JPS59159286A - Structure member and manufacture thereof - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The field of the invention is that of expanded composite metal components;
The present invention more particularly relates to structural members made from expanded composite metals suitable for use in high performance aircraft and the like, and methods of manufacturing such structural members.

When building high-performance aircraft, it is important to ensure that the structural components used in the aircraft have extremely high strength/weight ratios and extremely reliable properties. Riveted structural members are typically used to achieve the desired stiffness at selected points, as this is critical to ensuring that these structural members perform as intended when in use. It has become a common practice to achieve this and to prevent the presence of non-uniform stress zones or localized areas of weakness that typically occur in conventional welded structural assemblies. However, it has recently become possible to use extremely large quantities of titanium structural components in high performance aircraft through the use of superplastic forming processes.

In this case, after the titanium parts of the structural member are fastened together by diffusion bonding, the titanium material is inflated by careful application of fluid pressure while being heated to a temperature at which it exhibits the desired superplastic deformability. It has been found that the resulting titanium structural component has precisely shaped stiffening sections that provide the component with the desired high strength/weight ratio. Additionally, the component does not have non-uniform stress or weakened areas at the diffusion bond location, and the construction and use of the component is more versatile than previously used riveted structural assemblies. It is clear that Although it would be desirable to make similar structural components from high-strength aluminum alloys and the like for use in high-performance aircraft, the process used to produce improved titanium structural components is time consuming. , are not suitable for use in high strength aluminum alloys due to the presence of surface oxides which are not a significant problem with the aforementioned diffusion bonding techniques.

On the other hand, the processes typically used to manufacture expanded composite aluminum assemblies for use in heat exchangers or honeycomb structures and the like are susceptible to non-uniform stress regimes and the like that are useful in high-performance aircraft. It is not suitable for producing precisely shaped high-strength structural components with the property that the material is sufficiently removed.

One object of the present invention is to provide a new and improved structural member suitable for use in high performance aircraft and the like. Other objects of the present invention are to provide such improved members formed from high strength aluminum alloys, to provide new and improved methods of construction of such structural members, and The object of the present invention is to provide such a method, which is particularly adapted to the production of structural members using high-strength aluminum alloys.

Briefly stated, the new and improved structural member of the present invention has a layer of high strength, precipitation hardened aluminum alloy or the like, which alloy has a solid metallurgical bond. and hermetically sealing the metal layer portions to each other around precisely defined interface areas free of such bonds between the layers. Once the bond is formed, certain portions of the metal layer are selectively deformed in the non-bond areas, creating precisely stiffened sections of the structural member, so that the resulting product does not Uniform stress regions and localized weakening regions are substantially eliminated. Preferably, a layer of another aluminum material or the like is disposed between the precipitation hardened metal layers forming the structural member, thereby relieving the applied stress and providing the desired bond strength and bond reliability between the layers. And the airtightness of the joint can be obtained. After forming, the component is subjected to a treatment to precipitation harden the alloy.

According to the present invention, the new and improved structural member is obtained as a result of using the new and improved process of the present invention, which process further deposits a pattern (member) of anti-bond material. disposing on one surface of a hardened aluminum alloy or the like and interfacially abutting a corresponding second metal layer of the same alloy and thickness, preferably but not required, to said first layer; passing the metal layer between a pair of pressure bonding rolls to stretch the metal layer to a precisely predetermined thickness, i.e. said pattern of anti-bonding material while at least reducing potential solid phase metallurgical bonds to a sufficient degree that they are formed between the metal layers;
stretching in a precisely predetermined manner to precisely define selected unbonded areas between the layers. Preferably, the anti-bonding material is adapted to decompose and form a gas when heated to the selected temperature, and the alloy used in the member layer has a 60% or Preferably, sizing means or the like are provided to adapt the alloy to deform substantially, or even superplastically, to greater amounts of elongation deformation. Preferably, the alloy is selected to produce a selected equiaxed or non-equiaxed grain structure, thus allowing thermo-mechanical processes to be used to provide a selected axis of deformation of the alloy material. .

In a preferred embodiment of the method of the invention, wherein said metal layer is made of aluminum, the interfacial surface of said metal layer is then mechanically cleaned to remove oxides, and said metal layer is made of aluminum. Immediately prior to passing between pressure bonding rolls, the layer is heated at a limited temperature for a limited period of time to remove moisture from the layer surface without unduly regenerating oxides thereon. Preferably, at least one layer of another aluminum material or the like is disposed between the precipitation hardened metal layers when placing the metal layers in interfacial abutting relationship. Thus, the formation effect of the solid metallurgical joint described above is facilitated and enhanced, and further improved joint quality is achieved. According to the invention, said metal layers also improve the solid state metallurgical bond therebetween to hermetically seal said layers to each other around the non-bonded areas between them, and the non-bonded areas within said bond. heating the layer to reduce uniform stresses and areas of localized weakening, and heating the layer at a temperature below the selected temperature to improve the bond without substantially decomposing the anti-bonding material. Preferably.

The bonded metal layers are preferably constrained between contour molds or forming dies or the like, and the pattern of anti-bond material between the metal layers is formed precisely with the selected contour mold shape provided by the mold. Aligned. The metal layer is heated to the selected deformation temperature, a selected gas or other fluid pressure is induced in the unbonded region between the layers, and selected portions of the metal layer are shaped into a contour molded shape. It is deformed superplastically or in a similar manner to provide a precisely shaped stiffening portion of the desired structural member. This heating action also serves to further improve the bond between the metal layers and substantially eliminate non-uniform stresses and localized weakening areas within the bond. Preferably, the metal layer is heated to the selected temperature at a selected rate so that the debonding material thermally decomposes to form a gas for inducing the selected fluid pressure. do. This gas pressure plastically deforms the metal layer at a selected rate to thin the layer, while preventing local necking of the layer material within the deformed portions of the metal layer. In this way, a predetermined strength is imparted to the rigidity-enhancing portion of the structural system. Preferably, said metal layer material is then subjected to precipitation hardening of said material in a conventional manner to improve said strength. The structural member is thus precisely shaped to have an improved strength/weight ratio, substantially eliminating non-uniform stresses and areas of localized bond weakening, making it suitable for use in the manufacture of high performance aircraft and the like. It has been found that it provides the necessary high strength as well as performance reliability.

The present invention will be described in more detail below with reference to the accompanying drawings.

Referring to the accompanying drawings, reference numeral 10 in FIGS. 1 and 2 shows the new and improved structural member of the present invention, which structural member comprises a layer of high strength, precipitation hardened aluminum alloy or the like. It is shown to include members 12, 14. The alloy layer member is provided with a solid phase metallurgical bond (shown at 16 in FIG. 2) which connects the metal layer member to a precisely defined area free of such bond. The region (18 in FIG. 2) is hermetically sealed. The bonded portion or region 16 is substantially free of anomalous stresses or areas of localized weakening, and selected portions 20 of the metal layer member are deformed in the non-bonded areas to selectively stiffen the layer member. We are offering the parts that were made.

These reinforcements are molded to precise geometric contours so that the structural member has precisely predetermined strength and stiffness characteristics or the like. Thus, the structural members can be used in high performance aircraft and the like to achieve desired strength/weight characteristics while meeting design structural strength and stiffness specifications.

For example, in a structural member 10, the stiffening portion 20 provides selected stiffness of the member 10 and the area 20a where the member is attached to another member or the like.
It also provides the required strength. Of course, the structural reinforcement member 10 could alternatively be provided with any other corresponding pattern of reinforcement within the scope of the invention.

According to the invention, said new and improved structural member 10
is formed using the new and improved method of the present invention, resulting in the structural member having the desired properties described above.

That is, as the layer 12 of the precipitation hardening alloy is fed forward from the coil 22 or the like, the second metal layer 14, also preferably of the precipitation hardening alloy, e.g.
is advanced from a coil 24 or the like of layer surface 1.
2.1, 14.1 are brought into interfacial relationship with each other and the layer is passed between a pair of pressure bonding rolls 26 as indicated by arrows 22a, 24a in FIG.

In a preferred embodiment of the invention, metal layers 12 and 14 are typically, but not necessarily, of substantially equal thickness, with each layer comprising a precipitation hardening aluminum alloy. The aluminum alloy preferably has grain refining means or the like therein so that the alloy deforms to a substantial degree plastically or even superplastically when heated to a selected deformation temperature. It can be transformed into. However, other precipitation hardening alloys may be used for layers 12 and 14 within the scope of the present invention. For example, in the preferred embodiment of the present invention, the metal layers 12 and 14 are formed from a precipitation hardened aluminum alloy having a nominal weight composition as set forth in Table I below.

In such aluminum alloys, for example, the components of copper (Cu), zinc (Zn), and zirconium (Zr) are thought to act as grain refining means to improve the deformability of the alloy. When the alloy is subjected to thermo-mechanical treatment in accordance with well-known procedures, the alloy is heated to the deformation temperatures listed in Table I and stretched at selected deformation rates to render the alloy plastic or plastic to the levels listed in Table I. It is believed that it can be stretched superplastically. That is, the alloy can be deformed without fracture to the stated values at low but practical and controllable strain rates, as well as perfect thermo-mechanical conditions to achieve superplasticity. Even when deformed at a somewhat higher strain rate, the alloy can still be deformed to an elongation of 60% or more. Such properties make the alloy material suitable for forming aircraft mechanism layer members without significant non-uniform or unpredictable necking in the deformation region. Therefore,
When the alloy is formed into a rigid shape, it is formed by controlled gas or other fluid pressure inflation techniques to ensure that the resulting rigid component has predictable and reproducible strength properties. Ru.

The surfaces 12.1 and 14.1 of the metal layers are cleaned to remove bond-degrading oils and the like from the layers before they are brought into interfacial abutment with each other. is preferred. For example, in a preferred embodiment of the invention, the layer surface is mechanically cleaned with a wire brush or the like as schematically illustrated at 28 in FIG. will be removed.

If the metal layers 12 and 14 are also comprised of the preferred aluminum alloy material, the layer surfaces may be heated by an infrared lamp device or the like, as shown schematically at 30 in FIG. The layer surface is pressed by the bonding roll 26
Preferably, moisture is removed from the mechanically cleaned surfaces of the layers immediately before they are brought into interfacial abutment with each other. Heating the layer surface at a predetermined limited temperature and for a predetermined time removes moisture from the layer surface while preventing adequate regeneration of oxides on the layer surface. preferable. For example, from about 100° C. to about 15° C. for about 1 to 20 minutes before the aluminum layer material is advanced between the bonding rolls used.
Preferably, the surface temperature is 0° C., and particularly preferred heating conditions are heating at 150° C. for about 2 minutes.

In this way, the metal layers are better prepared for metallurgical bonding to each other as explained below.

According to the invention, 1 consisting of an anti-bonding or anti-welding substance
One or more pattern members 32 are arranged on at least one layer surface 12.1 of said metal layer surfaces, the other metal layer 14 being thus brought into interface with layer 12, said Cover the pattern. The anti-bonding pattern is precisely placed on the layer 12 by using a mask or the like, by transfer from a paper tape or the like, or by any other conventional manner within the scope of the invention. . For example, a strip of transfer paper 34 or the like is typically advanced from a reel 36 to a take-up reel 38 and passed over the metal layer surface 12.1 by a guide roll 40 to prevent bonding. The patterns 32 are transferred to the layer surface 12.1 when they are pressed onto the layer surface by the transfer roll 42. In this way, the anti-coupling pattern member having an arbitrarily selected contour is accurately placed on the metal layer 12. In one preferred process, the anti-bonding pattern is formed on the strip surface by a silk screen method, although any other conventional patterning method can be used and within the scope of the invention.

The metal layers 12 and 14 are then bonded together to form a composite metal sheet 44, with bonding between the layers defined by the bond inhibiting material as illustrated at 32a in FIGS. 4-5. The areas that have not been updated will be left behind.

For example, in the method of the invention, the metal layers 12 and 14 are pressed together between pressure bonding rolls 26 to form at least a potential solid metallurgical bond between predetermined portions of the metal layers. 46 (see FIG. 5), the metal layer is preferably stretched and thinned enough to form a metal layer, and the pattern of anti-bonding material is preferably stretched to reduce the thickness of the selected material free of such bonds. Preferably, an interfacial region 32a (see FIGS. 4 and 5) is defined between the layers. That is, by using rolling rolls 26 said layered material is rolled down to form a composite metal sheet 44, which has metal layers 12 and 14 stretched in the direction of rolling and bonded to each other;
It also includes an anti-coupling pattern 32, shown at 32a, which is also elongated in the same direction. Note that the pattern is applied to layers 12 and 1 within the composite sheet 44 at this point.
It is embedded between 4. The thickness reduction of the metal layers 12 and 14 is described, for example, in U.S. Pat. No. 2.691.81.
No. 5, the result is a solid green metallurgical bond between the layers. Note that the bonding prevention pattern 32 provided on the layer 12 was initially provided with a size and shape that would allow controlled stretching by the pressure roll 26 under these solid phase bonding conditions. Preferably, the inner metal layers, such as those listed in Table I, are pressed together at temperatures close to room temperature (up to about 100° C.), said metal layers being rolled 26 preferably at a temperature of about 100° C.
The layer thickness is reduced by about 50-80% and an initial solid state bond 46 is formed between the layers of the aluminum alloy material (see FIG. 5). . In this way, the interfacial contact area between the layers includes:
Solid state bonding occurs between layers 12 and 14 except at locations defined by stretched anti-bonding pattern 32a. What should be noted in this regard is that the metal layer 1
When 2 and 14 are of equal thickness and made of the same aluminum alloy material, the layer material is stretched symmetrically so that the anti-bonding pattern 32 is stretched in a precisely planned manner; The unbonded interface area 32a between the bonded metal layers will have a precisely defined contour shape.

According to the present invention, the anti-bonding material forming the pattern 32 is selected to withstand the rolling deformation and will not substantially decompose or separate under the pressure and temperature conditions encountered during the rolling. Preferably, however, the anti-binding material is chosen such that when heated above a predetermined relatively high temperature, it decomposes into pieces and generates gas. In a preferred embodiment of the invention, the anti-bonding material is such that it decomposes to produce gas when heated to a temperature corresponding to the appropriate or preferred plastic deformation temperature of the materials comprising the metal layers 12 and 14. ing. Preferably, for example, the metal layer materials 12 and 1
When 4 is an aluminum alloy listed in Table I, pattern 3
The anti-binding substance used in Table II is selected from the group having the components listed in Table II.

In accordance with the present invention, the composite metal sheet 44 is heated to a selected temperature by a heating device schematically illustrated at 45 in FIG. As schematically illustrated at 46a in FIG.
and 14 hermetically sealed together.

Preferably, when the anti-bonding pattern 32a is formed of a thermally decomposable material as described above, the metal layer improves the bonding portion 46 without substantially decomposing the anti-bonding material. Sintering is performed at a temperature that is relatively softer than the decomposition temperature of the bond-preventing substance. For example, the metal layer material is selected from Table I, and the anti-bonding material is selected from Table I.
I, the composite metal sheet 44 is about 1
The metal layers 12 and 14 are heated to a temperature in the range of about 150° C. to about 400° C. for a period of ˜8 hours to bond the metal layers 12 and 14 to the non-bonded region 32.
Completely hermetically sealed around a. In this way, the presence of a gas-tight bond between the metal layers prevents an undesirable reduction in the migration of the anti-bonding substance to the area where complete bonding is aimed, and the gases resulting from the decomposition of the anti-bonding substance are prevented from forming the layer. It also prevents the joint from acting between 12 and 14 and causing deterioration of the joint.

The pore sealing of the bond also prevents oxides from regenerating on the surface of the bonded aluminum layer within the bond area, which would also degrade the bond. This has a particularly advantageous effect if the layer material has a significant magnesium concentration and is prone to forming acicular magnesium oxide formations. Thus, the binding prevention pattern 32a
is guaranteed to accurately define the non-bonding region edges between the layers for the purposes described below. Such a hermetic seal would be desirable during use of the sentence member 10. In accordance with the present invention, heating the composite shaped sheet to improve the bond 46 also includes the bond 46 shown at 47 and 49 in FIG. This helps substantially reduce or even substantially eliminate the occurrence of non-uniform stresses and weak localized areas in the copper. That is, due to the growth of the bond, stress areas 47 that may have become bonded within the bond area during rolling reduction of the thickness of layers 12 and 14 are released;
Because artificial bonds 49 are reduced, bond interfaces can also be effectively removed between metal layers, concealing the fact that the strength of the bond across the interface is essentially that of the metal layer material itself. This will substantially correspond to the intensity.

In the method of the invention, layers 12 and 14 of alloy
If the alloy incorporates fine-grain casting or the like to promote the plastic deformability of the alloy material, the aforementioned thermal treatment for forming and improving the solid metallurgical bond 6 - Mechanical processes are also believed to promote the plastic deformability of the alloy material. That is, the aluminum alloy materials listed in Table I are subjected to a thickness reduction on the order of 50 to 80% to form the solid state bond 46, and the bonded layer is then refined. 250℃~400℃ for 1 to 8 hours
It is believed that such treatment improves the formability of the aluminum alloy when heated to a temperature in the range of , and exhibits greater elongation upon subsequent deformation, as discussed below.

In the method of the present invention, composite metal sheet 44 is preferably cut into sections 44a, as shown by dashed lines 48 in FIG. The anti-coupling pattern 32a will be included to form the individual structural members 10. Separated seat section 44
a is then shaped by blanking or bending as desired and is preferably placed between contour mold sections 50, 52 or the like as illustrated in FIG.

Here, the individual contour mold shaped portions 50a are shown at 32 in FIG.
a. It is aligned with the corresponding portion of the anti-coupling pattern member as shown at 1. When the pattern 32a is molded between the aforementioned solid state bonding layers 12 and 14, the non-bonding regions 32a are precisely defined and easily aligned with the contour mold shape. The composite metal sheet section 44a is then heated to the predetermined deformation temperature of the layers described above, and high fluid pressure is applied within the unbonded region 32a between the layers. This pressure deforms or expands at least one of the layers 12 or 14 to conform to the corresponding contour mold shape 50a, imparting a precisely defined and shaped shape to the structural member 10, as shown by dashed lines 20 in FIG. A rigid portion 20 is formed. Said high fluid pressure is within the scope of the invention by inserting a needle-like nozzle between the layers 12 and 14, or even through one of said layers into the uncoupled region 32a, in a known manner. is established between the metal layers by introducing. Preferably, however, if the anti-bonding material forming the pattern 32a is pyrolyzable and gas-generating as described above, the composite metal sheet section 44a is preferably heated to a metal layer deformation temperature; This also causes decomposition of the binding inhibiting substance. This creates the desired high gas pressure in situ between the metal layers to deform or expand certain portions of the layers to form the stiffened portion 20 of the component.

Metal layers 12 and 14 are formed from an aluminum alloy as described in Table I, the anti-bonding material is thermally decomposable as described in Table II, and the layer material is defined as having an elongation of 60% or more. In preferred embodiments of the invention, where substantial plastic deformation is effected, the heating rate of sheet section 44a is preferably regulated to be very gradual, thus ensuring that the desired high fluid pressure is applied to unbonded region 32.
a and achieve the desired deformation of the layer material by plastic deformation or the like without significant netting of the layer material to form the rigid section 20 of the member 10. Very low strain rates are achieved. Alternatively, faster heating rates can be used if grain growth within the selected alloy is a problem.

In the method of the present invention, the structural member 10 formed as described above is then subjected to a conventional precipitation hardening process to harden the alloy of layers 12 and 14 within the member and achieve the desired high strength of the member material. achieved. For example, the processing step typically includes heating the component to solution temperature and aging temperature in a conventional manner. For example, if the materials forming layers 12 and 14 are selected from Table I above, member 10 is heated to a solution temperature in the range of 480°C to 530°C for about 15 minutes to 1 hour and then removed from a heating furnace. Preferably, it is quenched within 5 seconds after removal in water at a temperature not exceeding about 60°C. Such heat treatment further improves the strength of the bond between the phase layers. The component material is then aged by heating the water to about 120 DEG C. to 190 DEG C. for about 3 to 24 hours. Alternatively, the material is aged for a longer period at or near room temperature by any conventional method. Although the procedures for hardening the alloy are well known and will not be described further, it should be understood that the hardening steps are conventional.

An alternative embodiment of the invention is illustrated diagrammatically in FIG. 9, in which the aforementioned parts are designated with corresponding numbers. In this alternative method, the metal layer members 12 and/or 14 also have an additional layer of another aluminum alloy or the like, the additional layer forming layers 12 and 14. selected to facilitate the formation and maintenance of solid metallurgical bonds between precipitation hardening alloys. The additional layer material 54 is preferably bonded to the precipitation hardened layer 12 and/or 14 by conventional hot or cold roll bonding or the like, so that layer 54 and precipitation hardened The bonding interface 56 between the alloy layers 12 and 14 is substantially free of non-uniform stresses or localized areas of weakness. The metal layers 12 and 14 are then cleaned and advanced as shown in FIG.
The additional metal layer members 54 are placed in interfacial abutment with each other as the metal layers are pressed together at a bonding roll 26 located between the precipitation hardened portions of layers 12 and 14;
A solid metallurgical bond as previously described is formed between metal layers 54 as illustrated in FIG. The initially joined parts are then sintered, expanded and hardened as described above, but
It has been found that the properties of the resulting component are further improved over structural components prepared by the previously described method.

Preferably, the additional layer material has a thickness of at least about 0.010 inches for roll bonding rather than separation, but otherwise includes member 10a.
layers 12 and 14 of precipitation hardened alloys that are stronger than most
Preferably, the thickness is limited to approximately 10% of the thickness of the layer 12 and/or 14 so that the thickness of the layer 12 and/or 14 is approximately 10%. For example layers 12 and 1
When the alloy forming No. 4 is selected from the precipitation hardened aluminum alloys of Table I, the additional aluminum material is preferably selected from the materials listed in Table III below.

The structural member obtained by this alternative method has further improved properties as schematically illustrated in FIG. That is, if the strip materials are bonded together without a controlled moisture removal step and without the aforementioned interlayers, the strength of the bond between the layers will increase as the layer material is sintered and heated for expansion. , when solution treated, the 13th
This is improved as shown by curve 57a in the figure. The peel strength of the bonded layers decreases as the layer material becomes more fully aged. When a regulated moisture removal preheat step is used in the bonding process as described above, a better bond is obtained between the layers, as shown by curve 57b in FIG. 13. Also in this case,
As curve 57b diagrammatically shows, a decrease in bond strength occurs as the layer material is cured. However, when the additional interlayer material described with reference to FIG. 9 is used, not only is the bond strength between the layers improved, but precipitation hardening forms the layer as shown by curve 57c in FIG. The retention of strength becomes even more pronounced as the material ages.

In another alternative embodiment of the present invention, schematically illustrated in FIG. Hardened alloy layers 12 and 14 are fed between the pressure bonding rolls 26 as they advance between these layers.

As illustrated in FIG. 11, the additional metal layer material also undergoes cleaning and drying in the same manner as for metal layers 12 and 14 previously described, and anti-bonding pattern 32 is removed from layer 12 as illustrated in FIG. , 14 or 58. In this alternative embodiment of the invention, the material of layer 56 is also selected to facilitate the formation of the solid metallurgical bond described above, and in the preferred embodiment of the invention is selected from Table III. It is made up of substances. That is, as shown in FIG. 12, solid metallurgical bonds 62 within member 10b are formed between opposing sides of metal layer 58 and respective precipitation hardenable alloy layers 12 and 14. ing. In this case as well, the thickness of the metal layer 58 is at least 0.
．． 254 mm (0.010 inch), which is preferably less than about 10% of the thickness of metal layers 12 and 14 for the reasons discussed above. This alternative process also has advantageous bonding characteristics as shown by curve 57c in FIG. Dew.

Example 1 Two 1145 aluminum alloy strips, each approximately 1.6 mm (0.063 inch) thick, are physically removed from the surface of the strip to form a substantially virgin metal surface on the strip. Scraping and wire brushing were used to remove the dirt. The strip surface was immediately heated to about 100° C. for 15 minutes to remove moisture from the surface without unduly reforming oxides on the surface. The strip is then placed in immediate interfacial relationship and passed between pressure bonding rolls heated to 100°C, where the strip is about 6
Roll bonding of the strip surfaces was achieved by imparting a thickness reduction of 0% to each other, forming a composite metal component with a solid metallurgical bond between the metal layers. The composite member is then heated in air at about 260° C. for 45 minutes;
The bond between metal strips has been improved. Comparative parts were prepared in a similar manner, but in this case, after wire brushing, the strip surfaces were held at room temperature (20° C.) for about 15 minutes before being roll bonded together. A conventional peel or peel strength test showed that the strips heated at 100°C for 15 minutes as described above before bonding produced a bond two to three times stronger than the bond of the relatively soft material. It was equipped with

Example 2 Two strips of 1145 aluminum alloy were roll bonded together as described in Example 1, but in this case the strip surfaces after wire brushing were heated to a temperature of 150°C for 15 minutes before being rolled together. held for minutes. In this case, the strip was found to have a joint that was 3 to 4 times stronger than the joint of the comparative member described in Example 1.

Example 3 Two strips of 1145 aluminum alloy were roll bonded together as described in Example 1, but in this case the strip surfaces after wire brushing were brought to a temperature of 200° C. for 15 minutes before being roll bonded together. held for minutes. It has been found that in this case the strips are bonded to each other with approximately twice the bond strength as in the previously described comparative member. In other instances where longer bond sintering times were used to improve the bond condition after initial roll bonding, even greater bond strength improvements were achieved.

EXAMPLE 4 Two strips of precipitation hardened 7075 aluminum alloy in T-O condition, each having a thickness of 1.6%, are rubbed to mechanically remove oxides from the strip surface. , wire brushed. A pattern element consisting of an epoxy-based anti-bond material, designated C in Table II, was placed at selected locations on the brushed surface of one of the strips using a silk screen and heated at 200° C. for 3 minutes. Cured by heating. The blunted surfaces are then immediately brought into interfacial abutment with the anti-bonding pattern in between, and heated to a temperature of about 100° C. to roll or pressure weld the strips. It was passed between pressure bonding rolls. The strip was stretched to reduce its thickness by 60% and formed into a composite metal part, which part was made precisely by the pattern of anti-bond material as it was stretched during roll bonding of the strip. solid state metallurgical bonds between the strips except for interstrip non-bonded regions defined in the strips. The platform member is heated for approximately 1 hour 26 to improve the metallurgical bond between the strips in the solid state and reduce non-uniform stress areas within the bonded strip material.
It was heated to a temperature of 0°C. At this point the material was found to have sufficient bond strength between the metal layers to withstand normal handling. The composite member was then placed between shaped molds with mold contours that matched the anti-bonding pattern between the metal layers and heated at a temperature of about 427° C. for 30 minutes. These conditions are suitable for decomposing the anti-bond material to generate gas in the non-bonded areas between the strips of material, such that a given portion of the strip material is
It was selectively deformed or expanded over the unbonded region to form a stiffening portion of the tilting member. Alternatively,
After these parts of the composite member are heated to the aforementioned temperature,
Expansion or deformation can also be achieved by introducing high fluid pressure into the unbonded areas between the strips through expansion nozzles inserted between the strips. The precipitation hardened part material was then hardened in a conventional manner.

The member has been found to be sufficiently rigid for use as a structural panel member or the like. It was found that there was no significant necking in the deformed portion of the member, and that the material within the deformed portion of the member layer was uniformly thinned in terms of relative softness.

Example 5 Two strips of precipitation hardened 7075-T-O aluminum alloy were rubbed and wire brushed to physically remove oxides from the surface of the strips. A pattern of anti-bonding material was placed on the wire brushed surface of one of the strips and aged and cured as described in Example 4. The surface of the strip was immediately heated to a temperature of about 150° C. for about 15 minutes to remove moisture without regenerating an excessively thick oxide on the brushed strip surface. The strips were then roll bonded together and heated as described with reference to Example 4 to improve the bond between the metal layers. At this point, the strip material was found to be bonded together with a substantially stronger bond than the bonding member described in Example 4. The composite member was then expanded and cured as in Example 4. The resulting stiffened composite member was found to have the properties described in Example 4.

Example 6 Two strips of precipitation hardened 7075-T-O aluminum alloy were rubbed and wire brushed to physically remove oxides from the surface of the strips. A pattern of anti-bonding material was placed on the wire brushed surface of one of the strips and aged and cured as in Example 4. The surface of the strip was heated to a temperature of about 150° C. for about 15 minutes to effect removal of moisture from the strip without regenerating excessively thick oxide on the brushed strip surface. The strips were then roll bonded together, heated and expanded as in Example 4.

The part is then heated at a temperature of 480°C for 15 minutes and then immediately quenched in water at a temperature below 30°C to precipitation harden the layer material of the part for about 20 minutes at a temperature of about 120°C.
Heated for 4 hours. It has been noted that the bond strength between the layer members decreases during heating of the joining member for precipitation hardening of the layer material. However, it has been found that the component is suitable for use as a structural panel component or the like.

Example 7 Two commercial grade "Alclad" 7075-T-O aluminum alloy strips were used to form an expanded structural member. Each strip is made of one layer of precipitation hardened 7075
It consists of an aluminum alloy and a layer of 7072 aluminum alloy roll bonded to each outer surface of the alloy in a known manner, the bond interface between the layers of said strip being free of non-uniform areas of stress or weak bond castles. It didn't exist. Said 7075
Due to its composition and the thermo-mechanical treatment it has already undergone, the alloy material is capable of plastic deformation to a substantial degree (more than 80% elongation), and the thickness of each strip is 1.6 m.
m (0.063 inch), and each of the 7072 alloy layers accounted for about 2.5-5.0% of the alloy thickness of the strip. The strips were scrubbed and the 7072 alloy surface of the strips was wire brushed to physically remove oxides. A pattern member consisting of the anti-bond material described in Table II C is placed on one of the brushed strip surfaces and cured as described in Example 4, the surface of the strip being processed at 150° C. for about 2 minutes. This removed moisture from the surface but did not recreate an excessive oxide layer on the brushed strip surface. The strip is then heated to 100°C
The composite metal parts were formed by roll-bonding them to each other between pressure-bonding rolls that were heated to a temperature of 100.degree. C. and reducing the thickness by 60%. The composite member has a solid metallurgical bond between the strips, except for precisely defined non-bonded areas between the strips by a now stretched pattern member of anti-bond material. ing. The composite member was heated at 260°C for 1 hour to improve the solid state bond between the members
The strips were heated to a temperature of 0.degree. C. to seal hermetically around the non-bonded areas and substantially eliminate areas of non-uniform stress or weak bonds between the strips. The composite member was then constrained between contour molds, and the contour shape provided by the mold was aligned with the unbonded areas between the strips.

The composite member is then heated for 30 minutes at a temperature of 430 DEG C. to thermally decompose the anti-bonding material and generate gas, while bringing the strip to a heated state for the desired plastic deformation. The strip material was then deformed by the gas into the contour molded shape to form the desired stiffening portion of the mating member. The mating member is then heated to a solution temperature of 480°C for 15 minutes, then heated to 30°C.
or below, and then heated for 24 hours at a hardening temperature of 120° C. to precipitation harden the strip.

The parts thus formed were found to be strong and rigid, with substantially uniform thinning in the deformed portion of the part and no significant necking. There are no non-uniform stress zones or significant weak bond areas in the component, and the component is precisely formed to have the intended dimensions and structural properties, which improve the structural strength of the aircraft. The dimensions and characteristics were suitable for use in parts. It was found that there were extremely strong connections between the layers.

Example 8 Two strips of Alclad 7075-T-O aluminum alloy were prepared as described above and approximately 0.
An additional strip of 1145 aluminum alloy with a thickness of 5 mm (0.020 inch) was similarly wire brushed and heated as described above to remove moisture. The pattern member made of the bond preventing material is
45 aluminum alloy material was added onto one surface and hardened. The surfaces of the 1145 alloy and the two Alclad strips are heated to a temperature of 150° C. for 2 minutes, and the two Alclad strips are brought into interfacial relationship with respective opposite sides of the additional strip material. , the three strips were roll bonded together with a 60% thickness reduction in the strip material to form a composite member as described above. The part side was then subjected to a heat treatment and expansion step and hardened as described above with reference to Example 6.

In this case, the component layers are very strongly connected to each other,
The component itself has the desired desired properties,
As mentioned above, it has been found that it is suitable for use in aircraft structural strength applications.

Example 9 Two strips of [Alclad] 7075-T-O
The aluminum alloy and one additional strip of 6061 aluminum alloy were roll bonded as in Example 8, heat treated, expanded and hardened.

It has been found that the structural member thus formed has the desired physical properties as described with reference to Example 8.

Example 10 Two strips of 2024 aluminum alloy and one additional strip of 6061 aluminum alloy were roll bonded, heat treated, expanded and formed into a structure as in Example 7. The expanded parts were heated for 15 minutes at a solution temperature of 495°C, immediately quenched in water at a temperature of 30°C or below, and heated for 12 hours at an aging temperature of 190°C. It has been found that the structural member thus formed also has desirable features suitable for use in aircraft structural components, as described with reference to Example 8.

Example 11 Two strips of 6061 aluminum alloy were roll bonded as in Example 6, heat treated, and expanded to form a structural member. Inflated member 530 for 15 minutes
C. solution temperature, immediately quenched in water at 30.degree. C. or below, and then heated at an aging temperature of 160.degree. C. for 18 hours to precipitation harden the component material. It has been found that structural members thus formed also have desirable properties for use in aircraft structural applications.

Two strips of 7475 aluminum alloy were roll bonded and heat treated as in Example 6 to form a structural member;
Inflated. The inflated member is at a temperature of about 495°C.
The parts were heated for 15 minutes at a solution temperature of 30°C, immediately quenched in water at a temperature of 30°C or lower, and aged for 3 hours at 120°C and 3 hours at 155°C to precipitation harden the part material.

It has been found that structural members thus formed also have desirable properties suitable for aircraft structural applications.

Although particular embodiments of the invention have been described to illustrate the invention, it is intended that the invention also include all modifications and equivalents of the disclosed embodiments that fall within the scope of the claims. I want you to understand.

[Brief explanation of drawings]

1 is a plan view of the new and improved structural member provided by the present invention; FIG. 2 is a cross-sectional view taken along line 2--2 of FIG. 1; and FIG. 3 is a plan view of the new and improved structural member provided by the present invention. 4 is a plan view of a product manufactured by the method of FIG. 3; FIG. 5 is an enlarged scale view taken along line 5-5 of FIG. 4; FIG. 6 is a partial sectional view similar to FIG. 5 illustrating one step in the method of the invention; FIG. 7 is a partial sectional view illustrating another step in forming the structural member of FIG. A cross-sectional view, similar to Figure 5. 8 is a sectional view similar to FIG. 5 illustrating the characteristics of the structural member of FIG. 1; FIG. 9 is a schematic similar to FIG. 3 schematically illustrating an alternative embodiment of the method of the invention; FIG. 10 is a cross-sectional view similar to FIG. 8 illustrating the properties of a structural member made using the method of FIG. 9; FIG. 11 is a diagrammatic representation of another alternative embodiment of the method of the invention. 12 is a cross-sectional view similar to FIG. 10 illustrating the characteristics of a structural member formed using the method of FIG. 11, and FIG. 13 is a schematic diagram similar to FIG. 1 is a graphical diagram schematically illustrating the characteristics of several members provided by; FIG. DESCRIPTION OF SYMBOLS 12, 14... Layer member, 16... Bonding part, 18... Non-bonding area, 20... Selectively stiffened part, 26... Pair of pressure bonding rolls, 28... Brushing device, 32... From bonding prevention material Naru Pattern Agent ``Asaaki Hako

Claims (1)

[Scope of Claims] (1) A method for manufacturing a structural member for use in an aircraft or the like, comprising a selectively stiffened portion, the method comprising: forming a bond preventing material on one surface of a metal layer; bonding the metal layers to each other to form a composite member while leaving a non-bonded region defined by the bond preventing material between the layers; inducing high fluid pressure within the metal layer to deform a predetermined portion of at least one layer of the metal layer to form a selectively stiffened portion of the member. at least one layer of the metal layer comprises a precipitation hardening alloy adapted to undergo substantial plastic deformation when heated, and the metal layer is passed between pressure bonding rolls to stretching the metal layer and reducing its thickness;
A solid metallurgical bond is formed between the layers to provide a composite member, while a pattern of bond preventing material is stretched to a predetermined extent to form a selected non-bonded interface between the metal layers. the regions are precisely defined and the metal layers improve the solid state metallurgical bond between the layers to hermetically seal the metal layers to each other around the non-knotted interfacial region; and also heated to a first temperature to substantially eliminate a substantial area of weakness in the bond between the layers outside of the unbonded region, and further wherein the metal layer has at least one layer exhibiting substantial plastic deformation properties. heating to a temperature indicated, high fluid pressure is induced in the unbonded interface region to plastically deform a portion of the at least one layer to form a selectively stiffened portion of the member; A method for producing a structural member, characterized in that the alloy of the metal layer is precipitation hardened. (2) The method of manufacturing a structural member according to claim 1, further characterized in that the precipitation hardening alloy is selected from the group consisting of aluminum alloys having the components listed in Table I. Production method. (3) A method of manufacturing a structural member having selectively stiffened sections for use in aircraft or the like, the method comprising disposing a pattern of anti-bond material on one surface of the metal layer. bonding the metal layers to each other to form a composite member while leaving a non-bonded region defined by the bond preventing material between the layers; and applying high fluid pressure within the non-bonded region. forming a selectively stiffened portion of the member by deforming a predetermined portion of at least one of the metal layer members. at least one metal layer comprising a precipitation hardened alloy member adapted to be plastically deformed to a substantial degree corresponding to an elongation of at least about 60% when heated to a temperature of is passed between pressure bonding rolls at a temperature below the selected temperature, thereby stretching itself and reducing its thickness, thereby forming a composite member between the metal layers. While a solid phase metallurgical bond is produced, said pattern of anti-bond material is stretched to a predetermined extent to precisely define selected non-bonded areas between layer members, The metal layer member is heated to a first temperature that is equal to or lower than the selected temperature, thereby improving the metallurgical bond between the layer members in a solid state, and at the same time, the layer member is heated to a first temperature that is equal to or lower than the selected temperature. The metal layer member is hermetically sealed around the interfacial region, substantially reducing the area of substantial weakening of the bond between the layer surfaces outside of the non-bonded region, and the metal layer member is further bonded to its precipitation hardened alloy. is heated to the selected temperature such that the metal layer is plastically deformed to the substantial extent, and a selected high fluid pressure is induced in the non-bonded interfacial region, thereby a predetermined portion of the precipitation hardened alloy layer in at least one layer of the component is plastically deformed to form a selectively stiffened portion of the component; A method for manufacturing a structural member, the method comprising undergoing a hardening process. (4) The method of claim 3, further comprising: the anti-bonding material being thermally decomposed at the selected temperature to induce the fluid pressure within the non-bonding interfacial region. , heating the anti-bonding material and metal layer member to the selected temperature is performed at a selected rate, such that the deformation of the precipitation hardened alloy layer is substantially localized in the layer. A method for manufacturing a structural member, characterized in that it is guaranteed to be carried out without generating any netting portions. (5) The method according to claim 4, further characterized in that the precipitation hardening alloy is selected from the group consisting of aluminum alloys having the components listed in Table I. . (6) A method according to claim 5, further comprising at least one layer of the layer member having an additional relatively thin layer of another aluminum material, the additional After the layer is introduced between the metal layer members, the metal layer members are passed between the pressure bonding rolls to facilitate the formation of the solid metallurgical bond therebetween. A method for manufacturing a structural member. 7. The method of claim 6, further comprising: said additional relatively thin aluminum material layer forming a precipitation hardening alloy of said metal layer member when said metal layer member is subsequently heated. A method for producing a structural member, characterized in that the aluminum material is selected from the group consisting of the aluminum materials listed in Table II so as to be compatible. (8) The method of claim 7, further comprising: said additional relatively thin layer of aluminum material being metallurgically bonded to a precipitation hardening alloy in one layer of said metal layer member. . A method for manufacturing a structural member, characterized in that the metal layer member is passed between the pressure bonding rolls as a part of the one metal layer member. (9) The method of claim 8, further comprising a second relatively thin additional layer of aluminum material metallurgically applied to the precipitation hardenable alloy layer in the other of the metal layer members. and is passed between the pressure bonding rolls as a part of the other metal layer member, and by passing this metal layer member between the pressure bonding rolls, the additional aluminum A method for manufacturing a structural member, characterized in that the solid phase metallurgical bond is formed between the thin layers made of a material. (10) In the method according to claim 7,
Additionally, the additional relatively thin layer of aluminum material is spaced apart from the precipitation hardened alloy layer in the one metal layer member and is in contact with the precipitation hardened alloy layer in the one metal layer member. A method for producing a structural member, characterized in that the bonding is performed when the metal layer members are metallurgically bonded to each other. (11) In the method according to claim 4, the anti-bonding material is selected from the group consisting of materials listed in Table II that thermally decompose to generate gas, and the materials in the group include the materials listed in Table II. A method for producing a structural member, characterized in that the decomposition temperature corresponding to the plastic flow temperature of the precipitation hardened alloy in the metal layer member is biased, and the precipitation hardened alloy exhibits an elongation of at least 60% at the temperature. (12) In the method according to claim 3,
Furthermore, the thickness of the metal layer member is sufficiently reduced when the solid metallurgical joint is formed by roll bonding, and the thickness of the metal layer member is sufficiently reduced to improve the solid metallurgical joint. A method for producing a structural member, characterized in that the precipitation hardening alloy material contained in the precipitation hardening alloy material is heated to a temperature sufficient to enhance the plastic flow properties. (13) A method of manufacturing a selectively stiffened aluminum structural member for use in an aircraft or the like, comprising providing a pair of aluminum metal layer members, each said layer being made of a precipitation hardened aluminum alloy. the alloy has a layer of aluminum material selected from the group consisting of: the alloy has a component that conditions the alloy to undergo superplastic deformation when heated to a selected temperature; providing an aluminum metal layer member comprising components; mechanically cleaning the layer member to remove oxides from the aluminum metal member; and cleaning one of the aluminum metal layer members. heating the mechanically cleaned surface of the metal layer member at a first temperature less than or equal to the selected temperature for a selected limited period of time; removing moisture from the cleaned surface of the layer without generating excessive regenerated oxides on the cleaned surface of the layer; and removing the moisture and removing the cleaned surface of the other metal layer member. arranging the metal layer member on the pattern so as to be in interfacial contact with the one metal layer member; passing the metal layer member between pressure bonding rolls at a temperature equal to or lower than the selected temperature; by stretching the component to reduce its thickness to form a solid metallurgical bond between the metal layer components, while stretching the pattern of anti-bond material to a predetermined extent; providing a precisely defined interfacial area between the layer members defined by the anti-bonding material and free of such bonds; and heating the metal layer member at a second temperature below the selected temperature. heating to a temperature that improves the solid state metallurgical bond between the metal layers, hermetically sealing the metal layer members to each other around the non-bonding interfacial region, and heating the aluminum metal layer member at a temperature sufficient to substantially reduce the area of structural weakening at the bond between the aluminum metal layers outside of the non-bonded interfacial region; inducing a selected high fluid pressure in the unbonded interfacial region while the heated metal layer member is heated to the selected temperature at which the material exhibits substantial plastic flow; deforming the metal layer member over the region by restraining the member from relative movement along the region and defining a desired profile mold shape on the non-bonded interface region; thereby causing at least one of said precipitation hardening alloys to be plastically deformed into said contour mold imparted with a desired shape for forming a structural member; A method of manufacturing a structural member comprising the step of treating the molded member to precipitation harden it. (14) In the method according to claim 16, the metal layer members are heated at a temperature within the range of about 1,500°C to 300°C for a period of about 5 to 60 minutes. A method of manufacturing a structural component, characterized in that moisture is substantially removed from the component without undue regeneration of oxides on the surface. (15) A method for manufacturing a structural member according to claim 14, wherein the metal layer member is heated at a temperature of about 150° C. for about 15 minutes. (16) The method according to claim 16, further comprising: thermally decomposing the anti-bonding material at the second temperature to induce the high fluid pressure within the non-bonding interface region; The anti-bond material and the metal layer are heated to the second temperature at a selected rate to ensure that deformation of the metal layer proceeds with the layer material undergoing substantial plastic deformation. A method for manufacturing a structural member, characterized in that: (17) In the method according to claim 16, the bond preventing material is selected from the group consisting of materials listed in Table II that thermally decompose to generate gas, and the material is A method for producing a structural member, characterized in that the method comprises providing a decomposition temperature corresponding to the preferred plastic deformation temperature of the precipitation-hardened alloy in the member. (18) The method according to claim 13, wherein the unidirectional precipitation hardened alloy layer of the metal layer member further includes an additional relatively thin aluminum material layer metallurgically bonded thereto. The layer is passed between the pressure bonding rolls as a part of the one metal layer member, and the additional aluminum material is introduced between the metal layer members to form the metal layer member. A method for producing a structural member, characterized in that the formation of the solid metallurgical bond between the precipitation hardened layers is facilitated. (19) In the method according to claim 18, the precipitation hardened alloy layer in the other metal layer member further includes:
Before the metal layer member is passed between the pressure bonding rolls, the relatively thin second layer of additional aluminum material is metallurgically bonded, thus removing the additional aluminum material. A method for producing a structural member, characterized in that when the second layer is also introduced between the metal layer members, the formation of the solid metallurgical bond between the metal layer members is facilitated. . (20) A method for manufacturing a selectively stiffened aluminum structural member for use in an aircraft or the like, the method comprising: providing a pair of aluminum metal layer members having substantially equal thickness; has a layer of an aluminum material selected from the group consisting of precipitation-hardened aluminum alloys, said alloy comprising components that condition the alloy to undergo superplastic deformation when heated to a selected temperature. providing an aluminum metal layer member having the components listed in Table I; and at least one additional aluminum material selected from the group consisting of materials having the components listed in Table II. providing a relatively thin layer member; mechanically cleaning a surface of the aluminum metal layer member to remove oxides therefrom; and cleaning one of the aluminum metal layer members. heating the mechanically cleaned surface of the metal layer member at a first temperature less than or equal to the selected temperature for a selected limited period of time; removing moisture from the cleaned surface of the layer without generating excessive regenerated oxides on the cleaned surface of the layer; positioning each of the additional layer members in interfacial abutment with opposing cleaned, dehumidified surfaces, and with the pattern between the pair of surfaces; and the selection. The metal layer member is passed between pressure bonding rolls that are at a temperature lower than the temperature of Stretching the pattern of anti-bonding material to a predetermined extent while forming a target bond, a precisely predetermined interfacial area defined by the anti-bonding material and where no such bond exists. and heating the metal layer member to a second temperature that is less than or equal to the selected temperature, the temperature improving the solid state metallurgical bond between the metal layers. hermetically sealing the metal layer members to each other around the non-bonding interface region and also substantially reducing the area of structural weakening at the bond between the aluminum metal layers outside of the non-bonding interface region. further heating the aluminum metal layer member to the selected temperature at which the precipitation hardened alloy layer exhibits the substantial plastic flowability; fluid pressure is induced in the non-bonded interfacial region while restraining the heated metal layer member from relative movement along the bonded portion thereof; defining a desired contour mold shape in the contour mold to deform the metal layer member over the region such that at least one of the precipitation hardened alloy layers is imparted with a desired shape to form a structural member; A method of manufacturing a structural member comprising the steps of: causing the formed member to be plastically deformed inward; and treating the formed member to precipitation harden the precipitation hardening alloy of the layer member. (21) In the method according to claim 20, the surface of the metal layer member is heated at a temperature in the range of about 150°C to 600°C for a period of about 5 to 30 minutes. 1. A method of manufacturing a manufacturing component, characterized in that moisture is substantially removed from the layered component without undue regeneration of oxides thereon. (22) A method for manufacturing a structural member according to claim 21, wherein the metal layer member is heated at a temperature of about 150° C. for about 15 minutes. (23) The method according to claim 20, further comprising: the anti-bonding material being thermally decomposed at the second temperature to induce the high fluid pressure within the non-bonding interface region; The anti-bonding material and the metal layer are heated to the second temperature at a selected rate to ensure that deformation of the metal layer proceeds with the layer material undergoing the substantial plastic deformation. A method for manufacturing a structural member, characterized in that: (24) A method of manufacturing a composite metal member, the step of providing a pair of metal layers in which at least one layer of the pair of metal layers is comprised of a precipitation hardening alloy, the alloy being heated to a selected temperature. providing a pair of metal layers having the alloy-forming components so as to undergo substantial plastic deformation when the metal layer is pressed; passing the metal layer between pressure bonding rolls; forming a solid metallurgical bond between the metal layers by stretching and reducing their thickness; and selecting the metal layer to improve the metallurgical bond in the solid state. heating the metal layer member to a first temperature below a temperature at which the metal layer member is thinned enough to form the solid state bond; the step is adjusted to enhance the plastic deformation properties of the one metal layer, and further comprises heating the metal layer to the selected temperature at which at least one layer exhibits the substantial plastic deformation. forming the metal layer into a selected shape while the one layer exhibits the enhanced plastic deformation properties; and precipitation hardening the alloy of at least the one metal layer. A method for manufacturing a composite metal member. (25) The method according to claim 24, wherein the precipitation hardening alloy is selected from the group consisting of aluminum alloys having the components listed in Table I. Method. (26) A method for manufacturing an Aluo member, comprising the steps of providing a pair of aluminum metal layers, mechanically cleaning the surface of the aluminum metal layer to remove oxides from the surface, and the metal layer heating at a first temperature for a selected limited period of time to substantially remove moisture from the mechanically cleaned surface of the metal layer without unduly regenerating oxides on the surface. Immediately thereafter, the dried metal layer is passed between pressure bonding rolls at a temperature below a selected level, thereby stretching the metal layer symmetrically and increasing its thickness. forming a solid metallurgical bond between the metal layers; and heating the metal layer to a second temperature, the second temperature being the metal in the solid state. a heating step at a temperature sufficient to improve the metallurgical bond between the layers and hermetically seal the metal layers together. (27) In the method according to claim 26, the metal layer member is heated at a temperature in the range of about 100°C to 150°C for a period of about 1 minute to 60 minutes. 1. A method of manufacturing an aluminum component, characterized in that moisture is substantially removed from the surface without excessively regenerating oxides on the surface. (28) A method for manufacturing an aluminum member according to claim 27, wherein the metal layer member is heated at a temperature of about 150° C. for about 15 minutes. (29) A structural member with selectively stiffened sections for use in aircraft or the like having a pair of precipitation hardened metal layer members between which a solid metallurgical material is applied. the metal layer members are hermetically sealed to each other around a precisely defined non-bonded interface area therebetween, with a mechanical bond substantially free of structural weakening therebetween; and wherein the member is a structural member having a deformed portion therein to provide a selected stiffening portion thereto, and the member is a structural member having a pattern of anti-bond material. on one side of a metal layer; covering the pattern with a second metal layer; and bonding the metal layers together to form the structural member, while the bond prevention material defined as
selectively deforming the structural member by leaving an unbonded region between the layers and inducing high fluid pressure in the unbonded region to deform a predetermined portion of at least one of the metal layers; forming a stiffened part in a structural member, wherein at least one of the metal layers comprises a precipitation hardening alloy, the alloy being selected The metal layer is stretched by being passed between pressure bonding rolls to reduce its thickness. ,
While the pattern of anti-bonding material is stretched to a predetermined extent to thereby provide the structural member by forming a solid metallurgical bond between the metal layers, The bonding interface area is precisely defined,
The metal layers are heated to a first temperature that is less than or equal to the selected temperature to improve the metallurgical bond between the layers in a solid state and to form an airtight seal with each other around the non-bonded interfacial region. and the non-uniform stress areas and substantial weaknesses in the bond between the layers are substantially reduced outside the unbonded region, and the metal layer further is heated to the selected temperature exhibiting substantial plastic deformation properties, and high fluid pressure is generated within the non-bonded interface region to cause at least a portion of the one metal layer to selectively stiffen the structural member. A structural member that is plastically deformed to form a strengthened portion, the structural member being treated to precipitation harden the alloy of at least one of the metal layers. (30) A structural member according to claim 29, wherein the structural member is comprised of a product obtained from the method, further comprising the components listed in Table I. A structural member characterized in that it is selected from the group consisting of aluminum alloys with: (31) A structural member according to claim 30, wherein the structural member is constituted by a product obtained from the method, and further the anti-bonding material is heated at the selected temperature. decomposing and inducing the selected fluid pressure in the unbonded interfacial region, the anti-bonding material and metal layer member being heated at a selected rate to the selected temperature. ,
Structural element, characterized in that it is ensured that said deformation of said mountain-hardened alloy layer takes place while it exhibits said substantial plastic deformability. (32) The structural member according to claim 31, wherein the structural member is manufactured by the method, wherein at least one of the layer members is made of another aluminum material. an additional, relatively thin-walled layer consisting of an additional, relatively thin-walled layer that is introduced into the metal layer member before the metal layer member is passed between the pressure bonding rolls; A structural member characterized in that the formation of the solid metallurgical bond between metal layers is thereby facilitated. (33) The structural member according to claim 31, wherein the structural member is constituted by a product obtained by the method, and further the bond preventing material is a pyrolyzable material according to Table II. and the material is selected from the group consisting of materials that generate gas by decomposing the material, and that the material has a decomposition temperature corresponding to the temperature at which the precipitation hardening alloy in the metal layer member exhibits the substantial plastic deformability. Characteristic structural members.