WO1994000256A1 - Formage a froid d'alliages d'aluminium a solidification rapide - Google Patents

Formage a froid d'alliages d'aluminium a solidification rapide Download PDF

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Publication number
WO1994000256A1
WO1994000256A1 PCT/US1993/005983 US9305983W WO9400256A1 WO 1994000256 A1 WO1994000256 A1 WO 1994000256A1 US 9305983 W US9305983 W US 9305983W WO 9400256 A1 WO9400256 A1 WO 9400256A1
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WO
WIPO (PCT)
Prior art keywords
sheet
alloy
recited
forming
cold
Prior art date
Application number
PCT/US1993/005983
Other languages
English (en)
Inventor
Anthony Testa
Paul S. Gilman
Original Assignee
Allied-Signal Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Allied-Signal Inc. filed Critical Allied-Signal Inc.
Publication of WO1994000256A1 publication Critical patent/WO1994000256A1/fr

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Classifications

    • 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
    • B21D49/00—Sheathing or stiffening objects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
    • B32B15/012—Layered products comprising a layer of metal all layers being exclusively metallic one layer being formed of an iron alloy or steel, another layer being formed of aluminium or an aluminium alloy

Definitions

  • the present invention relates to dispersion strengthened aluminum base alloys, and more particularly to a method for cold forming of the rapidly solidified aluminum alloy.
  • Description of the Prior Art In recent years the aerospace industry has searched for high temperature aluminum alloys to replace titanium and existing aluminum base alloys in applications requiring operating temperatures approaching 350"C. While high strength at ambient and elevated temperatures is a primary requirement, certain design applications mandate that candidate alloys also exhibit, in combination, ductility, toughness, fatigue and corrosion resistance, as well as lower density than the materials currently being used. In addition to the scientific requirements to be met in developing such alloys, stringent economic requirements must be met in the fabrication of such alloys into useful forms. In many cases, potential savings gained by direct alloy substitution are offset by the complexity and magnitude of forming operations necessary for fabricating desired shapes. It would be particularly advantageous if a high temperature aluminum base alloy could be easily shaped into desired forms with existing equipment, thereby eliminating the additional expenses associated with retooling or re-designing equipment for fabrication.
  • the alloys taught by Lyle et al., Roberts et al. and Hildeman et al. were produced by atomizing liquid metals into finely divided droplets by high velocity gas streams. The droplets were cooled by convective cooling at a rate of approximately 10 4o C/sec.
  • the alloys taught by Adam et al., Ray et al. and Skinner et al. were produced by ejecting and solidifying a liquid metal stream onto a rapidly moving substrate. The produced ribbon is cooled by conductive cooling at rates in the range of 10 5 to 10 7o C/sec.
  • the present invention provides an economical, efficient process for cold forming a dispersion strengthened, non heat treatable, aluminum base alloy wrought product into a useful shape or component.
  • Cold forming is defined as forming a wrought component at a temperature below 0.3 times the homologous melting temperature of alloy, i.e. the melting temperature of the alloy expressed in absolute degrees Kelvin.
  • a wrought product includes sheet, plate, extrusions, tubes and pipes.
  • Typical cold forming operations include the brake forming and stretch forming of sheet, and tube bending. These cold forming operations are such that the necessary equipment and required tooling are standard items in many sheet metal and tube fabricators. Moreover, selection of processing steps capable of being performed on existing equipment greatly improves economy of material usage, labor and time.
  • the present invention provides a process for producing a rolled product comprising the steps of: a. overlaying the outer surface of a first sheet composed of a rapidly solidified aluminum base alloy with a second sheet composed of a metal alloy and having equal or greater strength, and equal or greater thickness; and b. brake forming the first sheet along with the second sheet to the desired bend angle and bend radius on a conventional manual or automated equipment.
  • the invention provides a process for bending a tube composed of a rapidly solidified, dispersion strengthened aluminum alloy comprising the steps of (a) inserting the tube inside a supporting tube composed of a metal alloy and having equal or greater strength and equal or greater thickness, and (b) bending the supporting tube inside a tube assembly using standard tubing equipment and fixtures.
  • the invention provides a process for stretch forming a first sheet composed of a rapidly solidified, dispersion strengthened aluminum alloy comprising the steps of (a) overlaying the outer surface of said first sheet with a second sheet composed of a metal alloy and having strength and thickness equal to or greater than said first sheet. The sheet assembly is then stretch-formed over the desired die to the required shape.
  • the overlay sheets and tubes are not limited to, but can be chosen from various aluminum alloys and steels that have strengths equal to or greater than the rapidly solidified, strength dispersioned alloys and are readily cold formed by the particular cold forming operation selected.
  • the present invention encompasses any cold forming operation that is amenable to overlaying said alloy and co-forming the supported alloy product.
  • the products produced by the process of the invention maintain excellent mechanical properties including high strength and ductility at ambient as well as elevated temperatures.
  • the products produced by the process of the invention are substantially defect free. That is to say, the cold formed products exhibit little or no defects such as cracking in the cold deformed region.
  • Alloys preferred for use in the process of this invention include those rapidly solidified aluminum alloys which consist essentially of the formula Al bal Fe,Si b X c , wherein X is at least one element selected from the group consisting of Mn, V, Cr, Mo, W, Nb, Ta, "a” ranges from 2.0 to 7.5 at%, “b” ranges from 0.5 to 3.0 at%, “c” ranges from 0.05 to 3.5 at% and the balance is aluminum plus incidental impurities, with the proviso that the ratio ⁇ Fe + X ⁇ :Si ranges from about 2.0:1 to 5.0:1.
  • the cold forming of the rapidly solidified aluminum alloys removes the concern of property degradation that is possible during hot deformation.
  • the attractive properties achieved by rapid solidification are essentially not effected by cold forming.
  • the cold forming process eliminates the additional costs associated with hot forming of the alloys, including the cost of constructing special hot working dies, furnace time and the use of high temperature compatible presses, tube bending benches and hot stretch forming equipment. Cold forming equipment and tooling is readily available. Also, the orientation dependence of cold forming the alloys is now eliminated, facilitating the applicability of cold forming to components having complex shapes. Description of the Preferred Embodiments The present invention provides a process for producing cold formed products composed of a dispersion strengthened, non-heat treatable, aluminum base alloy in the form of a wrought product comprised but not limited to sheet, plate, extrusions or tubes.
  • the dispersion strengthened alloy is supported by a similar product form composed of a metal alloy that has strength and thickness equal or greater than the dispersion strengthened alloy.
  • the support material must be cold formable in the process and conditions chosen.
  • the overlay only has to be cold formable in the area that will be deformed.
  • the supported structure is cold formed into the desired shape using conventional metalworking procedures (including brake forming, stretch forming, tube bending and the like) , and conventional cold forming equipment.
  • alloys of the present invention involve rapidly solidified aluminum alloys, which consist essentially of the formula Al ⁇ Fe.Si t X,., wherein X is at least one element selected from the group consisting of Mn, V, Cr, Mo, W, Nb, Ta, "a" ranges from 2.0 to 7.5 at%, M b" ranges from 0.5 to 3.0 at%, "c” ranges from 0.05 to 3.5 at% and the balance is aluminum plus incidental impurities, with the proviso that the ratio ⁇ Fe + X ⁇ :Si ranges from about 2.0:1 to 5.0:1.
  • the alloys of the invention are rapidly solidified at cooling rates sufficient to greatly reduce the size of the intermetallic dispersoids formed during the solidification as well as allow for substantially higher quantities of transition elements to be added than possible by conventional solidification processes.
  • the rapid solidification process is one wherein the alloy is placed into a molten state and then cooled at a quench rate of at least about 10 5 to 10 7o C/sec to form a solid substance.
  • this method should cool the molten metal at a rate of greater than about 10 6o C/sec, i.e., via melt spinning, splat cooling or planar flow casting, which forms a solid ribbon.
  • These alloys have an as-cast microstructure which varies from a microeutectic to a microcellular structure, depending on the specific alloy chemistry. In the present invention, the relative proportions of these structures are not critical. Ribbons of said alloy are formed into particles by conventional comminution devices such as a pulverizer, knife mills, rotating hammer mills and the like. Preferably, the comminuted powder particles have a size ranging from about -40 mesh to about -200 mesh, U.S. standard sieve size.
  • the particles may then be canless vacuum hot pressed at a temperature ranging from about 275°C to 550°C, preferably ranging from about 300°C to 500°C, in a vacuum less than 10"* torr (1.33 x 10' 2 Pa), preferably less than 10" 5 torr (1.33 x 10 *3 Pa), and then compacted in a blind die.
  • compaction may also be performed by placing the comminuted powder in metal cans, such as aluminum cans having a diameter as large as 30 cm or more, hot degassed in the can under the aforementioned conditions, sealed therein under vacuum, and then thereafter re-heated within the can and compacted to full density, the compacting step being conducted, for example, in a blind die extrusion press.
  • metal cans such as aluminum cans having a diameter as large as 30 cm or more
  • hot degassed in the can under the aforementioned conditions sealed therein under vacuum, and then thereafter re-heated within the can and compacted to full density, the compacting step being conducted, for example, in a blind die extrusion press.
  • any technique applicable to the art of powder metallurgy which does not invoke liquefying (melting) or partially liquefying (sintering) the matrix metal can be used.
  • the resultant compacts are converted to a rolled product by a process comprising the steps of: a. compacting under vacuum a powder composed of particles produced by rapid solidification of said alloy to obtain a compacted billet having sufficient density to be formed into rolling stock of substantially full density; b. forming said billet into rolling stock at a temperature ranging from the incipient forming temperature to about 500"C; c. rolling said stock to reduce the thickness thereof by subjecting the stock to at least one rolling pass, said stock having a percent thickness reduction per pass ranging up to about 25 percent and a stock temperature ranging from about 230°C to about 500°C.
  • the resultant compacts comprise a forged product wherein a billet, compacted as before to sufficient density to be formed into a forging of substantially full density, is then forged at a stock temperature ranging from the incipient forging temperature to about 500"C.
  • the resultant billets comprise an extruded product, of either solid or tubular cross sections, wherein the billet, compacted to sufficient density for forming into an extrusion of substantially full density, is then extruded at a stock temperature ranging from the incipient extruding temperature to about 500 ⁇ C.
  • the present invention provides a method for cold forming rapidly solidified dispersion strengthened aluminum base alloys wherein forming is initiated without subjecting the alloy to heat treatment.
  • the bend was made parallel to the width of the sheet, i.e. 25.4mm.
  • the 3.175mm radius represents a bend of 2.5 times the sheet thickness, i.e. 2.5t.
  • Successful crack free bends were made in all orientations of the sheet in contrast to prior art practices, which require that bends be made solely in a direction 90° to the rolling direction and that such bends be made at 2.5t.
  • Example II The experiment performed in Example I was repeated, except that a bend blocker having a 1.588mm radius was used. This bend blocker imposed a bend of 1.27t for the 1.25mm aluminum alloy 8009 sheet. Crack free 90° bends were again made in all orientations. The prior art suggests that the cold brake forming of alloy 8009 to this tight a bend radii is virtually impossible.
  • Example III

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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)
  • Forging (AREA)

Abstract

Un alliage à base d'aluminium, non traitable à chaud et renforcé par phase dispersée, peut être formé à froid en des formes utiles obtenues à l'aide de machines classiques de formage à froid. Une première feuille de cet alliage à base d'aluminium prend appui sur une deuxième feuille composée d'un alliage métallique et présentant une résistance et une épaisseur au moins égales à celles de la première feuille. Cette première feuille, en relation de superposition avec la deuxième feuille, est alors formée selon le rayon de courbure désiré.
PCT/US1993/005983 1992-06-22 1993-06-22 Formage a froid d'alliages d'aluminium a solidification rapide WO1994000256A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US90234092A 1992-06-22 1992-06-22
US902,340 1992-06-22

Publications (1)

Publication Number Publication Date
WO1994000256A1 true WO1994000256A1 (fr) 1994-01-06

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1607147A1 (fr) * 2004-06-17 2005-12-21 PLANSEE Aktiengesellschaft Procédé et machine pour la production d'une tôle mince ou d'une feuille de matière métallique par laminage

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2289311A (en) * 1940-03-06 1942-07-07 Sk Wellman Co Composite blank and method of shaping
GB1086754A (en) * 1964-02-28 1967-10-11 Varian Associates Method of cold forming metal coil
US3798010A (en) * 1968-07-30 1974-03-19 Du Pont Explosion bonded aluminum to steel
FR2376745A1 (fr) * 1977-01-07 1978-08-04 Peugeot Aciers Et Outillage Procede de fabrication d'un produit composite metallique en profile ou en feuille utilisable notamment dans le batiment.
EP0172732A1 (fr) * 1984-08-25 1986-02-26 Alcan International Limited Moulage d'articles en métal
WO1989002365A1 (fr) * 1987-09-15 1989-03-23 Glyco-Metall-Werke Daelen & Loos Gmbh Materiau stratifie amorphe pour elements coulissants
WO1989009839A1 (fr) * 1988-04-15 1989-10-19 Allied-Signal Inc. Traitement thermomecanique d'alliages a base d'aluminium a temperature elevee rapidement solidifies

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2289311A (en) * 1940-03-06 1942-07-07 Sk Wellman Co Composite blank and method of shaping
GB1086754A (en) * 1964-02-28 1967-10-11 Varian Associates Method of cold forming metal coil
US3798010A (en) * 1968-07-30 1974-03-19 Du Pont Explosion bonded aluminum to steel
FR2376745A1 (fr) * 1977-01-07 1978-08-04 Peugeot Aciers Et Outillage Procede de fabrication d'un produit composite metallique en profile ou en feuille utilisable notamment dans le batiment.
EP0172732A1 (fr) * 1984-08-25 1986-02-26 Alcan International Limited Moulage d'articles en métal
WO1989002365A1 (fr) * 1987-09-15 1989-03-23 Glyco-Metall-Werke Daelen & Loos Gmbh Materiau stratifie amorphe pour elements coulissants
WO1989009839A1 (fr) * 1988-04-15 1989-10-19 Allied-Signal Inc. Traitement thermomecanique d'alliages a base d'aluminium a temperature elevee rapidement solidifies

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
K.R. VAN HORN 'ALUMINIUM ,VOL 3' 1967 , AMERICAN SOCIETY FOR METALS , METALS PARRK, OHIO, US "PRESS-BRAKE BENDING FORMING" *

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1607147A1 (fr) * 2004-06-17 2005-12-21 PLANSEE Aktiengesellschaft Procédé et machine pour la production d'une tôle mince ou d'une feuille de matière métallique par laminage

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