US20060151075A1 - Low internal stress Al-Zn-Cu-Mg plates - Google Patents

Low internal stress Al-Zn-Cu-Mg plates Download PDF

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US20060151075A1
US20060151075A1 US11/299,683 US29968305A US2006151075A1 US 20060151075 A1 US20060151075 A1 US 20060151075A1 US 29968305 A US29968305 A US 29968305A US 2006151075 A1 US2006151075 A1 US 2006151075A1
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plates
plate
thickness
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Sjoerd Van Der Veen
Fabrice Heymes
Julien Boselli
Philippe Lequeu
Philippe Lassince
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Constellium Issoire SAS
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Alcan Rhenalu SAS
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/10—Alloys based on aluminium with zinc as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/053—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with zinc as the next major constituent

Definitions

  • This invention relates generally to a method to relieve the level of residual stress throughout 7xxx series aluminum alloy plates subjected to stretching with permanent elongation.
  • 7xxx series alloy plates that is, Al—Zn—Mg type alloys with or without copper
  • a solution heat-treatment thereof to be able to display, after artificial aging, high mechanical properties throughout their thickness.
  • the presence of high thermal gradients close to the plate surface at the time of quenching causes non-homogeneous plastic strain.
  • internal stress residual stress
  • compression stress is located in the vicinity of the surface, and stretching stress in the center. The extent of this stress depends on the alloy and the structure of the material, along with the solution heat-treatment and quenching method; the order of magnitude is 200 MPa.
  • U.S. Pat. Nos. 6,159,315 and 6,406,567 disclose a method of stress relieving solution heat-treated and quenched plates, comprising a first cold stretch step in the L direction, followed by a cold-compression step in the ST direction.
  • Patent application WO 2004/053180 discloses a method of relieving the residual stress in a plate by means of edge compression. However, although it makes it possible to obtain plates with low residual energies, this compression method is difficult to implement.
  • Plastic strain typically makes it possible to relieve residual stress by a factor of approximately 10. This is illustrated in FIG. 2 .
  • the residual stress in thick semi-finished products considered as identical may vary significantly. This may be associated with the variation in their chemical composition, but also, and above all in many cases, with the variation in the production process parameters, such as casting, rolling, quenching, stretching and artificial aging; the influence of these process parameters on the level of residual stress in the finished product is still not clearly understood.
  • Some changes to the process indeed result in a relief in the level of residual stress (such as the choice of slower quenching or a higher artificial aging temperature), but they also change the compromise between some properties which are important for structural applications, such as, typically, the mechanical strength, damage tolerance and corrosion resistance.
  • EP 0 731 185 and U.S. Pat. No. 6,077,363 disclose a method for relieving residual stress in 2024 alloy plates. Optimizing the manganese content and the hot rolling outlet temperature makes it possible to obtain a recrystallization rate of over 50% throughout the thickness. Such a plate displays improved mechanical property homogeneity as a function of the thickness, and a reduced level of residual stress after stretching.
  • the residual stress in plates can be determined by means of the successive machining method disclosed in the article by Heymes, Commet et al., referred to above. A method based on this article is described in detail below, and this article is incorporated herein by reference.
  • a purpose of the present invention was to propose a method to obtain 7xxx series aluminum alloy plates which display, in a stretched temper, a naturally aged temper or in any artificially aged temper, a lower level of residual stress, without degrading the mechanical strength and damage tolerance. More specifically, it was desired to obtain plates which do not distort during machining, which is observed when the total elastic energy stored in the plate, W, is less than about 2 kJ/m 3 and preferentially less than about 1 kJ/m 3 .
  • the invention relates to a method for producing Al—Zn—Cu—Mg alloy plates comprising from 4 to 12% zinc, less than 4% magnesium and less than 4% copper, other elements ⁇ 0.5% each, and the remainder aluminum.
  • the method comprises hot rolling, solution heat-treatment, quenching, controlled stretching with permanent elongation greater than 0.5% and aging, wherein the elapsed time D between the end of quenching and the start of controlled stretching is less than about 2 hours, and preferentially less than about 1 hour.
  • the invention also relates to an inspection lot or a heat treatment batch of Al—Zn—Cu—Mg alloy plates comprising from 4 to 12% zinc, less than 4% magnesium and less than 4% copper, other elements ⁇ 0.5% each, the remainder aluminum, in a solution-treated, quenched, stretched and aged temper, wherein the total elastic energy W (expressed in kJ/m 3 ) of the plates displays a standard deviation less than or equal to 0.20+0.0030( R p0.2(L) [MPa] ⁇ 400) around an average value.
  • FIG. 1 is a schematic representation of the definition of the three main directions in a plate.
  • FIG. 2 is a schematic representation of a stretching curve.
  • Curve 2 represents the stress condition in the plate core.
  • Curve 1 represents the surface stress condition.
  • This figure shows the controlled stretching stress relieving principle: before the controlled stretching, the difference in the stress between the surface and the core is defined by x and ⁇ x. Controlled stretching reduces this difference (defined by y and ⁇ y) typically by a factor of 10.
  • FIG. 3 represents the definition of the parameters h, l and w of a plate.
  • the strain gauge (with its connection wire) can be seen schematically.
  • FIG. 4 is a schematic representation of the sequences of the measurement and calculations to determine a residual stress profile in the plate thickness using the successive layer removal method.
  • FIG. 5 is a schematic representation of the critical part of the method according to the invention.
  • D refers to the time interval between the end of quenching and the start of controlled stretching.
  • FIG. 6 shows the natural aging kinetics of 7010 and 7050 alloy plates for two different quenching rates.
  • the X-axis shows the yield stress in the L direction, the Y-axis the natural aging time.
  • FIG. 7 shows the effect of increasing the variation in yield stress values on residual stress profiles after quenching.
  • FIG. 8 shows the total elastic energy as a function of the thickness for batches of 7xxx alloy plates according to the invention (where D ⁇ 1 hour) (unfilled dots) and according to the prior art (where D ⁇ 8 hours) (black squares).
  • Al—Zn—Cu—Mg alloy refers to an aluminum-based alloy containing zinc, copper and magnesium alloy elements; such an alloy may also contain other alloy elements along with other elements, the presence of which may be intentional or not, e.g. impurities.
  • the tempers are defined in the European standard EN 515.
  • the chemical composition of standardized aluminum alloys is defined, for example, in the standard EN 573-3.
  • the static mechanical properties i.e. the ultimate tensile strength UTS or R m , the tensile yield stress TYS or R p0.2 , and the elongation at rupture A, are determined by means of a tensile test according to the standard EN 10002-1, the position and direction of test piece sampling being defined in the standard EN 485-1.
  • the toughness K IC was measured according to the standard ASTM E 399.
  • thick plate refers to a plate of a thickness greater than or equal to 6 mm.
  • the term “inspection lot” is defined in the standard EN 12258-1; it refers to a shipment or part of a shipment, submitted for inspection, and which comprises products of the same grade or alloy, of the same form, temper, size, shape, thickness or cross-section, and processed in the same manner.
  • heat treatment batch refers to a quantity of products of the same grade or same alloy, of the same form, thickness or cross-section, and which were produced in the same way, wherein the heat treatment or solution heat-treatment followed by quenching were performed in one furnace load. More than one solution-treatment batch can be included in one precipitation furnace load.
  • the “aging” comprises natural aging at ambient temperature and any artificial aging.
  • machining comprises any material removal method such as turning, free machining, milling, drilling, boring, tapping, electroerosion, straightening, polishing, and chemical machining.
  • structural element refers to an element used in mechanical construction for which the static and/or dynamic mechanical properties are particularly important for the performance and integrity of the structure, and for which a calculation of the structure is generally specified or performed. It typically consists of a mechanical component, the failure of which is liable to endanger the safety of said construction, its users or other parties.
  • these structural elements particularly comprise the elements making up the fuselage (such as the fuselage skin, stringers, bulkheads, circumferential frames), wings (such as the wing skin, stringers or stiffeners, ribs and spars) and the tails particularly consisting of horizontal or vertical stabilisers and floor beams, seat tracks and doors.
  • monolithic structural element refers to a structural element which has been obtained most frequently by machining, from a single piece of rolled, extruded, forged or cast semi-finished product, with no assembly, such as riveting, welding, bonding, with another piece.
  • the L (Length), LT (Long Transverse) and ST (Short Transverse) directions in a rolled product refer to the direction of rolling corresponding to the L direction. These three directions are defined in FIG. 1 .
  • the residual stress was determined using the method based on the successive removal of layers described in the article “Development of New Alloy for Distortion Free Machined Aluminum Aircraft Components”, F. Heymes, B. Commet, B. Dubost, P. Lassince, P. Lequeu, G M. Raynaud, in 1st International Non-Ferrous Processing & Technology Conference, 10-12 Mar. 1997—Adams's Mark Hotel, St Louis, Mo. The content of this article is incorporated herein by reference in its entirety.
  • This method mostly applies to stretched plates, wherein the stress state can be considered as biaxial with its two main components located in the L and LT directions, and therefore no component in the ST direction.
  • This method is based on the determination of the residual stress in the L and LT direction as measured in full thickness rectangular bars, which are cut from the plate along these directions. These bars are machined down the ST direction step by step and at each step, the stress and/or deflection is measured, as well as the thickness of the bar.
  • a most preferred way is to measure the strain by using a strain gauge bound to the surface opposite the machined surface at half-length of the bar. Then the two residual stress profiles in the L and LT directions can be calculated. The bar must be sufficiently long to avoid edge effects.
  • the one-way strain gauges with thermal expansion compensation are bonded to the lower surface of the bar (see FIG. 3 ), according to the manufacturer's instructions. They are then coated with an insulating lacquer. The value read on each of these gauges are then set to zero.
  • a measurement is performed after each machining pass. Between 18 and 25 passes are typically taken to obtain a sufficient number of points to calculate the stress profile.
  • the machining depth must not be less than 1 mm, so as to obtain a good cutting quality; for very thick plates, it may be up to 10 mm.
  • Chemical machining may also be used to remove a very thin layer of metal.
  • the machining interval should be the same for both samples (i.e. in the L direction and in the LT direction).
  • the bar is detached from the vice and the temperature is allowed to stabilise before the strain is measured.
  • the thickness h(i) and the strain ⁇ (i) are recorded. The diagram in FIG. 4 shows how these data are collected.
  • W L represents the stored elastic energy resulting from the residual stress profile in the L direction
  • W LT represents the stored energy resulting from the residual stress profile in the LT direction
  • W is the total elastic energy stored in the plate (expressed in kJ or kJ/m 3 ).
  • the method used to measure the stress and to obtain the stored elastic energies is described above specifically, giving, for example, the bar dimensions used in practice. It should be noted that these dimensions are not compulsory and do not restrict the method. The length of the bar does not affect the result. The length of two times h plus three times the gauge length is sufficient for measurements using strain gauges. The dimensions given are based on practical experience and have been adapted to the machining and measurement means used. Those skilled in the art will easily be capable of selecting other dimensions without altering the results.
  • the present invention applies to 7xxx series aluminum alloy plates, particularly plates, wherein the chemical composition meets the following criteria:
  • a problem can be solved by modifying the production process so that the natural aging between the end of quenching and the start of controlled stretching is minimized such that the total elastic energy (W) in the artificially aged state remains below a specific limit value.
  • This limit value represents a preferred maximum value to retain the machining strain at an acceptable level; for most applications, this limit value is about 2 kJ/m 3 for a plate between 60 mm and 100 mm thick, and preferentially about 1.5 kJ/m 3 . For particularly complex components, it should be about 1 kJ/m 3 .
  • FIG. 5 shows a diagram of the heat treatment process applied to a plate after rolling.
  • the solution heat-treatment can be performed, for example, in a single plateau, in several plateaus or in a ramp with or without a clearly defined plateau. The same applies for artificial aging.
  • An important phase within the scope of the present invention is the elapsed time D between the end of quenching and the start of controlled stretching. The inventors found that a long elapsed time D results in greater heterogeneity of the mechanical properties between the zones near the surface and the zones near the mid-thickness of the material. This heterogeneity may essentially be attributed to the differences in the cooling rate in the plate thickness.
  • FIG. 1 shows a diagram of the heat treatment process applied to a plate after rolling.
  • the solution heat-treatment can be performed, for example, in a single plateau, in several plateaus or in a ramp with or without a clearly defined plateau. The same applies for artificial aging.
  • An important phase within the scope of the present invention is the elapsed
  • the potentially hardening element content of the supersaturated solid solution is greater near the surface than at mid-thickness (as the semi-continuous casting process results in macro-segregation such that the concentration of eutectic elements, such as Cu, Mn and Zn, is higher close to the surface and the cooling rate during casting is also higher), and, secondly, close to the surface, a greater density of heterogeneous sites (gaps, dislocations, etc.) can be found, facilitating precipitation and resulting from the higher cooling rate and the higher plasticity during quenching.
  • FIG. 7 shows the effect of the increase in the variation in the yield stress values on the residual stress profiles after quenching.
  • a method according to the present invention may not give the same level of improved results for other structural hardening alloys, such as 2xxx and 6xxx series alloys.
  • structural hardening alloys such as 2xxx and 6xxx series alloys.
  • contents consists of Zn>12%, Mg>4% and Cu>4%
  • the stored energy is very high and the improvement obtained with a method according to the invention may be as significant.
  • these alloys may not respond well to solution heat-treatment.
  • R p0.2(L) refers to the yield stress of the finished plate measured according to the standards EN 10002-1 and EN 485-1.
  • the influence of the thickness on the level of residual stress and the total elastic energy is expressed here in terms of the yield stress, measured as recommended by the standard EN 485-1.
  • the method according to the invention may be applied advantageously to the manufacture of a plurality of plates wherein the thickness is between approximately 10 mm and approximately 250 mm, and more advantageously to plates wherein the thickness is greater than 25 mm, but these values are not restrictive.
  • a method according to the present invention also makes it possible to reduce the dispersion between the values of W for a plurality of plates belonging to the same inspection lot or heat treatment batch, such that all the plates have a standard deviation of the total elastic energy W of the different plates around an average value that is preferably less than or equal to 0.20+0.0086( R p0.2(L) [MPa] ⁇ 400)
  • R p0.2(L) refers to the average R p0.2(L) measurement performed according to the standard for each of the finished plates in the batch, according to the standards EN10002-1 and EN485-1.
  • the standard deviation between the measurements of the total elastic energy W of the different plates in a batch may depend on the number of plates contained in the batch. In particular, a standard deviation obtained on two measurements is not significant and may be very high or very low. From 3 plates, the standard deviation of the measurements may be considered, but preferentially, the quality control or heat treatment batches used within the scope of the present invention contain at least 5 plates.
  • a method according to the present invention enables the manufacturer to guarantee that a particular inspection lot or heat treatment batch comprises plates wherein the average total elastic energy is preferably less than about 3 kJ/m 3 .
  • this average value is less than about 2 kJ/m 3 , and a value less than about 1 kJ/m 3 is preferred, which requires excellent control of the critical processes and very rigorous management of production schedule at the solution heat-treatment, quenching and stretching stages.
  • the implementation of a method according to the instant invention may require an adaptation of the metal flows within the plant, because if the producer wishes to produce plates within an elapsed time D of less than a few hours, it may potentially be necessary to synchronize the quenching furnace with the stretching bench.
  • EP 1 231 290 A1 describes in example 1 thereof, a 38 mm thick 7449 alloy plate for which controlled stretching was performed 1 hour after quenching; however, this document does not provide any information on the benefit of this short time.
  • a method according to the present invention made it possible to produce inspection lots or heat treatment batches for which the elapsed time D between the end of quenching and the start of controlled stretching is systematically less than 2 hours, which made it possible to minimize the average and standard deviation of the total elastic energy W of the plates in these batches.
  • the industrial production of such an inspection lot requires a reorganization of the product flows around the machines required for the implementation of the method according to the invention.
  • natural aging is performed at a low temperature, i.e. at a temperature below about 10° C. and preferentially at a temperature below about 5° C., which makes it possible to obtain similar results in terms of total elastic energy W for times D between 2 hrs and 3 hrs.
  • One advantage of a method according to the invention is the overall relief in the level of stress in plates. This induces an overall reduction in the machining strain.
  • a further advantage of the method according to the invention is that the monitoring of the time elapsed between the end of quenching and the start of stretching also makes it possible to reduce the dispersion of the stress level observed between different nominally identical plates, even within the same production batch or heat treatment batch. This enables improved standardization of the machining processes for a given product series and reduces the number of incidents during the production of machine components in the machining workshop.
  • Table 2 shows the stored elastic energy in the different plates obtained, determined in the final temper.
  • Table 2 shows the stored elastic energy in the different plates obtained, determined in the final temper.
  • Table 7 shows the stored elastic energy in the different plates obtained, determined in the final temperature (i.e. after controlled stretching).
  • elapsed time D between the end of quenching and the start of stress relieving by means of stretching is reduced, a reduction in the overall stress level W L , W LT and W is observed.
  • TABLE 7 Stored elastic energy as a function of the natural aging time D for 7475 alloy W51 plates Alloy/ Natural aging time W W L W LT Plate temper D [h] [kJ/m 3 ] [kJ/m 3 ] [kJ/m 3 ] C1 7475 W51 1.75 2.24 1.6 0.64 C2 7475 W51 22.5 4.51 3.61 0.9 C3 7475 W51 48 5.18 3.97 1.21
  • Two rolling ingots made of AA7449 alloy were processed by means of homogenisation, hot rolling to a thickness between 16.5 and 21.5 mm, quenching and controlled stretching, followed by artificial aging.
  • the temper of the two products D1 and D2 obtained in this way was T651.
  • all the production parameters were nominally identical and well controlled and the only difference was the elapsed time D between the end of quenching and the start of stress relieving by means of stretching.
  • Table 8 shows the stored elastic energy in the different plates obtained, determined in the final temperature (i.e. after controlled stretching).
  • FIG. 8 shows the values of the stored energy in the plates according to the invention (where D ⁇ 1 hour) (unfilled dots) (“Optimized”) and according to the prior art (where D ⁇ 8 hours) (black squares).
  • the stored energy is maximal.
  • the method according to the invention results in, for a given thickness, firstly, a relief in the overall level of residual stress (i.e. the stored energy W total ) of approximately 50%, and, secondly, a significant reduction in the statistical dispersion of this value.
  • the effect of the invention on the overall level of residual stress is particularly remarkable for thicknesses between 40 and 150 mm and it is even more marked for thicknesses between 50 and 100 or even 80 mm.

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FR0413204A FR2879217B1 (fr) 2004-12-13 2004-12-13 Toles fortes en alliage ai-zn-cu-mg a faibles contraintes internes

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RU2614321C1 (ru) * 2016-05-04 2017-03-24 Открытое акционерное общество "Композит" (ОАО "Композит") Свариваемый сплав на основе алюминия для противометеоритной защиты
CN106756672A (zh) * 2016-12-07 2017-05-31 北京科技大学 一种提高汽车用Al‑Mg‑Si‑Cu系合金强度的处理方法
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US10835942B2 (en) 2016-08-26 2020-11-17 Shape Corp. Warm forming process and apparatus for transverse bending of an extruded aluminum beam to warm form a vehicle structural component
US11072844B2 (en) 2016-10-24 2021-07-27 Shape Corp. Multi-stage aluminum alloy forming and thermal processing method for the production of vehicle components

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FR2879217B1 (fr) 2004-12-13 2007-01-19 Pechiney Rhenalu Sa Toles fortes en alliage ai-zn-cu-mg a faibles contraintes internes
CN102282284A (zh) * 2009-01-16 2011-12-14 阿勒里斯铝业科布伦茨有限公司 残余应力水平低的铝合金板产品的制造方法
CN103725941B (zh) * 2014-01-16 2016-01-20 南通波斯佳织造科技有限公司 一种经表面处理的镁锌铜合金薄板及其制备方法
CN103725943B (zh) * 2014-01-16 2015-11-18 张霞 一种镁合金薄板及其制备方法
CN104846302B (zh) * 2015-06-02 2017-01-18 湖南大学 一种保持铝合金强度降低淬火残余应力的时效热处理方法
CN109234653B (zh) * 2018-10-23 2020-07-07 湖南大学 一种消减大型复杂铝合金模锻件残余应力的方法
CN111270114A (zh) * 2020-03-30 2020-06-12 天津忠旺铝业有限公司 一种高强度7150铝合金中厚板的制备工艺
FR3136242B1 (fr) 2022-06-01 2024-05-03 Constellium Valais Tôles pour éléments de chambres à vide en alliage d’aluminium

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WO2006064113A1 (fr) 2006-06-22
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FR2879217A1 (fr) 2006-06-16
EP1838891B1 (fr) 2015-12-09
FR2879217B1 (fr) 2007-01-19

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