US20070243097A1 - Process for Fabrication of Products Made of an Aluminium Alloy With High Toughness and High Fatigue Resistance - Google Patents

Process for Fabrication of Products Made of an Aluminium Alloy With High Toughness and High Fatigue Resistance Download PDF

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US20070243097A1
US20070243097A1 US11/571,189 US57118905A US2007243097A1 US 20070243097 A1 US20070243097 A1 US 20070243097A1 US 57118905 A US57118905 A US 57118905A US 2007243097 A1 US2007243097 A1 US 2007243097A1
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aluminium
alloy
barium
process according
product
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Emmanuelle Sarrazin
Jarry Philippe
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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
    • 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
    • C22C21/12—Alloys based on aluminium with copper as the next major constituent
    • C22C21/14—Alloys based on aluminium with copper as the next major constituent with silicon
    • 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
    • C22C21/16—Alloys based on aluminium with copper as the next major constituent with magnesium

Definitions

  • the invention relates to a new fabrication process for rolled, extruded, or forged products made of an aluminium alloy with high toughness and high fatigue resistance, particularly an Al—Zn—Cu—Mg type alloy, and products obtained using this process, and particularly structural elements made from such products intended for aircraft construction. It is based on the introduction of barium into an aluminium based liquid alloy.
  • type 7xxx alloys are typically used for wing structural elements for high capacity civil aircraft. These elements must have high mechanical strength, good toughness and good resistance to fatigue. Any new means of improving one of these groups of properties without degrading the others would be very useful.
  • Iron and silicon impurities also have a negative effect on the resistance to fatigue.
  • a drop in the residual content of iron and silicon will normally cause an increase in the resistance to fatigue, provided that normal precautions are taken during production of the liquid metal and during casting to avoid the formation of inclusions and the incorporation of hydrogen into the metal.
  • iron and silicon elements form practically insoluble inter-metallic phases with aluminium, such as Al 7 Cu 2 Fe, Al 6 (Fe x Mn 1-x ) (where 0 ⁇ x ⁇ 1), Al 12 Fe 3 Si, Al 9 Fe 2 Si 2 and Mg 2 Si. These phases are more harmful when they are large than when they are small. Unfortunately, there are few means of acting upon their size by varying physical parameters during casting (particularly the solidification rate).
  • Patent FR 1 507 664 (Metallgesellschaft Aktiengesellschaft) states that the addition of 0.001 to 2% of strontium and/or barium (Ba) into Al—Si type casting alloys with an Si content of between 5 and 14% leads to a fine eutectic structure; this effect is reinforced by the simultaneous addition of beryllium (Be).
  • Patent EP 1 230 409 B1 (RUAG Components) discloses that the addition of barium (between 0.1 and 0.8%) to aluminium alloys with a silicon content of at least 5% improves their thixotropic formability. For work hardening alloys with structural hardening, patent U.S. Pat. No.
  • patent GB 505 728 (L'Eléctrique) describes an aluminium based alloy intended for the manufacture of drawn wire and containing Zn 5-6.5%, Mg 2-3.5%, Si 0.15-0.5%, Mn 0.25-1%, Mo 0.20-0.60%, Co 0.20-0.60%, K 0-0.12%, Ba 0-0.25%, Sb 0-0.1%, W 0-0.50%, Ni 0-1%, Ti 0-0.40%, in which barium is added in chloride form so as to make the flux and dross more fluid; this barium content in the metallic product would also have a hardening effect.
  • Patent GB 596,178 (Tennyson Fraser Bradbury) describes the addition of the Na, K, Ba and/or P elements with a maximum total content of 0.15% to an aluminium based alloy containing Cu 5.00-9.50%, Zr, Ni, Ce 0.05-1.00 total, Si 0.02-0.40%, Fe 0.02-0.50%, Zn 0.00-0.25%. It is a casting alloy for pistons. Neither the function nor the method of adding barium are mentioned.
  • U.S. Pat. No. 4,631,172 (Nadagawa Corrosion Protection Co.) describes an aluminium based alloy used as a sacrificial anode containing 3.2% of Zn, 1.5% of magnesium, 0.02% of indium, 0.01% of tin and/or calcium and barium, the barium content varying between 0.002% and 1.0%.
  • Another composition contains Zn 2.5%, Mg 2.5%, In 0.02%, Ca and/or Ba 0.005-1.0%, Si 0.004-1.0%.
  • the addition of calcium and/or barium increases the current density and assures uniform wear of the sacrificial anode.
  • Patent application JP 61 096052 A describes an aluminium-based alloy sacrificial anode with composition Zn 1-10%, Mg 0.1-6%, In 0.01-0.04%, Sn 0.005-0.15%, Si 0.09-1%, Ca and/or Ba 0.005-0.45%.
  • Patent CH 328 148 (Wilhelm Neu) describes the introduction of a barium hydride into a zinc-aluminium type alloy containing not less than 40% of zinc.
  • U.S. Pat. No. 3,310,389 (High Duty Alloys Ltd) mentions the presence of barium, calcium and/or strontium with a total content of up to 0.2% in an aluminium-based alloy containing Cu 2.2-2.7%, Mg 1.3-1.7%, Si 0.12-0.25%, Fe 0.9-1.2%, Ni 0.9-1.4%, Ti 0.02-0.15%.
  • Patent RU 2 184 167 (inventor I. N. Fridljander et al) describes an aluminium-based alloy for structural applications in aeronautical construction with composition Cu 3.0-3.8%, Li 1.4-1.7%, Zr 0.0001-0.04%, Sc 0.16-0.35%, Fe 0.01-0.5%, Mg 0.01-0.7, Mn 0.05-0.5%, Ba 0.001-0.2%, Ga 0.001-0.08%, Sb 0.00001-0.001%.
  • Patent RU 1 678 080 (Institut khimii im. V. I. Nikitina) describes an aluminium-based alloy with composition Cu 5.0-5.5%, Cr 0.1-0.4%, Mn 0.2-0.6%, Zr 0.1-0.4%, Ti 0.1-0.4%, Cd 0.05-0.25%, Sr or Ba 0.01-0.1%.
  • the purpose of this invention is to propose a new process to modify the morphology of insoluble iron and silicon phases in work hardening alloys with structural hardening of the Al—Cu—Mg or Al—Zn—Cu—Mg type, and thus obtaining new products with a high mechanical strength that also have excellent toughness and resistance to fatigue.
  • the purpose of the invention is a process for fabrication of worked products made of an aluminium alloy of the Al—Cu, Al—Cu—Mg or Al—Zn—Cu—Mg type with high toughness and resistance to fatigue, including casting of a unwrought product (such as a extrusion billet, a forging billet or a rolling slab) and hot deformation of said unwrought product, said process being characterised in that between 0.005 and 0.1% of barium is added into said alloy.
  • a unwrought product such as a extrusion billet, a forging billet or a rolling slab
  • Another purpose of the invention is a structural element for aeronautical construction, made from a rolled, extruded or forged product made of an Al—Cu, Al—Cu—Mg or Al—Zn—Cu—Mg type alloy that contains between 0.005 and 0.1% of barium.
  • a product or structural element obtainable by the process according to this invention can advantageously be used in applications that require high toughness and/or resistance to fatigue, for example such as wing upper or lower surface elements (wing skin), stiffeners, stringers or ribs, or elements for sealed partitions (bulkheads).
  • FIG. 1 shows the morphology of Al—Fe—Cu type phases in the rough as-cast state after selective dissolution of the matrix in a 7449 alloy (micrographs obtained by a field effect gun scanning electron microscope (FEG-SEM):
  • FIG. 2 shows the morphology of Al—Fe—Cu type phases:
  • FIG. 3 shows the morphology of Al—Fe—Cu type phases in a sample that has both morphologies at the same time:
  • FIGS. 4 and 5 show the morphology of Al—Fe—Cu type phases in a 7449 type alloy with added barium. Note the “sea urchin shaped” morphology ( FIG. 4 ) and “broccoli shaped” morphology ( FIG. 5 ) of the eutectic compounds.
  • Alloy 7449 (with added barium) according to the invention magnification: see the bar at the bottom left of FIG. 4 that represents 1 ⁇ m).
  • FIG. 6 shows the morphology of Al—Fe—Cu type phases in the form of platelets in a 7449 alloy according to the state of the art.
  • FIG. 7 gives a comparison of the toughness Kapp measured on a 406 mm wide and 6.35 mm thick CCT type test piece (taken at one quarter of the thickness) as a function of R p0.2(L) 7449 alloy. Note that the products according to the invention (“Ba”) have better toughness than the products according to the state of the art (“ref”).
  • the static mechanical characteristics in other words, the ultimate tensile strength R m , the tensile yield stress R p0.2 , and the elongation at failure A, are determined using a tensile test according to standard EN 10002-1, the location and direction from which test pieces are taken being defined in standard EN 485-1.
  • the resistance to fatigue is determined by a test according to ASTM E 466, the fatigue crack propagation speed (so-called da/dn test) according to ASTM E 647, and the critical stress intensity factor K C , K CO or K app according to ASTM E 561.
  • the term “extruded product” comprises so-called “drawn” products, in other words products fabricated by extrusion followed by drawing.
  • a “worked product” means a product on which a deformation operation has been carried out after its solidification, this deformation operation possibly being rolling, forging, extruding, drawing or stamping, although this list is not limitative.
  • a “structure element” or “structural element” of a mechanical construction means a mechanical part that, if it fails, would endanger said construction, its users, passengers or others.
  • these structural elements include particularly elements making up the fuselage (such as the fuselage skin), stringers, bulkheads, circumferential frames, wings (such as wing skin), stringers or stiffeners, ribs and spars and the tail fin composed particularly of horizontal and vertical stabilisers, and floor beams, seat tracks and doors.
  • integral structure means the structure of a part of an aircraft that was designed to maximise continuity of the material over the largest possible dimension so as to minimise mechanical assembly points.
  • An integral structure can be fabricated either by in-body machining or by the use of shaped parts obtained for example by extrusion, forging or casting, or by welding of structural elements made from weldable alloys.
  • larger elements made of a single part can be obtained without assembly or with a smaller number of assembly points than for a structure in which thin or thick plates (depending on the destination of the structural element, for example fuselage element or wing element) are fixed to stiffeners and/or frames (that may be fabricated by machining from extruded or rolled products), usually by riveting.
  • This invention can be applied to all alloys based on structurally hardened work hardening aluminium of the Al—Cu, Al—Cu—Mg or Al—Zn—Cu—Mg type. More particularly, Al—Cu type alloys to which this invention could be applied are alloys containing between 1 and 7% of Cu, and more particularly between 3 and 5.5% of Cu.
  • the invention can be applied to Al—Cu—Mg type alloys containing between 1 and 7% of Cu and between 0.2 and 2% of Mg, and more particularly between 3.5 and 5.5% of Cu and between 1 and 2% of Mg, it being understood that the content of iron and silicon must not exceed 0.30% each.
  • These alloys may contain other alloying elements and impurities up to about 3% in total.
  • the alloy may also contain normal additions of zirconium, titanium or chromium.
  • the process according to the invention can advantageously be applied to Al—Mg—Cu type alloys or to alloys in the 2xxx series, particularly alloys conventionally used in aeronautical construction, namely 2024, 2024A, 2056, 2022, 2023, 2139, 2124, 2224, 2324, 2424, 2524 and their variants.
  • this invention excludes so-called free-machining alloys such as 2004, 2005 and 2030 that include additions of Pb, Bi or Sb, so as to obtain discontinuous chips.
  • Alloys of the Al—Zn—Cu—Mg type to which this invention can be applied are alloys containing between 4 and 14% of zinc, and more particularly between 7 and 10.5% of zinc, between 1 and 3% of Cu and more particularly between 1.4 and 2.5% of Cu, and between 1 and 3% of Mg, and more particularly between 1.7 and 2.8% of Mg, it being understood that the iron and silicon contents shall not exceed 0.30% each.
  • These alloys may contain other alloying elements and impurities, up to 2% in total. These elements include manganese.
  • the alloy may also contain normal additions of zirconium, titanium and chromium.
  • the process according to the invention can advantageously be applied to alloys in the 7xxx series, and particularly to alloys conventionally used in aeronautical construction, namely 7010, 7050, 7055, 7056, 7150, 7040, 7075, 7175, 7475, 7049, 7149, 7249, 7349 and 7449, and their variants.
  • the process according to the invention comprises casting of an unwrought product such as a rolling slab, an extrusion billet or a forging billet using any known process. This unwrought product is then hot worked, for example by rolling, extrusion or forging.
  • the invention is not applicable to products produced by fast solidification, i.e. with a solidification rate typically greater than 600° C./min that result in a significantly different microstructure.
  • the process may also include other heat treatment or mechanical treatment steps, usually homogenisation, cold working, dissolution, artificial or natural ageing, intermediate or final annealing.
  • These eutectic phases may be of the Al—Fe—Cu type (in alloys with added barium) or the Al—Fe—Si—Cu type (in alloys without added barium). It can be seen that silicon apparently disappears from precipitates in the presence of barium.
  • the principal properties of the product that are improved by the process according to the invention are particularly the toughness, resistance to fatigue, and resistance to crack propagation da/dn with a high stress intensity factor ⁇ K. This effect is particularly marked in an unrecristallised structure.
  • a barium and silicon alloy is added.
  • An Si (70%)-Ba (30%) type alloy is suitable; this product is available on the market.
  • the silicon content of the alloy may vary between 50% and 90%.
  • Other alloys of the same type also containing up to 20% of iron can also be used within the invention, the silicon content of the alloy then possibly varying between 30% and 90% and the barium content then varying between 10 and 40%.
  • barium is added in metallic form, preferably in the form of an inter-metallic compound or an alloy with one or several constituents of the target aluminium alloy.
  • an Al—Ba or Zn—Ba type alloy is suitable.
  • These inter-metallic compounds or alloys can be obtained directly by reduction of barium oxide BaO with aluminium or zinc using known processes.
  • the barium quantities used are very low, preferably less than 0.1% and even more preferably less than 0.05%. A value between 0.005% and 0.03% might be suitable.
  • the relatively low solubility of this alloy in liquid aluminium has to be allowed for.
  • the second embodiment is particularly interesting when it is applied to an aluminium alloy that has a fairly high silicon content, for example of the order of 0.10%.
  • metallic barium is expensive.
  • the first embodiment uses a less expensive barium alloy but increases the silicon content and possibly the iron content in the aluminium alloy. However, it is surprising to realise that this increase in the content of silicon and possibly of iron does not deteriorate the toughness or the resistance to fatigue. This is related to the fact that silicon and possibly iron are not incorporated in the same way; the phase morphology is significantly modified.
  • the yield stress R p0.2(L) of such a partly finished product or structural element is greater than 600 MPa.
  • the product according to the invention has better resistance to exfoliation corrosion (EXCO test), determined on test pieces taken from the mid-thickness, than a corresponding product without barium.
  • EXCO test exfoliation corrosion
  • the product according to the invention Due to its remarkable mechanical properties, there can be many possible applications for the product according to the invention, and it is particularly advantageous to use said product as a structural element in aeronautical construction, and particularly as an upper wing element or a lower wing element, such as a wing skin element, stiffener, stringer, rib or a bulkhead element.
  • the process according to the invention has several advantages.
  • the method of adding barium according to the invention prevents the use of hydrides that would increase the residual hydrogen content that could cause pores in the solidified metal.
  • Barium neutralises the harmful effect of residual silicon in aluminium-based alloys with structural hardening, which results in better toughness, particularly K IC and K app .
  • Barium also improves the resistance to corrosion and particularly the resistance to exfoliation corrosion.
  • a type 7449 aluminium alloy was produced with an added alloy containing about 52% of silicon and 30% of barium and 18% of iron (reference P4078-1#37).
  • Table 2 shows its chemical composition determined on a solid slug obtained from liquid metal taken from the runner.
  • the alloy was refined with 0.8 kg/t of AT5B and cast into rolling slabs at 685° C. at a rate of 65 mm/min. After cooling and scalping, the slabs were homogenized at 463° C. and hot rolled at a temperature of between 420 and 410° C. The plates obtained were put into solution for 6 hours at 120° C. and then for 17 hours at 150° C. Consequently, the final product was in the T351 metallurgical temper.
  • the silicon content of the type 7449 type aluminium alloy increases from 0.04% to 0.09% and the content of Fe increases from 0.03% to 0.06%
  • the microstructure of the sample with added barium shows “sea urchin shaped” eutectic compounds ( FIG. 4 ) or “broccoli shaped” eutectic compounds (see FIG. 5 ).
  • the microstructure of the sample without any added barium comprises eutectic compounds in the form of platelets ( FIG. 6 ).
  • EXCO resistance to exfoliation corrosion results

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Forging (AREA)
  • Powder Metallurgy (AREA)
  • Preventing Corrosion Or Incrustation Of Metals (AREA)
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  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Prevention Of Electric Corrosion (AREA)
US11/571,189 2004-06-25 2005-06-22 Process for Fabrication of Products Made of an Aluminium Alloy With High Toughness and High Fatigue Resistance Abandoned US20070243097A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
FR0406957A FR2872172B1 (fr) 2004-06-25 2004-06-25 Produits en alliage d'aluminium a haute tenacite et haute resistance a la fatigue
FR0406957 2004-06-25
PCT/FR2005/001572 WO2006010817A1 (fr) 2004-06-25 2005-06-22 Procede de fabrication de produits en alliage d’aluminium a haute tenacite et haute resistance a la fatigue

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US (1) US20070243097A1 (fr)
EP (1) EP1766102B1 (fr)
CN (1) CN100564571C (fr)
AT (1) ATE417136T1 (fr)
BR (1) BRPI0512590A (fr)
CA (1) CA2570618A1 (fr)
DE (1) DE602005011619D1 (fr)
FR (1) FR2872172B1 (fr)
WO (1) WO2006010817A1 (fr)

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US20110008202A1 (en) * 2005-01-19 2011-01-13 Otto Fuchs Kg Alluminum alloy that is not sensitive to quenching, as well as method for the production of a semi-finished product
RU2473709C1 (ru) * 2011-10-28 2013-01-27 Закрытое акционерное общество "Военно-промышленная инвестиционная группа "ВИЛС" Сверхпрочный деформируемый сплав на основе алюминия и изделие, выполненное из него
AU2008267121B2 (en) * 2007-05-14 2013-11-14 Arconic Technologies Llc Aluminium alloy products having improved property combinations and method for their production
RU2503734C1 (ru) * 2012-10-09 2014-01-10 Закрытое акционерное общество "Военно-промышленная инвестиционная группа "ВИЛС" Сверхпрочный сплав на основе алюминия и изделие из него
RU2514748C1 (ru) * 2013-03-29 2014-05-10 Открытое акционерное общество "Всероссийский институт легких сплавов" (ОАО "ВИЛС") ВЫСОКОПРОЧНЫЙ ДЕФОРМИРУЕМЫЙ СПЛАВ НА ОСНОВЕ АЛЮМИНИЯ СИСТЕМЫ Al-Zn-Mg-Cu ПОНИЖЕННОЙ ПЛОТНОСТИ И ИЗДЕЛИЕ, ВЫПОЛНЕННОЕ ИЗ НЕГО
CN105441838A (zh) * 2015-11-24 2016-03-30 苏州有色金属研究院有限公司 改善2×××-t3板疲劳裂纹扩展速率的热处理方法
US10661338B2 (en) 2010-04-26 2020-05-26 Hydro Extruded Solutions Ab Damage tolerant aluminium material having a layered microstructure
US20210017630A1 (en) * 2019-07-19 2021-01-21 University Of Florida Research Foundation, Inc. High temperature lightweight al-fe-si based alloys
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US11898232B2 (en) * 2015-09-29 2024-02-13 United Company RUSAL Engineering and Technology Centre LLC High-strength alloy based on aluminium and method for producing articles therefrom
CN117987694A (zh) * 2024-04-03 2024-05-07 有研工程技术研究院有限公司 一种高导电率、高耐腐蚀铝单丝及其生产工艺与应用

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US8840737B2 (en) 2007-05-14 2014-09-23 Alcoa Inc. Aluminum alloy products having improved property combinations and method for artificially aging same
FR2925523B1 (fr) * 2007-12-21 2010-05-21 Alcan Rhenalu Produit lamine ameliore en alliage aluminium-lithium pour applications aeronautiques
US8206517B1 (en) 2009-01-20 2012-06-26 Alcoa Inc. Aluminum alloys having improved ballistics and armor protection performance
CN104561692B (zh) * 2015-02-09 2017-01-11 苏州劲元油压机械有限公司 一种具有高耐摩擦能力的铝合金材料及其热处理工艺
CN107881369B (zh) * 2017-10-27 2020-06-30 大唐东北电力试验研究所有限公司 铝钙锑中间合金孕育剂及其制备方法
DE102018208435A1 (de) * 2018-05-29 2019-12-05 Volkswagen Aktiengesellschaft Plasmaspritzverfahren zur Beschichtung einer Zylinderlaufbahn eines Zylinderkurbelgehäuses einer Hubkolbenbrennkraftmaschine
RU2713526C1 (ru) * 2019-06-07 2020-02-05 Федеральное государственное автономное образовательное учреждение высшего образования "Национальный исследовательский технологический университет "МИСиС" Высокопрочный литейный алюминиевый сплав с добавкой кальция
CN111235443A (zh) * 2020-03-30 2020-06-05 天津忠旺铝业有限公司 一种低加工变形2系铝合金板材的制备方法

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FR2872172B1 (fr) 2007-04-27
CN1977063A (zh) 2007-06-06
ATE417136T1 (de) 2008-12-15
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