EP3299482B1 - Procédé de fabrication d'un alliage de 6xxx series de haute résistance pour forger. - Google Patents

Procédé de fabrication d'un alliage de 6xxx series de haute résistance pour forger. Download PDF

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Publication number
EP3299482B1
EP3299482B1 EP16189960.4A EP16189960A EP3299482B1 EP 3299482 B1 EP3299482 B1 EP 3299482B1 EP 16189960 A EP16189960 A EP 16189960A EP 3299482 B1 EP3299482 B1 EP 3299482B1
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EP
European Patent Office
Prior art keywords
temperature
aluminium alloy
hot
6xxx
ingot
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EP16189960.4A
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German (de)
English (en)
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EP3299482A1 (fr
Inventor
Svetlana Emirovna EBZEEVA
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Aleris Aluminum Duffell BVBA
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Aleris Aluminum Duffell BVBA
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Classifications

    • 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
    • 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
    • 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
    • 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

Definitions

  • the invention relates to high-strength AA6xxx-series aluminium alloy forgings particularly suitable for automotive, rail or transportation structural components, exhibiting a balance in high strength and corrosion resistance.
  • 6xxx aluminium alloy or "6xxx alloy” designate an aluminium alloy having magnesium and silicon as major alloying elements.
  • AA6xxx-series aluminium alloy designates any 6xxx aluminium alloy listed in "International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys” published by The Aluminum Association, Inc.
  • up to 0.25% Zn and ⁇ 0.25% Zn may include an alloy having no Zn.
  • Aluminium alloy compositions and tempers have been developed for obtaining satisfying strength and corrosion behaviour in car components such as chassis-suspension or body structure parts, but also rail or transportation structural components in particular when they are made from forgings.
  • high strength forgings obtained from extruded semifinished products, and from 6xxx-series aluminium alloys characterised by a minimum Si-content of 0.7% and minimum Mg-content of 0.6%, for example of the AA6082, AA6182, AA6110, or AA6056 type, are produced by:
  • EP-3018226-A1 (Constellium Valais) proposes a combination of 6xxx-series alloy and a process which intends to secure an ultimate tensile strength higher than 400 MPa, preferably higher than 450 MPa, and even higher than 480 MPa. This combination provides an aluminium alloy forged product obtained by the following steps:
  • Solidus Ts is the temperature below which the alloy exhibits a solid fraction equal to 1.
  • Solvus defines the temperature, which is the limit of solid solubility in the equilibrium phase diagram of the alloy.
  • eutectic alloying elements such as Si, Mg and Cu should be added to form precipitated hardening phases.
  • the addition of alloying elements generally results in a decrease in the difference between solidus and solvus temperatures.
  • the solidus to solvus range of the alloy becomes a narrow "window", with typically a solidus to solvus difference lower than 20°C, and consequently the solution heat treatment of the aforementioned elements usually achieved during extrusion cannot be obtained without observing incipient melting. Indeed local temperature gradients achieved during extrusion and forging, generally exceed 20°C implying that, as solvus is reached, parts of the product will display temperatures in excess of solidus Ts.
  • the aluminium rolled product is obtained by casting a rolling ingot from a 6xxx aluminium alloy comprising: Si: 0.65-1.40%; Mg: 0.6-1.2%; Cu: ⁇ 1.5%; Mn: 0.4-1.0%; Fe: ⁇ 0.5%; Cr: ⁇ 0.25%; Zr: ⁇ 0.2%; Zn: ⁇ 0.25%; Ti: ⁇ 0.2%, the rest being aluminium and inevitable.
  • the aluminium alloy according to the invention is of the AlMgSi type, which, compared with others such as e.g. AlZ-nMg alloys, provides an excellent combination of high tensile strength and resistance to corrosion.
  • the aluminium alloy can be provided as an ingot or slab for fabrication into a hot-rolled feedstock using casting techniques regular in the art for casting rolling products, e.g. DC-casting, EMC-casting, EMS-casting, and preferably having an ingot thickness in a range of about 220 mm or more, e.g. 300 mm or 350 mm.
  • the as-cast ingot is commonly scalped to remove segregation zones near the as-cast surface of the ingot.
  • thin gauge slabs resulting from continuous casting e.g. belt casters or roll casters, also may be used, and having a thickness of up to about 40 mm.
  • the process according to the invention consists in particular in replacing conventional homogenising followed by slow cooling, re-heating and extruding followed again by slow cooling of the AA6xxx alloy extrusion billets, by high temperature homogenising and raid cooling followed by heating in combination with hot-rolling instead of extrusion and controlling the hot-mill exit temperature, and the process does not comprise a separate post-rolling solution heat treatment, because as a result of the claimed processing steps b. and c., the larger part of the alloying elements which contribute to the formation of hardening particles are in solid solution in the lattice of the hot-rolled feedstock.
  • the present invention therefore provides a process to manufacture a range of 6xxx alloys with high mechanical properties, especially if applied to a sufficiently copper-containing AlMgSiCu, with strength levels in excess of 400 MPa and even 450 or 480 MPa, in combination with a good corrosion resistance.
  • an ingot is provided resulting from casting a 6xxx aluminium alloy, i.e. an aluminium alloy having magnesium and silicon as major alloying elements.
  • this aluminium alloy is a high-strength 6xxx aluminium alloy, such as AA6082, AA6182, AA6056, AA6110 or any copper-containing alloy derived from the said AA6xxx aluminium alloys.
  • This alloy has preferably a Cu content up to 1.5%.
  • the Cu-content is in a range of 0.2% to 1.5%, preferably 0.35% to 1.2%, and more preferably 0.5% to 1.0%, and provides a very high strength in combination with a good corrosion resistance.
  • the Cu-content is up to 0.3%, preferably in a range of 0.04% to 0.28%, and more preferably 0.09% to 0.27%, and provides still a high strength (somewhat lower than for the embodiment with very high Cu level) in combination with an excellent corrosion resistance.
  • one or more dispersoid forming elements are present, in particular Mn with a content of 0.4-1.0%, Cr up to 0.25% and preferably with a content of 0.05-0.25%, and Zr up to 0.25% and preferably with a content of 0.05-0.2%, are added to control recrystallization and maximize homogeneity of the grain size of the rolled and the forged component.
  • Si and Mg content are defined so as to ensure high level of dissolved or redissolved Mg 2 Si while minimising presence of undissolved Mg 2 Si in the forged component after the final solutionising step, preferably with a maximum content of 0.5%.
  • Mg 2 Si is combined with Mg to form Mg 2 Si.
  • the precipitation of Mg 2 Si contributes to increasing the strength of the final aluminium alloy forged product.
  • the final product does not have a sufficiently high strength, it means a tensile strength not higher than 400 MPa. If it is lower than 0.9%, tensile strength will be at most 450 MPa and with less than 1.1% it will be lower than 480 MPa.
  • the Si content is more than 1.40%, the level of undissolved Mg 2 Si is too high and rollability is reduced as well as corrosion resistance and toughness of the resultant final forged product.
  • Mg is combined with Si to form Mg 2 Si. Therefore Mg is indispensable for strengthening the product of the present invention. If the Mg content is lower than 0.7%, the effect is too weak. On the other hand, if the Mg content is higher than 1.2%, the ingot becomes difficult to be roll and the rolled feedstock to be forged. Moreover, a large amount of Mg 2 Si particles tends to precipitate during quenching process after the solution treatment.
  • the Mg content is preferably between 0.7% and 1.1% and more preferably between 0.8% and 1.0%.
  • Fe is an impurity and combines with other elements to form intermetallic compounds. These precipitated particles lower fracture toughness and fatigue strength of the final forged product.
  • the Fe content is higher than 0.5% it is difficult to obtain an aluminium alloy forged product with both high strength and high toughness as required for automotive structure and suspension applications.
  • its content is lower than or equal to 0.3% and more preferably, lower than or equal to 0.25%.
  • Mn forms intermetallic compounds, for example Al 6 Mn, which controls recrystallisation. However, if the Mn content is less than 0.4%, the effect is not sufficient. On the other hand, if the content of Mn is higher than 1.0%, coarse precipitated particles are formed and both the workability and the toughness of the aluminium alloy are reduced.
  • the Mn content is preferably between 0.5% and 0.9% and more preferably between 0.5% and 0.7%.
  • the 6xxx-series aluminium alloy consists of: Si: 0.65-1.4%; Mg: 0.6-1.2%; Cu: up to 1.5%; Mn: 0.4-1.0%; Fe: up to 0.5%; Cr: up to 0.25%; Zr: up to 0.2%; Zn: up to 0.25%; Ti: up to 0.2%, the rest being aluminium and inevitable impurities (typically at a level of each ⁇ 0.05% and total ⁇ 0.25%), and with preferred narrower compositional ranges as herein described and claimed.
  • the cast ingot for rolling according to the invention is homogenised between 2 and 24 hours at a temperature between 5°C and 80°C lower than solidus, and then rapidly cooled for example water quenched. More preferably the homogenization is performed at a temperature range of 480°C to 520°C. In the presence of a high volume fraction of Mn-, Zr, and Cr-containing dispersoids it is preferred to homogenize below 520°C in order to avoid any coarsening of these particles.
  • the soaking times for homogenization should be at least about 2 hours, and more preferably at least about 4 hours. A preferred upper-limit for the homogenization soaking time is about 15 hours.
  • the homogenised and quenched rolling ingot is heated to a soaking temperature T h below the solidus temperature Ts, between Ts-5°C and Ts-125°C.
  • solidus temperature is near 575°C for the alloys AA6082 and AA6182.
  • the ingots are preferably heated and held at the soaking temperature for several minutes up to about 2 hours.
  • the ingot is being hot-rolled in one or more rolling steps to a final gauge in a range of 2 mm to 40 mm, preferably 2 mm to 30 mm, and more preferably of 2 mm to 20 mm.
  • the hot-rolling process is carefully controlled such that the hot-mill exit-temperature of the feedstock is in a range of 200°C to 360°C, and preferably in a range of 200°C to 280°C, to ensure that the hot-rolled feedstock has a substantially unrecrystallized microstructure.
  • a hot-mill exit temperature in this temperature ranges suppresses in the feedstock the coarse precipitation of secondary phases such as Si and Mg 2 Si and AlMgCu-phases and thereby enabling a balance of high strength and good ductility in the final forged product.
  • the grain size in the final forged product is also too coarse.
  • the hot-mill entry-temperature is in a range of 400°C to 550°C, and preferably in a range of 435°C to 535°C and more preferably below 500°C, in order to reach the desired hot-mill exit-temperature.
  • the feedstock can be coiled or cut-to-length.
  • the balance of alloying composition and providing a substantially unrecrystalized microstructure in the hot-rolled condition allows for the subsequent production of forged products having a good balance in high-strength and ductility and corrosion resistance.
  • the use of hot-rolled feedstock allows for the production of much wider forged products compared to the use of extruded feedstock material.
  • the manufacturing of rolled feedstock is a robust production process enabling a more cost efficient production of high-volume forging feedstock compared to an extrusion process requiring dedicated extrusion dies and wherein only billets of limited dimensions can be processed.
  • hot-rolled feedstock provides a more homogeneous microstructure in the product and avoids the occurrence of so-called profile hot-spots which may frequently occur in an extrusion process due to for example non-equilibrium melting of eutectic phases as a result of temperature fluctuations across the profile in the extrusion process.
  • the rolled feedstock is cut-to-length and heated to the forging temperature, typically between 400°C and 560°C.
  • the feedstock is forged, typically die-forged, and preferably in a heated mould of typically between 150°C and 350°C.
  • the parts undergo a separate solutionising at a temperature between 460°C and 560°C, preferably between 520°C to 560°C, for a duration between 20 sec. and 5 hours and then quenched, for example using a device projecting sprayed water or a water based cooling liquid, down to room temperature.
  • the solutionising time is dependent on the thickness of the forged product, whereby thin products commonly require is shorter time at elevated temperature.
  • the product is optionally naturally aged at room temperature for a duration up to 30 days, and preferably between 6 hours and 30 days. Thereafter artificial ageing is applied to achieve T6 temper by a one-or multiple-step heat treatment at temperatures ranging from 150°C to 210°C for holding times ranging from 1 to 20 hours.
  • the process according to the invention allows for obtaining forged products made from Cu-containing 6xxx alloys, which were until now very difficult to solutionise because of their very narrow solvus-solidus temperature window and the risk of recrystallization during ultimate separate solutionising prior to final age-hardening treatment.
  • This process is particularly well suited to alloys with Mg 2 Si content comprised between 1.2% and 1.6%, Si excess up to 0.7%, particularly if comprised between 0.2% and 0.7%, and especially if copper content lies up to 1.5%, which gives a solvus to solidus temperature difference approximately equal to or even lower than 10°C, and renders such alloy very difficult to extrude when processed according to the prior art route.
  • this alloy comprises further to the Mn preferably a purposive addition of one or more additional dispersoid forming elements, viz. Zr between 0.05% and 0.25% and Cr between 0.05% and 0.25%, either Cr or Zr alone or Cr+Zr in combination, the microstructures of the rolled feedstock shows a strong fibrous retention providing an additional strengthening contribution, considered important in meeting high mechanical property values.
  • additional dispersoid forming elements viz. Zr between 0.05% and 0.25% and Cr between 0.05% and 0.25%, either Cr or Zr alone or Cr+Zr in combination
  • the microstructures of the rolled feedstock shows a strong fibrous retention providing an additional strengthening contribution, considered important in meeting high mechanical property values.
  • the forged components After having applied the process according to the invention in particular to 0.2% or more Cu containing AlMgSiCu aluminium alloys, the forged components have at T6 temper ultimate tensile strengths higher than 400 MPa, even higher than 430 MPa.
  • the forged product can be used as structural member on automotive vehicle structural members as well as in non-automotive structural members.
  • the automotive vehicle structural members include side impact beams, B-pillar inner and outer members, A-pillar outer members, tunnel reinforcements, door belt reinforcement members, hinge reinforcement members.
  • Such forged products are particularly suitable as chassis-suspension parts and especially suspension arms.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Forging (AREA)

Claims (12)

  1. Procédé pour fabriquer un produit forgé en alliage d'aluminium, comprenant les étapes suivantes consistant à :
    a) couler d'un lingot cylindrique à partir d'un alliage d'aluminium de la série 6xxx comprenant : Si : 0,65-1,4 % ; Mg : 0,6-1,2 % ; Cu : jusqu'à 1,5 % ; Mn : 0,4-1,0 % ; Fe : ≤ 0,5 % ; Cr : jusqu'à 0,25 % ; Zr : jusqu'à 0,2 % ; Zn : ≤ 0,25 % ; Ti : ≤ 0,2 %, le reste étant de l'aluminium et des impuretés inévitables ;
    b) homogénéiser le lingot coulé à une température TH qui est de 5° C à 80° C plus basse qu'une température de solidus Ts, TH étant typiquement dans la plage de 460° C à 570° C, pendant une durée entre 2 et 24 heures pour assurer un niveau élevé de dissolution des particules constitutives tout en assurant une précipitation est une minimisation de grossissement des phases dispersées ;
    c) refroidir rapidement ledit lingot jusqu'à température ambiante ;
    d) chauffer le lingot homogénéiser à une température Th entre (Ts-5°C) et (Ts-125°C) ;
    e) laminer à chaud le lingot réchauffé dans une ou plusieurs passes de laminage jusqu'à une épaisseur de sortie de laminoir à chaud dans la plage de 2 à 40 mm, et dans lequel la température de sortie du laminoir à chaud est dans la plage de 200° C à 360° C pour assurer que le produit laminé à chaud présente une microstructure sensiblement sans recristallisation ;
    f) chauffer le produit laminé coupé à longueur jusqu'à une température de forgeage, typiquement entre 400° C et 560° C ;
    g) forger, de préférence dans un moule chauffé entre 150° C et 350° C ;
    h) mettre en solution séparée à une température entre 460° C et 560° C, de préférence entre 520° C et 560° C, et à une durée entre 20 secondes et 5 heures ;
    i) tremper le matériau forgé et mis en solution ;
    j) en option, vieillissement à température ambiante pendant une durée allant jusqu'à 30 jours, et de préférence entre 6 heures et 30 jours ;
    k) vieillissement artificiel jusqu'à une températion T6 par traitement à chaud en une seule passe ou en une multiplicité de passe à des températures allant de 150° C à 210° C pendant des temps de maintien allant de 1 à 20 heures.
  2. Procédé selon la revendication 1, dans lequel la température d'entrée du laminoir à chaud est dans une plage de 440° C à 535° C.
  3. Procédé selon la revendication 1 ou 2, dans lequel la température de sortie du laminoir à chaud est dans une plage de 200° C à 280° C.
  4. Procédé selon l'une quelconque des revendications 1 à 3, dans lequel l'alliage d'aluminium de la série 6xxx comprend : Cu : 0,2 %-1,5 %, de préférence 0,35 %-1,2 %, et de manière plus préférée 0,5 %-1,0 %.
  5. Procédé selon l'une quelconque des revendications 1 à 3, dans lequel l'alliage d'aluminium de la série 6xxx comprend : Cu : jusqu'à 0,30 % de préférence 0,04 %-0,28 %, et de manière plus préférée 0,09 %-0,27 %.
  6. Procédé selon l'une quelconque des revendications 1 à 5, dans lequel l'alliage d'aluminium de la série 6xxx comprend : Si : 0,9 %-1,3 %, de préférence 1,1 %-1,3%.
  7. Procédé selon l'une quelconque des revendications 1 à 6, dans lequel l'alliage d'aluminium de la série 6xxx comprend : Mg : 0,7 %-1,1 %, de préférence 0,8 %-1,0 %.
  8. Procédé selon l'une quelconque des revendications 1 à 7, dans lequel l'alliage d'aluminium de la série 6xxx comprend : Mn : 0,5-0,9 %, de préférence 0,5 %-0,7 %.
  9. Procédé selon l'une quelconque des revendications 1 à 8, dans lequel la résistance ultime à la traction du produit forgé en alliage d'aluminium est supérieure à 400 MPa, de préférence supérieure à 430 MPa, et de manière plus préférée supérieure à 450 MPa.
  10. Procédé selon l'une quelconque des revendications 1 à 9, dans lequel le produit forgé en alliage d'aluminium est une partie structurelle d'un corps d'automobile.
  11. Procédé selon l'une quelconque des revendications 1 à 9, dans lequel le produit forgé en alliage d'aluminium est une partie du châssis d'une automobile.
  12. Procédé selon l'une quelconque des revendications 1 à 9, dans lequel le produit forgé en alliage d'aluminium est un bras de suspension pour automobile.
EP16189960.4A 2016-09-21 2016-09-21 Procédé de fabrication d'un alliage de 6xxx series de haute résistance pour forger. Not-in-force EP3299482B1 (fr)

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EP3299482B1 true EP3299482B1 (fr) 2019-05-29

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CN116403755A (zh) * 2023-04-12 2023-07-07 北京理工大学 一种高强高导电率再生铝合金导线及其制备方法

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CN110938765B (zh) * 2019-12-18 2022-02-22 东北轻合金有限责任公司 一种汽车底盘用高强Al-Mg-Si铝合金棒材的制造方法

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