CN111315910A - Method and system for shaping aluminum alloy blanks - Google Patents

Method and system for shaping aluminum alloy blanks Download PDF

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Publication number
CN111315910A
CN111315910A CN201880061712.0A CN201880061712A CN111315910A CN 111315910 A CN111315910 A CN 111315910A CN 201880061712 A CN201880061712 A CN 201880061712A CN 111315910 A CN111315910 A CN 111315910A
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Prior art keywords
blank
alloy
temperature
forming
sht
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克里斯蒂安·科罗舒尔茨
杰拉尔德·安亚索德
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Automation Press and Tooling AP&T AB
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Automation Press and Tooling AP&T AB
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/20—Deep-drawing
    • B21D22/26—Deep-drawing for making peculiarly, e.g. irregularly, shaped articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D37/00—Tools as parts of machines covered by this subclass
    • B21D37/16—Heating or cooling

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
  • Forging (AREA)
  • Heat Treatment Of Articles (AREA)

Abstract

The invention relates to a method for forming a 6xxx or 7xxx series Al alloy blank. The method comprises the following steps: heating the blank at a heating station to a Solution (SHT) temperature T of an alloy of the blankSHTAnd maintaining the blank at said SHT temperature until SHT is complete, cooling the blank at a cooling station and at a cooling rate sufficiently high that recrystallization in the alloy of the blank does not occur to an intermediate temperature T at which kinetic movement of the alloy in the blank ceasesITMShaping the blank in a shaping tool, quenching the shaped blank to room temperature TEAnd artificially aging the formed and quenched blank in an aging station. The invention further relates to a 6xxx or 7xxx series Al alloy blank forming system (1, 3).

Description

Method and system for shaping aluminum alloy blanks
Technical Field
The present disclosure relates to a method of heat treating a blank sheet of aluminum alloy, and in particular to a method suitable for blank sheets of any aluminum alloy grade, composition or condition.
Background
In the automotive industry in particular, hot forming of blank sheets is important, in particular of high strength aluminium alloys. There are various known methods for shaping aluminum alloy blanks. For example a hot forming die quenching process as proposed in WO 2010/032002 and WO 2015/136299.
However, such known methods have several drawbacks. For example, these methods are not applicable to all aluminum alloy grades. The method in WO 2010/032002 may be applicable to AA6082 material but not to any AA7xxx material. Further, the aluminum alloy grade material composition and condition may vary from material supplier to material supplier. The formed parts obtained using the known method are very sensitive to different compositions and conditions.
Further, the known processes have problems in being suitable for mass production due to the lack of stability, repeatability and precision of the formed parts.
Therefore, there is a need for a production method for shaping aluminum alloy blank sheets that alleviates the above-mentioned drawbacks of the known art.
Disclosure of Invention
The object of the present invention is to provide an improved solution which alleviates the above-mentioned drawbacks of the prior art devices. Furthermore, it is an object to provide a method that allows for improved accuracy of the formed part and that is applicable to any aluminum alloy grade, composition and condition.
The invention is defined by the appended independent claims, as well as the embodiments set forth in the appended dependent claims, in the following description and in the drawings.
According to a first aspect of the invention, there is provided a method of forming a 6xxx or 7 xxx-series Al alloy blank into a component. The method comprises the following steps: heating the blank at a heating station to a Solution (SHT) temperature T of an alloy of the blankSHTAnd combining the blankMaintaining at said SHT temperature until SHT is complete, cooling the blank at a cooling station and at a cooling rate sufficiently high that recrystallization in the alloy of the blank does not occur to an intermediate temperature T at which kinetic movement of the alloy in the blank ceasesITMShaping the blank in a shaping tool, quenching the shaped blank to room temperature TEAnd artificially aging the formed and quenched blank in an aging station.
By using the method according to the invention, a method is provided with a high accuracy of formed parts and a low amount of springback suitable for any 6xxx or 7 xxx-series aluminium alloy grade sheet blank.
The time for which the blank is held at or above the Solution Heat Treatment (SHT) temperature may be selected to be sufficient to ensure the highest concentration of hardening elements such as copper, zinc, magnesium, manganese, silicon, etc. in solid solution. The concentration and dissolution rate of these elements in solid solution may increase with increasing temperature.
By cooling the blank at a particular cooling rate, the SHT composition of the solid solution can be maintained at an intermediate temperature. If the blank is to be cooled at too slow a rate, the alloying elements may diffuse through the solid solution and concentrate at grain boundaries, large voids, undissolved particles, or other undesirable locations. To achieve improved strength characteristics of the formed part, it may be desirable to avoid such recrystallization and reduce the diffusion process and keep the alloying elements in solid solution by providing rapid cooling. The cooling rate to achieve this may be selected depending on the aluminium alloy grade and the composition of the blank. Further, the quenching rate may be selected according to the aluminum alloy grade and the composition of the blank.
The intermediate temperature may be a temperature in an intermediate temperature range above room temperature and below the SHT temperature. In the intermediate temperature range, the time required for a given amount of precipitation may increase due to the low solute diffusion coefficient. Although the thermodynamic potential of most aluminum alloy grades of precipitation is mostly high at intermediate temperatures due to high solute supersaturation, the rate of precipitate formation is low due to the inability of atoms to diffuse, increase nucleation or precipitation, and grow in this temperature range.
As an example, the intermediate temperature of the 7xxx series Al alloy blanks may be selected between 400 ℃ and 420 ℃. Further, for AA6082 Al alloy blanks, the intermediate temperature may be selected to be 300 ℃ to 350 ℃. At such temperatures, the dynamic motion in the alloy material of the blank may have stopped.
The cooling to the intermediate temperature may be performed at a cooling station separate from the forming tool. Thereby, a fast and uniform temperature cooling in the blank may be provided.
By way of example, for a 6xxx series Al alloy (such as AA6082), a cooling rate of at least 30K/s may be selected. Further, for 7xxx series Al alloys, a cooling rate of at least 30K/s, at least 50K/s, or preferably about 100K/s may be selected.
In one embodiment, the intermediate temperature may be selected according to the Al alloy of the blank and is above 100 ℃. The intermediate temperature should be selected to be the temperature at which the kinetic movement of the alloy material of the blank stops. The optimum intermediate temperature may be different depending on whether a 6xxx or 7xxx series Al alloy is used in the blank. However, the intermediate temperature may be higher than 100 ℃. Further, the intermediate temperature may be selected as the highest possible temperature at which kinetic motion stops in the alloy material of the present invention.
In one embodiment, the forming tool may be preheated to an intermediate temperature. Thereby, the blank may be formed at an intermediate temperature. Thereby, the temperature of the blank may be controlled during forming, which may improve the accuracy of the properties of the final formed part.
In one embodiment, the blank may be maintained at an intermediate temperature during the forming step in the forming tool. The temperature of the tool may be controlled so as to maintain the temperature of both the tool and the blank stable at an intermediate temperature during forming. After forming, the temperature of the forming tool may be controlled to quench the formed blank to room temperature. The forming tool may be provided with a temperature control function to control the temperature of the forming tool to an intermediate temperature throughout the forming step.
In one embodiment, the forming and quenching may be performed in separate forming tools. The first forming tool may form the blank at an intermediate temperature, and the second forming tool may quench the blank to room temperature. In further embodiments, the first forming tool may be preheated to an intermediate temperature, thereby maintaining the blank at the intermediate temperature during forming. The blank may then be transferred to a second forming tool and quenched to room temperature. The second forming tool may be a cold forming tool. Alternatively, the first forming tool may not be preheated, thereby cooling the blank during forming. The blank may then be quenched in a second forming tool to room temperature in a controlled manner in the second forming tool.
According to a second aspect of the invention, there is provided a 6xxx or 7xxx series Al alloy blank forming system. The system includes a heating device configured to heat the blank to its SHT temperature TSHTIs configured to cool the blank to an intermediate temperature T at which the kinetic movement of the alloy in the blank has ceasedITMAnd a cooling station at a cooling rate sufficiently high such that recrystallization in the alloy of the blank does not occur, a forming tool configured to form and quench the blank, and an aging station configured to provide an artificial aging process for the formed and quenched blank.
A heating station configured to heat the blank to its SHT temperature may mean a heating station comprising means capable of heating the blank inserted into the heating station to its SHT temperature. A cooling station configured to cool the blank to an intermediate temperature at which kinetic movement of the alloy in the blank has stopped and at a cooling rate sufficiently high such that recrystallization in the alloy of the blank does not occur may mean a cooling station comprising means capable of cooling the blank in a particular manner. A forming tool configured to form and quench a blank may mean a forming tool that includes a device capable of forming and quenching the blank. An ageing station configured to provide an artificial ageing process for the formed and quenched blank may mean an ageing station comprising means capable of performing such an artificial ageing process.
Further embodiments of the system according to the invention may be provided similarly as discussed above for the method. The heating station, cooling station, forming tool, and/or aging station may further comprise devices capable of providing additional functionality as discussed above with respect to the method.
Drawings
The invention will be described in more detail hereinafter with reference to the accompanying drawings, in which:
FIG. 1 shows a flow diagram of a method according to an embodiment of the invention;
FIG. 2 shows a block diagram of a system according to an embodiment of the invention;
FIG. 3 shows a diagrammatic view of a process of a method according to an embodiment of the invention;
FIG. 4 shows a flow diagram of a method according to an embodiment of the invention;
FIG. 5 shows a block diagram of a system according to an embodiment of the invention; and
fig. 6 shows a diagrammatic view of a process of a method according to an embodiment of the invention.
Detailed Description
The present invention will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, like numbering represents like elements.
As shown in fig. 1, a method 100 according to an embodiment of the invention includes a first step of heating 102 a 6xxx or 7xxx series Al alloy blank 2 to a Solution (SHT) temperature of the particular alloy of the blank 2. As further seen in fig. 2, a blank-forming system 1 is provided in which heating 102 is carried out in a heating station 10. In the heating station 10, when the blank 2 has reached its SHT temperature or higher, the temperature of the blank 2 is maintained at the SHT temperature or higher until solutionizing of the alloy of the blank 2 is completed.
In the next step, the blank 2 is cooled 104 to an intermediate temperature. In the blank-forming system 1, cooling 104 is performed at the cooling station 20. The intermediate temperature of the alloy of the blank 2 is chosen at which the kinetic movement of the alloy ceases. Cooling 104 is performed at a cooling rate that is high enough that recrystallization in the alloy of blank 2 does not occur.
In the next step, the blank 2 is shaped 106 in the blank-forming system 1 in the shaping tool 32 at the pressing station 30. The pressing station 30 may be a press suitable for forming aluminum alloy blank sheets, such as a hydraulic press, a servo press (servo hydraulic or servo mechanical).
After shaping 106 the blank 2, the shaped blank 2 'or shaped part 2' is quenched 108 to room temperature in the shaping tool 32.
Finally, the formed blank 2' is artificially aged 110 at an aging station 40. An ageing process is provided to control and limit the recrystallization in the alloy material of the blank 2.
Fig. 3 illustrates a method 100 of blank forming according to an embodiment of the present invention. Blank 2 is brought from room temperature TEHeating to SHT temperature TSHTAnd is maintained at TSHTDown for the required time t as discussed above1-t2. At t2Next, the blank 2 is rapidly cooled to the intermediate temperature T at the desired cooling rate as discussed aboveITM. The blank 2 is then brought at t in the forming tool 322-t3During which the shaping takes place. At t3Next, the shaped blank 2' is quenched to room temperature TE。
At the ageing station 40, by heating to an ageing temperature TAThe formed part 2' is subjected to an artificial ageing process. The component 2' is put in time t5-t6During which it is maintained at the ageing temperature TAAnd then until the aging process is completed. Time t3-t4Transfer of the formed blank to the aging station 40 is provided.
The blank 2 is transferred between the different stations 10, 20, 30, 40. The transfer may be performed such that minimal heat loss in the blank 2 is achieved.
Fig. 4 and 5 illustrate a method 200 and system 3 according to an embodiment of the invention. The steps of heating 202 and cooling 204 correspond to steps 102 and 104 discussed above. Next, the blank 2 is formed 206 in the blank-forming system 3 in the preheated first forming tool 32a at the pressing station 30. The first forming tool 32a is preheated to an intermediate temperature. So that the blank 2 is not further cooled when arranged in the first forming tool 32 a. An intermediate temperature may be maintained in the first forming tool 32a and the blank 2 throughout the forming process 106.
Next, the shaped blank is moved to a separate cold second forming tool 32 b. In the cold second forming tool 32b, the blank is quenched to room temperature. The cold second forming tool 32b may further form and quench the blank into its final formed part.
Fig. 5 further illustrates an optional aging arrangement that may be used in any of the embodiments presented above. In such an ageing embodiment, a first pre-ageing step is carried out at a pre-ageing station 40a, in which the formed part 2' is heated to an ageing temperature TAIs maintained at TAUntil the pre-ageing is complete and then cooling to room temperature TE. After transfer to the second ageing station 40b, the part 2' is reheated to TAIs maintained at TAFor a certain period of time and then cooled to room temperature TETo provide a baking finish of the part 2'. Alternatively, the component can be heated during the paint baking process to a temperature T corresponding to the temperature T during the pre-ageing processADifferent temperatures. Thereby providing a two-step aging process including pre-aging and paint baking.
Preferably, the pre-ageing process is integrated in the forming/stamping line and is carried out in direct connection with the forming of the component 2'. The baking finish process may be carried out at a later stage, which is any stage that may be suitable for use in a production line.
The use of a pre-ageing process prevents natural ageing after stamping in the second forming tool. Otherwise, natural aging may occur after about 30 minutes for 7xxx series Al alloy materials or after about one hour for 6xxx series Al alloy materials. The paint bake process does not affect the peak hardness of the formed part. The pre-aging process further enables post-processing activities such as transportation to another location, storage for a desired period of time, etc. to be performed prior to the assembly or joining operation. The paint-bake operation can then be performed at the most appropriate time to provide the best peak hardness in a short cycle time and at low cost. This may be, for example, after connecting the shaped part 2' to the desired assembly.
Fig. 6 illustrates a process of a blank forming method 200 according to an embodiment of the present invention. Blank 2 is brought from room temperature TEHeating to SHT temperature TSHTAnd is maintained at TSHTDown for the required time t as discussed above1-t2. At t2And t3In between, the blank 2 is cooled to the intermediate temperature T at the required cooling rate as discussed aboveITM. And then at t in the preheated first forming tool 32a3-t4During which the blank 2 is shaped. At t4And t5In the process, the formed blank 2' is quenched in the second forming tool 32b to room temperature TE。
Fig. 6 further illustrates a process of an embodiment including pre-aging and paint-baking steps as discussed above. At the pre-ageing station 40a, the ageing temperature T is reached by heatingAAnd during a time period t7-t8During which it is maintained at the ageing temperature TAThe shaped blank 2' is then subjected to an artificial ageing process. After cooling to room temperature, the blank 2' is reheated in a second ageing station 40b to an ageing temperature TAAnd at t11-t12Is kept at TAAnd then until the aging process is completed. The blank 2' shaped into the final shaped part is then cooled again to room temperature TE。
In the drawings and specification, there have been disclosed preferred embodiments and examples of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the following claims.

Claims (10)

1. A method (100) of shaping a 6xxx or 7 xxx-series Al-alloy blank (2), wherein the method comprises the steps of:
heating (102) the blank at a heating station (10) to a Solution (SHT) temperature (T) of the alloy of the blankSHT) And maintaining the blank at said SHT temperature until SHT is complete,
cooling (104) the blank at a cooling station (20) and at a cooling rate sufficiently high that recrystallization in the alloy of the blank does not occur to an intermediate temperature (T) at which kinetic motion of the alloy in the blank ceasesITM)，
Shaping (106) the blank in a shaping tool (32),
quenching (108) the shaped blank (2') to room temperature (T)E)，
The formed and quenched blank is artificially aged (110) in an aging station (40).
2. Method according to claim 1, wherein the intermediate temperature (T)ITM) Is selected according to the alloy of the blank (2) and when the kinetic movement of the material of the alloy is stopped, wherein the intermediate temperature is higher than 100 ℃.
3. Method according to any one of the preceding claims, wherein the forming tool (32) is preheated to the intermediate temperature (T;)ITM)。
4. Method according to any one of the preceding claims, wherein the blank (2) is kept at the intermediate temperature (T) in the forming tool (32) during the forming (106)ITM) The following steps.
5. Method according to any of the preceding claims, wherein the forming is performed in a first forming tool (32a) and the quenching is performed in a second forming tool (32 b).
6. A6 xxx or 7xxx series Al alloy blank forming system (1, 3), which comprises,
a heating station (10),is configured to heat the blank (2) to its SHT temperature (T)SHT)，
A cooling station (20) configured to cool the blank to an intermediate temperature (T) at which the dynamic motion of the alloy in the blank has ceasedITM) And at a cooling rate high enough that no recrystallization in the alloy of the blank occurs,
at least one forming tool (32) configured to form and quench the blank, an
An aging station (40) configured to provide an artificial aging process to the formed and quenched blank (2').
7. System according to claim 6, wherein the cooling station (20) is configured to cool the blank (2) to the intermediate temperature (T ™)ITM) The intermediate temperature is selected according to the alloy of the blank (2) and when the dynamic movement of the material of the alloy is stopped, and wherein the intermediate temperature is higher than 100 ℃.
8. The system according to claim 6 or 7, wherein the forming tool is configured to be preheated to the intermediate temperature prior to forming the blank.
9. System according to any one of claims 5-8, wherein the forming tool is configured to keep the blank (2) at the intermediate temperature (T) in the forming tool (32) during the forming (106)ITM) The following steps.
10. System according to any of claims 5-9, wherein the system comprises a first forming tool (32a) configured to form the blank (2), and a second forming tool (32b) configured to quench the blank.
CN201880061712.0A 2017-10-04 2018-10-03 Method and system for shaping aluminum alloy blanks Pending CN111315910A (en)

Applications Claiming Priority (3)

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EP17194723.7 2017-10-04
EP17194723.7A EP3467138B1 (en) 2017-10-04 2017-10-04 Method for forming aluminum alloy blank
PCT/EP2018/076913 WO2019068767A1 (en) 2017-10-04 2018-10-03 Method and system for forming aluminum alloy blank

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EP (1) EP3467138B1 (en)
JP (1) JP2020536166A (en)
KR (1) KR20200110737A (en)
CN (1) CN111315910A (en)
CA (1) CA3084330A1 (en)
ES (1) ES2906633T3 (en)
MX (1) MX2020003344A (en)
PL (1) PL3467138T3 (en)
PT (1) PT3467138T (en)
WO (1) WO2019068767A1 (en)

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EP3896188A1 (en) 2020-04-15 2021-10-20 Politechnika Wroclawska A method of manufacturing of energy-absorbing elements made of age-hardenable aluminum alloy sheets that facilitate further joining
WO2024091271A1 (en) * 2022-10-28 2024-05-02 Atieva, Inc. Hot-stamping aluminum formation process

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US20200299818A1 (en) 2020-09-24
PT3467138T (en) 2022-02-21
CA3084330A1 (en) 2019-04-11
EP3467138B1 (en) 2021-11-24
EP3467138A1 (en) 2019-04-10
JP2020536166A (en) 2020-12-10
PL3467138T3 (en) 2022-04-04
ES2906633T3 (en) 2022-04-19
KR20200110737A (en) 2020-09-25
MX2020003344A (en) 2020-07-28

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Application publication date: 20200619