EP4001446A1 - Hochfeste und bruchzähe 7xxx-legierungsprodukte für die luft- und raumfahrt - Google Patents

Hochfeste und bruchzähe 7xxx-legierungsprodukte für die luft- und raumfahrt Download PDF

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Publication number
EP4001446A1
EP4001446A1 EP21207643.4A EP21207643A EP4001446A1 EP 4001446 A1 EP4001446 A1 EP 4001446A1 EP 21207643 A EP21207643 A EP 21207643A EP 4001446 A1 EP4001446 A1 EP 4001446A1
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EP
European Patent Office
Prior art keywords
aluminum alloy
alloy product
ksi
day
optionally
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.)
Pending
Application number
EP21207643.4A
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English (en)
French (fr)
Inventor
Zhengdong Long
Philippe Paul Gomiero
Ravi Rastogi
Haoyan Diao
Jason Nicholas SCHEURING
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kaiser Aluminum Fabricated Products LLC
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Kaiser Aluminum Fabricated Products LLC
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Publication of EP4001446A1 publication Critical patent/EP4001446A1/de
Pending legal-status Critical Current

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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
    • C22C21/10—Alloys based on aluminium with zinc as the next major constituent
    • 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
    • C22F1/002—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working by rapid cooling or quenching; cooling agents used therefor
    • 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
    • C22F1/053—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 zinc as the next major constituent

Definitions

  • the present invention relates to high strength 7xxx aluminum alloy products.
  • the high strength 7xxx aluminum alloy can be fabricated to produce plate, extrusion or forging products suitable for aerospace structural components, especially large commercial airplane wing structure applications requiring better strength, fracture toughness, fatigue crack deviation resistance, anisotropic ductility, damage tolerance performance, and corrosion resistance performance.
  • the strength, fracture toughness, and corrosion resistance performances are the most critical material properties, which are significantly affected by chemical composition.
  • zinc is the major alloying element for achieving high strength through age strengthening.
  • Zinc in the most commonly used 7050 and 7075 aerospace aluminum alloys is in the range of 5.1 to 6.7 wt.%.
  • Magnesium is normally added along with zinc to produce MgZn2 and its variant phases, which are the predominant precipitation hardening phases.
  • Aluminum alloys having higher Zn and Mg content usually have higher strength. However, higher Zn and Mg content also negatively affect stress corrosion cracking (SCC) resistance and fracture toughness performance.
  • SCC stress corrosion cracking
  • 7xxx aluminum alloys copper is added in order to improve SCC resistance performance. Meanwhile, the addition of Cu also improves material strength. Most of the Cu is believed to substitute Zn in the metastable MgZn2 phases. In general, Cu has approximately an equivalent effect on strength as the same weight percent of Zn addition.
  • the additional new challenge for increased aircraft component utilization is the fatigue crack branching or deviation property. This is a phenomenon in which a crack suddenly changes its propagation direction away from the expected fracture plane under Mode I fatigue loading condition. Such crack deviation is an increasing concern for aircraft manufacturers since it is difficult to take into account during structural design.
  • the anisotropic ductility of aluminum alloy thick plate is another increasingly critical characteristic for aerospace application, especially for monolithic part machining technology recently used in airframe manufacturing.
  • the anisotropic ductility refers to significant ductility changes when the tensile testing orientation is in-between the commonly tested orientations, that are usually either parallel to or perpendicular to the material metal flow or microstructural direction, commonly notated as rolling direction (L).
  • the ductility is usually significantly lower when tensile direction differs from the standard orientations that are determined by metal flow direction.
  • EAC Environmentally Assisted Cracking
  • the high strength, fracture toughness, fatigue crack deviation resistance, and anisotropic ductility 7xxx aluminum alloy products such as plates, forgings and extrusions, suitable for use in making aerospace structural components like large commercial airplane wing components, comprises 6.5 to 7.2 wt. % Zn, 1.55 to 1.95 wt. % Cu, 1.75 to 2.15 wt. % Mg, 0.095 to 0.15 wt. % Zr, up to 0.15 wt. % incidental elements, with the total of these incidental elements not exceeding 0.35 wt. %, and the balance Al.
  • the aluminum alloy further comprises Mg/Cu and Zn/Mg ratios are in the range of 1.05 to 1.35, and 3.2 to 4.0 respectively.
  • an aluminum alloy having an optimized chemistry range, associated with precise Zn, Mg and Cu content as well as Mg/Cu and Zn/Mg ratios is capable of producing plate products with high strength, desirable fracture toughness, fatigue crack deviation resistance, higher anisotropic ductility, damage tolerance, and corrosion resistance properties, in a combination that has never been achieved before.
  • a high strength 7xxx thick plate aluminum alloy product offers a promising opportunity for significant fuel efficiency and cost reduction advantage for commercial airplanes.
  • An example of such an application for the present invention is the integral design wing box, which requires thick cross section 7xxx aluminum alloy products.
  • Material strength is a key design factor for weight reduction. Also important are ductility, damage tolerance, stress corrosion resistance, and fatigue crack growth resistance.
  • a high strength 7xxx aluminum alloy product is produced using a precise chemistry range.
  • the high strength, fracture toughness, better fatigue crack deviation and anisotropic ductility 7xxx aluminum alloy product comprises, consists of, or consists essentially of, 6.5 to 7.2 wt. % Zn, 1.55 to 1.95 wt. % Cu, 1.75 to 2.15 wt. % Mg, 0.095 to 0.15 wt. % Zr, up to 0.15 wt. % incidental elements, with the total of these incidental elements not exceeding 0.35 wt. %, and the balance Al.
  • the aluminum alloy further comprises Mg/Cu and Zn/Mg ratios in the range of 1.05 to 1.35, and 3.2 to 4.0 respectively.
  • the 7xxx aluminum alloy product provides high strength, high damage tolerance performance, better corrosion resistance as well as desirable fatigue crack deviation resistance, and better anisotropic ductility suitable for aerospace applications.
  • FIG.1 and FIG. 2 show graphs of the chemical composition range for the key Cu, Mg and Zn elements used to make the 7xxx aluminum alloy product according to the present invention.
  • the present invention includes alternate embodiments wherein the upper or lower limit for the amount of Zn in the aluminum alloy product may be selected from 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, and 7.2 wt.%.
  • the present invention includes alternate embodiments wherein the upper or lower limit for the amount of Cu may be selected from 1.55, 1.60, 1.65, 1.70, 1.75, 1.80, 1.85, 1.90, and 1.95 wt.%.
  • the present invention includes alternate embodiments wherein the upper or lower limit for the amount of Mg may be selected from 1.75, 1.80, 1.85, 1.90, 1.95, 2.00, 2.05, 2.10, and 2.15 wt.%.
  • the present invention includes alternate embodiments wherein the upper or lower limit for the amount of Zr may be selected from 0.095, 0.10, 0.11, 0.12, 0.13, 0.14, and 0.15 wt.%.
  • the present invention includes alternate embodiments wherein the upper or lower limit for the ratio of Mg/Cu may be selected from 1.05, 1.10, 1.15, 1.20, 1.25, 1.30, and 1.35.
  • the present invention includes alternate embodiments wherein the upper or lower limit for the ratio of Zn/Mg may be selected from 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, and 4.0.
  • the present invention includes alternate embodiments wherein the upper limit for the incidental elements is 0.15, 0.12, 0.10, 0.08, 0.05, 0.02, and 0.10 wt.%. In addition to the alternate upper and lower limits listed above, the present invention includes alternate embodiments wherein the upper limit for the total incidental elements is 0.35, 0.30, 0.25, 0.20, 0.15, 0.12, 0.10, 0.08, 0.05, 0.02, and 0.10 wt.%.
  • the aluminum alloy product is a thick plate including ⁇ 0.12 wt.% Si, preferably ⁇ 0.05 wt.% Si. In one embodiment, the aluminum alloy product is a thick plate including ⁇ 0.15 wt.% Fe, preferably ⁇ 0.10 wt.% Fe. In one embodiment, the aluminum alloy product is a thick plate including Zr in the range from 0.095 to 0.15 wt%. In one embodiment, the aluminum alloy product is a thick plate including ⁇ 0.04 wt.% Cr, preferably no Cr is added to the alloy other than that provided as an impurity. In one embodiment, the aluminum alloy product is a thick plate including 0.005 - 0.10 wt.% Ti.
  • the aluminum alloy product of the present invention may also include low levels of "incidental elements” that are not included intentionally.
  • the "incidental elements” means any other elements except those described above (Al, Zn, Cu, Mg, Zr, Si, Fe, Cr, and Ti).
  • the aluminum alloy product of the present invention is a thick plate have a thickness of 1-10 inches.
  • such thick plate products may have thicknesses of 1-3 inches, or 1-5 inches, or 3-5 inches, or 5-10 inches, or 5-8 inches, or 8-10 inches.
  • the ingots of the high strength aluminum alloy product may be cast, homogenized, hot rolled, solution heat treated, cold water quenched, optionally stretched, and aged to desired temper.
  • a thick plate high strength aluminum alloy is a plate product provided in a T7651 or T7451 temper and in the thickness range of 1 inch to 10 inch.
  • the ingots may be homogenized at temperatures from 454 to 491 °C (849 to 916°F).
  • the hot rolling start temperature may be from 385 to 450 °C (725 to 842°F).
  • the exit temperature may be in a similar range as the start temperature.
  • the plates may be solution heat treated at a temperature range of 454 to 491 °C (849 to 916°F).
  • the plates are cold water quenched to room temperature and may be stretched by about 1.5 to 3%.
  • the quenched plate may be subjecting to any aging practices known by those of skill in the art including, but not limited to, two-step aging practices that produce a final T7651 or T7451 temper.
  • the first stage temperature may be in the range of 100 to 140 °C (212 to 284 °F) for 4 to 24 hours and the second stage temperature may be in the range of 135 to 200 °C (275 to 392 °F) for 5 to 20 hours.
  • High strength 7xxx aluminum alloy plate products preferably have a yield tensile strength (YTS) in the LT direction ⁇ 67 ksi, or ⁇ 68 ksi, or ⁇ 70 ksi, or ⁇ 71 ksi.
  • YTS yield tensile strength
  • These 7xxx aluminum alloy products may also have T-L K1c values ⁇ 28 ksi-in 1/2 , or ⁇ 29 ksi-in 1/2 , or ⁇ 30 ksi-in 1/2 .
  • These 7xxx aluminum alloy products may also have K max - dev values ⁇ 33 NPa-m 1/2 , or ⁇ 34 MPa-m 1/2 , or ⁇ 35 MPa-m 1/2 , or ⁇ 36 MPa-m 1/2 , or ⁇ 37 MPa-m 1/2 , or ⁇ 38 MPa-m 1/2 .
  • These 7xxx aluminum alloy products may also have EAC values ⁇ 100 days, or ⁇ 110 days, or ⁇ 120 days, or ⁇ 130 days, or ⁇ 140 days, or ⁇ 150 days.
  • These 7xxx aluminum alloy plate products may also have any combination of or all the aforementioned YTS in the LT direction, T-L K1c, K max - dev , and EAC values.
  • these YTS and K1c values are found in thick plates having a thickness ⁇ 3 inches, or ⁇ 4 inches, and have the above-mentioned K max-dev , and EAC values.
  • the tensile testing was conducted based on ASTM B557 specification, the contents of which are expressly incorporated herein by reference.
  • the plane strain fracture toughness (K 1c ) was measured under ASTM E399, the contents of which are expressly incorporated herein by reference, using CT specimens.
  • EAC Environmentally Assisted Cracking
  • Alloys 1 to 18 are invention alloys. Alloy 19 to 39 are 7050 type non-invention alloys since they have too high Cu, too low Zn, too low Mg/Cu ratio, and too low Zn/Mg ratio. Alloy 40 to 50 are 7075 type non-invention alloys since they have too high Mg, too low Zn, too high Mg/Cu ratio, and too low Zn/Mg ratio.
  • FIG. 3 and FIG. 4 are graphs showing the chemical composition difference between the present 7xxx aluminum alloy products made from the invention alloys compared to non-invention alloys.
  • Ingots were homogenized, hot rolled, solution heat treated, quenched, stretched and aged to final temper plates in the thickness range from 1 inch to 8 inch.
  • the ingots were homogenized at a temperature from 465 to 485 °C (869 to 905°F).
  • the hot rolling start temperature is from 400 to 440 °C (752 to 824°F).
  • the plates were solution heat treated at temperature range from 470 to 485 °C (878 to 905°F), cold water quenched to room temperature and stretched at about 1.5 to 3%.
  • a two-step aging practice was used to produce final T7651 and T7451 tempers.
  • the first stage temperature is in the range of 110 to 130 °C (230 to 266 °F) for 4 to 12 hours and the second stage temperature is in the range of 145 to 160 °C (293 to 320 °F) for 8 to 20 hours.
  • the final production plates were characterized for strength, fracture toughness, corrosion resistance, fatigue crack deviation resistance, and anisotropic ductility that are critical for aerospace applications.
  • the tensile testing was conducted based on ASTM B557 specification, the contents of which are expressly incorporated herein by reference.
  • the plane strain fracture toughness (K 1c ) was measured under ASTM E399, the contents of which are expressly incorporated herein by reference, using CT specimens.
  • Table 2 gives the tensile properties and fracture toughness for aluminum alloy products using invention and non-invention alloy samples. The common terminologies familiar to those skilled in the art were used in this table for strength and fracture toughness.
  • Table 2 shows significantly better strength for aluminum alloy products using invention alloys (Sample 1-18) than non-invention alloys.
  • the fracture toughness for aluminum alloy products is also better for invention alloy compared with 7050 type non-invention alloys.
  • Fig. 5 demonstrates the higher strength of aluminum alloy products using the invention alloys compared with non-invention alloys.
  • the strength and fracture properties have to be considered together for aerospace applications.
  • the combination of strength and fracture toughness for aluminum alloy products made from invention alloys is much better than non-invention alloys based on Table 2.
  • FIG. 6 demonstrates that 3" thick aluminum alloy plates made from the invention alloy have a better combination of strength and fracture toughness compared with non-invention alloys.
  • the fatigue crack growth deviation was evaluated based on ASTM E647, the contents of which are expressly incorporated herein by reference.
  • the coupon orientation is L-S, which has the highest chance to have crack deviation during crack propagation.
  • FIG. 7 shows the orientation of this sample relative to the plate geometry.
  • FIG. 8 illustrates the coupon configuration used herein.
  • the standard Compact Tension, i.e. C(T) coupon was used for this test.
  • the dimension B is 6.35mm and W is 76.2mm for all testing coupons.
  • the determination of external crack deviation was based on "anything that would normally invalidate the E647 FCG test" (e.g. crack growth out of plane by more than 20° or crack deviation after the remaining ligament criterion is exceeded).
  • FIG. 9 is a graph showing the comparison of the combination of strength and K max - dev for aluminum alloy products made from the invention alloy compared to the non-invention alloys plates in the thickness range of 4 to 5 inches.
  • the tensile properties can be significantly different for different testing directions.
  • Such anisotropic material behavior is very important for high strength thick plate aerospace applications.
  • the orthotropic tensile coupons were extracted such that the gauge length was centered at T/2 location.
  • the tensile direction is 45 degrees off thickness (ST) direction (ST-45).
  • the testing results are given in Table 5.
  • Table 5 Anisotropic tensile properties for alloy lots for 4-4.25 inch thick plates.
  • Stress corrosion resistance is critical for aerospace application.
  • the standard stress corrosion cracking testing was performed in accordance with the requirements of ASTM G47, the contents of which are expressly incorporated herein by reference, which is alternate immersion in a 3.5% NaCl solution under constant deflection. Three specimens were tested per sample.
  • Table 6 gives the SCC testing results for both T7451 and T7651 tempers. It shows that the lots designated as T7451 temper pass the 35ksi stress threshold. In addition, a vast majority of samples at a higher 40ksi stress level also pass SCC to 30 days. The lots designated as T7651 temper pass the 25ksi threshold. In addition, they also pass SCC testing at a higher 30ksi stress level, to 30 day duration. Table 6: SCC testing performance of invention alloy.
  • Table 7 gives the chemical composition of such new high strength 7xxx alloys developed in recent years.
  • the plates were commercial scale plates.
  • the non-invention chemistries, especially Zn content, are significantly different compared with the present invention alloy.
  • EAC Environmentally Assisted Cracking

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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)
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  • Crystallography & Structural Chemistry (AREA)
  • Extrusion Of Metal (AREA)
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EP21207643.4A 2020-11-11 2021-11-10 Hochfeste und bruchzähe 7xxx-legierungsprodukte für die luft- und raumfahrt Pending EP4001446A1 (de)

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US202063112294P 2020-11-11 2020-11-11
US17/479,211 US20220145439A1 (en) 2020-11-11 2021-09-20 High Strength and High Fracture Toughness 7xxx Aerospace Alloy Products

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US (1) US20220145439A1 (de)
EP (1) EP4001446A1 (de)
CN (1) CN114540674A (de)
BR (1) BR102021022642A2 (de)
CA (1) CA3135591A1 (de)

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US20230114162A1 (en) * 2021-09-27 2023-04-13 Kaiser Aluminum Fabricated Products, Llc Dispersoids 7XXX Alloy Products With Enhanced Environmentally Assisted Cracking and Fatigue Crack Growth Deviation Resistance

Citations (2)

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Publication number Priority date Publication date Assignee Title
WO2006086534A2 (en) * 2005-02-10 2006-08-17 Alcan Rolled Products - Ravenswood Llc Al-zn-cu-mg aluminum base alloys and methods of manufacture and use
US20200232072A1 (en) * 2017-09-26 2020-07-23 Constellium Issoire Al-zn-cu-mg alloys with high strength and method of fabrication

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Publication number Priority date Publication date Assignee Title
US5865911A (en) * 1995-05-26 1999-02-02 Aluminum Company Of America Aluminum alloy products suited for commercial jet aircraft wing members
DE69629113T2 (de) * 1996-09-11 2004-04-22 Aluminum Company Of America Aluminiumlegierung für Verkehrsflugzeugflügel
US20050034794A1 (en) * 2003-04-10 2005-02-17 Rinze Benedictus High strength Al-Zn alloy and method for producing such an alloy product
US8840737B2 (en) * 2007-05-14 2014-09-23 Alcoa Inc. Aluminum alloy products having improved property combinations and method for artificially aging same
CN104532090B (zh) * 2014-12-31 2017-01-25 中国石油天然气集团公司 一种 580MPa 级铝合金钻杆用管体及其制造方法
CN104694860B (zh) * 2015-04-07 2016-08-24 中南大学 一种低纯度Al-Zn-Mg-Cu合金时效热处理方法
BR112019026036B1 (pt) * 2017-06-21 2024-02-06 Arconic Technologies Llc Produto de liga de alumínio forjado da série 7xxx, e componente estrutural aeroespacial
EP3670690A1 (de) * 2018-12-20 2020-06-24 Constellium Issoire Al-zn-cu-mg-legierungen und deren herstellungsverfahren

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2006086534A2 (en) * 2005-02-10 2006-08-17 Alcan Rolled Products - Ravenswood Llc Al-zn-cu-mg aluminum base alloys and methods of manufacture and use
US20200232072A1 (en) * 2017-09-26 2020-07-23 Constellium Issoire Al-zn-cu-mg alloys with high strength and method of fabrication

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CA3135591A1 (en) 2022-05-11
BR102021022642A2 (pt) 2022-05-24
CN114540674A (zh) 2022-05-27
US20220145439A1 (en) 2022-05-12

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