EP3117018A1 - High strength aluminum alloys - Google Patents
High strength aluminum alloysInfo
- Publication number
- EP3117018A1 EP3117018A1 EP15760680.7A EP15760680A EP3117018A1 EP 3117018 A1 EP3117018 A1 EP 3117018A1 EP 15760680 A EP15760680 A EP 15760680A EP 3117018 A1 EP3117018 A1 EP 3117018A1
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- European Patent Office
- Prior art keywords
- weight percent
- aluminum
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- alloy
- weight
- Prior art date
- 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.)
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Classifications
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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
- C22F1/05—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 of the Al-Si-Mg type, i.e. containing silicon and magnesium in approximately equal proportions
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/02—Alloys based on aluminium with silicon as the next major constituent
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
- C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
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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
- C22F1/043—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 silicon as the next major constituent
Definitions
- the present disclosure is generally directed to new high strength aluminum alloys, more particularly 6XXX series aluminum alloys and methods of manufacturing the same.
- the invention relates to a class of new 6XXX series high strength aluminum alloys with a fine grain structure and methods of manufacture and extrusion.
- Inventive aluminum alloys of the invention comprise from about 0.90 percent to about 1.2 percent by weight silicon, up to about 0.5 percent by weight iron, from about 0.05 percent to about 0.3 percent by weight copper, up to about 0.75 percent by weight manganese, from about 0.70 percent to about 1.0 percent by weight magnesium, up to about 0.25 percent by weight chromium, up to about 0.05 percent by weight zinc, up to about 0.1 percent by weight titanium, with the balance consisting essentially of aluminum.
- One object of the invention is to artificially age the extruded aluminum material and produce a fine grain structure in the final aluminum product which exhibits superior yield strength and elongation properties.
- One object of the invention is to provide an aluminum alloy with a minimum tensile yield strength of about 320 MPa.
- FIG. 1 of the drawings is a schematic cross section of an aluminum extrusion
- FIG. 2 of the drawings is a schematic cross section of an aluminum extrusion
- FIG. 3 of the drawings is a graphic representation of water quench rate for various charges of aluminum extrusion section 569310.
- FIG. 4 of the drawings is a graphic representation of water quench rate for various charges of aluminum extrusion section 569510.
- FIG. 5 of the drawings depicts locations for tensile testing of aluminum extrusion section 569310.
- FIG. 6 of the drawings depicts locations for tensile testing of aluminum extrusion section 569510.
- FIG. 7 of the drawings is a graphic representation of aluminum extrusion section 569310 natural age ultimate tensile strength against age time.
- FIG. 8 of the drawings is a graphic representation of aluminum extrusion section 569310 natural age yield strength against age time.
- FIG. 9 of the drawings is a graphic representation of aluminum extrusion section 569310 natural age elongation against age time.
- FIG. 10 of the drawings is a graphic representation of aluminum extrusion section 569310 artificial age ultimate tensile strength against age time.
- FIG. 11 of the drawings is a graphic representation of aluminum extrusion section 569310 artificial age yield strength against age time.
- FIG. 12 of the drawings is a graphic representation of aluminum extrusion section 569310 artificial age elongation against age time.
- FIG. 13 of the drawings is a graphic representation of aluminum extrusion section 569510 artificial age ultimate tensile strength against age time.
- FIG. 14 of the drawings is a graphic representation of aluminum extrusion section 569510 artificial age yield strength against age time.
- FIG. 15 of the drawings is a graphic representation of aluminum extrusion section 569510 artificial age elongation against age time.
- FIG. 16A of the drawings is a photomicrograph of a polished section of an aluminum alloy log of the invention (head, center at 200x magnification).
- FIG. 16B of the drawings is a photomicrograph of a polished section of an aluminum alloy log of the invention (head, center at 500x magnification).
- FIG. 17 of the drawings is a photomicrograph of a polished section of an aluminum alloy log of the invention (head, edge at lOOx magnification).
- FIG. 18A of the drawings is a photomicrograph of a polished section of an aluminum alloy log of the invention (butt, center at 200x magnification).
- FIG. 18B of the drawings is a photomicrograph of a polished section of an aluminum alloy log of the invention (butt, center at 500x magnification).
- FIG. 19 of the drawings is a photomicrograph of a polished section of an aluminum alloy log of the invention (butt, edge at 5 Ox magnification).
- FIG. 20 of the drawings is a photomicrograph of a polished and electro lyrically etched section of an aluminum alloy log of the invention (head, center, at 5 Ox magnification).
- FIG. 21 of the drawings is a photomicrograph of a polished and electro lyrically etched section of an aluminum alloy log of the invention (head, edge).
- FIG. 22 of the drawings is a photomicrograph of a polished and electro lyrically etched section of an aluminum alloy log of the invention (butt, center at 5 Ox magnification)
- FIG. 23 of the drawings is a photomicrograph of a polished and electrolytically etched section of an aluminum alloy log of the invention (butt, edge)
- FIG. 24 of the drawings is a photograph of a cross section of aluminum extrusion section 569310 showing unrecrystallized regions.
- FIG. 25 of the drawings is a photograph of a cross section of aluminum extrusion section 569310 showing unrecrystallized regions.
- FIG. 26 of the drawings is a photograph of a cross section of aluminum extrusion section 569510 showing fine grain recrystallization.
- FIG. 27 of the drawings is a photograph of a cross section of aluminum extrusion section 569510 showing fine grain recrystallization.
- FIG. 28 of the drawings is a photograph of an electrolytically etched cross section of aluminum extrusion section 569310 showing unrecrystallized regions with coarse grain recrystallization.
- FIG. 29 of the drawings is a photograph of an electrolytically etched cross section of aluminum extrusion section 569510 showing fully recrystallized grain structure.
- FIG. 30 of the drawings is a photograph of a transverse weld of aluminum extrusion section 569510.
- FIG. 31 of the drawings is a photograph of a weld of aluminum extrusion section 569310.
- FIG. 32 of the drawings is a schematic of the die design for section 569310.
- FIG. 33 of the drawings is a schematic of the die design for section 569510.
- FIG. 34 of the drawings is a graphic representation of yield strength against extrusion exit temperature for various charges of aluminum extrusion section 569310 artificially aged at 338/347°F for six hours.
- Embodiments of the present invention relate to high strength 6XXX series alloys comprising aluminum and additional elements.
- the alloys are cast into ingots and then heated or homogenized at a particular temperature range to uniformly disperse the alloying additions throughout the aluminum matrix.
- a billet of the inventive aluminum alloy is then extruded through a press at an initial billet temperature and at a particular extrusion speed, after which the resulting extruded aluminum product is quenched.
- the extrusion process is such that it provides suitable conditions for a fine grain recrystallized structure.
- Fine grain recrystallization is a primary objective of the inventive alloys described herein. The fine grain crystallization yields a final aluminum product with superior yield strength and elongation properties.
- Aluminum alloys of the invention are high strength 6XXX alloys.
- aluminum alloys of the invention comprise mostly aluminum along with at least about 1.05 weight percent silicon, at least about 0.12 weight percent copper, about 0.20 weight percent manganese, and at least 0.76 weight percent magnesium. Amounts of alloy components are stated in weight percent of alloy unless otherwise stated.
- aluminum alloys of the invention comprise from about
- aluminum alloys of the invention comprise: about 1.13 weight percent silicon, about 0.17 weight percent iron, about 0.16 weight percent copper, about 0.21 weight percent manganese, about 0.80 weight percent magnesium, about 0.004 weight percent chromium, about 0.006 weight percent zinc, about 0.014 weight percent titanium, and the balance consisting essentially of aluminum.
- the total amount of impurities in the aluminum alloy is approximately zero. In one embodiment the total amount of impurities in the aluminum alloy comprise about 0.15 percent by weight. In one embodiment the amount of any single impurity does not exceed about 0.05 percent by weight.
- Silicon may be present in the alloy in an amount between about 0.90 percent to about 1.20 percent by weight. In one embodiment silicon is present in an amount between about 1.05 to about 1.12 percent by weight; in one embodiment silicon is present in an amount between about 1.05 to about 1.10 percent by weight. Silicon may be present in the alloy in an amount of about 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1.00, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1.08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19, or 1.20 percent by weight.
- Iron may be present in the alloy in an amount up to about 0.50 percent by weight. In one embodiment iron is present in an amount up to about 0.25 percent by weight. Iron may be present in the alloy in an amount of about zero, 0.01, 0.02, 0.03, 0.04, 0.05, 0.06, 0.07, 0.08, 0.09, 0.10, 0.11, 0.12, 0.13, 0.14, 0.15, 0.16, 0.17, 0.18, 0.19, 0.20, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26, 0.27, 0.28, 0.29, 0.30, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.40, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49, or 0.50 percent by weight.
- Copper may be present in the alloy in an amount between about 0.05 percent to about 0.3 percent by weight. In one embodiment copper is present in an amount between about 0.05 to about 0.30 percent by weight; in one embodiment copper is present in an amount between about 0.12 to about 0.18 percent by weight; in one embodiment copper is present in an amount between about 0.09 to about 0.15 percent by weight. Copper may be present in the alloy in an amount of about 0.05, 0.06, 0.07, 0.08, 0.09, 0.10, 0.11, 0.12, 0.13, 0.14, 0.15, 0.16, 0.17, 0.18, 0.19, 0.20, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26, 0.27, 0.28, 0.29, or 0.30 percent by weight.
- Manganese may be present in the alloy in an amount up to about 0.75 percent by weight. In one embodiment manganese is present in an amount between about 0.15 to about 0.75 percent by weight; in one embodiment manganese is present in an amount between about 0.15 to about 0.20 percent by weight; in one embodiment manganese is present in an amount between about 0.51 to about 0.56 percent by weight.
- Manganese may be present in the alloy in an amount of about 0.01, 0.02, 0.03,
- manganese While the amount of manganese present in the alloy may be below 0.10% or also zero, it is not preferred due to a lowering of fracture toughness. Manganese adds resistance to the recrystallization process and to form a completely recrystallized grain structure it is preferable that the manganese should be kept as close to zero as possible. Adding manganese, however, has positive effects on the fracture toughness of the material. Manganese is added to obtain fine grain recrystallization without negatively affecting the alloy's fracture toughness.
- Magnesium may be present in the alloy in an amount between about 0.70 percent to about 1.0 percent by weight. In one embodiment magnesium is present in an amount between about 0.74 to about 0.80 percent by weight; in one embodiment magnesium is present in an amount between about 0.76 to about 0.82 percent by weight. Magnesium may be present in the alloy in an amount of about 0.70, 0.71, 0.72, 0.73, 0.74, 0.75, 0.76, 0.77, 0.78, 0.79, 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, or 1.0 percent by weight.
- Chromium adds resistance to the recrystallization process and to form a completely recrystallized grain structure it is preferable that the chromium should be kept as close to zero as possible.
- Chromium may be absent from the alloy (that is, zero percent by weight).
- Chromium may be present in the alloy in an amount up to about 0.250 percent by weight. In one embodiment chromium is present in an amount up to about 0.030 percent by weight; in one embodiment chromium is present in an amount up to about 0.010 percent by weight; in one embodiment chromium is present in an amount up to about 0.005 percent by weight.
- Chromium may be present in the alloy in an amount of about 0.005, 0.010, 0.015, 0.020, 0.025, 0.030, 0.035, 0.040, 0.045, 0.050, 0.055, 0.060, 0.065, 0.070, 0.075, 0.080, 0.085, 0.090, 0.095, 0.100, 0.105, 0.110, 0.115, 0.120, 0.125, 0.130, 0.135, 0.140, 0.145, 0.150, 0.155, 0.160, 0.165, 0.170, 0.175, 0.180, 0.185, 0.190, 0.195, 0.200, 0.205, 0.210, 0.215, 0.220, 0.225, 0.230, 0.235, 0.240, 0.245, or 0.250 percent by weight. Chromium is better at impeding recrystallization than manganese due to the different locations at which the dispersoids form.
- Zinc may be present in the alloy in an amount up to about 0.050 percent by weight. In one embodiment zinc is present in an amount up to about 0.020 percent by weight; in one embodiment zinc is present in an amount up to about 0.005 percent by weight. Zinc may be present in the alloy in an amount of about zero, 0.005, 0.010, 0.015, 0.020, 0.025, 0.030, 0.035, 0.040, 0.045, or percent by weight.
- Titanium may be present in the alloy in an amount up to about 0.100 percent by weight. In one embodiment titanium is present in an amount up to about 0.040 percent by weight; in one embodiment titanium is present in an amount up to about 0.015 percent by weight. Titanium may be present in the alloy in an amount of about zero, 0.005, 0.010, 0.015, 0.020, 0.025, 0.030, 0.035, 0.040, 0.045, 0.050, 0.055, 0.060, 0.065, 0.070, 0.075, 0.080, 0.085, 0.090, 0.095, or 0.100 percent by weight.
- Impurities may be present in the alloy in a total amount up to about 0.150 percent by weight. Impurities may be present in the alloy in a total amount of about zero, 0.005, 0.010, 0.015, 0.020, 0.025, 0.030, 0.035, 0.040, 0.045, 0.050, 0.055, 0.060, 0.065, 0.070, 0.075, 0.080, 0.085, 0.090, 0.095, 0.100, 0.105, 0.110, 0.115, 0.120, 0.125, 0.130, 0.135, 0.140, 0.145, or 0.150 percent by weight.
- Amounts of each element included in the inventive aluminum alloy may vary by between about 1% and about 25% of the desired value. Amounts of each element may vary by about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, or 25% of the desired value.
- the final alloy in an inventive alloy designed to comprise silicon at about 1.0 percent by weight where the amount of silicon may vary by 10%, the final alloy may comprise silicon at between about 0.9 percent by weight to about 1.1 percent by weight. In another non-limiting example, in an inventive alloy designed to comprise copper at about 0.15 percent by weight where the amount of copper may vary by 20%, the final alloy may comprise copper at between about 0.12 percent by weight to about 0.18 percent by weight.
- the alloy may be cast into logs or billets according to conventional methods.
- the alloy may be cast at a temperature above about 1300°F, more particularly between about 1310°F and about 1330°F.
- Logs may be cast into any appropriate size or shape as needed.
- the microstructure of the logs or billets may not be uniform due to the solidification process.
- Solidification starts with the a-aluminum, by nature of the phase diagram.
- the aluminum forms single crystal dendrites with respect to the direction of heat transfer while the area surrounding the dendrites is solute rich with Mg 2 Si which needs to be dissolved.
- the cast aluminum is homogenized.
- Homogenization may take place at a temperature below the casting temperature, preferably at a temperature between about 1045°F and about 1070°F.
- the cast aluminum should be homogenized at an elevated temperature and for sufficient time to permit the alloying elements energy needed to diffuse into the aluminum dendrite arms to develop a more uniform microstructure. In one embodiment, homogenization occurs over the span of several hours, in one embodiment homogenization occurs over about four hours. Homogenization may occur in a furnace such as a Canefco furnace. [0067] EXTRUDING AND QUENCHING
- the aluminum is extruded through a press to obtain a desired shape or form.
- the billet may be extruded through the press at any appropriate temperature based on the size and shape of the extrusion.
- Initial billet temperature should be selected to ensure the material has the ability to extrude easily. The temperature is chosen for productivity and ensuring a fine grain recrystallized structure. Initial billet temperature may be below the homogenization temperature.
- the initial billet temperature is over about 800°F; in one embodiment the initial billet temperature is between about 840°F and about 880°F; in one embodiment the initial billet temperature is between about 850°F and about 870°F; the initial billet temperature may be about 850°F, about 855°F, about 860°F, about 865°F, or about 870°F.
- the billet may be extruded through the press using a ram at any appropriate speed based on the size and shape of the extrusion.
- the press ram speed is between about 9.0 and about 13.0 inches per minute; in one embodiment the press ram speed is between about 9.0 and about 10.0 inches per minute; in one embodiment the press ram speed is between about 12.0 and about 12.5 inches per minute.
- the aluminum material exits the extruder at an exit temperature greater than the initial billet temperature.
- the exit temperature of the aluminum material is about 1040°F. Higher temperatures are preferred over lower exit temperatures because lower exit temperatures negatively affects the strength of the metal.
- the aluminum material is quenched with water.
- the temperature is decreased from a temperature of approximately the exit temperature down to approximately ambient temperature over the span of several seconds.
- the aluminum material is quenched in between about 8 to about 16 seconds; in one embodiment the aluminum material is quenched in between about 10 to about 14 seconds; the aluminum material may be quenched in about 8 seconds, about 9 seconds, about 10 seconds, about 11 seconds, about 12 seconds, about 13 seconds, about 14 seconds, about 15 seconds, or about 16 seconds.
- Sections of the aluminum extrusion may have any suitable thickness, and the preferred thickness of extrusion sections may range from about 0.050 inch to about 0.500 inch. In one embodiment the thickness of each wall of an aluminum extrusion is between about 0.080 and about 0.200 inches; in one embodiment the thickness of each wall of an aluminum extrusion is between about 0.080 and about 0.150 inches.
- the extruded aluminum material may be placed in a furnace to stabilize it. Stabilization may occur at any appropriate furnace temperature for any appropriate time; in one embodiment the furnace temperature is about 250°F and the aluminum is stabilized in the furnace for about two hours.
- the aluminum extrusion must be artificially aged by heating the aluminum material to an appropriate temperature for an appropriate time.
- Artificial aging temperatures may range from about 300°F to about 450°F; in one embodiment the temperature ranges from about 320°F to about 385°F; in one embodiment the temperature ranges from about 320°F to about 330°F; in one embodiment the temperature ranges from about 335°F to about 350°F; in one embodiment the temperature ranges from about 355°F to about 365°F; in one embodiment the temperature ranges from about 370°F to about 385°F; the temperature may be about 300°F, about 305°F, about 310°F, about 315°F, about 320°F, about 325°F, about 330°F, about 335°F, about 340°F, about 345°F, about 350°F, about 355°F, about 360°F, about 365°F, about 370°F, about 375°F, about 380°F, about 3
- Artificial aging conditions may be applied for between about 1 to about 16 hours; in one embodiment the artificial aging conditions are applied from about 2 to about 12 hours; in one embodiment the artificial aging conditions are applied from about 2 to about 10 hours; in one embodiment the artificial aging conditions are applied from about 4 to about 16 hours; in one embodiment the artificial aging conditions are applied from about 1 to about 6 hours; the artificial aging conditions may be applied for about 1 hour, about 2 hours, about 3 hours, about 4 hours, about 5 hours, about 6 hours, about 7 hours, about 8 hours, about 9 hours, about 10 hours, about 11 hours, about 12 hours, about 13 hours, about 14 hours, about 15 hours, or about 16 hours. In a preferred embodiment the artificial aging conditions are applied for about six hours. In one preferred embodiment, the artificial aging temperature ranges from about 335°F to about 350°F and the conditions are applied for about six hours.
- Tensile strength may be measured manually or by an automated process.
- Automated tests may be performed, for example, on a Zwick Automated Tensile Test Machine.
- Ultimate tensile strength of the extruded and artificially aged aluminum material may be greater than about 310 MPa; in one embodiment the ultimate tensile strength may range from about 310 MPa to about 370 MPa.
- the ultimate tensile strength may be about 310 MPa, about 315 MPa, about 320 MPa, about 325 MPa, about 330 MPa, about 335 MPa, about 340 MPa, about 345 MPa, about 350 MPa, about 355 MPa, about 360 MPa, about 365 MPa, or about 370 MPa.
- the ultimate tensile strength of an extruded and naturally aged inventive aluminum alloy may range from about 260 MPa to about 295 MPa.
- the ultimate tensile strength of the extruded and artificially aged aluminum material is greater than about 320 MPa; in a preferred embodiment the ultimate tensile strength of the extruded and artificially aged aluminum material is between about 340 MPa and about 360 MPa; in a preferred embodiment the ultimate tensile strength of the extruded and artificially aged aluminum material is about 350 MPa.
- Yield strength of the extruded and artificially aged aluminum material may be greater than about 275 MPa; in one embodiment the ultimate tensile strength may range from about 285 MPa to about 350 MPa. The ultimate tensile strength may be about 285 MPa, about 290 MPa, about 295 MPa, about 300 MPa, about 305 MPa, about 310 MPa, about 315 MPa, about 320 MPa, about 325 MPa, about 330 MPa, about 335 MPa, about 340 MPa, about 345 MPa, or about 350 MPa.
- the yield strength of an extruded and naturally aged inventive aluminum alloy may range from about 140 MPa to about 180 MPa. In a preferred embodiment the yield strength of the extruded and artificially aged aluminum material is greater than about 320 MPa; in a preferred embodiment the yield strength of the extruded and artificially aged aluminum material is between about 325 MPa and about 335 MPa.
- Elongation of the extruded and artificially aged aluminum material may be less than about 17%; in one embodiment the elongation may range from about 17% to about 7.0%).
- the elongation may be about 17.0%, about 16.5%, about 16.0%, about 15.5%, about 15.0%, about 14.5%, about 14.0%, about 13.5%, about 13.0%, about 12.5%, about 12.0%, about 11.5%, about 11.0%, about 10.5%, about 10.0%, about 9.5%, about 9.0%, about 8.5%, about 8.0%), about 7.5%, or about 7.0%.
- the elongation of an extruded and naturally aged inventive aluminum alloy may range from about 24.5% to about 21.0%.
- the elongation of the extruded and artificially aged aluminum material is between about 11.0% and about 14.0%.
- a primary objective of the new chemistry described herein is to achieve fine grain recrystallization. Typically when a grain structure is fully recrystallized with fine grains, elongation properties are better, owing to the slip distances within the grains. The slip distance in smaller grains is significantly reduced when compared to larger grains. Since grains are randomly oriented in three dimensional space, the slip plane orientations are also along random directions.
- the amount of dispersoid elements namely manganese and chromium, are adjusted.
- manganese is present in a range of about 0.15 to 0.2 and chromium is present at about 0.03 maximum. Both manganese and chromium add resistance to the recrystallization process, so to form a completely recrystallized grain structure, the elements would have been kept as close to zero as possible.
- Adding manganese has positive effects on the fracture toughness of the material. The manganese is added in an effort to obtain fine grain recrystallization without negatively affecting the fracture toughness.
- the extrusion process impacts the alloy's recrystallization properties.
- Extruder die design may impact the grain structure of the extruded aluminum material.
- Two aluminum billets run through two different dies at similar speeds and temperatures may yield different grain structures based on die design.
- the choke and number of ports for aluminum to flow through may impact the recrystallization process.
- a choke helps to east the aluminum metal through the due which, in turn, causes less strain energy to be present.
- the grains will not recrystallize from the as-cast structure if there is not enough energy to do so.
- Presence of a choke will reduce the strain energy as the metal is pushed through the die and may result in unrecrystallized regions. Absence of choke will increase the strain energy as the metal is pushed through the die and which may result in recrystallized regions.
- the number of ports may also impact the recrystallization process. Additional ports, or larger ports, may permit metal to flow through with greater ease. The extruded aluminum will choose these paths of lower resistance to flow. Increased metal flow will then increase the shear stresses in the metal, and increased shear stresses give the metal more energy to recrystallize.
- Initial billet temperature, extrusion speed, and exit temperatures also impact the recrystallization process and, ultimately, the extruded alloy's strength. Initial billet temperatures should be selected to ensure the material may be extruded easily while achieving the desired strength and grain structure.
- Conductivity of the extruded aluminum material may be between about 40.0 and 50.0.
- the conductivity may be about 40.0, about 41.0, about 42.0, about 43.0, about 44.0, about 45.0, about 46.0, about 47.0, about 48.0, about 49.0, or about 50.0.
- the conductivity is between about 46.0 to about 48.0; in one preferred embodiment the conductivity is about 46.0.
- HS6X was cast into 36 individual logs, each log was 10 inches in diameter and
- Chart 1 Temporary cast practice used for HS6X.
- Example 1 The sections are shown in FIG. 1 and FIG. 2. Though the sections look similar, there are a few notable differences. Section 569510 has a thinner wall when compared to section 569310. The center and bottom walls of section 569510 also contain regions where the area is not consistent also known as reduced areas. Seven charges of each section were run and all charges were water quenched after leaving the press. Reduced areas are indicated by arrows in FIG. 2.
- Table 3 Information gathered from press during extrusion process.
- Table 5 The ultimate tensile strength, yield strength, and elongation as a function of natural age time are displayed in FIG. 7, FIG. 8, and FIG. 9, respectively.
- Table 5 Natural Age Tensile and Conductivity Data for Section 569310
- Example 3 was placed in a furnace at 250°F for two hours in order to stabilize it. Stabilizing the metal prevented the loss of artificial aging response (e.g. strength loss) that occurs in 6XXX alloys when they have significant natural aging time. The stabilized pieces could then be used for artificial age testing independent of the effect of varying natural aging times on strength.
- both extruded sections 569310 and 569510 of Example 2 were aged and tested. Tensile test locations for section 569510 are shown in FIG. 6 (indicated by ovals). Since the section of 569510 had reduced areas indicated by arrows along the bottom of one side, both sides could not be used for testing purposes.
- Table 7 The ultimate tensile strength, yield strength, and elongation as a function of age time and temperature for section 569310 are displayed in FIGS. 10-12.
- Table 8 Artificial Age Tensile and Conductivity Data for Section 569510
- section 569310 had both its tensile and yield strength drop off
- section 569510 had only the tensile strength drop with the yield strength lingering at elevated strengths which is not common.
- Section 569310 had the same location from every charge tested while section 569510 was more randomized - sampling from front, middle, and rear sections rather than using the same location for every condition.
- section 569310 experienced better elongation. This could be due to the unrecrystallized grain structure in the center wall. In other words, there were not enough coarse recrystallized grains to interfere with the elongation.
- the inventive chemistry described here was created to avoid the issue of poor elongation resulting from coarse grains along the edges, but due to the die design of section 569310, the unrecrystallized portions were unavoidable with the extrusion process used.
- Sample slices were taken from one log of Example 1 after homogenization for characterization purposes. One slice was taken from the head (top) and the other was taken from the butt (bottom) of the log. Two micros were mounted from each slice; one along the edge in the transverse direction and one from the center in the longitudinal direction with respect to the casting direction. Images of the as-polished pieces are shown in FIGS. 16A, 16B, 17, 18A, 18B, and 19.
- section 569510 display fine grain recrystallization while section 569310 exhibits a mixed grain structure of unrecrystallized and coarse grains.
- the grain structure for pieces extruded through section 569510 is shown in FIGS. 26 and 27.
- Section 569310 showed signs of bad welds in the center walls as shown in
- FIG. 31 There is clear separation across the weld.
- the bad weld in the center wall was found in front, middle, and rear samples of charges four, five, and six, and in front and middle sections of charge seven. Since the bad weld was present in a significant amount of samples, it was determined that the design of the die was the most likely cause for the occurrence. Though the weld did not affect testing for this example, the die would need to be redesigned to prevent the bad weld from occurring.
- the die design for section 569310 is shown in FIG. 32; the die design for section 569510 is shown in FIG. 33. There were a few dissimilarities between the dies.
- the die for section 569310 contains four ports for the aluminum to flow through as well as a six degree choke around the outside of the shape. In contrast, the die for section 569510 has five ports and no choke. Both choke and the number of ports have an effect on the recrystallization process.
- the choke plays a big role in recrystallization of grains - specifically the lack of recrystallization.
- a choke helps to ease metal through the die which, in turn, causes less strain energy to be present. Grains will not recrystallize from the as-cast structure if there is not enough energy to do so. This lack of energy is what caused the unrecrystallized regions in section 569310 (FIG. 1) which had a six degree choke on the outside of the shape (FIG. 32). Section 569510 (FIG. 2) in comparison does not have any choke present (FIG. 33).
- the absence of choke (for example for section 569510) will increase the strain energy as the metal is pushed through, which could explain the recrystallization in the outer walls.
- Example 2 The exit temperatures of each section of Example 2 during extrusion varied depending on the charge.
- the first charges of both sections had a lower exit temperature than the other five. This negatively impacts the strength of the metal.
- the lower exit temperatures cause the Mg 2 Si precipitates to not dissolve completely which will cause them to become coarse and further apart from each other which allow more dislocations to move through the piece.
- FIG. 34 shows the yield strength as a function of exit temperature for the artificial age practice 338/347 °F for six hours for section 569310. Charges one and two experienced a lower strength than the rest of the group because of the lower exit temperature. Due to this drop in strength the first two charges were discarded from testing results.
- one HS6X composition is as follows:
- one HS6X composition is as follows:
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Abstract
Description
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US201461951309P | 2014-03-11 | 2014-03-11 | |
US201461954358P | 2014-03-17 | 2014-03-17 | |
PCT/US2015/019867 WO2015138551A1 (en) | 2014-03-11 | 2015-03-11 | High strength aluminum alloys |
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EP3117018A4 EP3117018A4 (en) | 2017-12-13 |
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EP (1) | EP3117018A4 (en) |
JP (1) | JP2017512260A (en) |
KR (1) | KR20170002382A (en) |
CN (1) | CN106488991A (en) |
CA (1) | CA2942338A1 (en) |
WO (1) | WO2015138551A1 (en) |
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CN105238962B (en) * | 2015-10-12 | 2017-10-24 | 苏州中色研达金属技术有限公司 | Electronic product appearance member high-performance 6XXX line aluminium alloys and its processing method |
CN105220030B (en) * | 2015-10-12 | 2018-03-27 | 苏州中色研达金属技术有限公司 | Electronic product appearance member 6XXX line aluminium alloys and its processing method |
CN111455232A (en) * | 2020-05-26 | 2020-07-28 | 广东兴发铝业(河南)有限公司 | Aluminum alloy round ingot for refrigerator and production method |
CN114774745B (en) * | 2022-04-22 | 2023-10-20 | 山东裕航特种合金装备有限公司 | High-strength aluminum alloy for electronic material and preparation method thereof |
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US4082578A (en) * | 1976-08-05 | 1978-04-04 | Aluminum Company Of America | Aluminum structural members for vehicles |
DE3243371A1 (en) * | 1982-09-13 | 1984-03-15 | Schweizerische Aluminium AG, 3965 Chippis | ALUMINUM ALLOY |
US4589932A (en) * | 1983-02-03 | 1986-05-20 | Aluminum Company Of America | Aluminum 6XXX alloy products of high strength and toughness having stable response to high temperature artificial aging treatments and method for producing |
JP2534266B2 (en) * | 1987-07-09 | 1996-09-11 | 古河電気工業株式会社 | Method for manufacturing winding body for wind noise prevention of electric wire |
JPH03247738A (en) * | 1990-02-22 | 1991-11-05 | Kobe Steel Ltd | Aluminum alloy excellent in bendability |
JPH0654405A (en) * | 1992-07-29 | 1994-02-25 | Nippon Light Metal Co Ltd | Aluminum alloy material for supporting slide plate |
JPH0941062A (en) * | 1995-07-27 | 1997-02-10 | Furukawa Electric Co Ltd:The | Alum.-magnesium-silicon type alum. alloy sheet material for automotive body sheet small in secular change and excellent in baking hardenability and its production |
JPH10219381A (en) * | 1997-02-03 | 1998-08-18 | Nippon Steel Corp | High strength aluminum alloy excellent in intergranular corrosion resistance, and its production |
JPH11310841A (en) * | 1998-04-28 | 1999-11-09 | Nippon Steel Corp | Aluminum alloy extruded shape excellent in fatigue strength, and its production |
US6361741B1 (en) * | 1999-02-01 | 2002-03-26 | Alcoa Inc. | Brazeable 6XXX alloy with B-rated or better machinability |
JP4386393B2 (en) * | 1999-06-23 | 2009-12-16 | 株式会社神戸製鋼所 | Aluminum alloy sheet for transport aircraft with excellent corrosion resistance |
JP3919996B2 (en) * | 2000-02-04 | 2007-05-30 | 株式会社神戸製鋼所 | Aluminum alloy for plasma processing apparatus, aluminum alloy member for plasma processing apparatus and plasma processing apparatus |
EP1205567B1 (en) * | 2000-11-10 | 2005-05-04 | Alcoa Inc. | Production of ultra-fine grain structure in as-cast aluminium alloys |
JP4865174B2 (en) * | 2001-09-28 | 2012-02-01 | 古河スカイ株式会社 | Manufacturing method of aluminum alloy sheet with excellent bending workability and drawability |
JP3953432B2 (en) * | 2003-03-10 | 2007-08-08 | 古河スカイ株式会社 | Pipe member for gaseous fuel tank, gaseous fuel tank and manufacturing method thereof |
JP2004277786A (en) * | 2003-03-14 | 2004-10-07 | Nippon Light Metal Co Ltd | Method for manufacturing heat treatment type aluminum alloy material for cold working superior in machinability |
WO2007114078A1 (en) * | 2006-03-31 | 2007-10-11 | Kabushiki Kaisha Kobe Seiko Sho | Aluminum alloy forging member and process for producing the same |
US20080041501A1 (en) * | 2006-08-16 | 2008-02-21 | Commonwealth Industries, Inc. | Aluminum automotive heat shields |
JP2009013503A (en) * | 2008-09-29 | 2009-01-22 | Showa Denko Kk | Aluminum alloy extruded material for machining, machined article made of aluminum alloy, and valve material for automotive part |
JP5366748B2 (en) * | 2009-09-30 | 2013-12-11 | 株式会社神戸製鋼所 | Aluminum alloy extruded material with excellent bending crushability and corrosion resistance |
JP2011074470A (en) * | 2009-09-30 | 2011-04-14 | Kobe Steel Ltd | Aluminum alloy extruded form with excellent bending crushability and corrosion resistance |
JP5421067B2 (en) * | 2009-10-30 | 2014-02-19 | 株式会社Uacj | Resin-coated aluminum alloy plate for beverage can body and method for producing the same |
FR2955336B1 (en) * | 2010-01-20 | 2013-02-15 | Alcan Rhenalu | PROCESS FOR MANUFACTURING 6XXX ALLOY PRODUCTS FOR VACUUM CHAMBER |
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JP5698695B2 (en) * | 2012-03-30 | 2015-04-08 | 株式会社神戸製鋼所 | Aluminum alloy forgings for automobiles and manufacturing method thereof |
JP5872443B2 (en) * | 2012-03-30 | 2016-03-01 | 株式会社神戸製鋼所 | Aluminum alloy forgings for automobiles and manufacturing method thereof |
US20140123719A1 (en) * | 2012-11-08 | 2014-05-08 | Sapa Extrusions, Inc. | Recrystallized 6XXX Aluminum Alloy with Improved Strength and Formability |
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2015
- 2015-03-11 CA CA2942338A patent/CA2942338A1/en not_active Abandoned
- 2015-03-11 US US15/125,086 patent/US20170022593A1/en not_active Abandoned
- 2015-03-11 EP EP15760680.7A patent/EP3117018A4/en not_active Withdrawn
- 2015-03-11 CN CN201580021121.7A patent/CN106488991A/en active Pending
- 2015-03-11 KR KR1020167028223A patent/KR20170002382A/en unknown
- 2015-03-11 JP JP2016575608A patent/JP2017512260A/en not_active Ceased
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EP3117018A4 (en) | 2017-12-13 |
JP2017512260A (en) | 2017-05-18 |
WO2015138551A1 (en) | 2015-09-17 |
CN106488991A (en) | 2017-03-08 |
US20170022593A1 (en) | 2017-01-26 |
KR20170002382A (en) | 2017-01-06 |
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