US20200299818A1 - Method and system for forming aluminum alloy blank - Google Patents

Method and system for forming aluminum alloy blank Download PDF

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Publication number
US20200299818A1
US20200299818A1 US16/652,908 US201816652908A US2020299818A1 US 20200299818 A1 US20200299818 A1 US 20200299818A1 US 201816652908 A US201816652908 A US 201816652908A US 2020299818 A1 US2020299818 A1 US 2020299818A1
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Prior art keywords
blank
temperature
alloy
ageing
forming
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Abandoned
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US16/652,908
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English (en)
Inventor
Christian Koroschetz
Gerald Anyasodor
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Automation Press and Tooling AP&T AB
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Automation Press and Tooling AP&T AB
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Application filed by Automation Press and Tooling AP&T AB filed Critical Automation Press and Tooling AP&T AB
Publication of US20200299818A1 publication Critical patent/US20200299818A1/en
Assigned to AUTOMATION, PRESS AND TOOLING, AP & T AB reassignment AUTOMATION, PRESS AND TOOLING, AP & T AB ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: Anyasodor, Gerald, KOROSCHETZ, CHRISTIAN
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    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/20—Deep-drawing
    • B21D22/26—Deep-drawing for making peculiarly, e.g. irregularly, shaped articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D37/00—Tools as parts of machines covered by this subclass
    • B21D37/16—Heating or cooling

Definitions

  • the present disclosure relates to a heat treatment method of blank sheets of aluminum alloys, and especially to a method suitable for blank sheets of any aluminum alloy grade, composition or temper.
  • the hot forming of blank sheets is important, in particular hot forming of blank sheets of high strength aluminum alloys.
  • a method of forming a 6xxx or 7xxx series Al alloy blank into a component comprises the steps of heating the blank to a solutionization (SHT) temperature, T SHT , for the alloy of the blank at a heating station and keeping the blank at said SHT temperature until SHT is complete, cooling the blank at a cooling station to an intermediate temperature, T ITM , at which the kinetic movement for the alloy in the blank stops and at a cooling rate that is high enough such that re-crystallization in the alloy of the blank does not occur, forming the blank in a forming tool, quenching the formed blank to room temperature, T E , and artificially ageing the formed and quenched blank in an ageing station.
  • SHT solutionization
  • a method is provided that, with high accuracy of the formed components and low amount of springbacks, is suitable for any 6xxx or 7xxx series aluminum alloy grade sheet blank.
  • the time in which the blank is kept at or above the solution heat treatment (SHT) temperature may be chosen to be sufficient to ensure maximum concentration of hardening elements, such as copper, zinc, magnesium, manganese, silicon etc. in the solid solution.
  • the concentration and rate of dissolution of these elements in the solid solution may increase with increasing temperature.
  • the SHT composition of the solid solution may be preserved at the intermediate temperature. If the blank were to be cooled in a too slow rate, the alloying elements may diffuse through the solid solution and concentrate at the grain boundaries, in large voids, undissolved particles or other undesired locations. To achieve improved strength properties of the formed part, it may be desirable to avoid such recrystallization and decrease the diffusion process and maintain the alloying elements in the solid solution by providing a rapid cooling.
  • the cooling rate to achieve this may be selected depending on the aluminum alloy grade and composition of the blank. Further, a quenching rate may be selected depending on the aluminum alloy grade and composition of the blank.
  • the intermediate temperature may be a temperature in an intermediate temperature range being above room temperature and below the SHT temperature.
  • the time required for a given amount of precipitation may increase due to low solute diffusion coefficients.
  • the rate of precipitate formation is low due to the inability of atoms to diffuse, increased nucleation or precipitation and growth at the temperature range.
  • an intermediate temperature for a 7xxx series Al alloy blank may be chosen between 400-420° C. Further, for a AA6082 Al alloy blank, the intermediate temperature may be chosen as 300-350° C. At such temperatures, the kinetic movement in the alloy material of the blank may have stopped.
  • the cooling to the intermediate temperature may be performed at a cooling station being separate from the forming tool.
  • the cooling may thereby be provided fast and with homogeneous temperature in the blank.
  • a cooling rate of at least 30 K/s may be chosen.
  • a cooling rate of at least 30 K/s, at least 50 K/s, or preferably about 100 K/s may be chosen.
  • the intermediate temperature may be selected depending on the Al alloy of the blank, and being above 100° C.
  • the intermediate temperature should be selected as a temperature wherein the kinetic movement of the alloy material of the blank stops.
  • the optimal intermediate temperature may differ.
  • the intermediate temperature may be above 100° C.
  • the intermediate temperature may be selected being the highest possible temperature at which the kinetic movement in the present alloy material stops.
  • the forming tool may be preheated to the intermediate temperature.
  • the blank may thereby be formed at the intermediate temperature.
  • the temperature of the blank may thereby be controlled during the forming, which may improve the accuracy in the properties of the final formed component.
  • the blank may be kept at the intermediate temperature during the forming step in the forming tool.
  • the temperature of the tool may be controlled in order to keep the temperature of both the tool and the blank stable at the intermediate temperature during the forming.
  • the temperature of the forming tool may be controlled in order to quench the formed blank to room temperature.
  • a temperature control function may be provided for the forming tool in order to control the temperature of the forming tool to the intermediate temperature throughout the forming step.
  • the forming and the quenching may be performed in separate forming tools.
  • a first forming tool may form the blank at the intermediate temperature, and a second forming tool may quench the blank to room temperature.
  • the first forming tool may be preheated to the intermediate temperature, thereby keeping the blank at the intermediate temperature during the forming.
  • the blank may then be transferred to the second forming tool, quenching the blank to room temperature.
  • the second forming tool may be a cold forming tool.
  • the first forming tool may not be preheated, thereby cooling the blank during the forming.
  • the blank may then in the second forming tool be quenched in a controlled manner to room temperature in the second forming tool.
  • a 6xxx or 7xxx series Al alloy blank forming system comprising a heating station configured to heat a blank to its SHT temperature, T SHT , a cooling station configured to cool the blank to an intermediate temperature T ITM , at which the kinetic movement for the alloy in the blank has stopped and at a cooling rate that is high enough such that re-crystallization in the alloy of the blank does not occur, a forming tool configured to form and quench the blank, and an ageing station configured to provide an artificial ageing process to the formed and quenched blank.
  • a heating station being configured to heat a blank to its SHT temperature it may be meant a heating station comprising means capable of heating a blank inserted into the heating station to its SHT temperature.
  • a cooling station configured to cool the blank to an intermediate temperature at which kinetic movement for the alloy in the blank has stopped and at a cooling rate that is high enough such that re-crystallization in the alloy of the blank does not occur it may be meant a cooling station comprising means capable of cooling a blank in the specified way.
  • a forming tool configured to form and quench a blank it may be meant a forming tool comprising means capable of forming and quenching the blank.
  • an ageing station configured to provide an artificial ageing process to the formed and quenched blank it may be meant an ageing station comprising means capable of such artificial ageing process.
  • the heating station, the cooling station, the forming tool and/or the ageing station may further comprise means capable of providing additional functions as discussed above for the method.
  • FIG. 1 shows a flow chart of a method according to an embodiment of the invention
  • FIG. 2 shows a block scheme of a system according to an embodiment of the invention
  • FIG. 3 shows a diagram view of a process of the method according to an embodiment of the invention
  • FIG. 4 shows a flow chart of a method according to an embodiment of the invention
  • FIG. 5 shows a block scheme of a system according to an embodiment of the invention.
  • FIG. 6 shows a diagram view of a process of the method according to an embodiment of the invention.
  • a method 100 comprises a first step of heating 102 a 6xxx or 7xxx series Al alloy blank 2 to the solutionization (SHT) temperature for the specific alloy of the blank 2 .
  • a blank forming system 1 is provided, wherein the heating 102 is performed in a heating station 10 .
  • the temperature of the blank 2 is kept at the SHT temperature or above until the solutionization of the alloy of the blank 2 is complete.
  • the blank 2 is cooled 104 to an intermediate temperature.
  • the cooling 104 is performed at a cooling station 20 .
  • the intermediate temperature is selected for the alloy of the blank 2 at which temperature the kinetic movement for the alloy stops.
  • the cooling 104 is performed at a cooling rate high enough such that re-crystallization in the alloy of the blank 2 does not occur.
  • the blank 2 is formed 106 in a forming tool 32 at a press station 30 in the blank forming system 1 .
  • the press station 30 may be a press suitable for aluminum alloy blank sheet forming, such as a hydraulic press, a servo press (servo hydraulic or servo mechanical).
  • the formed blank 2 ′, or formed component 2 ′ is quenched 108 in the forming tool 32 to room temperature.
  • the formed blank 2 ′ is artificially aged 110 at an ageing station 40 .
  • the ageing process is provided to control and limit the recrystallization in the alloy material of the blank 2 .
  • FIG. 3 illustrates the blank forming method 100 according to an embodiment of the present invention.
  • the blank 2 is heated from room temperature T E to the SHT temperature T SHT , and kept at the T SHT for a necessary time t 1 ⁇ t 2 as discussed above.
  • the blank 2 is rapidly cooled to the intermediate temperature T ITM at the necessary cooling rate as discussed above.
  • the blank 2 is then formed during t 2 ⁇ t 3 in the forming tool 32 .
  • the formed blank 2 ′ is quenched to room temperature T E .
  • the formed component 2 ′ is processed for artificial ageing by being heated to an ageing temperature T A .
  • the component 2 ′ is kept at the ageing temperature T A during a period t 5 ⁇ t 6 until the ageing process is complete.
  • the time t 3 ⁇ t 4 provides a transfer of the formed blank to the ageing station 40 .
  • the blank 2 is transferred between the different stations 10 , 20 , 30 , 40 .
  • the transfer may be performed such that minimal heat loss in the blank 2 is achieved.
  • FIGS. 4 and 5 illustrates a method 200 and system 3 according to an embodiment of the invention.
  • the steps of heating 202 and cooling 204 correspond to the steps 102 and 104 as discussed above.
  • the blank 2 is formed 206 in a preheated first forming tool 32 a at a press station 30 in the blank forming system 3 .
  • the first forming tool 32 a is preheated to the intermediate temperature.
  • the blank 2 is thereby not further cooled when arranged in the first forming tool 32 a .
  • the intermediate temperature may be kept in the first forming tool 32 a and the blank 2 throughout the forming process 106 .
  • the formed blank is moved to a separate cold second forming tool 32 b .
  • the blank is quenched to room temperature.
  • the cold second forming tool 32 b may further form and quench the blank to its final shaped component.
  • FIG. 5 further illustrates an optional arrangement of ageing which can be used for either of the above presented embodiments.
  • a first pre-ageing step is performed at a pre-ageing station 40 a , in which the formed component 2 ′ is heated to the ageing temperature T A , kept at T A until the pre-ageing is complete and then cooled to room temperature T E .
  • the component 2 ′ is again heated to T A , kept at T A for a time period and thereafter cooled to room temperature T E , to provide a paint baking of the component 2 ′.
  • the component can be heated to a different temperature in the paint baking process than the temperature T A in the pre-ageing process.
  • a two-step ageing process is thereby provided comprising pre-ageing and paint baking.
  • the pre-ageing process is integrated in the forming/stamping line, and performed in direct connection to the forming of the component 2 ′.
  • the paint baking process may be performed at a later stage, whichever may be suitable for the production line.
  • the use of the pre-ageing process prevents natural ageing after stamping in the second forming tool. Otherwise, natural ageing may occur after about 30 minutes for 7xxx series Al alloy materials or about one hour for 6xxx series Al alloy materials.
  • the paint baking process cannot take effect on the formed component to achieve peak hardness.
  • the pre-ageing process further enables post processing activities such as transport to another location, storage for a required period before assembly or joining operations. Then, the paint baking operation may be performed at the most suitable time to provide optimal peak hardness in a short cycle time and at a low cost. This may e.g. be after joining the formed component 2 ′ to a desired assembly.
  • FIG. 6 illustrates the process blank forming method 200 according to an embodiment of the present invention.
  • the blank 2 is heated from room temperature T E to the SHT temperature T SHT , and kept at the T SHT for a necessary time t 1 ⁇ t 2 as discussed above.
  • the blank 2 is cooled to the intermediate temperature T ITM at the necessary cooling rate as discussed above.
  • the blank 2 is then formed during t 3 ⁇ t 4 in the preheated first forming tool 32 a .
  • the formed blank 2 ′ is quenched to room temperature T E in the second forming tool 32 b.
  • FIG. 6 further illustrate the process of the embodiment comprising a pre-ageing and a paint baking step as discussed above.
  • the formed blank 2 ′ is processed for artificial ageing by being heated to the ageing temperature T A and kept at the ageing temperature T A during a period t 7 ⁇ t 8 .
  • the blank 2 ′ is in the second ageing station 40 b again heated to the ageing temperature T A and kept at T A between t 11 ⁇ t 12 until the ageing process is complete.
  • the blank 2 ′ formed to a final shaped component is then again cooled to room temperature T E .

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
  • Heat Treatment Of Articles (AREA)
  • Forging (AREA)
US16/652,908 2017-10-04 2018-10-03 Method and system for forming aluminum alloy blank Abandoned US20200299818A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP17194723.7 2017-10-04
EP17194723.7A EP3467138B1 (en) 2017-10-04 2017-10-04 Method for forming aluminum alloy blank
PCT/EP2018/076913 WO2019068767A1 (en) 2017-10-04 2018-10-03 METHOD AND SYSTEM FOR FORMING ALUMINUM ALLOY DRAFT

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US20200299818A1 true US20200299818A1 (en) 2020-09-24

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US16/652,908 Abandoned US20200299818A1 (en) 2017-10-04 2018-10-03 Method and system for forming aluminum alloy blank

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US (1) US20200299818A1 (enrdf_load_stackoverflow)
EP (1) EP3467138B1 (enrdf_load_stackoverflow)
JP (1) JP2020536166A (enrdf_load_stackoverflow)
KR (1) KR20200110737A (enrdf_load_stackoverflow)
CN (1) CN111315910A (enrdf_load_stackoverflow)
CA (1) CA3084330A1 (enrdf_load_stackoverflow)
ES (1) ES2906633T3 (enrdf_load_stackoverflow)
MX (1) MX2020003344A (enrdf_load_stackoverflow)
PL (1) PL3467138T3 (enrdf_load_stackoverflow)
PT (1) PT3467138T (enrdf_load_stackoverflow)
WO (1) WO2019068767A1 (enrdf_load_stackoverflow)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116159944A (zh) * 2022-12-28 2023-05-26 大连理工大学 一种航空铝合金薄壁结构件的成形方法
WO2024091271A1 (en) * 2022-10-28 2024-05-02 Atieva, Inc. Hot-stamping aluminum formation process

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3896188A1 (en) 2020-04-15 2021-10-20 Politechnika Wroclawska A method of manufacturing of energy-absorbing elements made of age-hardenable aluminum alloy sheets that facilitate further joining
CN115318925A (zh) * 2022-08-02 2022-11-11 河南理工大学 一种超硬铝合金7075耐蚀汽车b柱零件冷冲压成形方法

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US20170101705A1 (en) * 2015-10-08 2017-04-13 Novelis Inc. Optimization of aluminum hot working

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US20160053356A1 (en) * 2014-08-20 2016-02-25 Benteler Automobiltechnik Gmbh Method for producing a motor vehicle component from a hardenable aluminum alloy
US20170101705A1 (en) * 2015-10-08 2017-04-13 Novelis Inc. Optimization of aluminum hot working

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2024091271A1 (en) * 2022-10-28 2024-05-02 Atieva, Inc. Hot-stamping aluminum formation process
CN116159944A (zh) * 2022-12-28 2023-05-26 大连理工大学 一种航空铝合金薄壁结构件的成形方法

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Publication number Publication date
CN111315910A (zh) 2020-06-19
JP2020536166A (ja) 2020-12-10
EP3467138B1 (en) 2021-11-24
CA3084330A1 (en) 2019-04-11
MX2020003344A (es) 2020-07-28
KR20200110737A (ko) 2020-09-25
PT3467138T (pt) 2022-02-21
ES2906633T3 (es) 2022-04-19
EP3467138A1 (en) 2019-04-10
PL3467138T3 (pl) 2022-04-04
WO2019068767A1 (en) 2019-04-11

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