EP1566461B1 - Recristallisation d'une tôle en alliage métallique par chauffage convection ainsi que par chauffage à rayonnement infrarouge - Google Patents

Recristallisation d'une tôle en alliage métallique par chauffage convection ainsi que par chauffage à rayonnement infrarouge Download PDF

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Publication number
EP1566461B1
EP1566461B1 EP20040003805 EP04003805A EP1566461B1 EP 1566461 B1 EP1566461 B1 EP 1566461B1 EP 20040003805 EP20040003805 EP 20040003805 EP 04003805 A EP04003805 A EP 04003805A EP 1566461 B1 EP1566461 B1 EP 1566461B1
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EP
European Patent Office
Prior art keywords
sheet
heating
temperature
recited
infrared radiation
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
EP20040003805
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German (de)
English (en)
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EP1566461A1 (fr
Inventor
Richard Harry Hammar
Johne E. Carsley
John Robert Bradley
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Motors Liquidation Co
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Motors Liquidation Co
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Publication date
Application filed by Motors Liquidation Co filed Critical Motors Liquidation Co
Priority to EP20040003805 priority Critical patent/EP1566461B1/fr
Priority to DE602004009530T priority patent/DE602004009530T2/de
Publication of EP1566461A1 publication Critical patent/EP1566461A1/fr
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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
    • 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
    • C22F1/047—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 of alloys with magnesium as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/34—Methods of heating
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/46—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for sheet metals
    • C21D9/48—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for sheet metals deep-drawing sheets
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/52—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for wires; for strips ; for rods of unlimited length
    • C21D9/54—Furnaces for treating strips or wire
    • C21D9/663—Bell-type furnaces
    • C21D9/677—Arrangements of heating devices

Definitions

  • This invention pertains to the heating of a heavily cold worked metal alloy sheet to recrystallize its microstructure to a highly formable (e.g., superplastic) condition, and to raise its temperature for an immediate forming operation. More specifically, this invention pertains to a method combining infrared radiation heating with convection heating to rapidly heat the cold worked sheet under controlled conditions for such recrystallization and forming.
  • Body panels for automotive vehicles are currently being manufactured using a superplastic forming process applied to certain magnesium-containing aluminum alloy sheet stock.
  • the sheet stock is a specially prepared, fine grain microstructure aluminum alloy 5083.
  • AA5083 has a nominal composition, by weight, of about 4 to 5 percent magnesium, 0.3 to 1 percent manganese, a maximum of 0.25 percent chromium, about 0.1 percent copper, up to about 0.3 percent iron, up to about 0.2 percent silicon, and the balance substantially all aluminum.
  • the alloy is cast into a slab of a suitable thickness and subjected to a homogenizing heat treatment.
  • the slab is then gradually reduced in thickness by a series of hot rolling operations to a strip in the range of twenty to forty millimeters depending somewhat on the goal for the final thickness of the sheet.
  • the strip is then cold rolled, usually in stages with possible interposed anneals, to a final sheet thickness in the range of about one to three or four millimeters.
  • the result of the thermomechanical processing is a coil of smooth surface aluminum sheet stock, the microstructure of which has been severely strained.
  • the cold rolled strip is not suitable for a high elongation forming operation. It must be reheated to recrystallize the elongated, strained grains that characterize its microstructure by the nucleation and growth of nearly strain-free grains.
  • the goal of the recrystallizing heat treatment in the case of AA5083 sheet is to produce a very fine grained microstructure characterized by a principal phase of a solid solution of magnesium in aluminum, with well distributed, finely disbursed particles of intermetallic compounds containing minor alloying constituents such as, Al 6 Mn.
  • the recrystallized grain size in the microstructure is uniformly about ten to fifteen micrometers.
  • the fine-grained sheet can be heated and superplastically formed into a complex part like an automotive body panel.
  • the sheet can sustain substantial elongation at a suitable strain rate and at a temperature in the range of about 440°C (825°F) to about 550°C (1020°F).
  • the '588 patent describes practices for forming aluminum alloy sheet metal using a pressurized working fluid such as air.
  • the sheet metal blank is first placed on a pre-bending and heating tool. The heated tool heats the sheet metal blank to its forming temperature and pre-bends it, if desired, for placement on a second tool configured for stretch-forming the heated sheet into a body panel or the like.
  • the heated blank is then clamped at its edges and gas pressure is applied which forces the sheet into the tool cavity to assume the requisite shape of the part.
  • gas pressure is applied which forces the sheet into the tool cavity to assume the requisite shape of the part.
  • the heating on the pre-heat tool may further the grain growth of its microstructure.
  • a blank is taken from a cold rolled coil supplied without heat treatment, e.g., in the H18 temper, the metal is not formable because it has experienced a cold rolling reduction of 74% or more as a last processing step.
  • an unrecrystallized blank is placed on the preheat and pre-bend tool of the Rashid, et al, "588 patent disclosure, the sheet material is recrystallized as it is slowly heated to the panel forming temperature over a period of five to ten minutes.
  • the sheet Once the sheet has been recrystallized and reaches a forming temperature, for example, in the range of 825°F to 845°F (about 441°C to 452°C), it is bent and transferred to a heated forming press in which it is stretch formed into a vehicle body panel or the like.
  • a forming temperature for example, in the range of 825°F to 845°F (about 441°C to 452°C)
  • JP 2000-160260A discloses a method of heating a sheet in accordance with the preamble of the independent claim.
  • US 5,868,023 A discloses a method of forming a work-piece by local heating of the work-piece in a to be formed location using inductive or convective heating, or by thermal radiation.
  • the present invention achieves this object through the characterizing features of the independent claim.
  • a sheet blank of cold worked, H18 temper, AA 5083 material sized for vehicle body panel manufacture, and heat it to a suitable superplastic forming temperature.
  • a sheet is placed in an oven adapted for recirculating, forced flow, hot air convection heating of the sheet.
  • the principal initial rapid heating of the sheet is accomplished by also using infrared heating rods suitably closely spaced to a surface of the sheet.
  • the infrared radiant heating rods are turned on with the cold sheet in place, for example, on a ceramic hearth of the oven.
  • the efficient radiation heating rapidly raises the temperature of the thin metal and induces recrystallization of the cold worked strained grains of its microstructure.
  • the forced flow of hot air is directed against and across the surface of the sheet, also heating it.
  • the radiant heaters are turned off at a suitable, predetermined time during the heating cycle to avoid excessive heating or localized melting of the sheet.
  • the temperature of the circulating air is controlled to limit the maximum temperature of the sheet.
  • the circulating air flowing against the sheet serves to produce a more uniform temperature distribution in the sheet.
  • the air temperature may be controlled at about 482°C (900°F) to limit the radiantly heated sheet to about the same temperature.
  • the circulating air also serves to "cool" and limit the temperature of the much hotter about 815° to above 926°C (1500 to 1700°F) radiant heater elements.
  • the sheet is suitably recrystallized to a microstructure for superplastic forming and heated to a suitable temperature for such forming within a period of, for example, sixty to one hundred fifty seconds.
  • this period is comparable to the actual panel forming operation so that the heating operation no longer slows the panel manufacturing process.
  • the hot sheet is removed from the oven and, without intentional cooling, placed on a forming tool for pre-bending and/or final part formation.
  • This invention is likewise applicable to the static recrystallization of other pseudo single phase alloys such as aluminum alloys of the AA 2xxx series, other alloys of the AA5xxx series, alloys of the AA7xxx series, as well as suitable magnesium, ferrous and titanium superplastic alloys.
  • Figure 1 is a schematic flow diagram of a convection and radiant heating oven and related conveying and control equipment for use in heating cold worked sheet metal blanks in accordance with this invention.
  • Figure 2 is a cross sectional view of the oven taken at plane 2-2 of Figure 1.
  • Superplastic metals can undergo large uniform strains prior to failure.
  • the ability of a metal to deform superplatically depends primarily on its composition, grain size, strain rate, and deformation temperature. Metals that behave superplastically usually have a grain size less than about 10 micrometers and they are deformed within the strain rate range of 10 -5 to 10 -1 per second at temperatures greater than about half of their absolute melting temperature (0.5 T).
  • the fine grain size is believed to allow grain boundary sliding and grain rotation to contribute to the large superplastic strains. Therefore, in order to deform superplastically, an aluminum alloy or other superplastic alloy of, for example, titanium, copper or magnesium must first be capable of being processed into a fine grain structure that is resistant to grain growth during deformation.
  • This invention is applicable to superplastic sheet metal alloys that are statically recrystallized to a fine grain structure prior to a forming operation.
  • the practice of the invention will be illustrated in connection with magnesium-containing aluminum sheet alloys, specifically AA 5083.
  • Production of the alloy sheet includes a combination of hot rolling, cold rolling and a final heat treatment to develop small recrystallized grains of aluminum-magnesium solid solution with dispersed insoluble particles.
  • a combination of convection heating and infrared radiation heating is employed to rapidly heat a suitably cold worked sheet metal blank.
  • the heat is controlled to recrystallize the microstructure of the blank for uniform deformation and to heat it to a forming temperature suitable for the manufacturing process.
  • the heat treated sheet material is then subjected to its intended forming operation before cooling to ambient temperature.
  • Figures 1 and 2 illustrate a preferred embodiment of the process.
  • An incoming cold-worked sheet metal blank 10 is positioned on a support table 12 or conveyor just upstream of heat treating oven 14.
  • a blank for an automotive vehicle body panel may, for example, have dimensions of 1625 mm (64 inches) x 1117 mm (44 inches) x 1.6 mm. It is often coated on one or both sides with a film of boron nitride lubricant particles.
  • Oven 14 is sized to accommodate at least one such panel and enclose heating means described below.
  • the oven 14 is available, the blank 10 is pushed or otherwise suitably transported through slideable door 16 in the entrance end 18 of oven 14 onto a hearth 20 in the lower portion of oven 14.
  • the blank When the blank is positioned in oven 14, it is identified as 10'.
  • Hearth 20 is suitably formed of a ceramic or refractory material can be supported for example on beams 22 on the floor 24 of oven 14 as illustrated schematically in Figure 2.
  • Hearth 20 may have a slightly convex upper surface so that edges of the flat sheet 10' do not lie on the hearth and can be used for suitable movement of the blank in and out of oven 14.
  • the edges of the blanks may be guided in rails (not shown) or gripped by robots with suitable end effectors (not shown) for transporting the blank 10'.
  • the thin sheet 10' is heated by convection and radiation principally through its exposed upper surface as seen in Figures 1 and 2.
  • the hearth 20 is heated in the oven and provides a hot backing for sheet 10'.
  • other arrangements for supporting sheet 10 could be devised such as for heating from both sides.
  • the Figures 1 and 2 embodiment is preferred.
  • Blank 10 is heated in oven 14 by a combination of recirculating hot air convection heating and infrared radiant heating.
  • a plurality (six shown) of infrared heating rods 26 extend substantially the length of oven 14. They are aligned parallel to each other along the length of sheet 10 as it is supported on hearth 20 in oven 14. They are also positioned parallel to the upper surface of blank 10' and separated from it by a distance of 63,5 to 76,2 mm about two and a half to three inches.
  • Rods 26 are suitably commercially available, high wattage electrical resistance heaters for emission of infrared energy. Heating rods 26 are connected through lead 27 to electrical power source 28. Power source 28 is operated by controller 30 in performance of the heating process of this invention.
  • a preferred operating temperature of the rods during their heating mode for the AA5083 blanks is about 815°C to above 926°C or about 1500 to 1700°F.
  • Convection heating is used both to supplement the rapid heating by the infrared heaters and to control the highest temperature of the sheet 10'.
  • Blower 32 draws air from the return plenum of oven 14 through insulated hot air duct 34.
  • the hot air thus exhausted from oven 14 is drawn over electrical resistance heaters (powered, e.g., by a 480 V, 3-phase, 60 Hz source) located in air heater 36.
  • Blower 32 propels the heated air through duct section 38 back into oven 14.
  • a suitable hot air circulation rate for a body panel as described may be about 226 cubic meter (8000 cubic feet) per hour.
  • the heated air is introduced into oven 14 at its supply plenum 50 near the top 42.
  • the hot air flow is directed downwardly against the sheet metal stock 10' resting on the hearth 20.
  • a plenum 50 along the top of oven 14 carries the incoming heated air along the full length of the oven and directs flow downwardly through outlets spaced regularly along the length.
  • hot air is directed generally perpendicularly against sheet 10'.
  • a plurality of parallel, air return plenums 44 are positioned parallel to the length of the oven. Three are seen in cross-section in Figure 2. Each hot air return plenum 44 has a tapered inlet portion 46 extending between two infrared heating rods 26. Hot air rebounds from the surface of sheet 10' and is drawn by blower suction into inlets 46. The return air flows in each plenum 44 to the end of the oven where the separate return streams are gathered in a manifold, not shown, and channeled into return duct 34.
  • the hot air flow is started and power is supplied to the infrared heaters.
  • An exemplary goal for this heating process may be to heat the cold worked sheet to a temperature of about 482°C (900°F) in less than 150 seconds.
  • This heating program is to transform the microstructure from severely strained, cold worked grains to a recrystallized fine grain, pseudo single phase, soft (e.g., O Temper). And the sheet is to be heated to a temperature at which it can be stretched and/or drawn into a body panel or the like product of complex shape.
  • the hot air temperature impinging the sheet will be suitably controlled to about 482° to 487°C (900 to 910°F).
  • the infrared heaters, powered by supply 28 under controller 30 will be at, for example about 815°C (1500°F).
  • the high temperature radiant heaters rapidly heat sheet 10' toward its specified temperature.
  • the sheet is typically coated with a thin film of boron nitride particles which serves as a lubricant between the surface of the sheet and the surface of the tool over which the sheet will be stretched or drawn.
  • the white BN film raises the emissivity of the somewhat reflective aluminum sheet and the overall emissivity of the coated sheet may be about 0.2.
  • the radiant heaters are tuned off to prevent overheating or even localized melting of the sheet.
  • the timing is critical to maximize heating rate without excessive heating. Unless a reliable heating model for the oven, heating system, and work pieces is available, the time for radiant heater shut off will be determined experimentally on test panels. For example, it may be determined to shut off the radiant heaters 26 after they have been operating for 100 seconds. Thereafter, the flow of heated air continues to heat and/or cool portions of the sheet to bring sheet 10' to a uniform temperature of about 482°C (900°F) as quickly as practical. The flowing air also cools the radiant heaters 26 to help lengthen their useful life.
  • the heated sheet 10' is removed from oven 14 by pulling, sliding or lifting it through exit door 52 onto surface 48.
  • the hot sheet can then be placed on a forming tool to utilize its softened and formable condition. Since the removed heated sheet 10" is at its forming temperature it is transferred without undue delay to the forming tool. If some delay and cooling is anticipated it may be desired to heat the sheet 10' to a slightly higher temperature to tolerate such cooling before forming.
  • a controlled combination of radiant heating and convection heating is used to rapidly transform (recrystallize) a cold worked sheet of suitable metal alloy to a highly formable microstructure and heat it to a suitable forming temperature to utilize the newly acquired formability.
  • the heating period is less than 150 seconds, often 60 to 90 seconds.
  • the formability of the AA 5083 sheet typically exceeds 300 + % elongation by standard tensile test.

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

Claims (8)

  1. Procédé de formage d'une tôle (10) en une composition d'alliage métallique formable à l'état superplastique, comprenant les étapes consistant à :
    fournir une tôle (10) travaillée à froid de ladite composition d'alliage métallique,
    chauffer ladite tôle (10) travaillée à froid par une combinaison de rayonnement infrarouge et de convection à l'air chaud dans le même four (20) à une température de tôle prédéterminée pour recristalliser la microstructure travaillée à froid de ladite tôle (10) en une microstructure à grains fins convenable pour le formage superplastique, et
    à chauffer ladite tôle (10) jusqu'à une température de formage superplastique,
    caractérisé en ce que
    ledit chauffage comprend d'interrompre ledit chauffage par rayonnement infrarouge avant que ladite tôle (10) atteigne ladite température prédéterminée, et de poursuivre le chauffage de ladite tôle (10) jusqu'à ladite température prédéterminée avec ledit chauffage par convection, et
    en ce que la tôle chauffée (10) est formée.
  2. Procédé selon la revendication 1, dans lequel ledit chauffage par rayonnement infrarouge comprend de chauffer avec des éléments chauffants à résistance électrique (26), et l'interruption dudit chauffage par rayonnement infrarouge comprend de couper la puissance électrique vers lesdits éléments chauffants (26).
  3. Procédé selon la revendication 1, dans lequel ladite tôle (10) est une composition en alliage d'aluminium formable à l'état superplastique.
  4. Procédé selon la revendication 3, comprenant de fournir une tôle (10) travaillée à froid qui a subi une réduction par travail à froid jusqu'à un état tempéré H18.
  5. Procédé selon la revendication 3, dans lequel ladite tôle (10) est une tôle d'alliage d'aluminium contenant du magnésium.
  6. Procédé selon la revendication 1, dans lequel ledit rayonnement infrarouge est produit avec les éléments chauffants (26) à résistance électrique maintenus à une température dans la plage d'environ 815 à environ 926 °C (1500 à 1700 °F).
  7. Procédé selon la revendication 1, dans lequel ledit chauffage par convection à l'air chaud est accompli en commandant la température dudit air à une température prédéterminée au-dessus de ladite température de tôle prédéterminée.
  8. Procédé selon la revendication 7, dans lequel ledit chauffage par convection à l'air chaud est accompli en commandant la température dudit air dans une plage de 10 °F au-dessus de ladite température de tôle prédéterminée.
EP20040003805 2004-02-19 2004-02-19 Recristallisation d'une tôle en alliage métallique par chauffage convection ainsi que par chauffage à rayonnement infrarouge Expired - Fee Related EP1566461B1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP20040003805 EP1566461B1 (fr) 2004-02-19 2004-02-19 Recristallisation d'une tôle en alliage métallique par chauffage convection ainsi que par chauffage à rayonnement infrarouge
DE602004009530T DE602004009530T2 (de) 2004-02-19 2004-02-19 Rekristallisation eines Metalllegierungsbleches mittels Konvektions- und Infrarotstrahlungsheizung

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP20040003805 EP1566461B1 (fr) 2004-02-19 2004-02-19 Recristallisation d'une tôle en alliage métallique par chauffage convection ainsi que par chauffage à rayonnement infrarouge

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EP1566461A1 EP1566461A1 (fr) 2005-08-24
EP1566461B1 true EP1566461B1 (fr) 2007-10-17

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EP20040003805 Expired - Fee Related EP1566461B1 (fr) 2004-02-19 2004-02-19 Recristallisation d'une tôle en alliage métallique par chauffage convection ainsi que par chauffage à rayonnement infrarouge

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Publication number Priority date Publication date Assignee Title
SE534565C2 (sv) * 2009-06-23 2011-10-04 Linde Ag Glödgning av kallvalsade metallband

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4354827A (en) * 1981-04-17 1982-10-19 Midland-Ross Corporation Process and device for improving heat exchange in furnaces heated by radiant heaters
EP0832702B1 (fr) * 1996-09-25 2000-12-13 Alusuisse Technology & Management AG Méthode de fabrication de corps creux
JP2000160260A (ja) * 1998-11-20 2000-06-13 Sakaguchi Dennetsu Kk 薄板加熱用コンベアー炉
US6253588B1 (en) * 2000-04-07 2001-07-03 General Motors Corporation Quick plastic forming of aluminum alloy sheet metal

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DE602004009530D1 (de) 2007-11-29
DE602004009530T2 (de) 2008-02-07

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