US20060088438A1 - Aluminum-based alloy composition and method of making extruded components from aluminum-based alloy compositions - Google Patents

Aluminum-based alloy composition and method of making extruded components from aluminum-based alloy compositions Download PDF

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Publication number
US20060088438A1
US20060088438A1 US10/970,304 US97030404A US2006088438A1 US 20060088438 A1 US20060088438 A1 US 20060088438A1 US 97030404 A US97030404 A US 97030404A US 2006088438 A1 US2006088438 A1 US 2006088438A1
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Prior art keywords
weight
aluminum
composition
alloy
conform
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Abandoned
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US10/970,304
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English (en)
Inventor
Daniel Corrigan
Nagendra Murching
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Visteon Global Technologies Inc
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Visteon Global Technologies Inc
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Priority to US10/970,304 priority Critical patent/US20060088438A1/en
Assigned to VISTEON GLOBAL TECHNOLOGIES, INC. reassignment VISTEON GLOBAL TECHNOLOGIES, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MURCHING, NAGENDRA N.
Assigned to VISTEON GLOBAL TECHNOLOGIES, INC. reassignment VISTEON GLOBAL TECHNOLOGIES, INC. CORRECTIVE ASSIGNMENT TO ADD AN ADDTIONAL ASSIGNOR'S NAME PREVIOUSLY RECORDED ON REEL 015923 FRAME 0110. ASSIGNOR CONFIRM THE ASSIGNMENT. Assignors: CORRIGAN, DANIEL L., MURCHING, NAGENDRA N.
Priority to DE102005050481A priority patent/DE102005050481A1/de
Priority to JP2005304225A priority patent/JP2006118046A/ja
Publication of US20060088438A1 publication Critical patent/US20060088438A1/en
Assigned to JPMORGAN CHASE BANK, N.A., AS ADMINISTRATIVE AGENT reassignment JPMORGAN CHASE BANK, N.A., AS ADMINISTRATIVE AGENT SECURITY AGREEMENT Assignors: VISTEON GLOBAL TECHNOLOGIES, INC.
Assigned to JPMORGAN CHASE BANK reassignment JPMORGAN CHASE BANK SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: VISTEON GLOBAL TECHNOLOGIES, INC.
Assigned to WILMINGTON TRUST FSB, AS ADMINISTRATIVE AGENT reassignment WILMINGTON TRUST FSB, AS ADMINISTRATIVE AGENT ASSIGNMENT OF SECURITY INTEREST IN PATENTS Assignors: JPMORGAN CHASE BANK, N.A., AS ADMINISTRATIVE AGENT
Assigned to VISTEON GLOBAL TECHNOLOGIES, INC. reassignment VISTEON GLOBAL TECHNOLOGIES, INC. RELEASE BY SECURED PARTY AGAINST SECURITY INTEREST IN PATENTS RECORDED AT REEL 022575 FRAME 0186 Assignors: WILMINGTON TRUST FSB, AS ADMINISTRATIVE AGENT
Abandoned 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
    • C22C21/12—Alloys based on aluminium with copper as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
    • C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon

Definitions

  • the present invention relates to aluminum alloy compositions and methods of making extruded components from aluminum alloy compositions using conform extrusion.
  • the resulting shapes and lengths of aluminum alloy of constant cross-section may be solid or hollow (enclosing voids), simple or exceedingly complex. Furthermore, these shapes have all the desirable characteristics looked in for wrought products including an adequate metallurgical structure which can be bent, formed, forged, machined, or welded.
  • the conventional extrusion process can achieve production of highly intricate shapes, production of accurate shapes, provision of hinge features for moving assemblies, provisions of shapes that assemble with minimum fixing, production of a single shape to replace several parts, and provision of local strength and stiffening.
  • a typical extrusion apparatus/machine may occupy a substantial area of about 6 feet by 30 feet.
  • a conventional extrusion process requires cutting of each billet length to between about 24 to 36 inches, and preheating the billets to about 400° C., thereby resulting in a relatively timely consuming and substantial source of power.
  • the system requires stoppage for each billet loaded in the extrusion operation.
  • the present invention generally provides an alloy composition resulting in improved corrosion resistance and reduced die wear during die usage. This result is accomplished by adding predetermined levels of copper to the alloy to improve the corrosion resistance, zirconium to improve grain size after a brazing operation, manganese to improve strength and reduce grain growth. Moreover, an addition of a predetermined balanced proportion of zinc, magnesium and silicon to the alloy results in creating a relatively large number of small grain size after the brazing operation.
  • the present invention involves an aluminum-based alloy composition for vehicle components such as vehicle heat exchanger tubes.
  • the composition consists essentially of between about 0.15 to 0.6% by weight silicon to provide recrystallization, between about 0.2 to 0.7% by weight iron, between about 0.4 to 0.6% by weight copper, between about 1.1 to 1.4% by weight manganese, between about 0.15 to 0.3% by weight magnesium, between about 0.15 to 0.4% by weight zinc, between about 0.1 to 0.15% by weight zirconium, and the balance is aluminum.
  • the present invention includes a method of conform extruding an aluminum-based heat exchanger tube.
  • the method comprises pressing the aluminum-based alloy composition and forming a formable alloy composition to a predetermined configuration of the aluminum-based heat exchanger tube.
  • the method includes coining the aluminum-based alloy composition to shear the alloy composition, and shearing the composition to preheat the aluminum-based alloy composition, defining the formable alloy for providing formability of the alloy composition.
  • the method further includes propelling the formable alloy composition, and forcing the formable alloy composition through a die to a predetermined configuration of the aluminum-based heat exchanger tube.
  • FIG. 1 is a table depicting an aluminum-based alloy composition for vehicle components in accordance with one embodiment of the present invention
  • FIG. 2 is a systems diagram of a conform extrusion process for extruding the aluminum-based alloy composition in accordance with one example of the present invention
  • FIG. 3 a is a schematic diagram of a conform extrusion process for extruding the aluminum-based alloy composition to form an aluminum-based heat exchanger tube;
  • FIG. 3 b is an enlarged view of circle 3 b in FIG. 3 a of the conform extrusion process.
  • FIG. 4 is a flow chart depicting one method of conform extruding an aluminum-based heat exchanger tube in accordance with one example of the present invention.
  • Embodiments of the present invention provide an aluminum-based alloy composition and methods of making components, e.g., vehicle heat exchanger tubes, from the aluminum-based alloy composition.
  • the present invention provides a solution to concerns of apparatus size, efficiency, while maximizing in recrystallization and minimizing grain growth of the composition.
  • the composition includes added silicon for a reduced die wear, for enhanced die life, and for minimal grain growth. Recrystallization of the composition is further maximized with the use of copper, magnesium, and zinc. Grain growth of the composition is minimized by the use of zirconium, chromium, and manganese. Moreover, it is preferred that the silicon percent weight is relatively low, between about 0.15 and 0.30 to promote recrystallization. Additionally, it is to be understood that the composition is absent any titanium or chromium to minimize die wear.
  • FIG. 1 is a table 10 illustrating the elements comprising the aluminum-based alloy composition in accordance with one embodiment of the present invention.
  • the aluminum-based alloy composition includes silicon (Si), iron (Fe), copper (Cu), manganese (Mn), magnesium (Mg), zinc (Zn), and zirconium (Zr).
  • the alloy composition consists essentially of 0.15 to 0.60 Si weight (wt.) percent (%), 0.2 to 0.7 Fe wt %, 0.4 to 0.6 Cu wt %, 1.1 to 1.4 Mn wt %, 0.15 to 0.30 Mg wt. %, 0.15 to 0.40 Zn wt %, and 0.10 to 0.15 Zr wt %.
  • the alloy composition may be extruded to form vehicle components suitable for manufacturing air conditioning products, e.g., heat exchanger tubes. It has been found that, when extruded via a conform extrusion process, the alloy composition has the ability to restrict the grain size for suitable application. It has also been found that the composition has the ability to enhance corrosion resistance of a finished product, thereby extending the life of the product.
  • FIG. 2 illustrates a systems diagram 110 depicting a typical conform extrusion process line for the production of aluminum-based heat exchanger tubes from the aluminum-based alloy composition provided in the table of FIG. 1 .
  • the system comprises a feedstock pay-off unit 112 .
  • the feedstock pay-off unit 112 receives feedstock alloy composition to be casted therein into 9.5 to 12 millimeter feedstock rods.
  • the feedstock rods are then pulled into a feedstock straightener unit 114 .
  • both the feedstock pay-off unit 112 and the feedstock straightener 114 are non-powered units, since a conform machine (mentioned below) downstream has sufficient power to pull the feedstock rod through the feedstock units.
  • a feedstock cleaning system 116 This system may be any suitable system such as an ultrasonic system or a parorbital system. As known in the art, the principle of the parorbital system is a combined mechanical and chemical cleaning action.
  • the parorbital system may include a plurality of cleaning heads, wherein each cleaning head comprises entry and exit air knives to prevent the escape of cleaning fluid, and a plurality of hydro-converters which perform the cleaning.
  • each hydro-converter may contain two tungsten carbide dies of slightly larger diameter than the feedstock rod. A high velocity jet of cleaning fluid may then be injected into the hydro-converter in such a way to create a vortex around the feedstock rod. The vortex of fluid causes the feedstock rod to orbit at high speeds, and scrubs the surface of the rod against the tungsten carbide dies.
  • the system 110 further includes a conform process system 118 .
  • the conform process includes a conform machine comprising a grooved wheel and shaft assembly.
  • the composition is pressed through a die apparatus and is formed into a finished shape of a tube exiting the conform machine.
  • the conform line may be controlled by a computer system having software configured to provide desired features (listed below).
  • the features may be as follows: measurement and recording of operating parameters such as temperatures, speeds, and machine loads; tabular display of primary, secondary, and control parameters; graphic display on one second time base of any four primary parameters over the last 24 hours; graphic display on 1/10 second time base of any four control parameters; file recording of primary, secondary, and control parameters; review of recorded files; control of dynamic systems such as heaters and alarms; calibration of system inputs and outputs; and setup and calibration of control loops.
  • operating parameters such as temperatures, speeds, and machine loads
  • tabular display of primary, secondary, and control parameters graphic display on one second time base of any four primary parameters over the last 24 hours
  • file recording of primary, secondary, and control parameters review of recorded files
  • control of dynamic systems such as heaters and alarms
  • calibration of system inputs and outputs and setup and calibration of control loops.
  • Other features may be included without falling beyond the scope
  • a cooling system 120 cools the tube which are then coiled. The tube is then cut to a predetermined length. No heat treatment is necessary.
  • the cooling system 120 for the extrusion wheel and tooling may comprise of a storage tank with a product cooling trough mounted on top.
  • the rear of the tank may be a pumping station containing a pump and a heat exchanger for each cooling circuit.
  • a high volume pump can maintain the required level and flow velocity of the product cooling circuit.
  • the low volume circuits may supply cooling to the extrusion wheel and tooling.
  • Flow control valves for each of the cooling circuits may be mounted on the front of the tank and a closed system may be used to enable the water contacting the product and tooling circuits to be softened.
  • cooling system may be developed to control the cooling rate of the product upon leaving the extrusion die. A rapid quench or a more gradual cooling rate is possible. This in turn, assists in regulating the grain structure and hence properties of the extruded component.
  • FIG. 3 a illustrates a schematic view of a conform extrusion machine 210 for extruding an aluminum-based vehicle component, e.g., a heat exchanger tube, from an aluminum-based alloy composition.
  • the conform extrusion machine 210 includes a rotary wheel 212 that rotates to carry feedstock material through the machine 210 .
  • the rotary wheel 212 comprises a groove 214 radially formed thereon in which the feedstock material is fed.
  • the conform machine 210 further includes a pivot or shearing shoe 216 to which the rotary wheel 212 is adjacently disposed.
  • the shoe 216 cooperates with the rotary wheel 212 to form a lid on the groove 214 as the feedstock material is carried through the groove 214 , coining the feedstock material. Extrusion pressure is generated as the shoe 216 covers the groove 214 .
  • the machine 210 further includes an abutment 220 integrally connect to the shoe 216 and configured to cooperate with the rotary wheel 212 .
  • the abutment 220 dams the material to be extruded.
  • the abutment 220 causes the material to be sheared against the shoe 216 , resulting in superheating of the material and defining a formable alloy.
  • the material generates frictional heat and modification heat, i.e., temperatures of up to 500 degrees or more can be reached without using a heater.
  • the feedstock material is carried in the groove 214 , the material is maintained in a high plastic flow state due to the modification to the shear direction at the abutment 220 and the high temperature.
  • the extruded material is recrystallized, and is in a “tempered” state.
  • the form of feedstock material is a wire rod, in this embodiment, it is possible to extrude continuously without having to stop the machine in order to join pieces of material together.
  • the machine 210 further comprises an extrusion chamber 222 having an extrusion die 224 through which the material is extruded after passing the abutment 220 .
  • the abutment 220 is formed to cooperate with the rotary wheel 212 and to provide a dam of the material to be extruded, thereby forcing the material through the extrusion chamber 222 .
  • the abutment 220 forces the material to be propelled to the extrusion chamber 222 .
  • the material is forced through the die 224 to be formed into a predetermined configuration of the aluminum-based heat exchanger tube. Since the metallic wire is manufactured by continuous cast and rolling, it is relatively inexpensive and straightforward to make a relatively large coil of two tons or more. Furthermore, as shown, for machine is configured to allow a limited amount of scrap to flow away from the abutment.
  • the conform machine may be mounted in rollerbearings that incorporate multiple seals to retain oil and prevent ingress of foreign material.
  • a separate pressurized, filtered and cooled lubrication system insures that the bearings may be adequately lubricated and correct operating temperatures are maintained.
  • the bearings may be held in a rugged steel frame that is extended to carry the pivot shoe and a hydraulic shoe retaining system. The relative deflections of the wheel and tooling may be kept to a minimum, enabling adequate product tolerances to be maintained, despite the relatively high operating forces involved.
  • the main shaft may be driven by an infinitely variable, controlled DC electric motor, via a gear box.
  • the power output envelope of the drive may be matched to the production rates specified or desired.
  • the pivot shoe that carries the tooling may be inserted and retracted by hydraulic cylinders operated from the pendant control panel on the machine. When closed, the shoe may be clamped in place by hydraulic cylinders.
  • the system gives easy start up conditions and minimizes the risk of damage from overload when operating an unfamiliar product, since the clamp pressure can be released, allowing the shoe to back off.
  • FIG. 4 illustrates a flow chart of one method 310 of conform extruding an aluminum-based heat exchanger tube in accordance with one example of the present invention.
  • the method 310 comprises pressing an aluminum-based alloy composition consisting essentially of the following elements:
  • the temperature of the composition during the step of pressing ranges between about 4000 Celsius (C) and 500° C. More preferably, the temperature is at about 480° C.
  • the step of pressing includes coining the aluminum-based alloy composition to shear the alloy composition and shearing the composition to superheat the aluminum-based composition to define the formable alloy for providing formability of the alloy.
  • the method 310 further includes forming the formable alloy to a predetermined configuration of the aluminum-based heat exchanger tube.
  • the step of forming includes propelling the formable alloy to the extrusion chamber of the conform extrusion machine and forcing the formable alloy through the extrusion die to the predetermined configuration of the aluminum-based heat exchanger tube.
  • the extrusion die is held in a pivoting shoe in the die chamber.
  • the die chamber holds the abutment(s) that fit into the wheel groove(s) and divert the flow of the alloy into the die chamber.
  • the die chamber insures accurate alignment the tooling and allows tooling to be pre-assembled for rapid changes.
  • the die chamber accommodates a wide range of product dies.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Extrusion Of Metal (AREA)
US10/970,304 2004-10-21 2004-10-21 Aluminum-based alloy composition and method of making extruded components from aluminum-based alloy compositions Abandoned US20060088438A1 (en)

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Application Number Priority Date Filing Date Title
US10/970,304 US20060088438A1 (en) 2004-10-21 2004-10-21 Aluminum-based alloy composition and method of making extruded components from aluminum-based alloy compositions
DE102005050481A DE102005050481A1 (de) 2004-10-21 2005-10-13 Aluminiumbasierte Legierungszusammensetzung und Verfahren zur Fertigung extrudierter Komponenten aus aluminiumbasierten Legierungszusammensetzungen
JP2005304225A JP2006118046A (ja) 2004-10-21 2005-10-19 アルミニウムベース合金組成物

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060118282A1 (en) * 2004-12-03 2006-06-08 Baolute Ren Heat exchanger tubing by continuous extrusion
US20080041501A1 (en) * 2006-08-16 2008-02-21 Commonwealth Industries, Inc. Aluminum automotive heat shields
WO2024086118A1 (en) * 2022-10-17 2024-04-25 MELD Manufacturing Corporation 5000 series aluminum alloy products produced using solid state manufacturing
WO2024086117A1 (en) * 2022-10-17 2024-04-25 MELD Manufacturing Corporation 6000 series aluminum alloy products produced using solid state manufacturing

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060118282A1 (en) * 2004-12-03 2006-06-08 Baolute Ren Heat exchanger tubing by continuous extrusion
US7732059B2 (en) * 2004-12-03 2010-06-08 Alcoa Inc. Heat exchanger tubing by continuous extrusion
US20080041501A1 (en) * 2006-08-16 2008-02-21 Commonwealth Industries, Inc. Aluminum automotive heat shields
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