US20180291489A1 - Aluminum alloy with additions of copper, lithium and at least one alkali or rare earth metal, and method of manufacturing the same - Google Patents

Aluminum alloy with additions of copper, lithium and at least one alkali or rare earth metal, and method of manufacturing the same Download PDF

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Publication number
US20180291489A1
US20180291489A1 US15/484,288 US201715484288A US2018291489A1 US 20180291489 A1 US20180291489 A1 US 20180291489A1 US 201715484288 A US201715484288 A US 201715484288A US 2018291489 A1 US2018291489 A1 US 2018291489A1
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percent
weight
aluminum alloy
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zero
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US15/484,288
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English (en)
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Austin E. Mann
Andrew H. Baker
Rajiv Mishra
Sivanesh Palanivel
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Boeing Co
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Boeing Co
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Priority to US15/484,288 priority Critical patent/US20180291489A1/en
Assigned to UNIVERSITY OF NORTH TEXAS reassignment UNIVERSITY OF NORTH TEXAS ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MISHRA, RAJIV S., PALANIVEL, SIVANESH
Assigned to THE BOEING COMPANY reassignment THE BOEING COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BAKER, ANDREW H., MANN, AUSTIN E.
Application filed by Boeing Co filed Critical Boeing Co
Assigned to THE BOEING COMPANY reassignment THE BOEING COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: UNIVERSITY OF NORTH TEXAS
Priority to RU2018112213A priority patent/RU2761567C2/ru
Priority to EP18165961.6A priority patent/EP3388540B8/en
Priority to CA3000407A priority patent/CA3000407C/en
Priority to JP2018073627A priority patent/JP7507543B2/ja
Priority to BR102018007241-2A priority patent/BR102018007241B1/pt
Priority to CN202411246438.8A priority patent/CN119082568A/zh
Priority to CN201810313813.4A priority patent/CN108690926A/zh
Priority to KR1020180041370A priority patent/KR102549742B1/ko
Publication of US20180291489A1 publication Critical patent/US20180291489A1/en
Priority to US17/326,492 priority patent/US11846010B2/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/02—Making non-ferrous alloys by melting
    • C22C1/026—Alloys based on aluminium
    • 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
    • C22F1/057—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 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
    • 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
    • B22D21/02—Casting exceedingly oxidisable non-ferrous metals, e.g. in inert atmosphere
    • B22D21/04—Casting aluminium or magnesium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D7/00—Casting ingots, e.g. from ferrous metals
    • B22D7/005—Casting ingots, e.g. from ferrous metals from non-ferrous metals
    • 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
    • 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
    • C22C21/18—Alloys based on aluminium with copper as the next major constituent with zinc
    • 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
    • C22F1/002—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working by rapid cooling or quenching; cooling agents used therefor

Definitions

  • the present application relates to aluminum alloys and, more particularly, to aluminum alloys with additions of copper, lithium and at least one alkali or rare earth metal.
  • Friction stir welding is a solid-state joining process that uses a non-consumable tool to join two facing workpieces without melting the workpiece material. Friction stir welding, while categorically a solid state joining process, typically generates enough heat input to coarsen and even dissolve the main strengthening phases in many aluminum alloys. The coarsening and dissolution of primary precipitates ultimately results in a measurable drop in strength across the weld, often epitomized by a classic W-shaped hardness profile.
  • the disclosed aluminum alloy includes aluminum, about 1.8 to about 5.6 percent by weight copper, about 0.6 to about 2.6 percent by weight lithium, and at least one of lanthanum up to about 1.5 percent by weight, strontium up to about 1.5 percent by weight, cerium up to about 1.5 percent by weight, and praseodymium up to about 1.5 percent by weight.
  • the disclosed aluminum alloy includes aluminum, about 1.8 to about 5.6 percent by weight copper, about 0.6 to about 2.6 percent by weight lithium, at least one of lanthanum, strontium, cerium and praseodymium in a non-zero quantity up to about 1.5 percent by weight, each, magnesium in a non-zero quantity up to about 1.9 percent by weight, zirconium in a non-zero quantity up to about 0.16 percent by weight, and silver in a non-zero quantity up to about 0.7 percent by weight.
  • the disclosed aluminum alloy includes aluminum, about 1.8 to about 5.6 percent by weight copper, about 0.6 to about 2.6 percent by weight lithium, at least one of lanthanum, strontium, cerium and praseodymium in a non-zero quantity up to about 1.5 percent by weight, each, magnesium in a non-zero quantity up to about 1.9 percent by weight, zirconium in a non-zero quantity up to about 0.16 percent by weight, silver in a non-zero quantity up to about 0.7 percent by weight, manganese in a non-zero quantity up to about 0.6 percent by weight, zinc in a non-zero quantity up to about 1.0 percent by weight, and titanium in a non-zero quantity up to about 0.15 percent by weight.
  • the disclosed method for manufacturing an aluminum alloy includes the steps of: (1) weighing out starting materials to achieve a mass of material that includes aluminum, about 1.8 to about 5.6 percent by weight copper, about 0.6 to about 2.6 percent by weight lithium, and at least one of lanthanum up to about 1.5 percent by weight, strontium up to about 1.5 percent by weight, cerium up to about 1.5 percent by weight and praseodymium up to about 1.5 percent by weight; (2) loading the materials into a crucible; (3) inserting the crucible into a chamber; (4) evacuating the chamber to a predetermined vacuum level; (5) melting the materials to form a molten mass; and (6) casting the molten mass into a mold.
  • FIG. 1 is a flow diagram of an aircraft manufacturing and service methodology
  • FIG. 2 is a block diagram of an aircraft.
  • Aluminum alloys that have been improved by the addition of lanthanum (La), cerium (Ce), strontium (Sr), praseodymium (Pr), other rare or alkali earth metals, other lanthanides, and rare earth metal in the form of mischmetal, along with various other elements traditionally used in aluminum alloys.
  • Al alloys from the 2xxx series Al—Cu—Li alloys registered by the Aluminum Association have been improved by the addition La, Ce, Sr, Pr, other rare or alkali earth metals, and rare-earth ore in the form of mischmetal.
  • the disclosed aluminum alloys are designed to generate a dynamic response of the material to the friction stir welding (FSW) process. Without being limited to any particular theory, it is believed that the additional elements have three primary thermodynamic and physical criteria that improve the property of the disclosed aluminum alloy, set forth below.
  • the T1 phase (the primary strengthening phase in the Al—Cu—Li system) favors distorted lattice sites for nucleation.
  • the high degree of strain misfit generated by these additional elements will spur nucleation of the T1 phase.
  • the criteria described herein create an ideal scenario for nucleation and subsequent re-precipitation of the T1 phase during the FSW process.
  • the resulting effect will be a marked improvement in strength and other inherent material properties in the weld zone.
  • the additional elements would eliminate the measurable drop in strength typically observed across weld zones. This would result in a new class of aluminum alloys that could be implemented in more critical design spaces, and more amenable to a desirable and efficient fabrication process (e.g., FSW).
  • One general example of the disclosed aluminum alloy has the composition shown in Table 1.
  • the aluminum alloy of Table 1 comprises about 1.8 to about 5.6 percent by weight copper, about 0.6 to about 2.6 percent by weight lithium, at least one of lanthanum, strontium, cerium, and praseodymium in a non-zero quantity up to about 1.5 percent by weight, wherein each of the at least one of the lanthanum, strontium, cerium, and praseodymium can be present at the non-zero quantity up to about 1.5 percent by weight, and the balance is substantially aluminum.
  • the at least one of La, Sr, Ce, and Pr could be sourced from mischmetal.
  • Mischmetal is a rare-earth metal ore mixture, typically predominately Ce and La with smaller amounts of Pr, Sr, and neodymium (Nd), but potentially containing other lanthanides. Accordingly, low levels of other lanthanides may also be present in the disclosed aluminum alloy.
  • the aluminum alloy of the first embodiment may further include silicon in a non-zero quantity up to about 0.20 percent by weight or about 0.05 to about 0.20 percent by weight.
  • the aluminum alloy of the first embodiment may further include iron in a non-zero quantity up to about 0.30 percent by weight or from about 0.07 to about 0.30 percent by weight.
  • the aluminum alloy of the first embodiment may further include manganese in a non-zero quantity up to about 0.6 percent by weight or about 0.03 to about 0.6 percent by weight.
  • the aluminum alloy of the first embodiment may further include magnesium in a non-zero quantity up to about 1.9 percent by weight or about 0.05 to about 1.9 percent by weight.
  • the aluminum alloy of the first embodiment may further include chromium in a non-zero quantity up to about 0.10 percent by weight.
  • the aluminum alloy of the first embodiment may further include zinc in a non-zero quantity up to about 1.0 percent by weight or about 0.03 to about 1.0 percent by weight.
  • the aluminum alloy of the first embodiment may further include titanium in a non-zero quantity up to about 0.15 percent by weight or about 0.07 to about 0.15 percent by weight.
  • the aluminum alloy of the first embodiment may further include silver in a non-zero quantity up to about 0.7 percent by weight or about 0.05 to about 0.7 percent by weight.
  • the aluminum alloy of the first embodiment may further include zirconium in a non-zero quantity up to about 0.16 percent by weight or about 0.04 to about 0.16 percent by weight.
  • the aluminum alloy of the first embodiment may further include at least one of nickel, gallium, and vanadium in a non-zero quantity up to about 0.05 percent by weight each.
  • Another general example of the disclosed aluminum alloy has the composition shown in Table 2.
  • the aluminum alloy of Table 2 includes the elements listed and the balance is either aluminum or substantially aluminum along with various impurities.
  • at least one of La, Sr, Ce, and Pr must be present in a non-zero quantity.
  • One specific, non-limiting example of the disclosed aluminum alloy has the composition shown in Table 3.
  • Another specific, non-limiting example of the disclosed aluminum alloy has the composition shown in Table 4.
  • Yet another specific, non-limiting example of the disclosed aluminum alloy has the composition shown in Table 5.
  • the disclosed aluminum alloy can be made by a variety of techniques.
  • One method for manufacturing the disclosed aluminum alloy includes the steps of: (1) weighing out starting materials to achieve a mass of material within the composition of an aluminum alloy comprising about 1.8 to about 5.6 percent by weight copper, about 0.6 to about 2.6 percent by weight lithium, at least one of lanthanum, strontium, cerium, and praseodymium in a non-zero quantity up to about 1.5 percent by weight, each, and aluminum; (2) loading the materials into a crucible; (3) inserting the crucible into a chamber; (4) evacuating the chamber to a predetermined vacuum level wherein said chamber is optionally backfilled with an inert gas; (5) melting the materials to form a molten mass; and (6) casting the molten mass into a mold.
  • the molten mass is cast into a mold, the molten mass is cooled to form a solid mass, the solid mass is homogenized and water quenched to yield an ingot, the ingot is scalped and hot rolled, and the ingot is solution treated and water quenched, cold-rolled or stretched, and artificially or otherwise naturally aged to yield the aluminum alloy.
  • the weighing out of starting materials step may include the use of mischmetal as the source of at least one of lanthanum, strontium, cerium, and praseodymium in a non-zero quantity up to about 1.5 percent by weight, each.
  • Mischmetal is a rare-earth metal ore mixture, typically predominately Ce and La with smaller amounts of Pr, Sr, and Nd, but potentially containing other lanthanides. Mischmetals are cost-effective rare-earth elements one could use in the present invention to decrease the cost.
  • the rare-earth elements are relatively expensive because a larger contributor to the cost of the rare-earth elements is the step of isolating rare earth elements. By utilizing mischmetals, the isolation step is avoided, thus the final product will be less expensive yet similarly effective.
  • charge materials are weighed out and loaded in a graphite crucible.
  • the chamber is then evacuated to a vacuum level below about 0.05 Torr and backfilled with an inert gas (e.g., argon) to a partial pressure of about 760 Torr.
  • an inert gas e.g., argon
  • the charge is melted and cast into a graphite mold and allowed to air cool.
  • the as-cast ingot can then be homogenized at about 840° F. for about 24 hours and water quenched.
  • the ingot can then be scalped and hot rolled at about 900° F. to thickness. It will then be solution treated at 950° F. for about 1 hour and water quenched. Finally, it will be cold-rolled with about a 5% reduction and artificially aged. It can be artificially aged at about 310° F. for about 32 hour, yielding an aluminum alloy of the present invention.
  • the aircraft manufacturing and service method 100 includes, for example, specification and design 104 of the aircraft 102 and material procurement 106 .
  • component/subassembly manufacturing 108 and system integration 110 of the aircraft 102 takes place.
  • the aircraft 102 may go through certification and delivery 112 in order to be placed in service 114 .
  • routine maintenance and service 116 which may also include modification, reconfiguration, refurbishment and the like.
  • a system integrator includes, without limitation, any number of aircraft manufacturers and major-system subcontractors; a third party includes, without limitation, any number of venders, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on.
  • the aircraft 102 produced by example method 100 includes, for example, an airframe 118 with a plurality of systems 120 and an interior 122 .
  • the plurality of systems 120 include one or more of a propulsion system 124 , an electrical system 126 , a hydraulic system 128 , and an environmental system 130 . Any number of other systems may be included.
  • the disclosed aluminum alloy composition and article formed therefrom may be employed during any one or more of the stages of the aircraft manufacturing and service method 100 .
  • components or subassemblies corresponding to component/subassembly manufacturing 108 , system integration 110 , and or maintenance and service 116 may be fabricated or manufactured using the disclosed aluminum alloy composition.
  • the airframe 118 may be constructed using the disclosed aluminum alloy composition.
  • one or more apparatus examples, method examples, or a combination thereof may be utilized during component/subassembly manufacturing 108 and/or system integration 110 , for example, by substantially expediting assembly of or reducing the cost of an aircraft 102 , such as the airframe 118 and/or the interior 122 .
  • one or more of system examples, method examples, or a combination thereof may be utilized while the aircraft 102 is in service, for example and without limitation, to maintenance and service 116 .
  • the disclosed aluminum alloy composition and article formed therefrom is described in the context of an aircraft; however, one of ordinary skill in the art will readily recognize that the disclosed aluminum alloy composition and article formed therefrom may be utilized for a variety of applications.
  • the disclosed aluminum alloy composition and article formed therefrom may be implemented in various types of vehicles including, for example, helicopters, passenger ships, automobiles, marine products (boat, motors, etc.) and the like.

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US15/484,288 2017-04-11 2017-04-11 Aluminum alloy with additions of copper, lithium and at least one alkali or rare earth metal, and method of manufacturing the same Abandoned US20180291489A1 (en)

Priority Applications (10)

Application Number Priority Date Filing Date Title
US15/484,288 US20180291489A1 (en) 2017-04-11 2017-04-11 Aluminum alloy with additions of copper, lithium and at least one alkali or rare earth metal, and method of manufacturing the same
CA3000407A CA3000407C (en) 2017-04-11 2018-04-05 Aluminum alloy with additions of copper, lithium and at least one alkali or rare earth metal, and method of manufacturing the same
EP18165961.6A EP3388540B8 (en) 2017-04-11 2018-04-05 Aluminum alloy with additions of copper, lithium, silver and at least one of sr or a rare earth metal, and method of manufacturing the same
RU2018112213A RU2761567C2 (ru) 2017-04-11 2018-04-05 Алюминиевый сплав с добавками меди, лития и по меньшей мере одного щелочноземельного или редкоземельного металла и способ его получения
JP2018073627A JP7507543B2 (ja) 2017-04-11 2018-04-06 銅、リチウム、及び少なくとも１種のアルカリ土類金属又は希土類金属の添加物を含むアルミニウム合金、及びその製造方法
BR102018007241-2A BR102018007241B1 (pt) 2017-04-11 2018-04-10 Liga de alumínio, e, método para produzir uma liga de alumínio
CN202411246438.8A CN119082568A (zh) 2017-04-11 2018-04-10 铝合金和制造其的方法
CN201810313813.4A CN108690926A (zh) 2017-04-11 2018-04-10 铝合金和制造其的方法
KR1020180041370A KR102549742B1 (ko) 2017-04-11 2018-04-10 구리, 리튬, 및 적어도 하나의 알칼리 또는 희토류 금속으로 이루어진 첨가물을 가진 알루미늄 합금, 및 이를 제조하는 방법
US17/326,492 US11846010B2 (en) 2017-04-11 2021-05-21 Aluminum alloy with additions of copper, lithium and at least one alkali or rare earth metal, and method of manufacturing the same

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US (2) US20180291489A1 (enrdf_load_stackoverflow)
EP (1) EP3388540B8 (enrdf_load_stackoverflow)
JP (1) JP7507543B2 (enrdf_load_stackoverflow)
KR (1) KR102549742B1 (enrdf_load_stackoverflow)
CN (2) CN119082568A (enrdf_load_stackoverflow)
BR (1) BR102018007241B1 (enrdf_load_stackoverflow)
CA (1) CA3000407C (enrdf_load_stackoverflow)
RU (1) RU2761567C2 (enrdf_load_stackoverflow)

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US20190233921A1 (en) * 2018-02-01 2019-08-01 Kaiser Aluminum Fabricated Products, Llc Low Cost, Low Density, Substantially Ag-Free and Zn-Free Aluminum-Lithium Plate Alloy for Aerospace Application
US20210189538A1 (en) * 2018-05-02 2021-06-24 Constellium Issoire Method for manufacturing an aluminum-copper-lithium alloy having improved compressive strength and improved toughness
US11761061B2 (en) * 2017-09-15 2023-09-19 Ut-Battelle, Llc Aluminum alloys with improved intergranular corrosion resistance properties and methods of making and using the same
US11986904B2 (en) 2019-10-30 2024-05-21 Ut-Battelle, Llc Aluminum-cerium-nickel alloys for additive manufacturing
US12247272B2 (en) 2019-10-30 2025-03-11 Ut-Battelle, Llc Aluminum-cerium-copper alloys for metal additive manufacturing
US12305267B2 (en) 2017-02-22 2025-05-20 Ut-Battelle, Llc Rapidly solidified aluminum-rare earth element alloy and method of making the same

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CN109402472B (zh) * 2018-12-19 2021-04-30 长沙新材料产业研究院有限公司 一种用于增材制造的Al-Cu-Li-Sc-Zr铝合金粉末及其制备方法
US11203161B2 (en) * 2019-06-28 2021-12-21 The Boeing Company Methodology for rapid additively manufactured titanium strength assessment utilizing electrical resistivity
CN110423926B (zh) * 2019-07-29 2020-12-29 中国航发北京航空材料研究院 一种耐热铝锂合金及其制备方法
CN110656268B (zh) * 2019-09-27 2020-12-29 黄山市龙跃铜业有限公司 一种高强度抗疲劳铝合金及其制备方法
CN110564994A (zh) * 2019-10-14 2019-12-13 北京理工大学 一种低成本高强韧铝锂合金
CN112267081A (zh) * 2020-10-26 2021-01-26 广东兴发铝业（河南）有限公司 一种高力学性能的铝合金型材热处理方法
CN113088845A (zh) * 2021-04-07 2021-07-09 北京工业大学 一种Al-Cu-Li-Yb合金三级均匀化处理工艺
CN115449677A (zh) * 2022-10-11 2022-12-09 山东南山铝业股份有限公司 一种低密度高强度高塑性的铝合金及其制备方法
CN116287913A (zh) * 2023-02-10 2023-06-23 南京航空航天大学 一种增材制造用微量元素改性铝锂合金粉末及其制备方法

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