CN117178066A

CN117178066A - Method for machining chips comprising aluminum lithium alloy

Info

Publication number: CN117178066A
Application number: CN202280010406.0A
Authority: CN
Inventors: B·L·米德兰; G·E·科鲁兹恩斯基; A·L·索恩博勒; E·M·威廉斯
Original assignee: Aokoninke Technology Co ltd
Current assignee: Aokoninke Technology Co ltd
Priority date: 2021-01-19
Filing date: 2022-01-18
Publication date: 2023-12-05
Also published as: US20240117468A1; CA3202425A1; WO2022159374A1; KR20230133967A; EP4281593A1; JP2024504318A

Abstract

The present invention provides a method for machining chips comprising aluminum lithium alloy. The method includes cleaning machining chips comprising an aluminum-lithium alloy to remove at least a portion of a processing fluid from the machining chips and provide cleaned machining chips. The method further includes compressing the volume of cleaned chip to provide a compact having a density of at least 70% of a full theoretical density of the aluminum-lithium alloy.

Description

Method for machining chips comprising aluminum lithium alloy

Technical Field

The present disclosure relates to a method for machining chips comprising aluminum lithium alloy.

Background

Machining an aluminum ingot to produce a part may produce machining chips as a byproduct. Disposal of the machined chips can be expensive. Recycling or otherwise reusing machining chips presents challenges.

Disclosure of Invention

One non-limiting aspect according to the present disclosure is directed to a method for machining aluminum lithium alloy chips. The method includes obtaining machining chips generated during machining of an aluminum-lithium alloy using a machining fluid. The method includes cleaning a volume of machining chips to remove at least a portion of a processing fluid from the machining chips and thereby provide cleaned machining chips. The volume of cleaned machined chip is compressed to provide a compact having a density of at least 70%, at least 80%, at least 90%, or at least 95% of the full theoretical density of the aluminum-lithium alloy. In certain non-limiting embodiments of the method, cleaning the volume of machined chips comprises at least one of: the method includes contacting the machining chip with an aqueous solution to dissolve a machining fluid on the machining chip into the aqueous solution, and heating the machining chip in an inert atmosphere to pyrolyze the machining fluid on the machining chip. In certain non-limiting embodiments of the method, cleaning the volume of machined chips comprises at least one of: the machining chip is contacted with an aqueous solution to dissolve a machining fluid on the machining chip into the aqueous solution. In various non-limiting embodiments of the method, compressing the volume of cleaned machining chips comprises machining the volume of chips by at least one of: continuous rotary extrusion, conformal extrusion (conform extrusion), equal channel angular processing, equal channel angular extrusion, high pressure torsion, and shear assisted processing and extrusion. In certain non-limiting embodiments of the method, the aluminum-lithium alloy includes 0.1% to 5% by weight lithium, aluminum, and impurities.

Another non-limiting aspect according to the present disclosure is directed to a method for machining aluminum lithium alloy chips. The method includes obtaining machining chips generated during machining of an aluminum lithium alloy. The volume of the machined chip is compressed to provide a compact having a density of at least 70%, at least 80%, at least 90%, or at least 95% of the full theoretical density of the aluminum-lithium alloy. In various non-limiting embodiments of the method, compressing the volume of cleaned machining chips comprises machining the volume of chips by at least one of: continuous rotary extrusion, conformal extrusion, equal channel angular processing, equal channel angular extrusion, high pressure torsion, and shear assisted processing and extrusion. In certain non-limiting embodiments of the method, the aluminum-lithium alloy includes 0.1% to 5% by weight lithium, aluminum, and impurities.

Another non-limiting aspect according to the present disclosure is directed to a cohesive compact comprising aluminum-lithium alloy machining chips and having a density of at least 70%, at least 80%, at least 90%, or at least 95% of the full theoretical density of the aluminum-lithium alloy. In certain non-limiting embodiments, cohesive compacts are manufactured by methods according to the present disclosure. In certain non-limiting embodiments, an aluminum-lithium alloy including aluminum-lithium alloy machining chips comprises 0.1% to 5% by weight lithium, aluminum, and impurities.

Another non-limiting aspect according to the present disclosure is directed to a method for manufacturing an aluminum lithium alloy. The method includes introducing a cohesive compact comprising aluminum lithium alloy machining chips and having a density of at least 70%, at least 80%, at least 90%, or at least 95% of a full theoretical density of the aluminum lithium alloy into a molten bath of the aluminum lithium alloy to form the molten alloy. In certain non-limiting embodiments, cohesive compacts are manufactured by methods according to the present disclosure. Various non-limiting embodiments of the method further include solidifying at least a portion of the molten alloy to form an aluminum lithium ingot or other solid form from the molten alloy.

It should be understood that the invention disclosed and described in this specification is not limited to the aspects outlined in the summary of the invention. The reader will appreciate the foregoing details, as well as others, upon considering the following detailed description of various non-limiting and non-exhaustive aspects in accordance with the present specification.

Drawings

The features and advantages of examples, and the manner in which they are accomplished, will become more readily apparent and the examples will be better understood by reference to the following description taken in conjunction with the accompanying drawings in which:

the figure is a block diagram of a non-limiting embodiment of a method for recovering chips generated during machining of an aluminum-lithium alloy according to the present disclosure.

The exemplifications set out herein illustrate certain non-limiting embodiments in one form, and such exemplifications are not to be construed as limiting the scope of the claims appended hereto in any manner.

Detailed Description

The aluminum lithium alloy may have desirable properties, such as high strength to weight ratio. In particular, aluminum lithium alloys may have lower densities than conventional aluminum alloys, and are therefore desirable for reducing the weight of aerospace components. Components made from aluminum lithium alloys may be significantly more expensive than components made from alloys that do not contain lithium. Lithium is an expensive alloy additive due to its inherent cost, and aerospace and automotive parts produced from aluminum lithium alloys may require extensive machining, which produces a large amount of machining chips. Machining chips generated during machining of aluminum-lithium alloys may not be suitable for remelting because of the large surface area of the volume of the chips and the high melting losses caused during remelting. In addition, machining chips may require special machining due to the presence of lithium and may require separate machining from, for example, other aluminum alloys. The present disclosure provides a method for machining chips including aluminum lithium alloys that may improve the recyclability of the machining chips, thereby reducing material loss from the machining operation and recovering a machining stream having high material value.

The figures contain a block diagram of a non-limiting embodiment of a method for recovering chips generated during machining of an aluminum-lithium alloy according to the present disclosure. As shown, at 102, a volume of machined chips comprising an aluminum lithium alloy may be generated, for example, as a result of machining an aluminum lithium alloy ingot or other solid form to create a component, such as an aerospace component or an automotive component. In certain non-limiting embodiments of the method, the processing fluid may be used during machining. The bulk machined chip volume may include a density of no more than 50% of the full theoretical density of the aluminum lithium alloy. In certain non-limiting embodiments, the bulk machined chip volume may include a density of no greater than 45%, no greater than 40%, or no greater than 35% of the full theoretical density of the aluminum-lithium alloy.

As used herein, an "aluminum-lithium alloy" is an alloy that includes 0.1% to 5% by weight of lithium, aluminum, and impurities. In various forms, the aluminum lithium alloy may include 0.2% to 2% lithium by weight with the balance aluminum and impurities. In various non-limiting embodiments, the aluminum lithium alloy can include at least 0.5% lithium by weight, such as at least 1% to 5% lithium, at least 1.5% to 5% lithium, at least 2% to 5% lithium, or at least 2.5% to 5% lithium, all by weight. As is known in the art, certain aluminum lithium alloys may include additional intentional alloying additions such as copper, manganese, magnesium, zinc, titanium, zirconium, silicon, iron, chromium, and silver. Commercially available aluminum lithium alloys currently contain 2099, 2199, 2050, 2055, 2060, 2090, 8090, 2195, 2397, and 2070.

As used herein, "full theoretical density" refers to the density of an alloy that corresponds to the limit achievable in a non-porous fully dense product as calculated according to the aluminum and aluminum alloy density calculation program on pages 2-13 of the "aluminum standards and data 2017" published by the aluminum association company.

Aluminum and aluminum alloy machining may utilize a machining fluid to lubricate (e.g., lubricant) and/or cool and/or facilitate removal of machining chips generated by the machining operation. Referring again to the figures, the illustrated method further includes cleaning the machining chip to remove at least a portion of the machining fluid from a surface of the machining chip, thereby providing a cleaned machining chip, 104. The processing fluid may comprise, for example, a conventional cutting fluid or another substance for facilitating machining of ingots or other solid forms comprising aluminum lithium alloy. The machining fluid may inhibit compression of the machining chips into compacts and may also be an undesirable contaminant if the machining fluid is incorporated into an alloy produced from a starting material containing the machining chips.

Cleaning the machining chip to remove at least a portion of the machining fluid from the surface of the machining chip may include, for example, one or both of: the method includes contacting the machining chip with an aqueous solution to dissolve a machining fluid on a surface of the machining chip, and heating the machining chip in an inert atmosphere to pyrolyze the machining fluid on the machining chip (e.g., a pyrolysis process). Contacting the machining chip with an aqueous solution to dissolve the machining fluid on the surface of the machining chip may cause at least a portion of the machining fluid to dissolve in the aqueous solution. In various non-limiting embodiments, the aqueous solution may have a pH of 1 to 14, for example, a pH of 1 to 5, 6 to 7, 7 to 8, 6 to 8, or 8 to 14. In certain non-limiting embodiments, the aqueous solution may include water and one or more cleaning or solvating agents, such as detergent compounds, solvents, and/or surfactants. In certain non-limiting embodiments, cleaning the machining chips reduces the carbon content on the surface of the machining chips.

In various non-limiting embodiments, aluminum machining does not use a machining fluid, and machining chips may not include a machining fluid. Thus, cleaning the machined chip, step 104, may be optional.

Optionally, prior to compaction, the machining chips are granulated (i.e., reduced in size by machining) to reduce the average size of the chips and/or to provide a substantially uniform size distribution of the machining chips, 106. For example, the size of the machining chips may be reduced by grinding the chips using a grinding device prior to compaction. In certain non-limiting embodiments of the method of cleaning a machining chip to remove at least a portion of a processing fluid from a surface of the machining chip, the machining chip is granulated prior to cleaning the machining chip at 104. In other non-limiting embodiments, the machining chips are granulated after being cleaned at 104. Providing the machined chip with a substantially uniform size distribution may facilitate compression of the machined chip into a compact. As used herein, "substantially uniform size distribution" means that at least 90% of the smallest machined chip has a longest dimension that is at least 50% of the longest dimension of the largest machined chip. In certain embodiments, for example, the granulated machining chips may have a size distribution in which at least 90% of the machining chips have longest dimensions that are no more than 5mm from each other, such as no more than 2mm from each other or no more than 1mm from each other.

In various non-limiting embodiments, the machined chip is granulated to include a minimum size dimension of no greater than 10mm, such as no greater than 8mm, no greater than 6mm, or no greater than 4 mm. In certain non-limiting embodiments, the machining chip is granulated to include a minimum size dimension of at least 0.1mm, at least 1mm, at least 2mm, or at least 3 mm. For example, in certain non-limiting embodiments, the machined chip may be granulated to include a minimum size dimension of 0.1mm to 10mm, such as 1mm to 10mm, 1mm to 8mm, or 3mm to 4 mm.

As further shown, non-limiting embodiments of the method according to the present disclosure further include compressing the volume of cleaned machined chip (optionally, which has been cleaned and/or granulated) to provide a cohesive compact having a density of at least 70% of the full theoretical density of the aluminum-lithium alloy including the chip, 108. As used herein, "cohesive" means that objects remain together when not handled and do not readily scatter when handled. The density of the compacted part produced by compacting a mass of machining chips will be greater than the density of the mass of machining chips prior to compaction. Compressing the machined chips to form a compacted part may involve any suitable forming technique whereby a compressive force is applied to a mass of machined chips to form a cohesive compacted part having a density greater than the density of the mass of machined chips prior to compaction. Such shaping techniques may include one or more of the following: continuous rotary extrusion, conformal extrusion, equal channel angular processing, equal channel angular extrusion, high pressure torsion, and shear assisted processing and extrusion. One of ordinary skill will recognize or be able to ascertain additional forming techniques by which cohesive compacts of increased density may be formed by applying compressive forces to a large amount of machined chips.

In various non-limiting embodiments, compressing the volume of machined chips includes continuous rotary extrusion. In certain non-limiting embodiments, the density of the compacted member is at least 80% of the full theoretical density of the aluminum-lithium alloy, such as at least 85% of the full theoretical density of the aluminum-lithium alloy, at least 90% of the full theoretical density, at least 95% of the full theoretical density, at least 99% of the full theoretical density, or at least 99.9% of the full theoretical density. Increasing the density may reduce the volume of air present in the compacted part, thereby increasing the workability of the compacted part and reducing potential reactivity problems between atmospheric oxygen and lithium present in the machined chip. Additionally, increasing the density of the compacted part may reduce material loss during melting of the compacted part.

Accordingly, non-limiting aspects of the present disclosure are also directed to a cohesive compact comprising aluminum lithium alloy machining chips (optionally, which have been cleaned and/or granulated) and having a density of at least 70%, at least 80%, at least 90%, or at least 95% of the full theoretical density of the aluminum lithium alloy. The compacted part may be used as a feedstock for producing aluminum lithium alloy in ingot form or other solid form. In various non-limiting embodiments, compacts are manufactured by methods according to the present disclosure.

Another aspect according to the present disclosure is directed to a method of manufacturing an alloy. Referring again to the figure, in a non-limiting embodiment of the method, a compact is introduced into a molten bath of aluminum-lithium alloy to form the molten alloy, the compact comprising aluminum-lithium alloy machining chips (optionally, which have been cleaned and/or granulated) and having a density of at least 70% of the full theoretical density of the aluminum-lithium alloy, 110. The compacts may include shapes having reduced surface areas compared to swarf, such as rods, triangles, semi-continuous spirals, or combinations thereof. In various non-limiting embodiments of the method, the compacted part is manufactured by a method according to the present disclosure. At least a portion of the molten alloy may be solidified to form an aluminum lithium ingot or another solid form 112. Thereafter, in certain non-limiting embodiments, the aluminum lithium ingot (or other solid form) may be machined to form the part, 102. In certain non-limiting embodiments, the component may be an aerospace component or an automotive component.

Examples

The present disclosure will be more fully understood by reference to the following examples, which provide illustrative, non-limiting aspects of the disclosure. It should be understood that the disclosure described in this specification is not necessarily limited to the examples described in this section.

Example 1

Milling machining chips containing 16% by weight of coolant were machined by a vertical axis crusher (VAC II, available from PRAB kalamazo, michigan) followed by centrifugation in a diagonal axis wringer (available from PRAB kalamazo, michigan) to form machined chips. The coolant in the machined chip is reduced to less than 2% by weight. The vertical axis crusher breaks up long, thin portions of the machining chips and the wringer removes coolant from the machining chips. The machined machining chips are then screened through a classifying screen to achieve a uniform size of machined machining chips of less than 3mm by 3 mm. The uniformly machined chip was then fed into a continuously rotating extruder (available from CONFEX, dorset, united Kingdom) to form a compact of 10mm diameter and 98% density rods. Rod density was calculated by weighing a 36 "section of 10mm diameter rod and comparing the results to the calculated weight of a 10mm diameter 36" long rod with a density of 100%.

Example 2

Milling machining chips containing 16% by weight of coolant were cleaned in a multi-step process. The multi-step process removes free coolant by gravity drying milled machine chips on a 100 mesh screen. The dried machined chips were then washed twice in a ribbon mixer using mineral spirits (Exxsol). After each wash, mineral spirits were removed from the machining chips using a 100 mesh basket centrifuge. The machined chip was then placed in a steel cylinder and machined by a vacuum furnace operating at 400°f and 2-5 torr for 8 hours. This multi-step process reduces coolant on the machining chip to less than 0.05%. The machined chip was then ground to a uniform size of less than 3mm using a Hippo hammer mill. The uniformly machined chips were then fed into a continuously rotating extruder to form compacts of 10mm diameter rods having a density greater than 98%. Rod density was calculated by weighing a 36 "section of 10mm diameter rod and comparing the results to the calculated weight of a 10mm diameter 36" long rod with a density of 100%.

Example 3

Sections of the 36 inch long rods of examples 1 and 2 were melted in a non-inert 25 pound capacity induction melter containing a bath of raw aluminum plus 1% lithium. The rods from examples 1 and 2 sink below the surface oxide layer and are easily melted.

A typical disadvantage of feeding the machining chips into the melting furnace is the tendency of the machining chips to float on the top oxide layer. Because of the high surface area of the raw machining chips, if the machining chips are not submerged quickly, they tend to oxidize and convert to dross, rather than melt. This phenomenon may be even more pronounced because in the case of aluminum lithium alloys, the oxide layer on the aluminum melt is thicker, making the machining chip scrap more likely to float on the surface and oxidize, rather than melt. Reducing the surface area of the machined chip by forming the compacted part increases the ability of the compacted part to be immersed in a molten bath as compared to the unprocessed machined chip. The ability to sink into the molten bath may be achieved by using large diameter (e.g., at least 5mm, at least 10mm, at least 25 mm) rods or bars. A smaller diameter rod or bar that is conformally extruded into a longer length (e.g., at least 100 feet, at least 1000 feet) and crimped may be of sufficient mass to sink when added to the molten bath.

The residual level of contaminants on the rod may dictate the amount of extruded machining chips that may be added to the charge. For example, assuming a nominal sodium content of 3ppm for raw aluminum and lithium from the charge, the rod made from example 1 contained 15ppm sodium contamination, and 10% of the melted charge could be added as a compact for the machined chips. If the rod contains 10ppm sodium contamination, 20% of the melted charge may be added as compacts of the machining chips. If the rod contains 5ppm sodium contamination, 58% of the melted charge may be added as compacts of the machined chip.

The following numbered clauses are directed to various non-limiting embodiments and aspects according to the present disclosure.

1. A method for machining aluminum lithium chips, the method comprising:

obtaining machining chips generated during machining of an aluminum-lithium alloy using a machining fluid;

cleaning the machining chip to remove at least a portion of the machining fluid from the machining chip and provide a cleaned machining chip; and

the volume of the cleaned machined chip is compressed to provide a compact having a density of at least 70% of the full theoretical density of the aluminum-lithium alloy.

2. A method for machining aluminum lithium chips, the method comprising:

obtaining machining chips generated during machining of the aluminum-lithium alloy; and

the volume of the machined chip is compressed to provide a compact having a density of at least 70% of the full theoretical density of the aluminum-lithium alloy.

3. The method of clause 1, wherein the cleaning comprises at least one of: contacting the machining chip with an aqueous solution to dissolve a machining fluid on the machining chip into the aqueous solution, and heating the machining chip in an inert atmosphere to pyrolyze the machining fluid on the machining chip.

4. The method of clause 1, wherein the cleaning comprises contacting the machining chip with an aqueous solution to dissolve a machining fluid on the machining chip into the aqueous solution.

5. The method of clause 1, wherein the cleaning comprises reducing the carbon content on the surface of the machined chip.

6. The method of any one of clauses 1-5, wherein compacting comprises at least one of: continuous rotary extrusion, conformal extrusion, equal channel angular processing, equal channel angular extrusion, high pressure torsion, and shear assisted processing and extrusion.

7. The method of any of clauses 1-6, wherein the compacting comprises continuous rotary extrusion.

8. The method of any of clauses 1 and 3 to 7, wherein the processing fluid comprises a machining lubricant.

9. The method of any one of clauses 1 to 8, wherein the machining chip comprises:

0.1 to 5% by weight lithium;

aluminum; and

and (5) impurities.

10. The method of any one of clauses 1-9, further comprising:

granulating the machined chip.

11. The method of any one of clauses 1-10, wherein the volume of the machining chip is compacted to provide a compact having a density of at least 80% of the full theoretical density of the aluminum-lithium alloy.

12. The method of any one of clauses 1-11, wherein the volume of the machining chip is compacted to provide a compact having a density of at least 90% of the full theoretical density of the aluminum-lithium alloy.

13. The method of any one of clauses 1-12, wherein the volume of the machining chip is compacted to provide a compact having a density of at least 95% of the full theoretical density of the aluminum-lithium alloy.

14. The method of any one of clauses 1 to 13, wherein the machining chips are generated during machining of an aluminum lithium alloy to produce an aerospace component or an automotive component.

15. The method of any of clauses 1-14, wherein prior to compressing the volume, a density of the volume of machined chips is not greater than 50% of the full theoretical density of the aluminum-lithium alloy.

16. A method for machining aluminum lithium chips, the method comprising:

cleaning machining chips comprising an aluminum lithium alloy to remove at least a portion of a machining lubricant from the machining chips and provide cleaned machining chips, wherein the cleaning comprises at least one of: contacting the machining chip with an aqueous solution to dissolve a machining fluid on the machining chip into the aqueous solution, and heating the machining chip in an inert atmosphere to pyrolyze the machining fluid on the machining chip; and

compressing the volume of cleaned chip to provide a compact having a density of at least 70% of full theoretical density, wherein compacting comprises at least one of: continuous rotary extrusion, conformal extrusion, equal channel angular processing, equal channel angular extrusion, high pressure torsion, and shear assisted processing and extrusion.

17. The method of clause 16, wherein the cleaning comprises contacting the machining chips with an aqueous solution to dissolve machining fluid on the machining chips into the aqueous solution.

18. The method of any of clauses 16-17, wherein the cleaning comprises reducing a carbon content on a surface of the machined chip.

19. The method of any one of clauses 16 to 18, wherein the machining chip comprises:

0.1 to 5% by weight lithium;

aluminum; and

and (5) impurities.

20. A method for manufacturing an aluminum lithium alloy, the method comprising:

introducing the compacted member manufactured according to the method of any of clauses 1 to 18 into a molten bath of aluminum-lithium alloy to form a molten alloy.

21. The method of clause 20, further comprising solidifying at least a portion of the molten alloy to form an aluminum lithium ingot or other solid form from the molten alloy.

22. A method of manufacturing a component comprising an aluminum lithium alloy, the method comprising:

machining an ingot or other solid form according to clause 21 to form the part.

23. The method of clause 22, wherein the component is an aerospace component or an automotive component.

24. A cohesive compact, comprising:

a cleaned machined chip comprising an aluminum lithium alloy;

wherein the cohesive compact has a density of at least 70% of the full theoretical density of the aluminum lithium alloy.

25. The cohesive compact of clause 24, wherein the aluminum-lithium alloy comprises:

0.1 to 5% by weight lithium;

aluminum; and

and (5) impurities.

26. The cohesive compact of any of clauses 24-25, wherein the cohesive compact has a density of at least 90% of the full theoretical density of the aluminum-lithium alloy.

27. A method for manufacturing an aluminum-lithium alloy, the method comprising introducing the cohesive compact of any of clauses 24-26 into a molten bath of aluminum-lithium alloy to form a molten alloy.

28. The method of clause 27, further comprising solidifying at least a portion of the molten alloy to form an aluminum lithium ingot or other solid form from the molten alloy.

29. A method of manufacturing a component comprising an aluminum lithium alloy, the method comprising machining an ingot or other solid form according to clause 28 to form the component.

30. The method of clause 29, wherein the component is an aerospace component or an automotive component.

31. A method for recovering aluminum lithium chips, the method comprising:

cleaning the machining chip to remove at least a portion of the machining fluid from the machining chip and provide a cleaned machining chip;

compressing the volume of the cleaned machined chip to provide a compact having a density of at least 70% of the full theoretical density of the aluminum-lithium alloy;

introducing the compacted member into a molten bath of aluminum-lithium alloy to form a molten alloy; and

at least a portion of the molten alloy is solidified to form an aluminum lithium ingot or other solid form from the molten alloy.

Various non-limiting embodiments are described and illustrated herein to provide an overall understanding of the structure, function, and use of the disclosed methods and articles. The various non-limiting embodiments described and illustrated herein are non-limiting and non-exhaustive. Thus, the present invention is not limited by the descriptions of the various non-limiting and non-exhaustive embodiments disclosed herein. Rather, the invention is limited only by the claims. The features and characteristics illustrated and/or described in connection with the various non-limiting embodiments may be combined with the features and characteristics of other non-limiting embodiments. Such modifications and variations are intended to be included within the scope of the present description. Thus, the claims may be modified to incorporate any feature or characteristic specifically or inherently described or otherwise supported in this specification. Furthermore, the applicant reserves the right to modify the claims to expressly deny features or characteristics that may exist in the prior art. The various embodiments disclosed and described in this specification may include, consist of, or consist essentially of the features and characteristics described herein.

Any reference herein to "various embodiments," "some embodiments," "one embodiment," "an embodiment," or similar phrase means that a particular feature, structure, or characteristic described in connection with the example is included in at least one embodiment. Thus, appearances of the phrases "in various embodiments," "in some embodiments," "in one embodiment," "in an embodiment," or similar phrases in the specification are not necessarily referring to the same embodiment. Furthermore, the particular described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, a particular feature, structure, or characteristic shown or described in connection with one embodiment may be combined in whole or in part with features, structures, or characteristics of one or more other embodiments without limitation. Such modifications and variations are intended to be included within the scope of embodiments of the present disclosure.

In this specification, unless otherwise indicated, all numerical parameters should be understood to be open-ended and modified in all instances by the term "about," where the numerical parameters have inherent variability characteristics of the underlying measurement technique used to determine the numerical value of the parameter. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter described herein should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

In addition, any numerical range recited herein includes all sub-ranges subsumed within the recited range. For example, a range of "1 to 10" includes all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10, i.e., a minimum value equal to or greater than 1, and a maximum value of equal to or less than 10. Moreover, all ranges recited herein are inclusive of the endpoints of the recited ranges. For example, a range of "1 to 10" includes endpoints 1 and 10. Any maximum numerical limitation recited in this specification is intended to include all lower numerical limitations subsumed therein, and any minimum numerical limitation recited in this specification is intended to include all higher numerical limitations subsumed therein. Accordingly, applicants reserve the right to modify this specification (including the claims) to expressly state any sub-ranges subsumed within the ranges expressly stated herein. All of these ranges are inherently described in this specification.

The grammatical articles "a," "an," and "the" as used herein are intended to include "at least one" or "one or more," unless otherwise indicated, even if the singular is explicitly used in certain instances. Accordingly, the foregoing grammatical articles are used herein to refer to one or more (i.e., "at least one") of the specifically identified elements. Furthermore, the use of a singular noun includes the plural, and the use of a plural noun includes the singular, unless the context of use requires otherwise.

Those skilled in the art will recognize that the articles and methods described herein and their accompanying discussion are for illustrative purposes and that various configuration modifications are contemplated for the sake of conceptual clarity. Accordingly, as used herein, the specific examples/embodiments set forth and the accompanying discussion are intended to represent their more general categories. In general, any particular example is used to represent a category thereof and should not be taken as limiting, as not including the particular components, devices, operations/acts, and objects. While the present disclosure provides descriptions of various specific aspects for the purpose of illustrating various aspects of the disclosure and/or potential applications thereof, it is to be understood that variations and modifications will occur to those skilled in the art. Accordingly, one or more inventions described herein should be understood to be at least as broad as that claimed, rather than being defined as narrower than the specific illustrative aspects provided herein.

Claims

1. A method for machining aluminum lithium chips, the method comprising:

2. A method for machining aluminum lithium chips, the method comprising:

3. The method of claim 1, wherein the cleaning comprises at least one of: contacting the machining chip with an aqueous solution to dissolve a machining fluid on the machining chip into the aqueous solution, and heating the machining chip in an inert atmosphere to pyrolyze the machining fluid on the machining chip.

4. The method of claim 1, wherein the cleaning comprises contacting the machining chips with an aqueous solution to dissolve a machining fluid on the machining chips into the aqueous solution.

5. The method of claim 1, wherein the cleaning comprises reducing carbon content on a surface of the machining chip.

6. The method of any one of claims 1 to 5, wherein compacting comprises at least one of: continuous rotary extrusion, conformal extrusion, equal channel angular processing, equal channel angular extrusion, high pressure torsion, and shear assisted processing and extrusion.

7. The method of any one of claims 1-6, wherein the compacting comprises continuous rotary extrusion.

8. The method of any of claims 1 and 3-7, wherein the processing fluid comprises a machining lubricant.

9. The method of any one of claims 1 to 8, wherein the machining chip comprises:

0.1 to 5% by weight lithium;

aluminum; and

and (5) impurities.

10. The method of any one of claims 1 to 9, further comprising:

granulating the machined chip.

11. The method of any one of claims 1 to 10, wherein the volume of the machining chip is compacted to provide a compact having a density of at least 80% of the full theoretical density of the aluminum-lithium alloy.

12. The method of any one of claims 1 to 11, wherein the volume of the machining chip is compacted to provide a compact having a density of at least 90% of the full theoretical density of the aluminum-lithium alloy.

13. The method of any one of claims 1 to 12, wherein the volume of the machining chip is compacted to provide a compact having a density of at least 95% of the full theoretical density of the aluminum-lithium alloy.

14. The method of any one of claims 1 to 13, wherein the machining chips are generated during machining of an aluminum lithium alloy to produce an aerospace component or an automotive component.

15. The method of any one of claims 1 to 14, wherein a density of the volume of machined chips is no greater than 50% of the full theoretical density of the aluminum-lithium alloy prior to compressing the volume.

16. A method for machining aluminum lithium chips, the method comprising:

17. The method of claim 16, wherein the cleaning comprises contacting the machining chips with an aqueous solution to dissolve machining fluid on the machining chips into the aqueous solution.

18. The method of any one of claims 16 to 17, wherein the cleaning comprises reducing carbon content on a surface of the machining chip.

19. The method of any one of claims 16 to 18, wherein the machining chip comprises:

0.1 to 5% by weight lithium;

aluminum; and

and (5) impurities.

a compacted member manufactured according to the method of any one of claims 1 to 18 is introduced into a molten bath of an aluminum lithium alloy to form a molten alloy.

21. The method of claim 20, further comprising solidifying at least a portion of the molten alloy to form a lithium aluminum ingot or other solid form from the molten alloy.

machining an ingot or other solid form according to claim 21 to form the part.

23. The method of claim 22, wherein the component is an aerospace component or an automotive component.

24. A cohesive compact, comprising:

a cleaned machined chip comprising an aluminum lithium alloy;

25. The cohesive compact of claim 24, wherein the aluminum-lithium alloy comprises:

0.1 to 5% by weight lithium;

aluminum; and

and (5) impurities.

26. The cohesive compact of any one of claims 24-25, wherein the cohesive compact has a density of at least 90% of the full theoretical density of the aluminum-lithium alloy.

27. A method for manufacturing an aluminum-lithium alloy, the method comprising introducing the cohesive compact of any one of claims 24-26 into a molten bath of aluminum-lithium alloy to form a molten alloy.

28. The method of claim 27, further comprising solidifying at least a portion of the molten alloy to form a lithium aluminum ingot or other solid form from the molten alloy.

29. A method of manufacturing a component comprising an aluminum lithium alloy, the method comprising machining an ingot or other solid form of claim 28 to form the component.

30. The method of claim 29, wherein the component is an aerospace component or an automotive component.

31. A method for recovering aluminum lithium chips, the method comprising: