Background technology
Known when production is used for the work in-process of aviation structure or structural member, required various performances can not be all simultaneously and be optimised independently of one another.When chemical constitution that changes alloy and product processes parameter, antagonistic tendency may appear in several key propertys.Sometimes situation promptly is like this for following performance: at first be the performance that is collectively referred to as " static mechanical strength " (ultimate tensile stress R particularly
mWith stretching yield stress R
P0.2), secondly be the performance (particularly toughness and cracking resistance line growth intensity) that is collectively referred to as " damage tolerance ".And a few thing performance (as fatigue strength, erosion resistance, formability and elongation at break) is associated with these mechanical propertys (or " characteristic ") with a kind of complexity and usually unpredictable mode.Therefore, the optimization of all properties that is used for the material of physical structure (for example at aviation field) usually requires compromise between several key parameters.
For example, in the large vol civilian aircraft, use the wing structure member of 7xxx type alloy usually.These members must have high mechanical strength, good toughness and good fatigue strength.Any new measure that can improve these group one of performances and not damage other performance all will be very useful.
As for toughness, well-known, in order to improve the toughness of dispersion hardening aluminium alloy, must reduce the residual content of iron and silicon; This is at commercial being known as " Staley the 7th gold law " (J.T.Staley, " Microstructure and Toughness of High-Strength AluminumAlloys " Properties Related to Fracture Toughness, ASTM STP 605, AmericanSociety for Testing and Materials, 1976, p.71-103).In fact, this effect almost can be observed in all dispersion hardening aluminium alloys, and no matter their degree of flexibility.Iron and silicon are the natural impuritys of aluminium.Except the specific purification process (for example segregation method) that is used to produce raffinal, not the commercial run of standard does not reduce iron and silicone content in the liquid aluminum bath at present.And these elements are recycled at aluminium and these alloys and tend to accumulation when utilizing.In order to reduce the content of these impurity, what all can be done is exactly to dilute them with purer metal, this otherwise undertaken by the electrolytic metal (being called " primary aluminum ") that uses iron+aluminium content to be typically about 0.2-0.3%, or by using finishing metal to carry out.This operation has improved under the both of these case cost of (especially second kind situation under) significantly.
Iron and sila matter also have disadvantageous effect to fatigue strength.The reduction of iron and silicon residual content will improve fatigue strength usually, and prerequisite is in producing the process of liquid metal and will adopts common preventive measures to prevent to form inclusion in castingprocesses and introduce hydrogen in metal.
As everyone knows, iron and element silicon and aluminium form insoluble,practically intermetallic phase, for example Al
7Cu
2Fe, Al
6(Fe
XMn
1-X) (wherein 0<x<1), Al
12Fe
3Si, Al
9Fe
2Si
2And Mg
2Si.When they have large size, more harmful when these are compared them and have small size.Unfortunately, come possibility that their size is worked quite limited in when casting by change physical parameter (especially solidification rate).
In the face of the method by physical treatment reduces the intermetallic phase of iron and silicon and changes their size and the difficulty of form, expected changing their size and form by adding some chemical element.If this effect can observed words also only be only industrial available under the condition that can not have a negative impact to other performance of finished product.Therefore, Na and/or Sr are added in some Al-Si mold casting alloy, with the fibrous Si that obtains meticulous formation mutually rather than the prismatic phase of coarse formation.Patent FR1507664 (MetallgesellschaftAktiengesellschaft) mentions by having produced thin eutectic structure in strontium that adds 0.001-2% and/or the Al-Si cast moulding alloy that barium (Ba) to Si content is 5-14%; This effect is enhanced by adding beryllium (Be) simultaneously.It is the thixotroping formability that improves them at least in 5% the aluminium alloy to silicone content that patent EP1230409B1 (RUAG Components) discloses by adding barium (0.1-0.8%).Deforming alloy (alliages de corroyage) for dispersion hardening, patent US4,711,762 (Aluminum Company of America) proposed interpolation strontium (Sr), antimony (Sb) and/or calcium (Ca) in the Al-Zn-Cu-Mg type alloy to reduce Al
7Cu
2Fe, Al
2CuMg and Mg
2The size of Si phase.
The aluminum base alloy of baric has been described in other prior art document.In most of the cases, its effect is to make molten slag more mobile; On the other hand, its influence to product performance is not described.Thereby patent GB505728 (L ' El é ctrique) has described a kind of aluminum base alloy, and this alloy is used to produce cold drawn silk and comprises Zn 5-6.5%, Mg 2-3.5%, Si 0.15-0.5%, Mn 0.25-1%, Mo 0.20-0.60%, Co 0.20-0.60%, K 0-0.12%, Ba 0-0.25%, Sb 0-0,1%, W 0-0.50%, Ni 0-1%, Ti 0-0.40%, wherein barium adds with muriatic form, so that molten slag is more mobile; This barium content in metal product also should have sclerization.
Patent GB 596, it is that 0.15% Na, K, Ba and/or P element add in the aluminum base alloy that 178 (Tennyson Fraser Bradbury) have described maximum total content, this alloy comprises Cu 5.00-9.50%, Zr, Ni, Ce amounts to 0.05-1.00, Si 0.02-0.40%, Fe 0.02-0.50%, Zn 0.00-0.25%.It is the casting alloy that is used for piston.The effect of barium and addition manner are all not mentioned.
Patent US 4,631, and 172 (Nadagawa Corrosion Protection Co.) have described a kind of aluminum base alloy as sacrificial anode, it comprises 3.2%Zn, 1.5% magnesium, 0.02% indium, 0.01% tin and/or calcium and barium, barium content change between 0.002% to 1.0%.Comprise Zn 2.5% another kind of the composition, Mg2.5%, and In 0.02%, Ca and/or Ba 0.005-1.0%, Si 0.004-1.0%.Improved current density and guaranteed the uniform loss of sacrificial anode by adding calcium and/or barium.Patent application JP 61 096052 A have described a kind of aluminum base alloy sacrificial anode, and it consists of Zn 1-10%, Mg 0.1-6%, In 0.01-0.04%, Sn 0.005-0.15%, Si 0.09-1%, Ca and/or Ba 0.005-0.45%.
Patent CH 328 148 (Wilhelm Neu) has described barium hydride is incorporated into and has contained in the zinc-aluminium type alloy that is not less than 40% zinc.
Patent US 3,310,389 (High Duty Alloys Ltd) mention and exist total content to be up to 0.2% barium, calcium and/or strontium in aluminum base alloy, this aluminum base alloy comprises Cu 2.2-2.7%, Mg 1.3-1.7%, Si 0.12-0.25%, Fe 0.9-1.2%, Ni 0.9-1.4%, Ti 0.02-0.15%.
Patent RU 2 184 167 (contriver: I.N.Fridljander etc.) described a kind of aluminum base alloy that in the aviation structure, is used for structure applications, it comprises Cu 3.0-3.8%, Li 1.4-1.7%, Zr0.0001-0.04%, Sc 0.16-0.35%, Fe 0.01-0.5%, Mg 0.01-0.7, Mn 0.05-0.5%, Ba 0.001-0.2%, Ga 0.001-0.08%, Sb 0.00001-0.001%.
Patent RU 1 678 080 (Institut khimii im.V.I.Nikitina) has described a kind of aluminum base alloy, and it consists of Cu 5.0-5.5%, Cr 0.i-0.4%, Mn 0.2-0.6%, Zr 0.1-0.4%, Ti 0.1-0.4%, Cd 0.05-0.25%, Sr or Ba 0.01-0.1%.
Find that major part comprises uncommon element such as indium, nickel, lithium, cadmium, molybdenum or tungsten in these alloys, thus with normally used alloy phase in aviation structure are specific alloys than them, and this does not consider to add barium.
Embodiment
A) definition
Except as otherwise noted, otherwise all indicate and all are expressed as mass percent about alloy is formed.Therefore, mathematic(al) representation " 0.4Zn " is meant 0.4 times of the zinc content represented with mass percent; This has been applied to other chemical elements with having done necessary correction.The alloy label is according to Aluminum Association rule well known to those skilled in the art.In European standard EN515, define metallurgical state.For example, the chemical constitution of normalizing aluminium alloy limits in standard EN 573-3.Except as otherwise noted, otherwise static mechanical properties, in other words, ultimate tensile strength R
m, stretching yield stress R
P02Determine that by tension test position and the direction of obtaining sample are limited by standard EN 485-1 with elongation at break A according to standard EN 10002-1.Fatigue strength is determined that by the test according to ASTM E 466 fatigue crack growth rate (being also referred to as the da/dn test) is according to ASTM E 647, and critical stress intensity factor K
c, K
CoOr K
AppAccording to ASTME561.Term " extruded product " comprises so-called " stretching " product, promptly by extruding tensile product then.
Except as otherwise noted, the definition of European standard EN 12258-1 is suitable for.
In this explanation, " texturising product (produit corroy é) " is meant the product that it has been carried out deformation operation after it solidifies, this deformation operation can be rolling, forge, extrude, stretching or punching press, but this enumerating not is restrictive.
In this explanation, " structural member " of physical structure is meant so a kind of mechanical part, the described structure of entail dangers to, its user, its passenger and other people safety if these parts go wrong.For aircraft, these structural member especially comprise the member (such as fuselage skin) that constitutes fuselage, stringer, bulkhead, framework on every side, wing (such as wing cover), stringer or stiffener, rib and spar and the empennage that especially constitutes, and floor bearer, seat rail and door by level or vertical stabilizer.
In this explanation, " one-piece construction " is meant the structure of the part of aircraft, and this structure is designed to make the continuity maximization of material on big as far as possible size, to reduce the number of mechanical assembly point.One-piece construction can be made by carry out mechanical workout in body, perhaps for example made by the drip molding of extruding, forge or cast acquisition by using, but the structural member of perhaps being made by welding alloy by welding is made.Therefore, can obtain the bigger member made by single part, it need not to assemble or has less assembling and counts out, this be than thin or slab (purpose that depends on structural member, for example frame member or wing member) wherein usually by riveted joint be fixed on stiffener and/or framework (it can by extrude or rolled products by the mechanical workout manufacturing) on structure.
B) detailed description of the present invention
The present invention is applicable to all dispersion hardening distortion aluminum base alloys of Al-Cu, Al-Cu-Mg or Al-Zn-Cu-Mg type.More specifically, can be applicable to Al-Cu type alloy of the present invention is the Cu that comprises 1-7%, more particularly contains the alloy of 3-5.5%Cu.The present invention can be applicable to Al-Cu-Mg type alloy, and this alloy comprises the Cu of 1-7% and the Mg of 0.2-2%, and the more particularly Cu of 3.5-5.5% and the Mg of 1-2%, is appreciated that the content of iron and silicon must be no more than 0.30% separately.These alloys can comprise total and be up to about 3% other alloying element and impurity.These elements comprise manganese, lithium and zinc.And, and still as example, this alloy can also comprise conventional zirconium, titanium or the chromium that adds.Method of the present invention can advantageously be applied to the alloy in Al-Mg-Cu type alloy or the 2xxx series, the alloy that usually uses in the aviation structure particularly, promptly 2024,2024A, 2056,2022,2023,2139,2124,2224,2324,2424,2524 and their variant.On the other hand, the present invention gets rid of so-called non-machine and adds worker's alloy as 2004,2005 and 2030, and they comprise that interpolation Pb, Bi or Sb are so that obtain discontinuous bits.
Can be applicable to Al-Zn-Cu-Mg type alloy of the present invention is the zinc that comprises 4-14%, the zinc of 7-10.5% more particularly, the Cu of 1-3%, the Cu of 1.4-2.5% more particularly, the Mg of 1-3%, more particularly the alloy of the Mg of 1.7-2.8% is appreciated that the content of iron and silicon must be no more than 0.30% separately.These alloys can comprise total and be up to 2% other alloying element and impurity.These elements comprise manganese.And still as example, this alloy can also comprise conventional zirconium, titanium and the chromium that adds.Method of the present invention can advantageously be applied to the alloy in the 7xxx series, the alloy that usually uses in the aviation structure particularly, promptly 7010,7050,7055,7056,7150,7040,7075,7175,7475,7049,7149,7249,7349 and 7449, and their variant.
Method of the present invention comprises uses any currently known methods casting dumming spare, for example milled sheet, extrudes blank or forges blank.This dumming spare is subsequently by hot-work, for example by rolling, extrude or forge and carry out.The present invention also is not suitable for the product of making by fast setting, and promptly solidification rate is usually greater than 600 ℃/min, and this will cause visibly different microtexture.This method can also comprise other thermal treatment or mechanical treatment step, normally homogenizing, cold working, solution treatment, artificial or natural aging, centre or final annealing.
The applicant unexpectedly finds, the existence of very a small amount of barium has partly neutralized iron and silicon to the harmful effect of some performance, and this will make an explanation hereinafter.This causes intermetallic phase, and particularly the form of phase changes between (Al-Cu-Fe type) ferrous metal.The eutectic intermetallic phase is splitted (" sea urchin " or " cabbage " form is referring to Fig. 2), and they are the shape then more roomy (form of " petal ", " platelet " or " Caulis et Folium Brassicae capitatae leaf " is referring to Fig. 1) during baric not.These eutectic phases can be (in the alloy that adds barium) Al-Fe-Cu type or (not adding in the alloy of barium) Al-Fe-Si-Cu types.Can see, exist under the situation of barium that silicon obviously disappears by separating out.
By the salient features of the inventive method improved products especially toughness, fatigue strength with have the cracking resistance line growth intensity da/dn of heavily stressed strength factor Δ K.This effect is obvious especially in the tissue of non-recrystallization.
In the first embodiment, add the alloy of barium and silicon.Si (70%)-Ba (30%) type alloy is suitable; This product can obtain on market.The silicone content of this alloy can change between 50%-90%.The present invention also can use other alloy that comprises up to the same type of 20% iron, the silicone content of this alloy thereby can between 30%-90%, change, and barium content then can change between 10%-40%.
In second embodiment, with metallic forms, preferably to add barium with the intermetallic compound of one or more components of target aluminium alloy or the form of alloy.For example, Al-Ba or Zn-Ba type alloy are suitable.These intermetallic compounds or alloy can directly obtain by following manner: according to currently known methods, use aluminium or zinc reduction-oxidation barium BaO.
In these two kinds of embodiments, the consumption of barium is low-down, preferably less than 0.1%, even is more preferably less than 0.05%.Value between the 0.005%-0.03% may be suitable.When adding the Ba-Si alloy, should consider this alloy low relatively solubleness in liquid aluminium.Second kind of embodiment is useful especially when being applied to have the aluminium alloy of high relatively silicone content (for example about 0.10%).On the other hand, barium metal is expensive.First embodiment is used not too expensive barium alloy but has been improved silicone content in the aluminium alloy and possible iron level.But, be that the raising of the content of silicon and possible iron does not damage toughness or fatigue strength astoundingly.This is not to be that the fact of introducing in an identical manner is associated with silicon and possible iron; Phase morphology obviously changes.
The method according to this invention can be used for producing work in-process or the structural member of being made by Al-Zn-Mg-Cu type alloy, this alloy comprises 7-10.5% zinc, the magnesium of 1.4-2.5% copper and 1.7-2.8%, 7049,7149,7249,7349 or 7449 alloys for example, this alloy has the toughness K that measures according to standard A STM E561 on the CCT type test specimen with W=406mm and B=6.35mm that interior thickness obtains
App (L-T)For greater than 86MPa √ m.The yielding stress R of this work in-process or structural member
P0.2 (L)Greater than 600MPa.
The applicant also observes, and compares with the corresponding not product of baric, and product of the present invention has better anti-exfoliation corrosion (EXCO test), and it is to measure on the test specimen that interior thickness obtains.Anticorrosion stress-resistant also slightly improves.
Because its significant mechanical property, product of the present invention can have many possible application, and particularly advantageously use described product as the structural member in the aviation structure, and especially as upper surface of the airfoil member or wing lower surface member, wing cover member, stiffener, stringer, rib or be used for the member of bulkhead.
The method according to this invention has several advantages.The method of adding barium according to the present invention can prevent to use hydride, and this hydride can improve remaining hydrogen content, and this remaining hydrogen content can form the hole in the solidified metal.The neutralized disadvantageous effect of residual silicon in the dispersion hardening aluminum base alloy of barium, this has caused better toughness, especially K
ICAnd K
AppBarium has also improved erosion resistance, especially anti-exfoliation corrosion.
The following examples will be described favourable embodiment of the present invention, and this embodiment is exemplary and nonrestrictive.
Embodiment 1:
This experimental study by adding that Si-Ba type alloy is incorporated into barium in the liquid aluminum base alloy and with the possibility of the form casting Al-Zn-Cu-Mg type alloy of industrial size milled sheet.Two kinds of milled sheets of making of casting under similar condition by Al-Zn-Cu-Mg type aluminium, a kind of form with the mother alloy that contains about 28%Ba and 72%Si is added barium (adding) under about 750 ℃ liquid metal temperature, and another kind does not then add any barium.This liquid metal utilizes Ar+Cl
2Mixture is handled.Casting temp is 665 ℃, and casting speed is about 65mm/min.This metal of AT5B refining with 0.8kg.The sectional area of plate is about 2150 * 450mm.Table 1 shows chemical constitution, and this chemical constitution is to measure on the solid piece of extracting in by running channel that liquid metal obtained.
Table 1: chemical constitution
Sample | Fe | Si | Cu | Mg | Zn | Zr | Ti | Ba |
P4068#66 | 0.03 | 0.05 | 1.76 | 1.90 | 7.48 | 0.11 | 0.0230 | - |
P4069-2#66 | 0.11 | 0.12 | 1.86 | 2.03 | 8.40 | 0.10 | 0.0200 | 0.0100 |
In slag, found the barium (usage quantity tens percent) of a part of interpolation.
Embodiment 2
Utilize and add the alloy production 7449 type aluminium alloys (label P4078-1#37) that contain about 52% silicon and 30% barium and 18% iron.Table 2 shows its chemical constitution, and this chemical constitution is to measure on the solid piece of extracting in by running channel that liquid metal obtained.
This alloy is cast as milled sheet with the AT5B refining of 0.8kg/t and 685 ℃ of speed with 65mm/min.After cooling and scalping, this plate carries out homogenizing and 420-410 ℃ of following hot rolling at 463 ℃.Under the following conditions the sheet material that is obtained is carried out solution treatment: 120 ℃ following 6 hours following 17 hours at 150 ℃ then.Therefore, final product is in the T351 metallurgical state.
Owing to added the Si-Ba alloy, the silicone content of 7449 type aluminium alloys is increased to 0.09% from 0.04%, and Fe content is increased to 0.06% from 0.03%.
Also produce standard 7449 alloys similarly without any barium.Table 2 shows its chemical constitution, and this chemical constitution is to measure on the solid piece of extracting in by running channel that liquid metal obtained.
Table 2: chemical constitution
Sample | Fe | Si | Cu | Mg | Zn | Zr | Ti | Ba |
P4078-1#37 (FE02-029(888887)) | 0.06 | 0.09 | 1.84 | 1.94 | 8.72 | 0.12 | 0.019 | 0.023 |
P4013-1-#66 (FE02-028(888885)) | 0.03 | 0.04 | 1.83 | 2.20 | 8.29 | 0.12 | - | - |
The microtexture of having added the sample of barium demonstrates the cocrystalization compound (Fig. 4) of " sea urchin shape " or the cocrystalization compound (see figure 5) of " cabbage shape ".The microtexture of not adding the sample of any barium comprises the cocrystalization compound (Fig. 6) of platelet form.
On the thick sheet of 40mm, measuring the static mechanical characteristic under the T79 state.On the CCT of W406 and B=6.35mm type test specimen, measure toughness K
App (L-T)
Table 3: mechanical characteristics
| P4013-1-#66 (baric) | P4078-1#37 (not baric) | |
| 1/4t | 1/2t | 1/4t | 1/2t | Unit |
R
p0.2(L) | 595 | 622 | 609 | 622 | MPa |
R
p0.2(LT) | 590 | 601 | 611 | 608 | MPa |
R
m(L) | 610 | 643 | 628 | 647 | MPa |
R
m(LT) | 609 | 617 | 636 | 631 | MPa |
R
p0.2(ST) | | 573 | | 575 | MPa |
R
m(ST) | | 622 | | 626 | MPa |
A%(L) | 11.6 | 10.4 | 10.3 | 9.7 | % |
A%(LT) | 10.7 | 9.9 | 8.7 | 8.6 | % |
A%(ST) | | 4.4 | | 5.7 | % |
K
1C(T-L) | | 22.3 | | 20.9 | MPa√m |
K
1C(L-T) | | 23.3 | | 23 | MPa√m |
K
app(L-T) | 69.3 | 91.6 | 54.3 | 83.9 | MPa√m |
K
eff(L-T) | 73.6 | 98.8 | 58.6 | 90.3 | MPa√m |
The anti-exfoliation corrosion result (EXCO) who measures on the test specimen that interior thickness obtains demonstrates 7449 alloys of baric, and (the EXCO performance: EA) (the EXCO performance EB) is compared and is had better anti-exfoliation corrosion with the reference product of baric not.Anticorrosion stress-resistant also slightly improves.