goes far beyond the difflculties of developing '~ ~. - , . .
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materials with suitable combinations of properties not achieved before. Economics also plays a large role in the choice of materials. The ultimate product forms are often complex shapes, and the potential savings resulting from possible composition substitution is only a part of the picture. The new aluminum alloys would be particularly valuable if they could be shaped into desired forms using cost effective techniques such as forging while retaining their preshaped properties and/or if they could be fabricated economically into the same complex shapes now used with other materials so as to eliminate the need for retooling for fabrication of weight saving structures. Moreover, to be commercially useful, the fabricated parts must have reproducible properties. From a vantage point of commercial viability, the reproducibility will be attainable under a practical range of conditions.
The use of powder metallurgy routes to produce high strength aluminum has been proposed and has been the subject of considerable research. Powder metallurgy techniques generally offer a way to produce homogenous materials, to control chemical composition and to incorporate dispersion strengthening particles into the alloy. Also, difficult-to-handle alloying elements can at times be more easily introduced by powder metallurgy than ingot melt techniques. The preparation of dispersion strengthened powders having improved properties by a powder metallurgy technique known as mechanical alloying has been disclosed, e.g., in U.S. Patent No.

3,591,362. Mechanically alloyed materials are characterized by fine grain structure which is stabilized by uniformly distributed dispersoid particles such as oxides and/or carbides. U.S. Patent Nos. 3,740,210 and 3,816,080 pertain particularly to the preparation of mechanically alloyed dispersion strengthened aluminum. Other aspects of mechanically alloyed aluminum-base alloys have been disclosed in U.S. Patent Nos. 4,292,079, 4,297,136 and 4,409,038.
For most uses a powder must be fabricated into a final product, e.g., by degassing, compaction, consolidation and shaping in one or more steps. To obtain complex parts the fabrication may take the form, e.g., of extruding, forging and machining. Usually, the less machining required to make a part the greater the economy in : :

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~L 2 ~3 L~ 3 6 material use, labor and time. It will be appreciated that it is an advantage to be able to make a complex shape by forging rather than by a route which requires the shaping by manual labor on an individual basis.
It is academic that composition of an alloy often dictates the fabrication techniques that can be used to manufacture a particular product. In general, the target properties which must be attained in the type aluminum alloys of th~s invention before other properties will be considered are strength, density and ductility.
One of the marked advantages of mechanically alloyed powders is that they can be made into materials having the same strength snd ductility as materials made of similar compositions made by other routes, but with a lower level of dispersoid. This enables the production of alloys which can be fabricated more easily without resorting to age hardening additives. While the mechanical alloying route produces materials that are easier to fabricate than other aluminum alloys of comparable composition, the demands for strength and low density and the additlves used to obtain higher strength and/or lower densi~y usually decrease workability of the alloy system. (Workabillty takes into account at least ductility at the working temperature and the load necessary to form the material.) The extent of the effect is generally related to the level of additive in the alloy. The additives not only a~fect the method by which the material can be fabricated, but also the fabrlcation techniques affect the properties of the materials.
It has now been found that low density dispersian strengthened, mechanically alloyed aluminum-lithium-magnesium alloys can be fabricated into forged parts characterized by improved strength along with adequate ductility by extruding and forging the alloys under controlled narrow conditions. It has further been found that controlling the extrusion of the materials under specific conditions makes possible a wider range of conditions under which the materials can be forged. This further enhances the commercial value of the alloys and improves the reproducibility of the forged parts.
It has also been found that the temperatures at which the alloya should be forged are in a lower range than would be expected from normal handbook practice for forging aluminum alloys, e.g., as , :. ~ ' '' ,':
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~ PC-1090 descrlbed in the Metals Handbook, 8th Ed., Vol. 5 (1970) on pp.
127-132.

BRIEF DESCRIPTION OF DRA~INGS

Figure 1 i8 a plan drawing of a "Cruciform"-type forging.
Figure 2 is a plan drawing of a "Hook"~type forging.

SUMMARY OF THE INVENTION

The present invention is directed to a method for obtaining a forged product composed of a disperslon strengthened, low density aluminum-base alloy comprised of, aluminum, lithium and magnesium, said alloy being derived from a powder of said alloy prepared by a mechanical alloying process, and said method for obtaining the forged product being comprised of a sequence of steps comprising: degassing and compacting said powder under vacuum to obtain a compaction billet having a density sufficiantly high to obtain an extruded billet of subgtant~ally full density; extruding the resultant compaction billet at a temperature in the range of above the lncipient extrusion temperature up to about 400C (750F) said extru~ion being carried out with lubrication through a conical die to provide an extruded billet of substantially full density; and forging the resultant extruded billet ~aid resultant billet being sub~ected to at least a first forging treatment at a temperature in the range of about 230C
(450F) up to about 400C (750F), with the proviso that for maximizing strength the forging is carried out at the lower end of the forging temperature range when the extrusion i6 carried out a~
the higher end of the extruslon temperature range.
Degassing i8 carried out at a temperature higher than any temperature to be subsequently experienced by the aIloy, and compaction is carrled out at least to the extent that the poro~ity is isolated, and preferably to at least about 95% of full density and higher.
By incipient extrusion temperature is meant the lowest temperature et which a given alloy can~be extruded on a given ..:.

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' ~`2~ 36 extrusion press ae a given extrusion ratio. The extrusion ratio is at least 3:1 and may range, for example, to about 20:1 and higher.
By a conical die is meant a die in whlch the transition from the extrusion liner to the extruslon die is gradual.
Advantageously the angle of the head of the die with the liner is less than about 60, and preferably it is about 45.
Alloys of the present invention consist essentially of, by weight, about 0.5 to about 4% Li, about O.S to about 7% Mg, 0 up to about 4% Si, a small but effective amount for increased strength, e.g. about 0.05%, up to about 5% carbon, a small but effective amount for increased strength and stability up to about 1% oxygen, and the balance essentially aluminum, and having a dispersoid content of a small but effective amount for increased strength up to about 10 volume % dispersoid.
In a preferred embodiment of the present process the alloys contain about 1.5% up to about 2.5% lithium and about 2% up to about 4% magnesium, 0.5% to about 1.2% carbon and up to less than 1%
oxygen, and the ex~rusion is carried out at a temperature in the range of about 230C (450F) to about 400C (750F). Advantageously 20 the extrusion is carried out below about 370C t700F), preferably in the range of about 260C (500F) to about 360C (675F), and most preferably at about 260C (500F). For thls alloy system, the forging operation (or in a multi~step forging operation the initial forging step) is carried out at a temperature of about 230C (450F) 25 to about 400C (750F) when extrusion is carried out at about 260C, and the forging operation (or initial forging step) is carried out at a narrow range at the lower end of the extrusion temperature range, e.g. at about 260C (500F) when extrusion is prevlously carried out at 370C (700F). In accordance with the present invention low density alloys of such system can be provided which are characterized by an 0.2% offset yield strength (YS) of at least 410 MPa (60 ksi), an elongation of at least 3%. In one aspect of the invention the Al-Li alloys have a density of less than 2.57 g/cm .

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DETAILED ASPECTS OF THE INVENTION
_ (A) Composition The essential components of the matrix of the alloy systems of the present invention are aluminum, magneslum and lithium. In one embodiment the alloys contain silicon. The alloys are characterized in that they are dispersion strengthened and they are formed from mechanically alloyed powders. In one preferred embodiment they are prepared as forged articles. The dispersion strengthening agents comprise carbides and oxides and/or silicides.
Carbon and oxygen along with small amounts of magnesium and lithium are present as a small weight percentage of the alloy system in combination as insoluble dispersoids such as oxides andlor carbides. Other elements may be incorporated in the allo~ so long as they do not interfere with the desired properties of the alloy for a particular end use. Also, a minor amount of impurities may be picked up from the charge materials or in preparing the alloy. Additional insoluble, stable dispersoids or dispersoid forming agents may be incorporated in the system, e.g., for strengthening of the alloy at elevated temperatures, 80 long as they do not otherwise adversely affect the alloy.
Unless otherwise speclfied, concentration of components is given in weight %.
The lithium level in the alloys may range, for example, from about 0.5 to about 4 %, advantageously in an amount of about l up to about 3%, and preferably from about 1.5 or 1.6 up to about 2.5%. The lithium is introduced into the alloy system as a powder (elemental or preferably prealloyed with aluminum) thereby avoiding problems which accompany the melting of lithium in ingot metallurgy methods. Magnesium may be present, for example, in an amount of about 0.5% to about 7%. Advantageously, ths magnesium levsl may range from above 1 up to about 5%, preferably it is about 2 up to about 4 or 4.5%. Exemplary alloys contain abovs 1.5 up to about 2.5%
lithium and about 2 to about 4.5~ magnssium.
The silicon level may range, for example, from O up to about 4%. In the silicon-containing alloys the sllicon level may range from a 3mall but effective amount for strength up to about 4%.

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7 PC-lO90 Advantageously the silicon-containing alloys contain about 0.2 up -to about 2% and preferably about 0.5% to abou~ 1.5%, and typically about 0.5 to about 1%.
Carbon is present in the system at a level ranging from a small but effective amount for increased strength up to about 5%.
Typically the level of carbon ranges from about 0.05 up to about 2%, advantageously from about 0.2% up to about 1% or 1.5%, preferably about 0.5 up to about 1.2%. The carbon is generally provided by a process control agent during the formation of the mechanically alloyed powders. Preferred process control agents are methanol, stearic acid, and graphite. In general the carbon present will form carbides, e.g., with one or more of the components of the system.
Oxygen is usually present in the system, and it is usually desirable at a very low level. In general, oxygen is present in a small but efEective amount for increased strength and stability, e.g., about 0.05% up to 1%, and preferably, it does not exceed about 0.4 or 0.5%. As disclosed in a co-pending application Canadian Serial No. 460,308 now Canadian Patent 1,230,507 the low oxygen content is believed to be critical. When the oxygen content is above 1% the alloy is found to have poor ductility. In a}loys containing above 1.5% Li, the oxygen content preferably daes not exceed about 0.5%.
It will be appreciated that the alloys may contain other elements which when present may enhance certain properties and in the amounts in whicX they are present do not adversely affect the alloy of a particular end use.
The dispersoid comprises oxides and carbides present in a range of a small but effective amount for increased strength up to about 10 volume % (vol. %) or even higher. Preferably the dispersoid level is as low as possible consistent with desired strength.
Typically the dispersoid level is about 1.5 to 7 vol. %. Preferably it is about 2 to 6 vol. %. The dispersoids may be present~ for example, as an oxide of aluminum, lithium, or magnesium or combinations thereof. The dispersoid can be formed during the mechanical alloying step and/or later consolidation and thermomechanical processing. Possibly they may be added as such to -~ the powder charge. Other dispersoids may be added or formed in-situ ,.- ., .: : .

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so long as they are stable in the aluminum alloy matrix at the ultimate temperature of service. Examples of dispersoids that may be present are Al203, ~lOOH, Li20, Li2Al204, LiAlO2, LiAl508 3 Li5Al04 and MgO. The dispersoids may be carbides, e.g., Al4C3.
In a preferred alloy system the li-thium content is about 1.5 up to about 2.5%, the magnesium content is about 2 up to about 4~, the carbon content is about 0.5 to about 2%, and the oxygen content is less than about 0.5%, and the dispersoid level is about 2 or 3 to 6 volume ~. For example, the alloys may be comprised of:
Al-4Mg-1.5Li-1.2C, Al-5Mg-lLi-l.lC, Al-4Mg-1.75Li-l.lC, Al-2Mg-2Li-l.lC, Al-2Mg-2.5Li-l.lC, Al-4Mg-2.5Li-0.7C and Al-2Mg-2.5Li-0.7C, Al-4Mg-1.5Li-.5Si-l.lC, Al-4Mg-1.5Li-lSi-l.lC, Al-2Mg-1.5Li-.5Si-l.lC, Al-2Mg-1.5Li-lSi-l.lC, Al-2Mg-2Li-.5Si-l.lC, Al-2Mg-2Li-lSi-l.lC, Al-2Mg-1.75Li-lSi-0.7C, Al-4Mg-1.5Li-lSi-0.7C, Al-4Mg-1.5Li-.5Si-2C.
(B) Alloy Preparation Prior to Fabrication (13 Mechanical Alloying to Form Powders Powder compositions treated in accordance with the present invention are all prepared by a mechanical alloying technique. This technique is a high energy milling process, which is described in the aforementioned patents. Briefly, aluminum powder is prepared by subjecting a powder charge to dry, high energy milling in the presence of a grinding media, e.g. balls, and a process control agent, under conditions sufficient to comminute the powder particles to the charge, and through a combination of comminution and welding actions caused repeatedly by the milling, to create new, dense composite particles containing fragments of the initial powder materials intimately associated and uniformly interdispersed.
Milling is done in a protective atmosphere, e.g. under an argon or nitrogen blanket, thereby Eacilitating oxygen control since virtually the only sources of oxygen are the starting powders and the process control agent. The process control agent is a weld-controlling amount of a carbon-contributing agent and may be, for example, graphite or a volatili~able oxygen-containing hydrocarbon such as organic acids, alcohols, heptanes, aldehydes and ethers. The formation of dispersion strengthened mechanically .. : ~

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g PC- 1 090 alloyed aluminum is given in detail in U.S. Patents No. 3,740~210 and 3,816,08Q, mentioned above. Suitably the powder is prepared in an attritor using a ball-to-powder weight ratio of 15:1 to 60:1. As indicated above, preferably process control agents are methanol, stearic acid, and graphite. Carbon from these organic compounds and/or graphite is incorporated in the powder and contributes to the dispersoid content.
(2) Degassing and Compaction Before the dispersion strengthened mechanically alloyed powder is consolidated it must be degassed and compacted. Degassing and compacting are effected under vacuum and generally carried out at a temperature in the range of about 480C (895F) up to ~ust below incipient liquefication of the alloy. As indicated above, the degassing temperature should be higher than any subsequently experienced by the alloy. Degassing is preferably carried out, for example, at a temperature in the range of from about 480C (900F) up to 545C (1015F) and more preferably above 500C (930F). Pressing is carried out at a temperature in the range of about 545C (1015~F) to about 480C (895F).
In a preferred embodiment the degassing and compaction are carried out by vacuum hot pressing (VHP). However, other techniques may be used. For example, the degassed powder may be upset under vacuum in an extrusion press. To enable the powder to be extruded to substantially full denslty, eompactlon should be such that the porosity is isolated, thereby avoiding internal contamination of the billet by the extrusion lubricant. This is achieved by carrying out compaction to at least 85% of full density, advantageously above 95%
density, and preferably the material is compacted to over 99% of full density. Preferably the powders are compacted to 99% of full density and higher, that is, to substantially full density.
The resultant compaction products formed in the degassing and compaction step or steps are then consolidated.
(C) Fabrication (1) Consolidation Consolidation in the present process is carried out by extrusion. The extrusion of the material not only is necessary to insure full density in the alloy, but also to break up surface oxide , on the particles. The extrusion temperature is critical and wl~hin a narrow range. The lubrication practice and the conical die-typs equipment used for extrusion are also important.
The extrusion temperature is chosen so that the maximum temperature achieved in the extruder is no greater than 10C (50F) below the solidus temperature. Typically it will be in the range of about 230C (450F) and about 400C (750F). Advantageously, it should be carried out below about 370C (700F) and should not exceed about 345C (650F). Preferably it should be lower than about 330C
(625F). The temperature should be high enough so ehat the alloy can be pushed through the die at a reasonable pressure. Typically this will be above about 230C (450F). It has been found that a eemperature of about 2~0C (500F) for extruslon is highly advantageous. By carrying out the extrusion at about 260C ~500F), l~ there is the added advantage of greater flexibility in conditions which may be used during the forging operation. This flexibility decreases at the higher end of the extrusion temperature range.
The above given extrusion tamperature ranges which must be used for the Al-Li-Mg are those whlch will maximize the strength of the alloy since strength is currently the initial screening test for the forged parts made from the aluminum-base alloys. It will be appreciated that when the strength requirements are not as rigorous the teachings of this invention can be used to trade-off strength against some other property.
The extrusion ln the present process is carried out in a conical-faced die as defined above, as opposed to a shear-faced die.
Lubrication is applied to the die or the compaction billet or both of them. The lubricant~, which aid in the extru~ion operation, must be compatible with the alloy compaction billet and the extrusion press, e.g. the liner and die. The lubricant applied to the billet further protects the billet from the lubricant applied to the extrusion press.
Properly formulated lubricants for specific metals are well known in the art. Such lubricants take into account, for example, requirements to prevent corrosion and to make duration of contact of the billet with the extrusion press less critical. Examples of lubrlcants for the billets are kerosene, mineral oil, fat emulsion and mineral oil containing sulfuri~ed fatty oils. Fillers such as chalk, sulfur and graphite may be added. An example of a lubricant for an extrusion press is colloidal graphite carried in oil or water, molydisulfide, boron sulfide, and boron nitride.
The extruded billets are then in condition to be forged.
If necessary the billets may be machined to remove surface imperfections.
(2) Forging In general forged aluminum alloys of the present invention will benefit from forging temperatures being as low as possible consistent with the alloy composition and equipment. Forging may be carried out as a slngle or multi-step operation. In multi-step forging the temperature control applies to the initial forging or blocking-type step. As in the extrusion step, it is believed that for high strength the aluminum alloys of this invention should be forged at a temperature below one where a decrease in strength will occur. In the Al-Mg-Li alloyæ system forging should be carried out below about 400C (750F), and preferably less than 370C) (700F), e.g. in the range of 230C (450F) to about 345C (650F), typically 20 about 260C (500F). Despite the fact that forgeability may increase with temperature, the higher forging temperatures have now been found to have an adverse effect on strength. In a multi-step forging operation it has been found that it is the initial step that is critical. In subsequent forging steps of a multi-step operatlon after the initial forging ætep the temperature range for forging may be above that recommended for this process.
As noted above, while it is known in the art that conditions of for~ing aluminum alloys wlll vary with composition, it was surpriæing that the forging conditionæ - particularly the temperature - at which the alloys could be forged iæ related to the temperature at which the alloy is consolidated, and in particular extruded.
(3) Age Hardening A heat treatment may be carried out, if deæired, on alloy systems susceptible to age hardening. In alloys having age hardenable components additional strength may be gained, but this may be with the loss of other properties, e.g. corrosion resistance. It : '. . ' ' ' :
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is noted that alloys of this invention containing silicon can be age hardened without significant loss of corrosion resistance. It is a particular advantage of the present invention that low density aluminum alloys can be made with high strength, e.g. over 410 MPa (60 ksi) in the forged condition without having to resort to precipitation hardening treatments which might result in alloys which have less attractive properties other than strength.
It is noted that in conversion from F to C, the temperatures were rounded off, as were the conversion from ksi to MPa and inches to centimeters. Also alloy compositions are nominal.
With respect to conditions~ for commercial production it is not practical or realistic to impose or require conditions to the extent possible in a research laboratory facility. Temperatures may stray, for example, 50F of the target. Thus, having a wider window for processing conditions adds to the practical value of the process.
The invention is further described in, but not limited by, the examples given below. In all the examples the alloys are prepared from dispersion strengthened alloys comprising aluminum, magnesium, lithium, carbon and oxygen, prepared by a mechanical alloying technique. In EXAMPLE 8, silicon is present in the alloy.

This example illustrates the processing conditions used to prepare forged Al-Mg-Li dispersion strengthened mechanlcally alloyed bodies composed of aluminum, magnesium, lithium, carbon and oxygen 25 containing about 1.1~1.2% carbon and less than 1~ oxygen.
Mechanically alloyed powders are prepared having the nominal magnesium and lithium contents given in TABLE I. The powders are vacuum hot pressed (~IP) to form 27.9 cm (11 in) diameter degassed compaction billets.
The compaction billets are then extruded at temperatures of about 260 and 370~C (500 and 700F) at ram speeds of 45.7 and 25.4 cm (18 and 10 in), depending on the extrusion temperature. All billets are sandblasted and coated with Fel-Pro C-300~ ta molybdenum disulfide air drying product of Fel-Pro Inc.) prior to heat-up for extrusion, and the extrusion liner coated with resin and swathed ;~q , _ ~284896 with the lubricant LUBE-A-TUBEIM hot extrusion 230A (a graphite in heavy oil product of G. Whitfield Richards Co.). All the extrusion pushed successfully except for some surface tearing at 700aF. Alloy compositions and extrusion conditions, are given in TABLE I.

TABLE I
Alloy Temp. Ram Speed Type Mg Li C (F) cm (in.)/min A 4 1.5 260 (500) 45.7 (18) B 4 1.75 260 (500) 45.7 (18) C 2 2 260 (500) 45.7 (18) D 4 1.5 370 (700) 25.4 (10) E 4 1.75 370 (700) 25.4 (10) F 2 2 370 (700) 25.5 (10) Eight 8.75 cm (3.5 in.) lengths of material from each extrusion are cut for forging trials. The trial consisted of using flat dies to upset the preforms parallel to the billet axis.
Forgings are performed at nominal temperatures 260C (500F) and 400C (750F) at ram speeds of 50 cm (20 in.)/min and 5 cm (2 in.)/min to final heights of 5 cm (1 in.) and 2.5 cm (0.5 in.) and strains of -0.67 and -0.83, respectively. The top and bottom forging platens are inductlon heated to the same temperatures as the soak temperatures and were lubricated with White and Bagley 296gM graphite base lubricant just before upsetting. Extrusion and forging data are summarized in TABLE II. In general the 260C (500F) extrusions forged better than the 370C (700F) extrusions, and this is believed to be due to the better extruded surface quality of the 500F
extrusions. Surface grinding prior to forging should improve forgeability. The 2Mg-2Li alloy extruded at 370C (700F) had the poorest forgeability. For all of the other alloys a forging condition can be found that does not cause edge cracking. In general, the alloys extruded at 260C (500F) have a higher hardness than material extruded at 370C (700F). The 4Mg-1.5Li composition extruded at 260C (500F) did not soften under any of the forging conditions tried, The 2Mg-2Li alloys soften after forging at about 400C (750F).

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Forging Extrusion Final Soak Ram Sp Soak T Billet Die T Ram Sp Height Forging Har~ness 5Alloy ID T F in/min F T F F in/min in. Appear.* 8 4Mg-1,5Li500 10 As Ext 84 500 -- 500 20 0.95 3 87 2 500 -- 500 20 0.53 2 87 3 500 425 500 2 0.980 2 86 4 500 430 501 2 0.540 2 86 750 680 737 20 1.0 2 85 6 750 -- 734 20 0.520 3 84 7 750 690 735 2 0.960 3 83 8 750 690 747 2 0.525 3 82 4Mg-1.75Li 500 18 As Ext 86 500 440 497 20 0.8 1 88 2 500 440 496 20 0.52 1 87 3 500 -- 497 2 1.0 2 85 4 500 -- 495 2 0.53 3 86 750 680 752 20 0.965 3 85 6 750 680 760 20 0.540 2 86 7 750 680 760 2 0.940 2 84 8 750 670 760 2 0.510 3 84 2Mg-2Li 500 18 As Ext 85 1 500 440 494 20 0.965 3 84 2 500 -- 493 20 0.580 2 85 3 500 440 496 2 1.0 3 82 4 500 -- 49S 2 0.560 2 85 750 680 759 20 0.935 3 80 6 750 -- 759 20 0.510 3 81 7 750 680 752 2 0.960 3 80 8 750 690 755 2 0.50 1 80 4Mg-1.5Li700 10 As Ext 83 500 480 495 20 0.980 2 85 2 500 460 515 20 0.530 2 86 3 500 450 575 2 1.0 2 8g 4 500 450 512 2 0.565 2 87 750 -- 754 20 0.980 3 83 6 750 680 754 20 0.530 2 82 7 750 -- 754 2 1.03 2 82 8 750 670 754 2 0.5 2 82 ~2~4~g6 TABLE II (CONTINUED) Forgin~
Extrusion Flnal Soak Ra~ Sp Soak T Billet Die T Ram Sp Height Forging Har~ness Alloy ID T F in/min F T F F in/min in. Appear.* B
4Mg-1.75Li 700 10As Ext 80 1 500 -- 51420 1.01 3 83 2 500 460 51320 0.565 1 84 3 500 450 514 2 1.025 3 84 4 500 440 512 2 0.515 1 85 750 700 74920 0.99 3 82 6 750 -- 74220 0.535 2 83 7 750 700 745 2 0.98 3 82 8 750 700 742 2 0.55 1 81 152Mg-2Li 700 10As Ext 80 -1 500 -- 50620 0.975 2 80 2 500 440 50320 0,575 1 82 3 500 440 506 2 1.025 2 79 4 500 -- 504 2 0.6 2 80 750 690 74220 1.01 2 77 6 750 680 74620 0.42 2 79 7 750 690 749 2 0.93 2 77 8 750 -- 745 2 0,45 1 77 In the ~ABLE: 500F = 260C; 700F = 370C; 1 inch ~ 2.5 cm *1 = poor 2 - good 3 ~ excellent This example concerns the aging respon6e of extruded and forged alloys described in EXAMPLE l.
To 6treamline the aging study two forgings from each alloy of EXAMP~E 1 are selected. One of each type is forged at 260C
(500F) at 50.8 cm (20 in)/min to 2.54 cm (l in.) final height, and the other is forged at 400C (750F) at 5.08 cm (2 in)lmin to 1.27 cm (0.5 in) final height. These are the two extreme forging conditions.
The compositions 4Mg-l.75Li and 2Mg-2Li show hardness increases at about 125C (255F) after solution treating at about 480C (900F), and from the hardness data it can be predicted that both these alloys can be aged to achieve the desired target YS in the forged condition of about 410 to 450 MPa (60-65 ksi). The "as-extruded" alloys appear to age slower than the forged stock. It i~ assumed that the additlonnl working of forging speeds the aging kinetics.

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~2a4~6 EX~MPLE 3 This example illustrates forgeability of alloys in a cruciform forging test. Cruciform forging trials are performed on extruded billets of the type shown in Example 1, all alloys being extruded with lubrication through a 3.875 in. dia. conical die in an 8:1 extrusion ratio.
The "cruciform"-type forging is shown in plan view in Figure 1. The center portion of the forging is a cruciform formed from two perpendicular raised ribs. The rib portion of the forging is thicker than the base portion. The forging in the tests is made in a two-step operation: (1) blocking extrusion preform on flat dies; (2) forging blocker into raised rib "cruciform", the blocking extrusion corresponding to an initial forging step in a forging operation. The 5 in. x 3.675 in. dia. extruded preforms are blocked in the extrusion direction to 2.5 in. high. The blockers are "squared-up" by repeatedly pressing perpendicular to the extrusion direction forming an octahedron approximately 2.5 in. high with a 5.25 in. diagonal. The flat dies are held at about 315C (600F +
25DF) and no lubricant is used. Extruded surface roughness produced cracking during the blocker operations. Preforms with gross surface surface defects had been ground prior to blocking and had less tendency to crack than did as-extruded surfaces. Blocker cracking also occurred due to high forging speeds, necessitating blocking speed to be lowered from 50.8-63.5 cm (20-25 in)/min to 12.7 cm (5 in)/min.
All cruciforms are final forged at 370C (700F), at a constant die temperature of 315C (600F), press rate of 12.7 cm (5 in)/min, utilizing full press tonnage of 1500 tons. The die was lubricated with a l to 3 mixture of Withrow-A-Paste~M (a lubricant of a graphite type produce of Arthur C. Withrow Co.) and mineral oil.
Cruciforms of acceptable appearance were forged of each material.
Most problems :Ln blocker cracking appear to be due to surface imperfections. Some cracking in the cruciform was related to slight cracking in the blocker. Recorded in TAB~E III are extrusion temperature, blocker temperature, forging temperature and "as-forged' hardness for varlous aluminum alloys of this invention.

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TABLE III
Ext. Block Forged Temp. Temp. Temp. Aæ-Forged Alloy Type F F F Hardness, RB
4Mg-1.5Li 500 500 700 79 4Mg-1.5Li 700 500 700 80 4Mg-1.75Li 500 500 700 80 2Mg-2Li 500 500 700 80 5~0 700 700 78 4Mg-1,75Li 700 500 700 79 7~0 700 700 80 2Mg-2Li 700 700 700 71 All of the 4Mg-1.5Li alloys have "as-forged" ~ardnesses greater than 78 RB except for the alloy extruded, blocked and forged at 370C (700F) and it was ascertained that in these forgings a hardness of 78 RB or better correlates to a YS of 410 MPa (60 ksi) or better. Accordingly, the inference can be made that alloys extruded at 370C (700F) and blocked at 260C (500F) would meet tbe target forged YS requirement of 410 MPa (60 ksi).
The "as-forged" hardness of compositlons 4Mg-1.75Li and 2Mg-2Li can be improved by aging treatments. The 2Mg-2Li ~ges slower than the 4Mg-1.75Li alloy.

This example lllustrates the tensile proper~ies of various Al-Mg-Li alloys of this invention in the extruded, blocked, forged and/or aged condltions of cruciform-type forgings tested at two different sites.
Tensile propertles oE various Al-Mg-Li alloys, essentially of the type descrlbed in EXAMPLE 1, in the extruded, blocked, forged and/or aged conditions are given in TABLE IV. The blocked and forged cond1tions, viz. "Block Temp" and "Forge Temp", respectively, refer .. , ' ~L28~8~36 to the temperatures of the two steps given in EXAMPLE 3 for forming the cruciform-type forging. All tests are carried out in the rib portion of the cruciform. The key to the temper of the tensile sample (TPR) is: 1 = as-extruded, 2 = as-blocked, 3 = "as-forged", 4 - forged and solution treated at 480C (900F) for 2 hours and water quenched (WQ) then aged at 125C (255F) for 2 hours, and 5 =
solution treated as in TPR 4 but aged at 150C (300F) for 24 hours;
Mod s Young's Modulus. Tensile properties obtained on different test equipment for a duplicate set of forged cruciform forgings on either the base (B) or rib (R) portion in various tempers and orientations are given in TABLE V.
Reference to TABLE IV sho~s:
The non-heat treatable Al-4Mg-1.5Li alloy extruded at 260C
(500F), blocked at 260C (500F) and forged at 370C (700F), has a 15 444 MPa (64.4 ksl) YS, 518 MPa (75.2 ksi) UTS (ultimate tensile strength) and 11% El (elongation to failure). The "as-extruded", YS
477 MPa (69.3 ksi), is higher than the forged material, w~ile the "as-extruded" ductility, 7% El, is lower. The strengths of the 260C
(500F) blocker are less than the forged strengths. The 4Mg-1.5Li 20 alloy extruded at 370C (700F), blocked at 260C (500F) and forged at 370C (700F~, has a YS = 424 MPa (61.5 ksi~.
For all conditions tested the 4Mg-1.75Li alloy extruded at 260C (500F) has a YS of greater than 410 MPa (60 ksi)~ Solution treatlng and aging raises the YS to approxlmately 572 MPa (83 ksi) with ~ust a slight decrease ln ductility from the "as-forged"
conditlon. The 370C (700F) extrusion blocked at 260C (500F) can also be aged (TPR = 4) to 551 MPa(80 ksl) yleld strength. For the same aglng treatment the 370C (700F) extrusion blocked at 370C
(700F) has a 537 MPa (78 ksi) YS.
The 2Mg-2Li alloy extruded at either 260C ~500F) or 370C
(700F) produce forgings that have lower as-forged strength than the alloys containing 4~ magneslum. Aglng at (TPR ~ 5) increases the YS
to 530 MPa (77 ksl) and 502 MPa (73 ksl), respectively, for the 260C
(500F) and 370C (700F) extruslons blocked at 370C (700F).
The tests demonstrate the importance of extrusion temperature in processing mechanically alloyed Al-Mg-Li alloys to maximize strength in the final forging. Blocker temperature has a .,, ~2~ 6 secondary effect on forged strength with the lower blocker temperature leading to high strengths. Final forging temperature appears to be of less importance as long as the material has been extruded and blocked at relatively low temperatures.
A comparison of data for "as-forged" longitudinal samples in TABLES IV and V shows the consistency of results in different testing equipment.

TABLE IV
Ext. Blocker Forge Tensile Properties 10 Temp. Temp. Temp. YS UTS El. RA Mgd F F F TPR Orient. ksi ksi % ~ 10 psi Al-4Mg-1.5Li 500 -- -- 1 L 69.3 74.8 7 12.5 10.9 500 -- -- 1 T 67.9 78.7 0 1 14.0 500 500 -- 2 L 61.7 73.7 3.5 8.5 11.2 500 500 700 3 L 64.4 75.2 11 22 10.9 500 700 -- 2 L 59.9 72.2 7.5 12 10.8 500 700 700 3 L 58.8 71.8 -- 19 11.1 Al-4Mg-1.5Li 700 -- -- 1 L 65.9 73.1 6 11 11.5 700 -- -- 1 T 61.9 73.2 2 4.5 11.2 700 500 -- 2 L 57.7 75.3 3.5 9.5 10.2 700 500 700 3 L 61.5 74.6 -- 9.5 10.0 700 700 -- 2 L 55.1 71.4 7.5 12.5 10.9 700 700 700 3 L 55.6 70.7 -- 17.0 10.5 Al-4Mg-1.75Li 500 -- -- 1 L 75.9 96 0.5 1.0 11.4 500 -- -- 1 T 65.9 79.3 0 0.5 11.2 500 500 -- 2 L 62.5 80.2 0 1.5 10.7 500 500 700 3 L 63.5 74.4 -- 9.0 11.1 500 500 700 4 L 82.7 87.4 -- 8.25 10.5 500 700 -- 2 L 58.2 73.8 2.0 7.0 10.0 500 700 700 3 L 61.7 75.5 4.5 4.0 11.6 500 700 700 4 L 82.6 88.1 3.5 11 10.5 ~ 2~ 39~

PC-lO9O

TABLE IV (CONTINVED) Ext. Blocker Forge Tensile Properties Temp. Temp. Temp. YS UTS El. RA Mgd F F F TPR Orient. ksi ksi % % 10 psi Al-2Mg-2Li 500 -- -- 1 L 73.5 91.1 0.5 2.5 11.6 500 -- -- 1 T 60.1 71.1 0 1.0 11.7 500 500 -- 2 L 53.8 67.5 0 1.5 10.4 500 500 700 3 L 56.6 69.5 4.5 11.0 9.8 500 700 -- 1 L 53.8 67.5 0 1.5 10.4 500 700 700 3 L 56.6 69.5 4.5 11.0 9.8 500 700 700 5 L 77.3 84.5 2 4.3 10.6 Al-4Mg-1.75Li 15 700 -- -- 1 L 63.8 70.2 2.0 4.0 11.1 700 ~ 1 T 61.9 72.9 1.0 0.5 11.3 700 500 -- 2 L 55.9 72.4 2.0 9.5 10.4 700 500 700 3 L 58.3 72.3 6.5 11.0 10.7 700 500 700 4 L 80 85.7 3.510 10.4 20 700 700 700 3 L 53.1 73 6.5 lO.5 10.8 700 700 700 3 L 56.1 71.3 6.5 10.0 11.2 700 700 700 4 L 78 85 3.5 9 10.3 700 700 700 4 L 75.5 84.3 7.0 10.1 11.2 Al-2Mg-2Li 25 700 -- -- 1 L 65.7 76.4 1 4.5 11.6 700 -- -- 1 T 56.6 68.5 1 0.5 11.3 700 500 -- 2 L 48.3 64.2 2 7.0 9.2 700 500 700 3 - -- -- ~- __ __ 700 500 700 3 - -- -- -- __ __ 30 700 700 -- 2 L 48.7 64.3 2 4.5 9.2 700 700 700 3 L 48.2 63.6 9 15 11.3 700 700 700 5 L 73 80.1 3.54.0 11.1 TABLE V
Alloy 35 (Extrusion ~ Blocker Test YS UTS
Conditions) Orient. Temper* ksi ksi % El Al-4Mg-1.5Li T R F 64.7 75.2 6.7 (500F Extrusion) T R ST + A 65.7 75.2 8.1 (500F Blocker) T BST + A 66.8 76.0 9.5 T B ST 65.0 76.8 8.1 L RST ~ A 69.2 77.6 12.3 L RST + A 68.8 78 10.9 L R F 69.2 78.1 8.1 L R F 70.4 77.7 8.1 T BST + A 64.8 74.0 10.2 i.~`,'~

.
., ~L28~96 2] PC-1090 TABIE V (CONTINUED) Alloy (Extrusion & Blocker TestYS UTS
Conditions) Orient. Temper* ksi ksi ~ El Al-4Mg-1.5Li T R F 60.8 72.8 9.5 (500F Fxtrusion) T R ST + A 64.8 74.0 9.5 (700F Blocker)T B ST ~ A 61.2 72.8 12.3 T B ST 62.8 73.2 12.3 L R ST + A 62.4 72.8 15.1 L R ST + A 60.4 72.8 12.3 L R F 60.0 72.4 lO.9 L R F 60.0 71.6 10.9 T B ST + A 60.8 72.4 10.2 Al-4Mg-1.5Li T R F 60.4 74.9 8.1 (700F Extrusion) T R ST + A 61.2 74.4 6.7 (500F Blocker)T B ST + A 61.2 74.4 8.1 T B ST 60.4 73.6 8.1 L R ST + A 63.2 74.8 10.9 L R ST + A 63.3 75.2 12.3 L R F 63.6 75.2 6.7 L R F 63.2 74.8 8.1 T B ST + A 60.8 73.2 6.7 Al-4Mg-1.5Li T R F 58.8 72.8 9.5 (700F Extrusion) T R ST + A 62.8 75.2 12.3 (700F Blocker)T B ST + A 61.2 74.0 9.5 T B ST 60.8 73.2 8.1 L R ST + A 62.0 74.8 11.6 L R ST ~ A 60~0 73.6 9.5 L R F 59.2 73.2 8.1 L R F 58.8 73.6 10.9 T B ST + A 60.0 73.5 12.3 Al-4Mg-1.75Li T R F 61.6 75.2 6.7 (500F Extrusion) T R ST + A 86.8 90.8 5.3 (500F Blocker)T B ST + A ô8.8 92.06.7 T B ST 69.4 77.9 6.7 L R ST + A 90.5 93.7 6.7 L R ST + A 90.8 94.0 5.3 L R F 67.2 75.6 3.9 L R F 68.4 79.2 3.9 T B ST + A 86.8 89.2 5.3 : .
: ~ . : . .

.

~2~ 396 TABLE V (CONTINUED) Alloy (Extrusion ~ Blockar Test YS UTS
Conditions) Orient. Temper* ksi ksi % El Al-4Mg-1.75Li T R F 65.2 75.6 5.3 (500F Extrusion) T R ST + A88.4 93.2 3.9 (700F Blocker) T BST + A 86.8 91.6 3.9 T B ST 65.6 76.0 8.1 L RST + A 89.2 92.8 6.7 L RST + A 88.1 91.4 5.3 L R F 63.2 76.4 6.7 L R F 63.2 69.2 3.2 T BST + A 85.4 88.7 2.5 Al-4Mg-1.75Li T R F 60.0 72.8 8.1 (700F Extrusion) T R ST + A83.6 88.4 3.9 (500F Bloc~er) T BST + A 85.2 89.7 5.3 T B ST 63.6 76.0 10.9 L RST + A 85.2 89.2 5.3 L RST ~ A 85.2 89.2 3.9 L R F 61.6 72.8 8.1 Al-4Mg-1.75Li T R F 60.4 72.8 3.9 (700F Extrusion) T R ST + A83.2 89.2 6.7 (700F Blocker) T BST + A 81.9 86.7 3.9 T B ST 61.2 74.0 10.9 L RST + A 83.2 88.0 6.0 L RST + A 82.8 86.8 6.7 L R F 58.8 74.0 9.5 L R F 58.8 74.4 9.5 T BST + A 84.0 87.2 3.9 Al-2Mg-2Li T R F 59.6 74.0 5.3 (500F Extrusion) T R ST + A81.6 88.8 3.9 (500F Blocker) T BST + A -- 76.6 --T B ST 58.1 68.2 2.5 L RST + A 84.4 90.8 3.9 L RST + A 82.0 89.2 2.5 L R F 60.0 72.8 3.2 L R F 58.0 72.8 2.5 T BST + A 82.8 88.8 2.5 89~;

TABLE V (CONTINUED) Alloy (Extrusion ~ Blocker Test YS UTS
Conditions) Orient. Temper* ksi ksi ~ El Al-2Mg-2Li T R F58.0 70.8 3.9 (500F Extrusion) T RST + A80.5 86.5 1.8 ~700F Blocker) T BST + A-- 81.2 --T B ST 58.0 69.6 3.9 L RST + A 82.4 87.2 6.7 L RST + A 80.0 86.4 2.5 L R F 54.0 67.2 3.8 L R F 53.6 68.8 2.5 T BST ~ A 80.0 84.0 2.5 Al-2Mg-2Ll T R F 50.4 65.2 8.1 (700~F Extrusion) T R ST + A 75.2 80.4 6.7 (700F Blocker) T BST ~ A 74.4 81.2 5.3 T B ST 51.6 65.0 8.1 L RST + A 76.4 81.2 3.2 L RST ~ A 73.2 79.2 5.3 L R F 50.0 64.8 10.9 L R F 49.6 64.0 6.7 T BST + A 74.8 79.2 3.9 *Tempers: F ~ As-Forged - 370C (700F) ST ~ Solutlon Treated - 495C (925F)/lhr/WQ
A = Aged - 125C (255F~/10hr/AC

This example illustrates the tensile properties of the dlspersion strengthened alloys of this invention in "Hook"-type forglng samples. All materials were prepared as extruded billets essentlally as shown in EXAMPLE 1 The "Hook" forging die set used in the test~ consists of a high deformation 1st blocker die, a 2nd blocker die which raises the ribs of the forging and a finish die which produces minimal deformation but achieves flnal tolerances in the part. For this test to avoid the time and expense of using the finish die, evaluation of the forgings was made after the 2nd blocker, l.e. at an intermediate forging step.
Figure 2 shows a plan drawing of the finished "Hook"-type forging. Tensile specimens were heat treated in sets of two, representing the longitudinal (L) and the short transverse (ST) orientations.

':

~L~Z~89~i TABLE VI shows propertles in two direc~ions for forgings in two conditlons: F (as-forged) and T4 (solution ~reated and naturally aged) for an alloy system containing 4Mg-1.5Li. The data show no significant difference in results between the F and T4 conditions.
The best properties exhibited in TABLE VI are for the alloy of tast 1, i.e. in the as-forged condition processed at 260C (500F) extrusion and first blocker temperatures. The data confirm that strength is primarily controlled by extrusion temperature and secondarily by blocker temperature.
TABLE VI
1st 2nd Ext. Blocker Blocker Temp. Temp. Temp. YS UTS El RA
(F) (F) (F) Orient. Temper (k3i) (ksi) % %
500 500 610 L F 67.0 76.2 13 25 500 500 610 ST F 62.4 71.7 11 15 500 500 610 L T4 66.4 76.0 14 23 500 500 610 ST T4 62.0 71.7 7 11 500 675 610 L F 65.6 74.0 14 26 500 675 610 ST F 58.8 71.1 10 20 500 675 610 L T4 64.2 74.2 13 23 500 675 610 ST T4 60.2 71.7 11 21 700 500 610 L F 59.6 72.8 12 18 700 500 610 ST F 59.0 71.8 9 12 700 500 610 L T4 59.4 72.6 13 20 700 500 610 ST T4 59.8 71.5 7 14 700 675 610 L F 59.8 70.0 14 23 700 675 610 ST F 54.4 68.3 11 18 700 675 610 L T4 56.4 70.2 14 22 700 675 610 ST T4 53.4 67.1 12 21 Similar tests carried out on alloys containing 4Mg-1.75Li and 2Mg-2Li in blocked forgings showed that the Li level affected both the strength and age hardening aspects of the alloy~ markedly.
A comparison with results on "cruciform" forgings shows that there is essentially the same trend in the alloy properties resultlng from the processing conditions.

- ' ' `~' ' .

. .: . . .

~ 2~896 This example illustrates the effect of normal forging practice on the tensile properties of a forged sample of an alloy of the type Al-4Mg-1.5Li. An extruded billet is prepared from a vacuum hot pressed compaction billet as described ln EXAMPLE 1. The compaction billet was extruded from 27.9 cm (ll in~ to 9.53 cm (3-3/4 in) diameter rod at temperatures of 650-700F through a shear-faced die at an extrusion ram speed of 0.1 in/sec. and a breakthrough pressure of 1100-1600 tons. The extrusion liner was lubricated but not the billets. A "Hook" forging was made At a temperature of 420C
(788F) in the first blocker and 488C (838F) in the second blocker.
Tensile tests on various locations on the specimen showed it to have in the as-forged condition the average properties: YS of 368 MPA
(52.7 ksi), UTS of 470 MPa (68.3 ksi), El of 14.5% and RA of 19.7%.
In the solution treated condition of l hour at 480C (900F)/glycol quench condition the average properties are: YS of 352 MPa (51.5 ksi), UTS of 466 MPa (67.6 ksi), El of 14% and the RA of 19.9%. The method of this example is not effective for achieving the maximum strength potential of the alloy.

EXA~PLE 7 This example lllustrates the effect of normal forging practice on the tensile properties of a cruciform forging. An extruded billet of an alloy of the 4Mg-l.SLi-type is prepared as described in EXAMPLE 6. The first blocker temperature of the cruciform forging is carried out at 370C (700F). A lubricant, a Withrow A Paste-mineral oil mixture, is used in the finish forging which is carried out at various temperatures. Finlsh forging temperatures and tenslle properties of the finish cruciform forgings in the longitudinal and transverse directions are shown in TABLE VII.
The method of this sxample is not effective for achieving ~aximum strength potential of the alloy.

: , ~ , ................................. .
~ , ' ~ 2~ S96 TABLE VII
Forging Temp. YS UTS El RA
Direc~ion(F) (ksi) (ksi) (~) (%) Longitudinal 600 52.668.212 15 600 51~1 65.212 20 650 52.4 67.811 16 650 51.7 67.411 18 700 52.3 66.712 17 700 52.0 65.911 19 750 51.8 66.411 16 750 51.6 66.613 16 800 51.3 66.413 17 800 50.9 66.211 16 15 Short 600 49.9 62.7 5 6 Transverse600 51.3 65.3 5 3 600 50.3 57.7 2 5 600 53.1 62.6 2 7 700 49.9 65.111 13 750 4g.9 63.9 6 10 800 49.8 65.811 11 This example illustrates dispersion strengthened low density alloys of this invention composed of aluminum, lithium, magnesium, siliconj carbon and oxygen, and containing about 1.1 to 1.2~ carbon and less than 1~ oxygen.
Mechanically alloyed powders are prepared having the nominal magneslum, lithium and silicon contents given in TABLE VIII.
The powders are vacuum hot pressed to compaction billets and extruded essentially as described in EXAMPLE l, except that all extruded blllets are prepared at 260C (500F) and at ram speeds of 25.4 cm (10 in)/min. Extruded billets are forged at 260C (500F) to form "Hook"-type forgings essentially as described in EXAMPLE 5. An age hardening treatment i8 applied to the forged product consisting of a 35 solution treatment at a temperature of about 520C (970F), water quenching, and aging at about 145 to 175C (300 to 340F) for up to 18 hours.

. .
~, . .
.

. .
' ' 848~6 The alloys of this invention in the forged, age hardened condltion have high strength, with advantageous preservation of corrosion resistant properties in the alloy. It is believed that the increased strength i9 due to the precipitation of a silicide such as Mg2Si and/or lithium silicide.

TABLE VIII
Alloy Type Mg Li Si G 4 1.5.5 H 4 1.51.0 I 2 1.5.5 J 2 1.51.0 K 2 2 .5 L 2 2 1.0 Although the present invention has been described in conjunction with preferred embodiments, it is to be understood that modifications and variations may be resorted to without departing from the spirit and scope of the invention, as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of tne invention and appended claLms.

Claims (24)

1. A method for obtaining a forged produce composed of a dispersion strengthened, low density aluminum-base alloy comprised of aluminum, lithium and magnesium, said alloy being derived from a powder of said alloy prepared by a mechanical alloying process, said method being comprised of a sequence of steps comprising: degassing and compacting said powder under vacuum to obtain a compaction billet having a density sufficiently high to obtain an extruded billet of substantially full density; extruding the resultant compaction billet at a temperature in the range of above the incipient extrusion temperature up to about 400°C (750°F) said extrusion being carriedout with lubrication through a conical die to provide an extruded billet of substantially full density; and forging the resultant extruded billet, said resultant billet being subjected to at least a first forging treatment at a temperature in the range of about 230°C
(450°F) up to about 400°C (750°F), with the proviso that for maximizing strength the forging is carried out at the lower end of the forging temperature range when the extrusion is carried out at the higher end of the extrusion temperature range.

2. A method according to claim 1, wherein the degassing and compacting steps are carried out by vacuum hot pressing the powder.

3. A method according to claim 1, wherein degassing and compacting are carried out at a temperature of 480°C (900°F) to 545°C
(1015°F).

4. A method according to claim 1, wherein extrusion is carried out at a temperature of about 260°C (500°F) and said forging is carried out at a temperature in the range of about 260°C (500°F) up to about 370°C (700°F).

5. A method according to claim 1, wherein extrusion is carried out at a temperature of about 370°C (700°F) and said forging step is carried out at a temperature of about 260°C (500°F).

6. A method according to claim 1, wherein the extrusion is carried out at a temperature of at least 230°C (450°F).

7. A method according to claim 1, wherein said forged alloy is subjected to an aging treatment.

8. A method according to claim 1, wherein extrusion of the compaction billet is carried at an extrusion ratio of at least 3:1.

9. A method according to claim 1, wherein said dispersion strengthened alloy is comprised, by weight, of about 0.5 to about 4%
lithium, about 0.5 up to about 7% magnesium, 0 up to about 4%
silicon, a small but effective amount for increased strength up to about 5% carbon, a small but effective amount for increased stability and strength up to about 1% oxygen, and the balance essentially aluminum, said alloy having a dispersoid content of a small but effective amount for increased strength and stability up to about 10%
by volume.

10. A method according to claim 1, wherein said dispersion strengthened alloy is comprised, by weight, of about 1.5 to about 2.5% lithium, about 2 to about 4% magnesium and about 0.5 to about 2%
carbon and less than about 1% oxygen, and the dispersoid content is about 3 to 6% by volume and said alloy in the forged condition has a yield strength of at least about 410 MPa (60 ksi) and elongation of at least 3%.

11. A method according to claim 9, wherein the dispersion strengthened alloy contains silicon.

12. A forged produce produced by the method of claim 1.

13. A forged produce produced by the method of claims 9 or 10.

14. A dispersion strengthened alloy consisting essentially of, by weight, about 0.5 to about 4% lithium, about 0.5 to about 7%
magnesium, 0 up to about 4% silicon, a small but effective amount for increased strength up to about 5% carbon, a small but effective amount for increased stability and strength up to about 1% oxygen, and the balance essentially aluminum, and having a dispersoid content of a small but effective amount for increased stability and strength up to about 10% by volume, said alloy being in the forged condition and produced by the method of claim 1.

15. An extruded and forged dispersion strengthened, mechanically alloyed aluminum-base alloy consisting essentially of about 1.5 up to about 2.5% Li, about 2% up to about 4% Mg, about 0.5 to about 1.2% C and a small but effective amount up to about 1% 0, said alloy having YS of at least 410 MPa (60 ksi) and an elongation of at least 3%.

16. An extruded and forged dispersion strengthened, mechanically alloyed aluminum-base alloy of claim 15, wherein the lithium content is about 2.5% and the carbon content is at least 1%.

17. An extruded and forged dispersion strengthened, mechanically alloyed aluminum-base alloy of claim 15, wherein the lithium content is about 2.5% and the carbon content is less than 1%.

18. An extruded and forged dispersion strengthened, mechanically alloyed aluminum-base alloy of claim 15, wherein the lithium content is about 1.5%, the magnesium content about 4%.

19. An extruded and forged dispersion strengthened, mechanically alloyed aluminum-base alloy of claim 15, wherein the lithium content is about 1.75%, the magnesium content is about 4%.

20. An extruded and forged dispersion strengthened, mechanically alloyed aluminum-base alloy of claim 15, wherein the lithium content is about 2%, the magnesium content about 2%.

21. An extruded and forged dispersion strengthened, mechanically alloyed aluminum-base alloy consisting essentially of about 0.5 to about 4% lithium, about 0.5 to about 7% magnesium, 0 up to about 4% silicon, a small but effective amount for increased strength up to about 5% carbon, a small but effective amount for increased stability and strength up to about 1% oxygen, and the balance essentially aluminum, and having a dispersoid content of a small but effective amount for increased stability and strength up to about 10% by volume.

22. An extruded and forged dispersion strengthened, mechanically alloyed aluminum-base alloy of claim 21, wherein the silicon content is about 0.2 up to about 2%.

23. An extruded and forged dispersion strengthened, mechanically alloyed aluminum-base alloy of claim 21 wherein the silicon content is about 0.5 up to about 1.5%.

24. An extruded and forged dispersion strengthened, mechanically alloyed aluminum-base alloy of claim 21, wherein the carbon content is up to about 2%.