WO2005047557A1 - Procede de fabrication d'un produit d'alliage pres de la cote desiree - Google Patents

Procede de fabrication d'un produit d'alliage pres de la cote desiree Download PDF

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Publication number
WO2005047557A1
WO2005047557A1 PCT/US2004/037943 US2004037943W WO2005047557A1 WO 2005047557 A1 WO2005047557 A1 WO 2005047557A1 US 2004037943 W US2004037943 W US 2004037943W WO 2005047557 A1 WO2005047557 A1 WO 2005047557A1
Authority
WO
WIPO (PCT)
Prior art keywords
product
plates
plate
ingot
component
Prior art date
Application number
PCT/US2004/037943
Other languages
English (en)
Inventor
Gregory B. Venema
Sallie L. Blake
Jeffrey J. Witters
M. Dan Goodyear
Michael P. Addabbo
Amy J. Gonyer
Original Assignee
Alcoa 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 Alcoa Inc. filed Critical Alcoa Inc.
Publication of WO2005047557A1 publication Critical patent/WO2005047557A1/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
    • 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
    • C22F1/047—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 magnesium 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
    • C22F1/053—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 zinc as the next major constituent

Definitions

  • the present invention relates to a process for manufacturing metal alloy plate product in a near-net shape prior to heat treatment. More particularly, the invention relates to the production of a metal alloy product in which a metal alloy plate or sheet is produced in dimensions that are similar to the desired final dimensions of the product, then heat treated, stretched and aged.
  • Aluminum alloys are extensively used in aircraft and automobiles as well as other products that benefit from the unique combination of properties such as low weight (compared to ferrous alloys), high strength, fracture toughness, and corrosion resistance.
  • Aircraft and automotive structural components are typically produced from a sheet or plate to which additional structural members are attached.
  • the upper and lower wing panels of an aircraft are typically produced from aluminum alloy plate (referred to as the skin) which is reinforced by extruded components (referred to as stringers).
  • the stringers are fixed to the skin by fasteners such as rivets.
  • Aluminum aircraft components produced from flat rolled products are traditionally manufactured from direct chill cast ingots that may be several feet thick.
  • the ingot is then hot-rolled to a preliminary plate or sheet thickness.
  • Subsequent cold rolling may be performed prior to heat treating, stretching and artificial or natural aging.
  • the mechanical properties of the alloy such as yield strength and fracture toughness are improved by solution heat treating the alloy at elevated temperatures which alters the microstructure of the solute components in the alloy.
  • the metal is then quenched to lock in the microstructure of the alloy achieved during solution heat treatment. After heat treatment, the material is stretched, artificially or naturally aged and machined or chemically milled to its final shape.
  • Some final products e.g. aircraft wing ribs
  • the ingot is hot-rolled, solution heat treated and quenched. Rapid quenching immediately following solution heat treatment is desirable for rapid locking of the elements needed for strengthening in the microstructure.
  • a slow quench rate risks loss of mechanical properties.
  • the quench rate is dependent on the plate thickness. As the thickness of the plate increases, the quench rate for the plate decreases which results in lower achievable mechanical properties.
  • some aluminum alloys have mechanical properties that are readily lost if rapid quenching is not performed. It would be desirable to produce such alloys in thick cross-sections utilizing high quench rates to take advantage of improved mechanical properties.
  • the product thickness has been limited by the quench sensitivity of those alloys and slower quench rates. Increasing the quench rate or reducing the cross section thickness, will result in improved mechanical properties.
  • an ingot of a heat treatable metal alloy such as aluminum alloy in the F temper (the temper of the alloy as fabricated) is rolled to a flat product. Material from the flat product is removed to achieve a shape similar to the desired final (net) shape, referred to herein as the near-net shape.
  • the near-net shaped product is solution heat treated and stretched. The stretching step flattens, stress relieves and brings the shape to the desired final dimensions. The stretched product is then artificially aged.
  • Suitable alloys for use in the present invention are aluminum alloys including alloys of the Aluminum Association (AA) series 2XXX, 6XXX and 7XXX.
  • the final product may be an aircraft component such as a wing panel or an automotive component.
  • Fig. 1 is a cross section of a component produced according to the present invention.
  • Fig. 2 is a plot of electrical conductivity for the lower surfaces of plates produced according to the present invention and control plates;
  • Fig. 3 is a plot of electrical conductivity for the upper surfaces of plates produced according to the present invention and control plates;
  • Fig. 4 is a plot of tensile strength for plates produced according to the present invention and control plates;
  • Fig. 5 is a plot of fracture toughness for plates produced according to the present invention and control plates, both in the T7651 temper; and [0012] Fig. 6 is a plot of fracture toughness for plates produced according to the present invention and control plates, both in the T7451 temper.
  • the present invention includes a method of producing heat treatable metal products having a superior combination of properties and economies of production.
  • the invention may be used with various alloy systems including aluminum, magnesium, copper and other alloys which rely on heat treatment for precipitation of solute for strengthening purposes, referred to herein as a "heat treatable metal alloy".
  • the present invention is especially useful for AA 2XXX, 6XXX and 7XXX series aluminum alloys.
  • a heat treatable metal alloy product is produced as an ingot by direct chill casting or the like.
  • the term ingot is meant to include other bulk metal products.
  • the metal alloy ingot is rolled into a flat product. Material from the flat product is removed resulting in a shape of the product that is near-net to a desired final shape.
  • Near-net shape it is meant that the product is dimensionally similar to the dimensions of the desired final shape. Material removal may be accomplished by various techniques including via machining.
  • the near-net shaped product is then solution heat treated and quenched. Solution heat treatment may be performed in any type of solution heat treat furnace using either a spray or an immersion quench system. The orientation of the product in a solution heat treat furnace may be selected to account for potential quench distortion and equipment design.
  • the product By removing material so that the product achieves a near-net shape, the product is thinner and the quench rate for the product is higher than the quench rate for an ingot or a traditional flat product. Accordingly, superior properties are achievable in a product produced according to the present invention due to the opportunity for high quench rate.
  • the solution heat treated product is then stretched to achieve the desired final dimensions for the product.
  • final dimensions refers to the dimensions of the product after practicing the present invention, which may not necessarily be the ultimate dimensions of a completed component. Further altering of the product dimensions may occur depending on the end use for the product. Stretching of a product reduces the residual stresses in the product, provides flatness to the product and may improve metallurgical properties of the product in certain alloys.
  • stretching decreases the dimensions of the stretched product by about 1.25% in each of the product thickness and the product width, i.e. has a target stretch of about 2.5%.
  • the step of removing material so that the product achieves a near-net shape should take into account the decrease in the thickness and width of the product during stretching. For example, the dimensions of the product in its near-net shape should be 1.25% larger in each of the product thickness and the product width so that the stretching step results in the desired the final dimensions.
  • the stretched product which is in its desired final shape is aged such as via artificial aging.
  • artificial aging is performed on a plate or sheet product.
  • the artificial aging process may be performed more rapidly in both the heat up of the product and the cool down of the product providing greater control and consistency.
  • Ingots A and B were scalped and homogenized using standard fabrication practices and procedures. Both ingots were hot rolled into plates 3.5 inches thick by 74 inches wide by 600 inches long using standard hot rolling temperatures and pass schedules. Each of the two 3.5 inch x 74 inch plate pieces were cut in half along its length to yield two sets of two 300 inch long plates.
  • One plate from Ingot A and one plate from Ingot B were processed according to the present invention to produce plates having integrally formed stringers on a web (referred to as ISP plates).
  • the two ISP plates were machined from the F temper down the full length to produce the cross section configuration shown in Fig. 1 and are referred to as ISP A plate and ISP B plate.
  • the other plates from each of Ingots A and B were processed in their original configurations as control plates and are referred to as Control A plate and Control B plate.
  • Fig. 2 shows the % IACS (International Annealed Copper Standard) electrical conductivity across the width (longitudinal, transverse direction) of bottom sides (lower surface during quenching) of the ISP A and B plates (smooth side, without the machined stringers) and of the Control plates A and B.
  • Fig. 3 shows the % IACS electrical conductivity for the top sides of the plates (upper surfaces during quenching). The data for the top side of the ISP plates was taken on stringers at the edge of the plates (Edge Stringer) and on stringers midway across the plates (W/2 Stringer).
  • the data for the top side of the control plates was taken at halfway across the width of the plates (W/2).
  • the % IACS electrical conductivity for the ISP plates was uniformly lower than for the control plates.
  • Lower % IACS electrical conductivity is indicative of higher quench rate. As such, product with thinner cross sections than conventional products can be produced according to the present invention at higher quench rates.
  • each plate Prior to artificial aging the four plate sections, each plate was again cut in half to yield a piece of plate approximately 150 inches long.
  • the 150 inch plates were aged to each of T7651 type temper and T7451 type temper.
  • Two control plates and two ISP plates were aged to each temper condition.
  • the plates were sectioned for mechanical property testing. To ensure an accurate comparison between the control plate properties and the ISP plate properties, special care was taken to keep all of the test plane references relative to the original rolled plate thickness. This was important to eliminate variability in test results associated with chemical composition or grain structure gradients through thickness.
  • Tensile strength testing was performed on the webs of the ISP and control plates from each of Ingots A and B at a plane halfway through the thickness of the plate web (t/2) at width locations of the plate edge (Edge) and midway across the plate (W/2).
  • Fracture toughness testing was performed at planes of halfway through the thickness of the plate web (Web/2), one quarter through the thickness of the stringer (t/4) and halfway through the thickness of the stringer (t/2) at several locations across the plate including the plate edge (Web Edge), the stringer edge (Stringer Edge), midway across the plate in the web (Web W/2), and midway across the plate in the stringer (Stringer W/2).
  • Fig. 4 shows the longitudinal transverse tensile strength data in KSI units (ultimate yield strength or UTS and tensile yield strength or TYS) for the ISP and control plates produced from Ingots A and B, aged to T7651.
  • the ISP plate strengths are generally equal to or slightly above the control group.
  • Fig. 5 shows the fracture toughness for the ISP and control plates produced from Ingots A and B aged to T7651
  • Fig. 6 shows similar data for plates aged to the T7451 temper.
  • the ISP plates generally exhibited 10% to 20% higher fracture toughness than the control plates in all locations for both tempers.
  • the present invention allows for machining (or other material removal) of bulk metal into a near-net shape prior to solution heat treatment, stretching and aging with superior properties in the final product compared to conventionally manufactured product that is machined after aging.
  • the present invention provides economical benefits in the production of aluminum alloy products. Productivity may be increased due to higher quench rates and shorter aging practices of the near-net shape product with concomitant energy savings.
  • certain aluminum alloy products with complicated shapes have not previously been produced from flat-rolled wrought products. Extrusion, forging and casting processes are typically employed to manufacture such products and those processes do not always impart the mechanical properties achievable with wrought products.
  • the shapes of extruded, forged or cast products may be manufactured in a wrought product by removing material from a flat-rolled (wrought) product to achieve a near-net shape prior to solution heat treatment.
  • Further potential benefits of the present invention include reduced weight of components and manufacturing cost savings for the end use customer.
  • the total weight for structural components may be reduced by manufacturing product according to the present invention.
  • Fasteners and other related structural members required for joining components to each other are minimized or avoided when the product is machined to its near-net shape as an integrally manufactured product.
  • the stiffening members e.g. stringers
  • the opportunity for cost savings to the end use customer may include reduced process time to achieve the final part configuration (e.g. less machining or chemical milling time) and reduced process scrap.

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  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Metal Rolling (AREA)

Abstract

La présente invention se rapporte à un procédé permettant de fabriquer un produit métallique apte au traitement thermique, qui comprend les étapes successives consistant : à fournir un lingot d'un alliage métallique apte au traitement thermique ; à rouler le lingot pour former un produit plat ; à éliminer de la matière du produit, afin que l'on obtienne une forme près de la cote d'une forme finale désirée ; et à procéder au traitement de mise en solution du produit. Le produit est étiré jusqu'à ce qu'il obtienne la forme finale désirée, et vieilli jusqu'à ce qu'il se dote des propriétés mécaniques désirées.
PCT/US2004/037943 2003-11-12 2004-11-12 Procede de fabrication d'un produit d'alliage pres de la cote desiree WO2005047557A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US10/706,846 US20050098245A1 (en) 2003-11-12 2003-11-12 Method of manufacturing near-net shape alloy product
US10/706,846 2003-11-12

Publications (1)

Publication Number Publication Date
WO2005047557A1 true WO2005047557A1 (fr) 2005-05-26

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP4386097A1 (fr) * 2022-12-12 2024-06-19 Constellium Rolled Products Ravenswood, LLC Produits ecrouis en alliage 7xxx avec un compromis amélioré de propriétés de traction et de ténacité et procédé de production
WO2024126341A1 (fr) * 2022-12-12 2024-06-20 Constellium Rolled Products Ravenswood, Llc Produits corroyés 7xxx présentant un compromis amélioré des propriétés de traction et de ténacité et procédé de production

Families Citing this family (5)

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Publication number Priority date Publication date Assignee Title
FR2848480B1 (fr) * 2002-12-17 2005-01-21 Pechiney Rhenalu Procede de fabrication d'elements structuraux par usinage de toles epaisses
US8083871B2 (en) 2005-10-28 2011-12-27 Automotive Casting Technology, Inc. High crashworthiness Al-Si-Mg alloy and methods for producing automotive casting
US8673209B2 (en) * 2007-05-14 2014-03-18 Alcoa Inc. Aluminum alloy products having improved property combinations and method for artificially aging same
US8840737B2 (en) * 2007-05-14 2014-09-23 Alcoa Inc. Aluminum alloy products having improved property combinations and method for artificially aging same
US8206517B1 (en) 2009-01-20 2012-06-26 Alcoa Inc. Aluminum alloys having improved ballistics and armor protection performance

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US20010006082A1 (en) * 1999-12-28 2001-07-05 Timothy Warner Aircraft structure element made of an Al-Cu-Mg alloy
US20030140990A1 (en) * 1999-04-12 2003-07-31 Pechiney Rhenalu Method of manufacturing formed pieces of type 2024 aluminum alloy
US20040182483A1 (en) * 2002-12-17 2004-09-23 Fabrice Heymes Process for manufacturing structural components by machining plates
WO2004083478A1 (fr) * 2003-03-17 2004-09-30 Corus Aluminium Walzprodukte Gmbh Procede de production d'une structure d'aluminium monolithique integree et produit en aluminium usine a partir de cette structure

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US4954188A (en) * 1981-12-23 1990-09-04 Aluminum Company Of America High strength aluminum alloy resistant to exfoliation and method of making
US4589932A (en) * 1983-02-03 1986-05-20 Aluminum Company Of America Aluminum 6XXX alloy products of high strength and toughness having stable response to high temperature artificial aging treatments and method for producing
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US5865911A (en) * 1995-05-26 1999-02-02 Aluminum Company Of America Aluminum alloy products suited for commercial jet aircraft wing members
US5810949A (en) * 1995-06-07 1998-09-22 Aluminum Company Of America Method for treating an aluminum alloy product to improve formability and surface finish characteristics
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JP4285916B2 (ja) * 2001-02-16 2009-06-24 株式会社神戸製鋼所 高強度、高耐食性構造用アルミニウム合金板の製造方法

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030140990A1 (en) * 1999-04-12 2003-07-31 Pechiney Rhenalu Method of manufacturing formed pieces of type 2024 aluminum alloy
US20010006082A1 (en) * 1999-12-28 2001-07-05 Timothy Warner Aircraft structure element made of an Al-Cu-Mg alloy
US20040182483A1 (en) * 2002-12-17 2004-09-23 Fabrice Heymes Process for manufacturing structural components by machining plates
WO2004083478A1 (fr) * 2003-03-17 2004-09-30 Corus Aluminium Walzprodukte Gmbh Procede de production d'une structure d'aluminium monolithique integree et produit en aluminium usine a partir de cette structure

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP4386097A1 (fr) * 2022-12-12 2024-06-19 Constellium Rolled Products Ravenswood, LLC Produits ecrouis en alliage 7xxx avec un compromis amélioré de propriétés de traction et de ténacité et procédé de production
WO2024126341A1 (fr) * 2022-12-12 2024-06-20 Constellium Rolled Products Ravenswood, Llc Produits corroyés 7xxx présentant un compromis amélioré des propriétés de traction et de ténacité et procédé de production

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