US20190330716A1 - Aluminum alloy sheet having excellent ridging resistance and hem bendability and production method for same - Google Patents

Aluminum alloy sheet having excellent ridging resistance and hem bendability and production method for same Download PDF

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US20190330716A1
US20190330716A1 US16/309,234 US201716309234A US2019330716A1 US 20190330716 A1 US20190330716 A1 US 20190330716A1 US 201716309234 A US201716309234 A US 201716309234A US 2019330716 A1 US2019330716 A1 US 2019330716A1
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rolling
hot
good
sheet
aluminum alloy
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Ryo KURAMOTO
Hiroki Takeda
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UACJ Corp
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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
    • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
    • C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
    • 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
    • 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
    • C22F1/043—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 silicon as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/05—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 of the Al-Si-Mg type, i.e. containing silicon and magnesium in approximately equal proportions
    • 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

Definitions

  • the present disclosure relates to an aluminum alloy sheet that is preferably used in the members and components of various automobiles, ships, aircraft, and the like, such as automobile body sheets and body panels, as well as construction materials, structural materials, various machinery and appliances, household electrical appliances, the components thereof, and the like.
  • the present disclosure relates to: an aluminum alloy sheet with excellent ridging resistance and excellent hem bendability, which is preferred for the applications; and a method for producing the aluminum alloy sheet.
  • aluminum alloy sheets have also increasingly tended to be used as automotive body sheets applied to automobile body panels, in place of conventional cold rolled steel sheets.
  • An aluminum alloy sheet has a specific gravity about one-third the specific gravity of a conventional cold rolled steel sheet while having a strength approximately equivalent to the strength of the conventional cold rolled steel sheet, and can contribute to a reduction in the weight of an automobile.
  • Aluminum alloy sheets have also been recently often used in molded components such as the panels and chassis of electronic and electrical instruments and the like, in addition to automotive applications. Like automotive body sheets, such aluminum alloy sheets have been often pressed and used.
  • Al—Mg—Si-based alloys and Al—Mg—Si—Cu-based alloys as well as Al—Mg-based alloys have been primarily used as aluminum alloy sheet materials for automobile body sheets.
  • the Al—Mg—Si-based alloys and the Al—Mg—Si—Cu-based alloys which are alloys having aging properties, result in improvement in strength after coating baking, in comparison with a strength before the coating baking, by using a heating step in the coating baking.
  • the Al—Mg—Si-based alloys and the Al—Mg—Si—Cu-based alloys have been recently increasingly applied to automotive materials because of having an advantage that a relatively low strength and excellent formability are achieved before the coating baking while a higher strength is achieved after the coating baking.
  • the aluminum alloy sheet materials for automobile body sheets have particularly required excellent formability and excellent surface quality.
  • the edges of sheets have been commonly often subjected to hemming-bending in the case of integrating outer and inner panels.
  • the hemming-bending can be considered to be very severe working for a material because 180-degree bending is performed at an extremely small bending radius.
  • it has been strongly required that the aluminum alloy sheet materials for automobile body sheets have particularly had hem bendability among types of formability.
  • the surface quality of an aluminum alloy sheet material is a feature characterizing appearance quality after molding.
  • Al—Mg—Si-based alloys and Al—Mg—Si—Cu-based alloys have an advantage that generation of a Lueders mark which has been problematic in Al—Mg-based alloys is inhibited.
  • the aluminum alloys also often have a problem that a ridging mark in which recesses and projections having a stripe shape are formed on a sheet surface after press molding is generated.
  • the ridging mark is a fine recessed and projected pattern that appears in a stripe shape in a direction parallel to the direction of rolling in a step of producing a sheet as a material when the sheet is molded.
  • the ridging mark is particularly prone to be generated under a severe press molding condition.
  • a material on which a ridging mark is prevented from being generated has been strongly demanded with increasingly demanding the complicated and thinned shapes of automobile bodies in recent years.
  • resistance to generation of a ridging mark in molding is referred to as “ridging resistance”.
  • Patent Literature 1 Japanese Patent No. 2823797
  • Patent Literature 2 Japanese Patent No. 3590685
  • Patent Literature 3 Unexamined Japanese Patent Application Kokai Publication No. 2009-263781
  • Patent Literature 4 Unexamined Japanese Patent Application Kokai Publication No. 2010-242215
  • Patent Literature 5 Unexamined Japanese Patent Application Kokai Publication No. 2014-234542
  • Patent Literature 6 Japanese Patent No. 5113318
  • Patent Literature 7 Japanese Patent No. 4939091
  • Patent Literature 5 proposes that ridging resistance is improved by controlling a crystal particle diameter.
  • balancing with bendability has been insufficiently examined in the aluminum alloy sheet produced by this method.
  • differential speed rolling and plural intermediate annealing treatments as well as usual hot rolling and cold rolling have been required, and a very complicated production step has been needed.
  • Patent Literature 6 and 7 propose that hem bendability which is a feature important for an automobile body sheet material is greatly improved by growing a cube orientation.
  • the improvement of ridging resistance and the improvement of hem bendability by control of a crystal orientation require structure controls contradictory to each other, and the achievement of the structure controls requires use of a very complicated and high-cost production step.
  • the present disclosure was made under such circumstances and is to provide an aluminum alloy sheet for molding that has excellent ridging resistance, can allow the generation of a ridging mark to be reliably suppressed even under a severe molding condition, and also has excellent hem bendability.
  • An objective of the present disclosure is to also provide a production method by which such an aluminum alloy sheet for molding that has excellent performance can be reliably and stably produced at low cost on a mass production scale.
  • examples of the causes of generating a ridging mark in an aluminum alloy sheet include a band-shaped structure (stripe-shaped structure) formed by crystal grains enlarged in a rolling direction in a hot rolling step and a cold-rolling step.
  • the suppression of the formation of the band-shaped structure or the decomposition of the band-shaped structure before producing a production sheet is required for suppressing the generation of a ridging mark.
  • Conceivable examples of steps in which the action of the decomposition of the band-shaped structure can be expected include a solution treatment step performed after the cold-rolling step. In the solution treatment step, recrystallization proceeds, and therefore, recrystallized grains generated by the recrystallization can decompose the band-shaped structure.
  • the present inventors repeatedly examined a method for effectively decomposing a band-shaped structure becoming the origin of a ridging mark. As a result, it was found that the power to decompose the band-shaped structure is increased by increasing the particle diameters of recrystallized grains generated by recrystallization. It can be considered that the band-shaped structure is decomposed by the coarse recrystallized grains, whereby strong linearity in a rolling direction, which is a feature of a ridging mark, is greatly decreased, and consequently, the generation of the ridging mark can be suppressed.
  • the present inventors found that a band-shaped structure formed in the case of hot rolling is allowed to be fine as a technique for enhancing the effect of decomposing a band-shaped structure by recrystallized grains.
  • the present inventors also considered that a decrease in hot-rolling temperature is effective for allowing a band-shaped structure formed in a hot-rolling step to be fine.
  • a decrease in hot-rolling temperature also leads to improvement in bendability.
  • a rolling texture can be grown by cold rolling at a sufficient rolling reduction after hot rolling at a low temperature.
  • the grown rolling texture can contribute to the growth of a cube orientation in solution treatment.
  • a decrease in hot-rolling temperature can be considered to be related to improvement in bendability because improvement in the cube orientation density of a product sheet leads to the possibility of improving bendability as described above.
  • texture control may commonly limit some of production steps and precludes the construction of a production method by which another feature is simultaneously improved.
  • the texture control is performed by adjusting working and a heat history, and the working and the heat history may restrict each other.
  • it is required to coarsen recrystallized grains in solution treatment simultaneously with the texture control.
  • Particle-diameter control for coarsening recrystallized grains may require a reduction in the strain energy accumulated by rolling due to heat treatment (for example, performance of intermediate annealing) other than solution treatment, and such heat treatment may cause the inhibition of the formation of a rolling texture contributing to the growth of a cube orientation.
  • the present inventors repeated the intensive examination of means for achieving both improvement in ridging resistance based on coarsening of recrystallized grains and improvement in bendability based on the growth of a cube orientation due to texture control.
  • both the improvement in ridging resistance and the improvement in bendability can be achieved by restricting the amounts of Mn and Cr in view of the constituent elements of the aluminum alloys.
  • Mn and Cr are elements that suppress the growth of crystal grains.
  • the restriction of the amounts of these added Mn and Cr to lower levels than usual enables the promotion of an increase in recrystallization particle diameter in solution treatment and the decomposition of a band-shaped structure, thereby improving ridging resistance.
  • an increase in crystal particle diameter as well as the growth of a cube orientation in solution treatment is achieved by selecting a step of growing a rolling texture by hot rolling and cold rolling.
  • the present inventors found that ridging resistance and hem bendability are reliably and prominently improved by restricting the amounts of Mn and Cr in an Al—Mg—Si-based alloy and an Al—Mg—Si—Cu-based alloy to lower levels than usual and controlling the crystal particle diameters and crystal orientation of a final sheet by controlling a hot-rolling temperature, omitting intermediate annealing, adopting a sufficient cold rolling reduction, and performing solution treatment in a method for producing the Al—Mg—Si-based alloy and the Al—Mg—Si—Cu-based alloy, as described above.
  • the present disclosure provides an aluminum alloy sheet with excellent ridging resistance and excellent hem bendability, the aluminum alloy sheet including: an aluminum alloy including 0.20 to 1.50 mass % Mg, 0.30 to 2.00 mass % Si, and one or two of 0.005 to 0.080 mass % Mn and 0.005 to 0.080 mass % Cr, satisfying 0.005 ⁇ Mn+Cr ⁇ 0.080 mass %, and including the balance Al and inevitable impurities, wherein the aluminum alloy sheet has a sheet thickness t; the position of the middle (t/2) of the sheet thickness is regarded as a center, and the crystal particle diameter d 1 of an L-LT plane in a sheet thickness in a range of ⁇ (t/8) from the center is 30 to 80 ⁇ m; the crystal particle diameter d 2 of an L-ST plane in the entire sheet thickness is 60 ⁇ m or less; and the cube orientation area rate C of a crystal orientation on a sheet surface is 10% or more.
  • the aluminum alloy included in the aluminum alloy sheet of the present disclosure further includes one or more of 0.01 to 0.40 mass % Zr, 0.03 to 1.00 mass % Fe, 0.005 to 0.300 mass % Ti, and 0.03 to 2.50 mass % Zn, and includes Cu that may be restricted to 1.50 mass % or less.
  • a method for producing the aluminum alloy sheet according to the present invention is a method for producing the aluminum alloy sheet with excellent ridging resistance and excellent hem bendability, the method including: a casting step of casting the aluminum alloy; a hot-rolling step of hot-rolling an ingot to form a hot-rolled sheet; a cold-rolling step of cold-rolling the hot-rolled sheet without subjecting the hot-rolled sheet to intermediate annealing, to form a cold-rolled sheet; and a solution treatment step of performing solution treatment of the cold-rolled sheet, wherein in the hot-rolling step, a hot-rolling start temperature is set at 300 to 450° C., and a hot-rolling end temperature is set at 200 to 450° C.; in the cold-rolling step, the cold-rolled sheet having a final sheet thickness is formed at a rolling reduction of 50.0% or more; and in the solution treatment step, the solution treatment of the cold-rolled sheet is performed at a temperature of 480 to 590° C.
  • the hot-rolling start temperature may be set at 300 to 450° C.
  • the hot-rolling end temperature may be set at 200 to 350° C.
  • the hot-rolling start temperature may be set at 350 to 450° C.
  • the hot-rolling end temperature may be set at more than 350° C. and 450° C. or less.
  • the production method described above may further include a homogenization treatment step of performing homogenization treatment of the ingot at a temperature of 480 to 590° C. for 0.5 to 24 hours between the casting step and the hot-rolling step.
  • an aluminum alloy sheet that can allow the generation of a ridging mark to be reliably suppressed even under a severe molding condition and that has excellent hem bendability.
  • an aluminum alloy sheet having excellent ridging resistance and excellent hem bendability can be produced at a cost lower than that in a conventional production method.
  • FIG. 1 is an explanatory diagram of a measurement plane with particle diameters d 1 and d 2 and a cube orientation area rate C in the present invention.
  • An aluminum alloy sheet having excellent ridging resistance and excellent hem bendability according to the present disclosure and a method for producing the aluminum alloy sheet will be described in detail below.
  • the constituent composition of an aluminum alloy included in the aluminum alloy sheet according to the present disclosure will be described, and the controls of the crystal particle diameters and crystal orientation of the aluminum alloy sheet will be described.
  • the method for producing an aluminum alloy sheet including a step of performing such controls of crystal particle diameters and a crystal orientation, will be described.
  • a simple expression of “%” for describing the constituent composition of the alloy means “mass %”.
  • the aluminum alloy sheet according to the present disclosure includes an Al—Mg—Si-based alloy or an Al—Mg—Si—Cu-based alloy, and the constituent composition of the aluminum alloy includes 0.20 to 1.50% Mg, 0.30 to 2.00% Si, and one or two of 0.005 to 0.080% Mn and 0.005 to 0.080 mass % Cr, and satisfies 0.005 mass % ⁇ Mn+Cr ⁇ 0.08 mass %.
  • the aluminum alloy of the present disclosure further including one or more selected from 0.01 to 0.40% Zr, 0.03 to 1.00% Fe, 0.005 to 0.300% Ti, and 0.03 to 2.50% Zn, and including Cu restricted to 1.50% or less, and the balance Al and inevitable impurities, is also preferably used. The reason why each of the elements described above is limited will now be described.
  • Mg which is a fundamental alloy element of the Al—Mg—Si-based or Al—Mg—Si—Cu-based alloy targeted in the present disclosure, contributes, together with Si, to improvement in strength.
  • a Mg content is set at 0.20 to 1.50%.
  • a Mg content of less than 0.20% results in a decrease in the amount of generated G.P. zone contributing to improvement in strength by precipitation hardening in coating baking, and therefore prevents the sufficient effect of improving strength from being obtained.
  • a Mg content of more than 1.50% results in the generation of a coarse Mg—Si-based intermetallic compound, thereby deteriorating press formability, primarily bending workability.
  • a Mg content set at 0.30 to 0.90% is preferred for particularly allowing the bending workability of a final sheet to be more favorable.
  • Si which is also a fundamental alloy element of the Al—Mg—Si-based or Al—Mg—Si—Cu-based alloy targeted in the present disclosure, contributes, together with Mg, to improvement in strength.
  • Si is generated as a crystallized product of a metal Si particle in casting.
  • a Si content is set at 0.30 to 2.00%.
  • a Si content of less than 0.30% prevents the above-described effect from being sufficiently obtained.
  • a Si content of more than 2.00% results in the generation of coarse Si particles and a coarse Mg—Si-based intermetallic compound, thereby causing the deterioration of press formability, particularly bending workability.
  • a Si content set at 0.50 to 1.30% is preferred for obtaining a more favorable balance between press formability and bending workability.
  • Mn and Cr contribute to improvement in strength and to the refinement and stabilization of a crystal grain structure.
  • the contents of these additional elements are strictly restricted from the viewpoint of controlling the crystal particle diameters of a final sheet.
  • a Mn content is set at 0.005 to 0.080%
  • a Cr content is set at 0.005 to 0.080% in order to obtain the crystal particle diameters defined in present disclosure.
  • Mass production stability is poor when both Mn and Cr are less than 0.005%, while the crystal particle diameters become fine, and it is difficult to obtain the crystal particle diameters defined in the present disclosure when both Mn and Cr are more than 0.080%.
  • one or two of Mn and Cr are included.
  • Mn and Cr further satisfy 0.005 ⁇ Mn+Cr ⁇ 0.080%. It is necessary to also restrict the total of the Mn and Cr amounts in order to obtain the crystal particle diameters defined in the present disclosure.
  • a crystal particle diameter is excessively increased when Mn+Cr is less than 0.005%, while a crystal particle diameter is excessively decreased when Mn+Cr is more than 0.080%. It is preferable that Mn+Cr satisfies 0.010% ⁇ Mn+Cr ⁇ 0.050%.
  • a decrease in the contents of Mn and Cr also leads to improvement in hem bendability and formability because Mn and Cr allow an intermetallic compound resulting in the deterioration of hem bendability and formability to be formed in a material.
  • Zr exhibits the effect of the improvement in strength and the refinement and stabilization of the crystal grain structure, described above.
  • a Zr content of less than 0.01% prevents the above-described effect from being sufficiently obtained.
  • a Zr content of more than 0.40% results not only in the saturation of the above-described effect but also in the generation of a large number of intermetallic compounds, thereby causing the possibility of deteriorating formability, particularly hem bendability.
  • the content of Zr is preferably set at 0.01 to 0.40%.
  • the content of Zr is more preferably set at 0.01 to 0.30%.
  • Fe is also an element effective for improvement in strength and for crystal grain refinement.
  • An Fe content of less than 0.03% prevents the above-described effect from being sufficiently obtained.
  • an Fe content of more than 1.00% results in the generation of a large number of intermetallic compounds, thereby deteriorating press formability and bending workability, and in an extreme decrease in crystal particle diameter after solution treatment, thereby precluding the obtainment of the crystal particle diameters defined in the present disclosure.
  • the Fe content is preferably set at 0.03 to 1.00%.
  • An Fe content set at 0.05 to 0.50% is more preferred for particularly minimizing the deterioration of the bending workability and facilitating the obtainment of the crystal particle diameters defined in the present disclosure.
  • Zn is an element that contributes to improvement in strength through improvement in aging property and that is effective for improving surface treatability.
  • a Zn content of less than 0.03% prevents the above-described effect from being sufficiently obtained.
  • a Zn content of more than 2.50% results in the deterioration of formability. Accordingly, the Zn content is preferably set at 0.03 to 2.50%.
  • the Zn content is more preferably set at 0.03 to 1.00%.
  • Ti exhibits the effect of the refinement of an ingot structure.
  • a Ti content is preferably set at 0.005 to 0.300%.
  • a Ti content of less than 0.005% prevents the above-described effect from being sufficiently obtained.
  • a Ti content of more than 0.300% results not only in the saturation of the effect of the addition of Ti but also in the possibility of generating a coarse crystallized product.
  • the Ti content is more preferably set at 0.005 to 0.200%.
  • the addition of 500 ppm or less of B, simultaneous with the addition of Ti results in the still more noticeable effect of the refinement and stabilization of the ingot structure.
  • Cu is an element that may be added for improving strength and formability.
  • a Cu content of more than 1.50% results in the deterioration of corrosion resistance (intergranular corrosion resistance and filiform corrosion resistance).
  • the Cu content is preferably restricted to 1.50% or less.
  • the Cu content is preferably restricted to 1.00% or less when it is intended to attempt further improvement of corrosion resistance.
  • the Cu content is preferably restricted to 0.05% or less when corrosion resistance is particularly regarded as important.
  • B, Ca, Na, and the like of which the amount of each is less than 0.05% and the total is less than 0.15% may be included as inevitable impurities because of having no influence on the features of the aluminum alloy sheet according to the present disclosure.
  • the aluminum alloy sheet according to the present disclosure it is also very important to control the crystal particle diameters and crystal orientation of the aluminum alloy sheet which is a final sheet.
  • the ridging resistance and hem bendability of the final sheet are reliably and stably improved by controlling the crystal particle diameters and crystal orientation of the alloy sheet while adjusting the constituent composition of the alloy.
  • Particle diameters d 1 and d 2 and a cube orientation area rate C intended to define the aluminum alloy sheet according to the present disclosure will be described in detail below while referring to FIG. 1 illustrating positions at which the particle diameters d 1 and d 2 and the cube orientation area rate C are measured.
  • a band-shaped structure particularly having a strong influence on the generation of a ridging mark is present in a region in the vicinity of the middle in the sheet thickness direction of the aluminum alloy sheet.
  • recrystallization that a crystal particle diameter in the region is increased to an appropriate size causes the decomposition of the band-shaped structure to be promoted, thereby preventing the generation of a ridging mark.
  • the region in the vicinity of the middle in the sheet thickness direction refers to a region in a range of ⁇ (t/8) from a center in the thickness direction assuming that the sheet thickness is t, and the position of the middle (t/2) of the sheet thickness is regarded as the center (hereinafter, the region may be referred to as “region in vicinity of middle”).
  • the setting of the crystal particle diameter d 1 in an L-LT plane in the region in the vicinity of the middle at 30 ⁇ m or more is required for decomposing a band-shaped structure formed in production steps.
  • a crystal particle diameter d 1 of less than 30 ⁇ m prevents a band-shaped structure causing the generation of a ridging mark from being sufficiently decomposed and results in the generation of a ridging mark.
  • the crystal particle diameter d 1 is preferably set at 45 ⁇ m or more, and still more preferably at 60 ⁇ m or more.
  • a crystal particle diameter d 1 of more than 80 ⁇ m results in the great deterioration of elongation and formability, and therefore, the crystal particle diameter d 1 is set at 80 ⁇ m or less, and preferably at 70 ⁇ m or less.
  • the crystal particle diameter d 2 in an L-ST plane in the entire sheet thickness is set at 60 ⁇ m or less.
  • the crystal particle diameter d 2 is preferably set at 50 ⁇ m or less.
  • the lower limit value thereof is preferably set at 10 ⁇ m.
  • the control of a crystal orientation is required simultaneously with the control of the crystal particle diameters of the aluminum alloy sheet described above.
  • the control of the crystal orientation of a sheet surface layer particularly having a strong influence on hem bendability is important for improving the hem bendability.
  • the cube orientation area rate C of the crystal orientation in the sheet surface is set at 10% or more.
  • the cube orientation area rate C is more preferably set at 15% or more. It may be considered that the setting of the upper limit thereof at 60% is appropriate because molding may become difficult as a result of an increase in that anisotropy of a material.
  • a specific method for measuring crystal particle diameters and a crystal orientation will be described.
  • the thickness is decreased to an optional L-LT plane in the range of the region in the vicinity of the middle by caustic etching, and mechanical polishing, buffing-polishing, and electrolytic polishing are then performed to form a measurement plane.
  • the mechanical polishing, buffing-polishing, and electrolytic polishing of an optional L-ST surface of the aluminum alloy sheet are performed to form a measurement plane.
  • the mechanical polishing, buffing-polishing, and electrolytic polishing of the aluminum alloy sheet surface are performed to form a measurement plane.
  • the orientation data of a texture is acquired by measuring each of the above-described measurement planes by a backscattered electron diffraction measurement apparatus (SEM-EBSD) attached to a scanning electron microscope. Then, the crystal particle diameters d 1 and d 2 are obtained from the obtained orientation data by using EBSD analysis software (“OIM Analysis” manufactured by TSL). A circle equivalent diameter calculated by regarding a crystalline boundary line having a misorientation of 5° or more as a crystal grain boundary is regarded as a crystal particle diameter. The crystal orientation area rate C is measured from the orientation data obtained in a similar manner by using the EBSD analysis software.
  • the cube orientation area rate C is calculated by regarding a crystal orientation of 15° or less from (001) ⁇ 100> orientation as a cube orientation. It is preferable that a measurement region on each measurement plane is set at an area of 1000 ⁇ m ⁇ 1000 ⁇ m or more in the case of the L-LT plane or at an area of 1000 ⁇ m ⁇ 1000 ⁇ m or more (or the total sheet thickness) in the case of the L-ST plane, and a measurement step spacing is set at around 1/10 of the crystal particle diameter. It is preferable that each of d 1 , d 2 , and C is determined based on the arithmetic mean value of values obtained by measuring three or more spots.
  • surface roughening and the like are prevented by controlling the crystal particle diameter d 2 in the L-ST plane of the entire sheet thickness while increasing the crystal particle diameter d 1 to an appropriate size in the L-LT plane in the region in the vicinity of the middle in recrystallization in solution treatment to decompose the band-shaped structure in order to improve ridging resistance, and hem bendability is improved by further controlling the cube orientation area rate C of the crystal orientation in the sheet surface, as described above.
  • the aluminum alloy sheet excellent in surface quality such as ridging resistance or surface roughening resistance and in hem bendability can be obtained.
  • a sheet thickness in which a ridging mark can be prevented by controlling crystal particle diameters as in the case of the present disclosure is not particularly restricted but can be applied to a final rolled sheet having a predetermined sheet thickness required by a product. This is because a band-shaped structure having a strong influence on the generation of a ridging mark is formed in a region in the vicinity of a middle (a region in a range of ⁇ (t/8) from the center (t/2) of a sheet thickness, regarded as a center, along a thickness direction) after hot rolling, and the rate of the region in the vicinity of the middle to the total sheet thickness t is not changed even when rolling proceeds, and the sheet thickness is decreased.
  • a sheet thickness preferably commonly used for the present disclosure is 0.5 to 5.0 mm.
  • a method for producing an aluminum alloy sheet according to the present disclosure will now be described. With regard to the material structure of a final sheet, it is necessary to perform hot rolling, cold rolling, and solution treatment in a process of producing the sheet under a particular condition in order to control crystal particle diameters and a crystal orientation, in the present disclosure.
  • the crystal particle diameters d 1 and d 2 and cube orientation area rate C defined in the present disclosure it is necessary to allow a recrystallization particle diameter in the solution treatment to be larger than a recrystallization particle diameter generated in a conventional method.
  • the constituent composition of the aluminum alloy it is effective to allow the amounts of Mn and Cr which are elements that suppress crystal grain growth to be smaller than usual.
  • the setting of the amount of Mn+Cr in the range defined in the present disclosure results in a moderate increase in crystal particle diameter in the solution treatment and enables a particle diameter d 1 of 30 ⁇ m to 80 ⁇ m to be obtained in a region in the vicinity of the middle of a sheet thickness.
  • the cold rolling can be performed until achieving a final sheet thickness without performing intermediate annealing.
  • a rolling texture can be sufficiently grown to obtain the cube orientation area rate C defined in the present disclosure because the intermediate annealing is not performed. It is necessary to appropriately control a cold rolling reduction in order to obtain the predetermined crystal particle diameters and cube orientation density, and a feature such as ridging resistance by the end temperature of the hot rolling.
  • the above-described method for producing an aluminum alloy sheet according to the present disclosure has technological significance in the restriction of the constituent composition of the aluminum alloy, the control of the hot-rolling temperature in the hot rolling, the omission of the intermediate annealing, and the control of the cold rolling reduction. Accordingly, the method can be carried out in steps of which the number is equal to or less than the number of steps currently commonly used in a method for producing an automobile body sheet material, that is, steps in order of casting, homogenization treatment, hot rolling, cold rolling, intermediate annealing, cold rolling, and solution treatment. This is also a favorable feature from the viewpoint of a reduction in the cost of an automobile body sheet material.
  • a typical and preferable method for producing an aluminum alloy sheet having the above d 1 , d 2 , and C defined in the present disclosure will be described below.
  • a molten aluminum alloy is cast, optionally subjected to homogenization treatment, and then subjected to hot rolling, cold rolling, and solution treatment in the order mentioned above.
  • the aluminum alloy having the constituent composition described above is melted according to a usual method, and cast by a usual casting method such as a continuous casting method (CC casting method) or a semi-continuous casting method (DC casting method), which is selected as appropriate.
  • a usual casting method such as a continuous casting method (CC casting method) or a semi-continuous casting method (DC casting method), which is selected as appropriate.
  • Homogenization treatment of an ingot obtained in the casting step may be performed as needed.
  • heat treatment is preferably performed at a temperature of 480 to 590° C. for 0.5 to 24 hours.
  • Hot rolling of the ingot subjected to the homogenization treatment or the cast ingot in the case of performing no homogenization treatment is performed. Any of the following treatment methods can be applied as needed in a process from the homogenization treatment step or the casting step to the start of the hot rolling.
  • the ingot is cooled to ordinary temperature or a temperature around ordinary temperature in a cooling process after the homogenization treatment, then heated again to a temperature at which the hot rolling is started, and retained (preheated) for 24 h or less as needed, and the hot rolling is started at the temperature.
  • the ingot is cooled to the temperature at which the hot rolling is started in the cooling process after the homogenization treatment, and retained (preheated) for 24 h or less as needed, and the hot rolling is started at the temperature.
  • the lower limit of retention time is not particularly limited, and the hot rolling may be started immediately after reaching the predetermined temperature.
  • a higher cooling rate after the homogenization treatment is preferred because of facilitating improvement in mechanical characteristics such as ASYA, ASEL, and BHYS required for an automobile body sheet material.
  • the ingot is cooled to ordinary temperature or a temperature around ordinary temperature after the casting step, then heated again to the temperature at which the hot rolling is started, and retained for 24 h or less, and the hot rolling is started at the temperature.
  • the lower limit of retention time is not particularly limited, and the hot rolling may be started immediately after reaching the predetermined temperature.
  • a common step of hot-rolling an aluminum alloy is adopted in the fundamental content of the hot rolling. In the present disclosure, however, it is essential to restrict hot-rolling conditions in order to suppress excessive coarsening of crystal grains in the hot-rolling step, as described above.
  • a hot-rolling start temperature and a hot-rolling end temperature are defined for hot-rolling temperatures. In the present disclosure, the hot-rolling start temperature is set at 300 to 450° C., and the hot-rolling end temperature is set at 200 to 450° C.
  • the hot-rolling conditions are classified roughly into the following two conditions A and B.
  • the hot-rolling start temperature is set at 300 to 450° C.
  • the hot-rolling end temperature is set at 200 to 350° C.
  • a hot-rolling start temperature of less than 300° C. precludes rolling or results in the remarkable deterioration of productivity.
  • a hot-rolling start temperature of more than 450° C. is prone to result in recrystallization in the hot rolling, causes the formation of an excessively coarse recrystallized structure in the aluminum alloy including small amounts of Mn and Cr, used in the present disclosure, and may result in the generation of a strong ridging mark in a product sheet.
  • a hot-rolling end temperature of less than 200° C.
  • a hot-rolling end temperature of more than 350° C. may result in recrystallization, thereby forming a coarse recrystallized grain structure.
  • the hot-rolling start temperature is set at 350 to 450° C.
  • the hot-rolling end temperature is set at more than 350° C. and 450° C. or less.
  • the hot-rolling end temperature of the condition B is in a temperature range in which the coarse recrystallized grain structure may be formed under the condition A, but is a condition which has been found to enable a band-shaped structure causing a ridging mark to be decomposed by appropriately controlling a subsequent cold rolling reduction even when a temperature exceeds 350° C. which is the condition of the hot-rolling end temperature described in the condition A.
  • the condition B has a feature that the hot-rolling start temperature is set at 350 to 450° C., and a lower limit value is set at a higher temperature than the lower limit value of the condition A.
  • the feature enables a cooling temperature range from the homogenization treatment or the casting to the hot rolling to be narrowed, thereby saving energy.
  • the upper limit value of the hot-rolling start temperature is set at 450° C. which is the same as that of the condition A. The reason thereof is also the same as that of the condition A and is because recrystallization is prone to occur in the hot rolling at more than 450° C.
  • the hot-rolling end temperature is set at more than 350° C. and 450° C. or less. This range is wider than the range defined in the condition A.
  • the hot-rolling end temperature In combination with the setting of the hot-rolling start temperature at 350° C. or more, it is easy to adjust the hot-rolling end temperature to a target temperature.
  • the reason why the hot-rolling end temperature is set at 450° C. or less is because a hot-rolling end temperature of more than 450° C. causes recrystallized grains in the hot rolling to be excessively coarsened, thereby preventing a band-shaped structure from being sufficiently decomposed in subsequent steps.
  • the rolling reduction in the cold-rolling step is set at 50.0% or more, and preferably at 66.0% or more.
  • a rolling reduction of less than 50.0% prevents a rolling texture formed in the rolling from being sufficiently grown and results in an insufficient cube orientation area rate C formed in solution treatment.
  • the upper limit value of the rolling reduction which depends on a facility used, is set at 90% from the viewpoint of productivity.
  • a ridging mark can be more reliably prevented in a material having a hot-rolling end temperature of 300° C. to 350° C. in the condition A by setting a cold rolling reduction at 76.5% or more.
  • the reason thereof is the same as that of the condition B of the hot rolling described below.
  • the hot-rolling end temperature is high, and strain energy accumulated at the time of the completion of the hot rolling by recovering is less than that of the hot-rolling condition A.
  • a technique in which a cold rolling reduction is higher than that in the condition A is adopted in order to grow a rolling texture contributing to the formation of a cube orientation to a level equivalent to that of the condition A.
  • the higher cold rolling reduction promotes recrystallization around second phase particles existing in a material structure (particle-stimulated nucleation), thereby resulting in the more effective decomposition of a band-shaped structure.
  • the hot-rolling end temperature in the condition B is higher than that in the condition A, and coarse recrystallized grains are easily formed in the hot-rolling.
  • the rolling reduction in the cold-rolling step is preferably set at 76.5% or more, and more preferably at 80.0% or more.
  • a rolling reduction of 76.5% or more results in the sufficient growth of a rolling texture formed in the rolling, in a sufficient cube orientation area rate C formed in solution treatment, and in sufficient ridging resistance.
  • the preferred upper limit value of the rolling reduction in the condition B which depends on a facility used, is set at 90% from the viewpoint of productivity.
  • a material achieving temperature in the solution treatment is 480 to 590° C., and preferably 500 to 590° C.
  • a material achieving temperature of less than 480° C. may prevent recrystallization and may result in insufficient solution, thereby preventing strength meeting an objective from being obtained.
  • a material achieving temperatures of more than 590° C. may cause the sheet to be melted, thereby precluding stable production.
  • Retention time in the solution treatment is not particularly limited, and is preferably 0 second to 5 minutes, and more preferably 0 second to 1 minute from the viewpoint of productivity. In such a case, “0 second” means that cooling is performed immediately after reaching the material achieving temperature.
  • a cooling rate in a temperature range from a retention temperature to 150° C. is preferably set at 100° C./min or more, whereby sufficient formability and bake hardenability can be obtained.
  • the cooling rate is more preferably set at 300° C./min or more.
  • the upper limit value of the cooling rate which depends on a cooling apparatus and a cooling method, is set at 10000° C./min from the viewpoint of productivity and operability in the present disclosure.
  • the conditions of the preliminary aging treatment are preferably a temperature of 50 to 150° C. and a retention time of 1 to 100 hours.
  • the preliminary aging treatment has no essential influence on crystal particle diameters and a crystal orientation. Accordingly, it is not necessary to perform the preliminary aging treatment in the present disclosure.
  • the constitution of the disclosure achieving improvement in ridging resistance and hem bendability, which is a principal challenge of the present disclosure, includes the crystal particle diameters d 1 and d 2 and cube orientation area rate C described above.
  • the above-described constitution of the disclosure is controlled by defining the constituent composition of the alloy and the conditions of the production steps in the specific ranges in the present Examples.
  • a surface roughening property is also suppressed by d 1 and d 2 , and therefore, the surface roughening property was also evaluated in the present Examples.
  • strength as a mechanical characteristic was also further evaluated in the present Examples. This is because strength is a feature inherently required by an automotive body sheet and the like although examples of the challenges of the present disclosure do not include strength.
  • An aluminum alloy having a constituent composition denoted by each of alloy reference characters A to S in Table 1 was melted according to a usual method, and cast into a slab by a DC casting method. Then, each obtained slab was subjected to homogenization treatment, and spontaneously cooled to a temperature around room temperature. Hot rolling, cold rolling, and solution treatment of the slab subjected to the homogenization treatment were performed to form a sheet material sample. In addition, a sheet material sample was also produced by performing homogenization treatment, then performing cooling to a hot-rolling start temperature, and performing hot rolling, cold rolling, and solution treatment on an as-is basis. Such production steps will be described below while setting forth treatment conditions in Table 2.
  • Hot- Sheet Solution Preheating rolling thick- treatment condition start Hot-rolling ness Cold Presence or Achieving Reten- Production Alloy Cooling after before hot temper- end after hot rolling absence of temper- tion process reference homogenization rolling ature temperature rolling reduction intermediate ature time No.
  • Each cast slab was subjected to homogenization treatment under conditions of 530° C. and 8 hours, and then to cooling after the homogenization treatment, preheating before hot rolling, and the hot rolling in turn under various conditions set forth in Table 2.
  • the cooling after the homogenization treatment is expressed as “spontaneous cooling to room temperature”
  • cooling to room temperature was temporarily performed after the homogenization treatment
  • reheating was performed from the room temperature to a hot-rolling start temperature
  • preheating in which retainment was performed at the temperature for 2 hours was performed.
  • cooling after the homogenization treatment is expressed as “cooling to hot start temperature”
  • cooling to the hot-rolling start temperature was performed after the homogenization treatment, and preheating in which retainment was performed at the temperature for 10 minutes was performed.
  • hot rolling was performed at a start temperature and an end temperature set forth in Table 2.
  • a sheet thickness after the hot rolling is set forth in Table 2.
  • cold rolling of the hot-rolled sheet was performed at a cold rolling reduction set forth in Table 2, to obtain a cold-rolled sheet having a final sheet thickness of 1.0 mm.
  • a hot-rolled sheet of 4 mm was subjected to cold rolling to 2.0 mm, then subjected to intermediate annealing at 500° C. for a retention time of 10 seconds by using a continuous annealing furnace, and then subjected to cold rolling again to obtain a cold-rolled sheet having a final sheet thickness of 1.0 mm.
  • Solution treatment was performed under the conditions set forth in Table 2. A continuous annealing furnace was used for the solution treatment. Then, cooling was performed to a temperature around room temperature at a cooling rate of 600 to 1000° C./min, immediately followed by performing preliminary aging treatment at 80° C. for 5 hours.
  • the preliminary aging treatment has an influence on mechanical properties but has no influence on crystal particle diameters and a crystal orientation.
  • a sample was collected from a region within 50 mm from the center of the sheet material in a width direction, and the crystal particle diameters and cube orientation area rate C of the sample were measured.
  • the particle diameter d 1 the particle diameter d 1 of an L-LT plane at a position having a thickness of ⁇ 0.05 mm from the center (t/2) of the sheet thickness was measured.
  • the particle diameter d 2 of the L-ST plane of the collected sample was measured.
  • the cube orientation area rate C of an L-LT plane obtained by polishing a surface of the collected sample to a thickness of about 60 to 100 ⁇ m was measured.
  • the ridging resistance of each sheet material sample was evaluated using a conventionally performed simple evaluation technique. Specifically, JIS No. 5 test pieces were collected along a direction at 90° with respect to a rolling direction. The test pieces were subjected to 5% and 15% stretches, respectively. Assuming that a stripe pattern (stripe-shaped recessed and projected pattern) generated on a surface along the rolling direction was regarded as a ridging mark, the presence or absence of generation of the stripe pattern was determined by visual observation. The 5% stretch is equivalent to a strain amount on the assumption of usual press molding, while the 15% stretch is equivalent to a strain amount on the assumption of particularly severe molding. “Good” represents no stripe pattern, and “Poor” represents the state of a clear stripe pattern. Similarly, the presence or absence of surface roughening was also determined. “Good” represents no occurrence of surface roughening, and “Poor” represents that surface roughening of which the degree was problematic for surface quality occurred. The results are set forth in Table 3.
  • a hemming test for evaluating the hem bendability of each sheet material sample was conducted.
  • JIS No. 5 test pieces in a direction at 90° with respect to a rolling direction were collected 90 days after a day on which the solution treatment was performed.
  • the hemming test was conducted based on JISH7701.
  • a prestrain was set at 8%
  • a punch tip radius in pre-hemming was set at 0.5 mm
  • the thickness of an intermediate sheet in this hemming was set at 1.0 mm.
  • the surface of the outer periphery was observed, 0 to 2 points described in JISH7701 were evaluated as acceptable, “Good”, and 3 to 4 points were evaluated as unacceptable, “Poor”.
  • a JIS No. 5 test piece was cut from each sheet material sample produced as described above in a direction parallel to the rolling direction 7 days after the day on which the solution treatment was performed, and the 0.2% yield strength (ASYS) and elongation (ASEL) of the test piece were evaluated by a tensile test.
  • a 0.2% yield strength value (BHYS) obtained by stretching the test piece by 2% and then performing heat treatment of the test piece in an oil bath at 170° C. for 20 minutes as heat treatment corresponding to coating baking treatment was also measured.
  • the constituent composition of the alloy is in the range defined in this disclosure, and crystal particle diameters d 1 and d 2 and a cube orientation area rate C after the solution treatment are in the ranges defined in the present disclosure.
  • no ridging mark was generated, and no surface roughening occurred in the 5% and 15% stretches, and it was confirmed that there were no problems in both stretches.
  • All of ASYA, ASEL, and BHYS as the mechanical properties required for an automobile body sheet material sufficiently satisfied required performances.
  • Each of production process Nos. 26 to 31 in Table 3 is an example in which the constituent composition of the alloy is outside the range defined in the present disclosure.
  • a crystal particle diameter d 1 after the solution treatment was smaller than the range defined in the present disclosure because the amount of Mn+Cr was more than 0.080%.
  • a ridging mark was generated in the 15% stretch simulating severe press molding although no ridging mark was generated in the 5% stretch because temperatures at which the hot rolling was started and ended are in the ranges defined in the present disclosure.
  • the amount of Mn+Cr was less than 0.005%, and therefore, both of crystal particle diameters d 1 and d 2 after the solution treatment were larger than the ranges defined in the present disclosure, whereby surface roughening occurred.
  • Each of production process Nos. 32 to 35 in Table 3 is an alloy to which either of Si and Mg which were essential additional elements was added in an amount that was less or more than the addition range defined in the present disclosure.
  • Operation conditions in production conditions were allowed to be the conditions of the present disclosure, whereby each of these sheet material samples included crystal particle diameters d 1 and d 2 and a cube orientation area rate C.
  • ridging mark resistance, hem bendability, and surface roughening resistance were acceptable.
  • at least either elongation (ASEL) or 0.2% yield strength (ASYA, BHYS) did not satisfy the criterion of a mechanical property for an automobile body sheet material.
  • Si and Mg are essential additional elements, it is found that the amounts of added Si and Mg should be allowed to be appropriate amounts also set in consideration of mechanical properties.
  • the subject matter of the present disclosure is improvement in ridging resistance and hem bendability by allowing production conditions to be appropriate while regulating the amounts of added Mn and Cr, and in this respect, there is no problem.
  • Each example of production process Nos. 36 to 38 in Table 3 is an example in which the contents of essential elements (Si, Mg, Mn, and Cr) are within the appropriate ranges, and the production conditions thereof satisfy the ranges of the present disclosure, but at least any of Cu, Fe, Zn, Zr, and Ti which are selective elements is excessively added. Since the contents of Si, Mg, Mn, and Cr were within appropriate ranges, crystal particle diameters d 1 and d 2 and a cube orientation area rate C were satisfied, and ridging mark resistance, hem bendability, and surface roughening resistance were acceptable.
  • essential elements Si, Mg, Mn, and Cr
  • the aluminum alloy sheet according to the present disclosure can allow the generation of a ridging mark to be reliably suppressed even under a severe molding condition, and has excellent hem bendability in view of formability.
  • the method for producing an aluminum alloy sheet according to the present disclosure enables reliable and stable production at low cost on a mass production scale.
  • the present disclosure can be utilized in molded components such as the panels and chassis of electronic and electrical instruments and the like, as well as in automotive applications such as automotive body sheets applied to the body panels of automobiles.
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