US20180171440A1 - High zinc aluminum alloy products - Google Patents

High zinc aluminum alloy products Download PDF

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Publication number
US20180171440A1
US20180171440A1 US15/824,655 US201715824655A US2018171440A1 US 20180171440 A1 US20180171440 A1 US 20180171440A1 US 201715824655 A US201715824655 A US 201715824655A US 2018171440 A1 US2018171440 A1 US 2018171440A1
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Prior art keywords
aluminum alloy
alloy strip
embodiments detailed
zinc
variation
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Ali Unal
John Newman
David Tomes
Gavin Wyatt-Mair
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Arconic Technologies LLC
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Arconic Inc
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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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/001—Continuous casting of metals, i.e. casting in indefinite lengths of specific alloys
    • B22D11/003—Aluminium alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
    • B22D11/0622—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars formed by two casting wheels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002—Castings of light metals
    • B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C

Definitions

  • Casting aluminum alloys to form cast aluminum alloy products is known.
  • the present invention relates to cast aluminum alloy products, and products derived therefrom.
  • the present invention is a cast product comprising an aluminum alloy strip; wherein the aluminum alloy strip comprises: 4 wt. % to 28 wt. % zinc; and wherein a variation of a weight percent of the zinc is 15% or less between a surface and a thickness center of the aluminum alloy strip.
  • the aluminum alloy strip comprises 6 wt. % to 28 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 8 wt. % to 28 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 10 wt. % to 28 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 4 wt. % to 15 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 6 wt. % to 12 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 4 wt. % to 10 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 4 wt. % to 8 wt. % zinc.
  • the variation of the zinc weight percent is 12% or less between the surface and the thickness center of the aluminum alloy strip.
  • the present invention is a cast product comprising an aluminum alloy strip; wherein the aluminum alloy strip comprises: (i) 4 wt. % to 28 wt. % zinc; (ii) 1 wt. % to 3 wt. % copper; and (iii) 1 wt. % to 3 wt. % magnesium; and wherein a variation of a weight percent of the zinc is 15% or less between a surface and a thickness center of the aluminum alloy strip.
  • the aluminum alloy strip comprises 4 wt. % to 15 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 4 wt. % to 12 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 4 wt. % to 10 wt. % zinc.
  • the aluminum alloy strip comprises 1 wt. % to 2.5 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip comprises 1 wt. % to 2.0 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip comprises 1 wt. % to 1.5 wt. % copper.
  • the aluminum alloy strip comprises 1 wt. % to 2.5 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip comprises 1 wt. % to 2.0 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip comprises 1 wt. % to 1.5 wt. % magnesium.
  • the cast product comprises an aluminum alloy strip; wherein the aluminum alloy strip comprises: 4 wt. % to 28 wt. % zinc and 1 wt. % to 3 wt. % copper. In one or more embodiments detailed herein, a variation of a weight percent of the zinc is 15% or less between a surface and a thickness center of the aluminum alloy strip.
  • FIG. 1 is a schematic of a non-limiting method of making the cast product
  • FIG. 2 is an enlarged cross-sectional schematic of the molten metal delivery tip and rolls shown in FIG. 1 ;
  • FIG. 3 shows the variation in zinc weight percentage from surface to a thickness depth of 3,000 micrometers in a cast product
  • FIG. 4 shows the variation in zinc weight percentage from surface to a thickness depth of 3,000 micrometers in a cast product
  • FIG. 5 shows the variation in zinc weight percentage from surface to a thickness depth of 3,000 micrometers in a cast product
  • FIG. 6 shows the variation in zinc weight percentage from surface to a thickness depth of 3,000 micrometers in a cast product
  • FIG. 7 shows the variation in zinc weight percentage from surface to a thickness depth of 3,000 micrometers in a cast product
  • FIG. 8 shows the variation in zinc weight percentage from surface to a thickness depth of 3,000 micrometers in a cast product
  • FIG. 9 shows the variation in zinc weight percentage from surface to a thickness depth of 3,000 micrometers in a cast product
  • FIG. 10 shows the variation in zinc weight percentage from surface to a thickness depth of 3,000 micrometers in a cast product
  • FIG. 11 shows the variation in zinc weight percentage through depth of a prior art ingot cast by direct chill casting
  • FIG. 12 shows the variation in zinc weight percentage through depth of a prior art cast product
  • FIG. 13 shows the weight percentages of zinc, magnesium and copper across grains from the surface to 200 micrometers thickness depth in a cast product according to an embodiment of the present invention.
  • FIG. 14 shows the weight percentages of the zinc, magnesium and copper across grains through thickness depth for a direct chill cast prior art product
  • FIG. 15 shows the structure of a cast product according to an embodiment of the present invention.
  • FIG. 16 shows the structure of a cast product according to an embodiment of the present invention.
  • FIG. 17 shows the structure of a cast product according to an embodiment of the present invention.
  • the term “or” is an inclusive “or” operator, and is equivalent to the term “and/or,” unless the context clearly dictates otherwise.
  • the term “based on” is not exclusive and allows for being based on additional factors not described, unless the context clearly dictates otherwise.
  • the meaning of “a,” “an,” and “the” include plural references.
  • the meaning of “in” includes “in” and “on.”
  • the term “at least one of A, B, or C” and the like, means “only A”, “only B”, “only C”, or “any combination of A, B, and C.”
  • the present invention is a cast product comprising an aluminum alloy strip; wherein the aluminum alloy strip comprises: 4 wt. % to 28 wt. % zinc; and wherein a variation of a weight percent of the zinc is 15% or less between a surface and a thickness center of the aluminum alloy strip.
  • the aluminum alloy strip comprises 6 wt. % to 28 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 8 wt. % to 28 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 10 wt. % to 28 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 4 wt. % to 15 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 6 wt. % to 12 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 4 wt. % to 10 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 4 wt. % to 8 wt. % zinc.
  • the variation of the zinc weight percent is 12% or less between the surface and the thickness center of the aluminum alloy strip.
  • the present invention is a cast product comprising an aluminum alloy strip; wherein the aluminum alloy strip comprises: (i) 4 wt. % to 28 wt. % zinc; (ii) 1 wt. % to 3 wt. % copper; and (iii) 1 wt. % to 3 wt. % magnesium; and wherein a variation of a weight percent of the zinc is 15% or less between a surface and a thickness center of the aluminum alloy strip.
  • the aluminum alloy strip comprises 4 wt. % to 15 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 4 wt. % to 12 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 4 wt. % to 10 wt. % zinc.
  • the aluminum alloy strip comprises 1 wt. % to 2.5 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip comprises 1 wt. % to 2.0 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip comprises 1 wt. % to 1.5 wt. % copper.
  • the aluminum alloy strip comprises 1 wt. % to 2.5 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip comprises 1 wt. % to 2.0 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip comprises 1 wt. % to 1.5 wt. % magnesium.
  • the cast product comprises an aluminum alloy strip; wherein the aluminum alloy strip comprises: 4 wt. % to 28 wt. % zinc and 1 wt. % to 3 wt. % copper. In one or more embodiments detailed herein, a variation of a weight percent of the zinc is 15% or less between a surface and a thickness center of the aluminum alloy strip.
  • the present invention is a cast product comprising an aluminum alloy strip; wherein the aluminum alloy strip comprises: 4 wt. % to 25 wt. % zinc; and wherein a variation of a weight percent of the zinc is 15% or less between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip.
  • the aluminum alloy strip comprises 6 wt. % to 25 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 8 wt. % to 25 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 10 wt. % to 25 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 4 wt. % to 15 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 4 wt. % to 12 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 4 wt. % to 10 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 4 wt. % to 8 wt. % zinc.
  • the variation of the zinc weight percent is 12% or less between the surface and the thickness depth of 3,000 micrometers in the aluminum alloy strip.
  • the present invention is a cast product comprising an aluminum alloy strip; wherein the aluminum alloy strip comprises: (i) 4 wt. % to 25 wt. % zinc; (ii) 1 wt. % to 3 wt. % copper; and (iii) 1 wt. % to 3 wt. % magnesium; and wherein a variation of a weight percent of the zinc is 15% or less between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip.
  • the aluminum alloy strip comprises 4 wt. % to 15 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 4 wt. % to 12 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip comprises 4 wt. % to 10 wt. % zinc.
  • the aluminum alloy strip comprises 1 wt. % to 2.5 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip comprises 1 wt. % to 2.0 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip comprises 1 wt. % to 1.5 wt. % copper.
  • the aluminum alloy strip comprises 1 wt. % to 2.5 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip comprises 1 wt. % to 2.0 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip comprises 1 wt. % to 1.5 wt. % magnesium.
  • aluminum alloy means an aluminum metal with soluble elements either in the aluminum lattice or in a phase within aluminum. Elements may include aluminum, copper, iron, magnesium, nickel, silicon, zinc, chromium, manganese, titanium, vanadium, zirconium, tin, scandium, lithium. Elements are added to influence physical properties of the aluminum alloy and performance characteristics.
  • 7xxx aluminum alloys and the like means an aluminum alloy selected from 7xxx aluminum alloys registered with the Aluminum Association and unregistered variants of the same.
  • the term “cast product” means a product that has been produced by a casting method such as continuous casting as detailed in U.S. Pat. Nos. 6,672,368 and 7,125,612. In one or more embodiments detailed herein, the term “cast product” includes a product produced from the “cast product”. In one or more embodiments, the term “cast product” includes a rolled product produced from the “cast product”.
  • centerline segregation means the enrichment or depletion of alloying elements in a central portion of an aluminum alloy strip. In embodiments, centerline segregation is determined based on a variation of the weight percent of an alloying element in a specified thickness depth of an aluminum alloy strip. In one or more embodiments detailed herein, centerline segregation is determined based on a variation of weight percent of an alloying element of greater than 15% between a surface and a thickness depth of 3,000 micrometers. In one or more embodiments detailed herein, centerline segregation is determined based on a variation of weight percent of an alloying element of greater than 15% between a surface and a thickness center of the aluminum alloy strip.
  • the “weight percent of an alloying element” in a specified thickness depth is determined using the “macro-segregation procedure” detailed herein.
  • the term “strip” may be of any suitable thickness, and is generally of sheet gauge (0.006 inch to 0.249 inch) or thin-plate gauge (0.250 inch to 0.400 inch), i.e., has a thickness in the range of from 0.006 inch to 0.400 inch. In one embodiment, the strip has a thickness of at least 0.040 inch. In one embodiment, the strip has a thickness of less than 0.320 inch. In one or more embodiments detailed herein, the strip has a thickness of from 0.0070 to 0.18 inches. In one or more embodiments detailed herein, the strip has a thickness of from 0.08 to 0.2 inches.
  • surface means a top surface or a bottom surface of the cast product.
  • thickness center means a depth of half the total thickness of the cast product or half thickness (t/2).
  • the aluminum alloy strip may include any aluminum alloy having 4 wt. % to 28 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip may include at least one of 1 wt. % to 3 wt. % copper and 1 wt. % to 3 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy may include 7xxx (zinc based) aluminum alloys.
  • the aluminum alloy strip has 4 wt. % to 28 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 4 wt. % to 27 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 4 wt. % to 25 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 4 wt. % to 22 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 4 wt. % to 20 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 4 wt. % to 18 wt. % zinc.
  • the aluminum alloy strip has 4 wt. % to 15 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 4 wt. % to 13 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 4 wt. % to 11 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 4 wt. % to 10 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 4 wt. % to 9 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 4 wt. % to 8 wt. % zinc.
  • the aluminum alloy strip has 4 wt. % to 7 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 4 wt. % to 6 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 4 wt. % to 5 wt. % zinc.
  • the aluminum alloy strip has 5 wt. % to 28 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 6 wt. % to 28 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 7 wt. % to 28 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 8 wt. % to 28 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 9 wt. % to 28 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 10 wt. % to 28 wt. % zinc.
  • the aluminum alloy strip has 11 wt. % to 28 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 13 wt. % to 28 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 15 wt. % to 28 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 18 wt. % to 28 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 20 wt. % to 28 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 22 wt. % to 28 wt. % zinc.
  • the aluminum alloy strip has 5 wt. % to 27 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 7 wt. % to 25 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 8 wt. % to 23 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 9 wt. % to 20 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 10 wt. % to 18 wt. % zinc. In one or more embodiments detailed herein, the aluminum alloy strip has 12 wt. % to 15 wt. % zinc.
  • the aluminum alloy strip has 1 wt. % to 2.8 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip has 1 wt. % to 2.6 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip has 1 wt. % to 2.4 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip has 1 wt. % to 2.2 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip has 1 wt. % to 2.0 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip has 1 wt.
  • the aluminum alloy strip has 1 wt. % to 1.6 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip has 1 wt. % to 1.4 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip has 1 wt. % to 1.2 wt. % copper.
  • the aluminum alloy strip has 1.2 wt. % to 3 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip has 1.4 wt. % to 3 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip has 1.6 wt. % to 3 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip has 1.8 wt. % to 3 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip has 2.0 wt. % to 3 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip has 2.2 wt.
  • the aluminum alloy strip has 2.4 wt. % to 3 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip has 2.6 wt. % to 3 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip has 2.8 wt. % to 3 wt. % copper.
  • the aluminum alloy strip has 1.2 wt. % to 2.8 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip has 1.4 wt. % to 2.6 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip has 1.6 wt. % to 2.4 wt. % copper. In one or more embodiments detailed herein, the aluminum alloy strip has 1.8 wt. % to 2.2 wt. % copper.
  • the aluminum alloy strip has 1 wt. % to 2.8 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip has 1 wt. % to 2.6 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip has 1 wt. % to 2.4 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip has 1 wt. % to 2.2 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip has 1 wt. % to 2.0 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip has 1 wt.
  • the aluminum alloy strip has 1 wt. % to 1.6 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip has 1 wt. % to 1.4 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip has 1 wt. % to 1.2 wt. % magnesium.
  • the aluminum alloy strip has 1.2 wt. % to 3 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip has 1.4 wt. % to 3 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip has 1.6 wt. % to 3 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip has 1.8 wt. % to 3 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip has 2.0 wt. % to 3 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip has 2.2 wt.
  • the aluminum alloy strip has 2.4 wt. % to 3 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip has 2.6 wt. % to 3 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip has 2.8 wt. % to 3 wt. % magnesium.
  • the aluminum alloy strip has 1.2 wt. % to 2.8 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip has 1.4 wt. % to 2.6 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip has 1.6 wt. % to 2.4 wt. % magnesium. In one or more embodiments detailed herein, the aluminum alloy strip has 1.8 wt. % to 2.2 wt. % magnesium.
  • the aluminum alloy strip has 0.1 wt. % to 1.0 wt. % manganese. In one or more embodiments detailed herein, the aluminum alloy strip has 0.2 wt. % to 1.0 wt. % manganese. In one or more embodiments detailed herein, the aluminum alloy strip has 0.4 wt. % to 1.0 wt. % manganese. In one or more embodiments detailed herein, the aluminum alloy strip has 0.6 wt. % to 1.0 wt. % manganese. In one or more embodiments detailed herein, the aluminum alloy strip has 0.8 wt. % to 1.0 wt. % manganese.
  • the aluminum alloy strip has 0.1 wt. % to 0.8 wt. % manganese. In one or more embodiments detailed herein, the aluminum alloy strip has 0.1 wt. % to 0.9 wt. % manganese. In one or more embodiments detailed herein, the aluminum alloy strip has 0.1 wt. % to 0.7 wt. % manganese. In one or more embodiments detailed herein, the aluminum alloy strip has 0.1 wt. % to 0.5 wt. % manganese. In one or more embodiments detailed herein, the aluminum alloy strip has 0.1 wt. % to 0.3 wt. % manganese.
  • the aluminum alloy strip has 0.05 wt. % to 0.3 wt. % chromium. In one or more embodiments detailed herein, the aluminum alloy strip has 0.1 wt. % to 0.3 wt. % chromium. In one or more embodiments detailed herein, the aluminum alloy strip has 0.15 wt. % to 0.3 wt. % chromium. In one or more embodiments detailed herein, the aluminum alloy strip has 0.2 wt. % to 0.3 wt. % chromium. In one or more embodiments detailed herein, the aluminum alloy strip has 0.25 wt. % to 0.3 wt. % chromium.
  • the aluminum alloy strip has 0.05 wt. % to 0.25 wt. % chromium. In one or more embodiments detailed herein, the aluminum alloy strip has 0.05 wt. % to 0.2 wt. % chromium. In one or more embodiments detailed herein, the aluminum alloy strip has 0.05 wt. % to 0.15 wt. % chromium. In one or more embodiments detailed herein, the aluminum alloy strip has 0.05 wt. % to 0.1 wt. % chromium. In one or more embodiments detailed herein, the aluminum alloy strip has 0.15 wt. % to 0.25 wt. % chromium.
  • the aluminum alloy strip has 0.04 wt. % to 0.25 wt. % zirconium. In one or more embodiments detailed herein, the aluminum alloy strip has 0.04 wt. % to 0.2 wt. % zirconium. In one or more embodiments detailed herein, the aluminum alloy strip has 0.04 wt. % to 0.18 wt. % zirconium. In one or more embodiments detailed herein, the aluminum alloy strip has 0.04 wt. % to 0.15 wt. % zirconium. In one or more embodiments detailed herein, the aluminum alloy strip has 0.04 wt. % to 0.1 wt. % zirconium.
  • the aluminum alloy strip has 0.1 wt. % to 0.25 wt. % zirconium. In one or more embodiments detailed herein, the aluminum alloy strip has 0.15 wt. % to 0.25 wt. % zirconium. In one or more embodiments detailed herein, the aluminum alloy strip has 0.2 wt. % to 0.25 wt. % zirconium.
  • the aluminum alloy strip has 0.07 wt. % to 0.14 wt. % zirconium.
  • the aluminum alloy strip includes at least one of zinc, copper, magnesium, manganese, chromium, or zirconium. In one or more embodiments detailed herein, the aluminum alloy strip is free of at least one of copper, magnesium, manganese, chromium, or zirconium.
  • the aluminum alloy strip may contain secondary elements and/or other elements.
  • secondary elements are Fe, Si, and/or Ti.
  • other elements includes any elements of the periodic table other than aluminum (Al), Zn, Cu, Mn, Cr, Zr, Mg, Fe, Si, and/or Ti.
  • a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 15% or less. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 14% or less. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 13% or less. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 12% or less. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 11% or less.
  • a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 10% or less. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 9% or less. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 8% or less. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 7% or less. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 6% or less.
  • a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 5% or less. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 4% or less. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 3% or less. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 2% or less.
  • a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 0.1% to 15%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 0.1% to 14%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 0.1% to 13%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 0.1% to 12%.
  • a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 0.1% to 11%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 0.1% to 10%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 0.1% to 9%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 0.1% to 8%.
  • a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 0.1% to 7%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 0.1% to 6%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 0.1% to 5%. In one or more embodiments detailed herein, a variation of the zinc weight percent is 0.1% to 4% between a surface and a thickness center of the aluminum alloy strip.
  • a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 1% to 15%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 2% to 15%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 3% to 15%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 4% to 15%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 5% to 15%.
  • a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 6% to 15%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 7% to 15%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 8% to 15%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 9% to 15%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 10% to 15%.
  • a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 11% to 15%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness center of the aluminum alloy strip is 12% to 15%.
  • a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 15% or less. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 14% or less. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 13% or less. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 12% or less.
  • a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 11% or less. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 10% or less. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 9% or less. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 8% or less.
  • a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 7% or less. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 6% or less. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 5% or less. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 4% or less.
  • a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 3% or less. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 2% or less.
  • a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 0.1% to 15%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 0.1% to 14%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 0.1% to 13%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 0.1% to 12%.
  • a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 0.1% to 11%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 0.1% to 10%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 0.1% to 9%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 0.1% to 8%.
  • a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 0.1% to 7%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 0.1% to 6%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 0.1% to 5%. In one or more embodiments detailed herein, a variation of the zinc weight percent is 0.1% to 4% between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip.
  • a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 1% to 15%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 2% to 15%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 3% to 15%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 4% to 15%.
  • a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 5% to 15%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 6% to 15%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 7% to 15%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 8% to 15%.
  • a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 9% to 15%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 10% to 15%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 11% to 15%. In one or more embodiments detailed herein, a variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the aluminum alloy strip is 12% to 15%.
  • the aluminum alloy has a zinc weight percent of 4% to 28% or any other weight percent range detailed herein and does not exhibit centerline segregation.
  • the casting of the aluminum alloy strip detailed herein may be accomplished via a continuous casting apparatus capable of producing continuously cast products that are solidified at high solidification rates.
  • a continuous casting apparatus capable of achieving the above-described solidification rates is the apparatus described in U.S. Pat. Nos. 6,672,368 and 7,125,612, incorporated by reference in their entirety.
  • the aluminum alloy strip is continuously cast using the MicromillTM process described in U.S. Pat. Nos. 6,672,368 and 7,125,612.
  • a molten aluminum alloy metal M may be stored in a hopper H (or tundish) and delivered through a feed tip T, in a direction B, to a pair of rolls R 1 and R 2 , having respective roll surfaces D 1 and D 2 , which are each rotated in respective directions A 1 and A 2 , to produce a solid cast product S.
  • gaps G 1 and G 2 may be maintained between the feed tip T and respective rolls R 1 and R 2 as small as possible to prevent molten metal from leaking out, and to minimize the exposure of the molten metal to the atmosphere, while maintaining a separation between the feed tip T and rolls R 1 and R 2 .
  • a plane L through the centerline of the rolls R 1 and R 2 passes through a region of minimum clearance between the rolls R 1 and R 2 referred to as the roll nip N.
  • the molten metal M directly contacts the cooled rolls R 1 and R 2 at regions 2 and 4 , respectively.
  • the metal M Upon contact with the rolls R 1 and R 2 , the metal M begins to cool and solidify.
  • the cooling metal produces an upper shell 6 of solidified metal adjacent the roll R 1 and a lower shell 8 of solidified metal adjacent to the roll R 2 .
  • the thickness of the shells 6 and 8 increases as the metal M advances towards the nip N. Large dendrites 10 of solidified metal (not shown to scale) may be produced at the interfaces between each of the upper and lower shells 6 and 8 and the molten metal M.
  • the large dendrites 10 may be broken and dragged into a center portion 12 of the slower moving flow of the molten metal M and may be carried in the direction of arrows C 1 and C 2 .
  • the dragging action of the flow can cause the large dendrites 10 to be broken further into smaller dendrites 14 (not shown to scale).
  • the metal M is semi-solid and may include a solid component (the solidified small dendrites 14 ) and a molten metal component.
  • the metal M in the region 16 may have a mushy consistency due in part to the dispersion of the small dendrites 14 therein.
  • a freeze front of metal may be formed at the nip N.
  • the central portion 12 may be a solid central portion, 18 containing the small dendrites 14 sandwiched between the upper shell 6 and the lower shell 8 .
  • the small dendrites 14 may be 20 microns to 50 microns in size and have a generally globular shape.
  • the three portions, of the upper and lower shells 6 and 8 and the solidified central portion 18 constitute a single, solid cast product (S in FIG. 1 and element 20 in FIG. 2 ).
  • the aluminum alloy cast product 20 may include a first portion of an aluminum alloy and a second portion of the aluminum alloy (corresponding to the shells 6 and 8 ) with an intermediate portion (the solidified central portion 18 ) therebetween.
  • the solid central portion 18 may constitute 20 percent to 30 percent of the total thickness of the cast product 20 .
  • the rolls R 1 and R 2 may serve as heat sinks for the heat of the molten metal M.
  • heat may be transferred from the molten metal M to the rolls R 1 and R 2 in a uniform manner to ensure uniformity in the surface of the cast product 20 .
  • Surfaces D 1 and D 2 of the respective rolls R 1 and R 2 may be made from steel, copper, nickel, or other suitable material and may be textured and may include surface irregularities (not shown) which may contact the molten metal M.
  • the control, maintenance and selection of the appropriate speed of the rolls R 1 and R 2 may impact the ability to continuously cast products.
  • the roll speed determines the speed that the molten metal M advances towards the nip N. If the speed is too slow, the large dendrites 10 will not experience sufficient forces to become entrained in the central portion 12 and break into the small dendrites 14 .
  • the roll speed may be selected such that a freeze front, or point of complete solidification, of the molten metal M may form at the nip N.
  • the present casting apparatus and methods may be suited for operation at high speeds such as those ranging from 25 to 500 feet per minute; alternatively from 40 to 500 feet per minute; alternatively from 40 to 400 feet per minute; alternatively from 100 to 400 feet per minute; and alternatively from 150 to 300 feet per minute.
  • the linear rate per unit area that molten aluminum is delivered to the rolls R 1 and R 2 may be less than the speed of the rolls R 1 and R 2 or about one quarter of the roll speed.
  • Continuous casting of aluminum alloys may be achieved by initially selecting the desired dimension of the nip N corresponding to the desired gauge of the cast product S.
  • the speed of the rolls R 1 and R 2 may be increased to a desired production rate or to a speed which is less than the speed which causes the roll separating force increases to a level which indicates that rolling is occurring between the rolls R 1 and R 2 .
  • Casting at the rates contemplated by an embodiment of the present invention i.e. 25 to 400 feet per minute) solidifies the aluminum alloy cast product about 1000 times faster than aluminum alloy cast as an ingot cast and improves the properties of the cast product over aluminum alloys cast as an ingot.
  • the rate at which the molten metal is cooled may be selected to achieve rapid solidification of the outer regions of the metal. Indeed, the cooling of the outer regions of metal may occur at a rate of at least 1000 degrees Celsius per second.
  • the continuous cast strip may be of any suitable thickness, and is generally of sheet gauge (0.006 inch to 0.249 inch) or thin-plate gauge (0.250 inch to 0.400 inch), i.e., has a thickness in the range of from 0.006 inch to 0.400 inch. In one embodiment, the strip has a thickness of at least 0.040 inch. In one embodiment, the strip has a thickness of less than 0.320 inch.
  • EMA Electron Probe Micro Analyzer
  • EPMA line scans are set with an initial spot of 100 micrometers diameter about 50 micrometers from the sample surface moving in the thickness direction until the other surface is reached.
  • the defocused beam spots are calculated to maintain a 50 micrometer separation to provide 50% overlap between points.
  • a JEOL JXA 8530F Field Emission Electron Probe Microanalyzer Hyperprobe with 4 Wave dispersive spectrometers and JEOL SDD-EDS are used to gather the data.
  • the operating conditions are:
  • Analyzed elements may include: Ti, Zr, Mg, Si, Mn, Fe, Cu, Zn and Al
  • the wave dispersive spectrometer (WDS) crystal and spectrometers are used as detailed in the Table 1.
  • a background measurement is collected every 50 spots for 5 seconds on positive and negative background locations. Elements measured are quantitatively analyzed using the JEOL quant ZAF analysis package for metals with atomic number correction by Philibert-Tixier method and flourescence excitation correction by Reed method.
  • the concentration of alloying elements through depth of a sample was determined using a quantometer consistent with the method used to analyze the samples from U.S. Pat. No. 6,672,368.
  • Samples are first mounted and polished in Lucite using standard metallographic preparation techniques for aluminum.
  • An EPMA is used to profile the distribution of the alloying elements across a thickness to show the micro-segregation of the alloying elements.
  • EPMA line scans are set with a focused spot moving with a 1 micrometer step across several grains to provide overlapping points through multiple grains.
  • a JEOL JXA 8530F Field Emission Electron Probe Microanalyzer Hyperprobe with 4 Wave dispersive spectrometers and JEOL SDD-EDS are used to gather the data.
  • the operating conditions are:
  • Analyzed elements may include: Ti, Zr, Mg, Si, Mn, Fe, Cu, Zn and Al
  • the WDS crystal and spectrometers are used as detailed in Table 1.
  • a background measurement is collected every 50 spots for 5 seconds on positive and negative background locations. Elements measured are quantitatively analyzed using the JEOL quant ZAF analysis package for metals with atomic number correction by Philibert-Tixier method and flourescence excitation correction by Reed method.
  • Aluminum alloy samples were cast using the apparatus detailed in U.S. Pat. No. 6,672,368 at a speed of 55 feet per minute to 85 feet per minute and had a final thickness detailed in the tables below.
  • the average weight percentages of the zinc, magnesium and copper from the surface to 3,000 micrometers thickness depth in each sample was determined using either the “macro-segregation” procedure detailed herein or via quantometer.
  • Table 2 below shows the average weight percentages of zinc, copper and magnesium from surface to a thickness depth of 3,000 micrometers in each of the cast samples and the method used to determine the weight percentages in each sample:
  • Table 3 shows the variation of zinc weight percentages in each of the samples from surface to a thickness depth of 3,000 micrometers:
  • the average weight percentages of the zinc, magnesium and copper from the surface to the thickness center in each sample were determined using either the “macro-segregation” procedure detailed herein or via quantometer. Table 4 below shows the average weight percentages of zinc, copper and magnesium from surface to a thickness center in each of the cast samples and the method used to determine the weight percentages in each sample:
  • Table 5 shows the variation of zinc weight percentages in each of the samples from surface to a thickness center in each sample:
  • FIGS. 3-10 The data generated for each sample is plotted in FIGS. 3-10 .
  • the inventors surprisingly found that the variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in samples 1-7 according to the present invention is less than 15%. Moreover, the variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers of sample 8 is greater than 15%. Similarly, based on visual inspection of FIGS. 11-12 , the variation of the zinc weight percent between a surface and a thickness depth of 3,000 micrometers in the direct chill cast prior art product and the continuously cast prior art product is greater than 15%.
  • the inventors surprisingly found that the variation of the zinc weight percent between a surface and a thickness center in samples 1-8 according to the present invention is less than 15%. Moreover, based on visual inspection of FIGS. 11-12 , the variation of the zinc weight percent between a surface and a thickness center of the direct chill cast prior art product and the continuously cast prior art product is greater than 15%.
  • the weight percentages of the zinc, magnesium and copper across grains from the surface to 200 micrometers thickness depth in sample 6 was determined using the “micro-segregation” procedure detailed herein. The data is presented in FIG. 13 .
  • the weight percentages of the zinc, magnesium and copper across grains through thickness for a direct chill cast prior art product are shown in FIG. 14 .
  • FIG. 15 shows the structure of sample 6.
  • the structure of samples of aluminum alloys having average zinc contents of 16% and 25% cast using the apparatus detailed in U.S. Pat. No. 6,672,368 at a speed of 55 feet per minute are shown in FIGS. 16 and 17 , respectively.
  • FIGS. 15-17 show products of the present invention have a globular grain structure and are substantially free of micro-segregation.
  • the products of the present invention may be substantially free of dendrites and consist primarily of globular non-dendritic grains—i.e., a globular grain structure.
  • the products are substantially free of micro-segregation effects.

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CN113122759A (zh) * 2021-03-29 2021-07-16 烟台南山学院 一种抗蠕变性耐高温铸造铝合金及其制造方法

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