Classifications

• • 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
  • C22C21/10—Alloys based on aluminium with zinc 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

• This invention pertains to a weldable wrought aluminium AA7000-series alloy in the form of a rolled, extruded or forged product and to a method of producing said product.
• the invention further relates to a welded component comprising such a product.
• alloy designations and temper designations refer to the Aluminum Association designations in Aluminum Standards and Data and the Registration Records, as published by the Aluminum Association.
• Alloys AA7075 and AA7055 are examples of this type of alloy and have achieved widespread use in aerospace applications because of their high strength and other desirable properties.
• Alloy AA7055 comprises 7.6-8.4% of Zn, 1.8 to 2.3% of Mg, 2.0 to 2.6% of Cu, 0.08-0.25% of Zr, below 0.10% Si and below 0.15% Fe, the balance being aluminium together with incidental elements and impurities.
• Alloy AA7075 comprises 5.1 to 6.1% of Zn, 2.1 to 2.9% of Mg, 1.2 to 2.0 % of Cu, 0.18 to 0.28 % Cr, below 0.40% Si, below 0.50% Fe and below 0.30% Mn, the balance being aluminium together with incidental elements and impurities.
• the alloy When artificially aged to its highest strength, which ageing treatment usually involves a period of 20 hours or more at a relatively low ageing temperature of between 100 and 150 0 C, the alloy is obtained in a condition which is commonly referred to as a T6 temper condition. In this condition however, alloys AA7075 and similar alloys are susceptible to stress corrosion cracking ("SCC"), exfoliation corrosion (“EXCO”) and intergranular corrosion (“IGC”).
• SCC stress corrosion cracking
• EXCO exfoliation corrosion
• IRC intergranular corrosion
• AA7000-series having a combination of improved IGC-resistance, improved strength properties, reduced hot crack sensitivity during welding and, when in an artificially aged condition, having a hardness of more than 180 HB.
• the present invention provides a wrought aluminium AA7000-series alloy product, consisting essentially of, in wt%:
• - Zr ⁇ 0.30 preferably 0.04 to 0.15, more preferably 0.04 to 0.13 - Ti ⁇ 0.30, preferably ⁇ 0.20, more preferably ⁇ 0.10
• the product having reduced hot crack sensitivity also having improved strength and toughness properties, and when in artificially aged condition having a hardness of more than 180 HB.
• the hardness is more than 185 HB, and more preferably more than 190 HB.
• a hardness of more than 210 HB has been obtained in the age hardened condition.
• the iron and silicon contents should preferably be kept low, for example not exceeding about 0.08% Fe and/or about 0.07% Si or less. In any event, it is conceivable that still slightly higher levels of both impurities, up to about 0.14% Fe and/or up to about 0.12% Si may be tolerated, though on a less preferred basis. In particular for the mould plates or tooling plates embodiments, even higher levels of up to 0.3% Fe and up to 0.25% Si or less, are tolerable.
• the alloy By increasing the Zn-content of the alloy along with the Mg-content, whilst keeping the Cu-content low, it is possible to obtain very high strengths, while maintaining toughness levels equal or higher than a AA7055 reference material, and with good weldability which is believed to a large extent to be the resultant of the low copper content of the alloy.
• the alloy also provides a high hardness when in artificially aged condition such as a T6 or T7-type temper, but with improved weldability compared to an AA7075 reference material in T6 condition, which is believed to be because of the low copper content of the alloy.
• the artificial aged material may for example be a T6, T74, T76, T751 , T7451 , T7651 , T77 or T79 temper.
• Each of the disperso ⁇ d forming elements Zr, Sc, Hf, V, Cr and Mn can be added to control the grain structure and the quench sensitivity.
• the optimum levels of disperso ⁇ d formers depend on the processing, but when one single chemistry of main elements (Zn, Cu and Mg) is chosen within the preferred window and that chemistry will be used for all relevant products forms, then Zr levels are preferably less than 0.13%.
• a preferred maximum for the Zr level is 0.15%.
• a suitable range of the Zr level is 0.04 to 0.15%.
• a more preferred upper-limit for the Zr addition is 0.13%.
• Zr is a preferred alloying element in the alloy product according to this invention.
• the addition of Sc is preferably not more than 0.50% or more preferably not more than 0.3%, and even more preferably not more than 0.18%.
• the sum of Sc+Zr should be less then 0.3%, preferably less than 0.2%, and more preferably at a maximum of 0.17%, in particular where the ratio of Zr and Sc is between 0.7 and 1.4%.
• Cr disperso ⁇ d former that can be added, alone or with other disperso ⁇ d formers
• Cr levels should preferably be below 0.3%, and more preferably at a maximum of 0.20%, and even more preferably 0.15%.
• a preferred lower limit for the Cr would be 0.04%.
• Cr alone may not be as effective as solely Zr, at least for use in tooling plate of the alloy wrought product, similar hardness results may be obtained.
• the sum of Zr + Cr should not be above 0.20%, and preferably not more than 0.17%.
• the preferred sum of Sc+Zr+Cr should not be above 0.4%, and more preferably not more than 0.27%.
• Mn can be added as a single disperso ⁇ d former or in combination with one of the other disperso ⁇ d formers.
• a maximum for the Mn addition is 0.80%.
• a suitable range for the Mn addition is in the range of 0.05 to 0.40%, and preferably in the range of 0.05 to 0.30%, and even more preferably 0.12 to 0.30%.
• a preferred lower limit for the Mn addition is 0.12%, and more preferably 0.15%.
• the sum of Mn plus Zr should be less then 0.4%, preferably less than 0.32%, and a suitable minimum is 0.12%.
• the alloy is free of Mn, in practical terms this would mean that the Mn-content is ⁇ 0.02%, and preferably ⁇ 0.01%, and more preferably the alloy is essentially free or substantially free from Mn.
• substantially free and “essentially free” we mean that no purposeful addition of this alloying element was made to the composition, but that due to impurities and/or leaching from contact with manufacturing equipment, trace quantities of this element may, nevertheless, find their way into the final alloy product.
• the alloy has no deliberate addition of V such that it is only present, if present, at regular impurity levels of less than 0.05%.
• the copper content has a considerable influence on the hot crack sensitivity of the alloy and consequently also on the weldability of the alloy. It was found that weldability was further improved at copper contents of 0.28% or below 0.25%. A very good weldability was obtained at copper contents of lower than 0.25% or even lower than 0.20%. A preferred minimum addition for the Cu-content is 0.03% and more preferable 0.08%.
• the Zn content is in the range of 7.5 to 14.0%, preferably the amount of Zn is in a range having a lower limit of 8.5%, 9.0% or 9.5% and an upper limit of 12.0%, 11.0% or 10.0%, for example Zn preferably in the range of 8.5 to 11.0% and more preferably Zn is in the range of 8.5 to 10.0%, in particular for use in aerospace applications.
• the upper limit for the Zn-content is 14.0%, preferably 12.0% and more preferably 11.0%.
• the corrosion resistance and particularly the EXCO is maintained at a high level, which is of particular relevance for aerospace applications of the alloy product according to this invention.
• the Mg content is in the range of 1.0 to 5.0% or 2.5 to 5.0%.
• a preferred upper limit is 4.5%.
• alloy product according to this invention is used as tooling plate a more preferred upper limit for the Mg content is 4.0%.
• the addition of Mg markedly increases the strength of the alloy.
• a maximum content of 5.0% is used to avoid formation of unfavourable Mg-precipitates such as Mg 5 AI 3 or Mg 5 AI 8 , which may produce an undesirable susceptibility to IGC and SSC.
• the amount of Mg in the alloy is at least the value provided by the relation Mg >6.6 - (0.45xZn), and preferably wherein Mg >10 - (0.79xZn).
• Mg and Zn form MgZn 2 precipitates, which is a precipitate having a profound effect on the final hardness and strength properties after quenching and ageing. If the Mg content lies above the values given by the relations above, the excess Mg will contribute to the strengthening of the alloy.
• the present invention is directed at an alloy composition which, when processed to a variety of products, such as, but not limited to, sheet, plate, thick plate, etc, will meet or exceed the desired material properties.
• the property balance of the product will out-perform the property balance of the product made from nowadays commercially used alloys.
• the alloy product according to this invention is processed to thicker gauges of more than 1 inch (25.4 mm) up to about 1 1 inch (279.4 mm) or more and will provide improved properties for structural aircraft components such as integral parts machined from plate, or to form an integral spar for use in an aircraft wing structure, or in the form of a rib for use in an aircraft wing structure or as upper wing plate.
• the thicker gauge products can be used also as tooling plate or mould plate, e.g. moulds for manufacturing formed plastic products via die-casting, injection moulding or comparable methods. When thickness ranges are given hereinabove, it will be immediately apparent to the skilled person that this is the thickness of the thickest cross sectional point in the alloy product made from such a thin plate or thick plate.
• the alloy products according to the invention can also be provided in the form of a stepped extrusion or extruded spar for use in an aircraft structure, or for example in the form of a forged spar for use in an aircraft wing structure.
• the alloy products have been extruded into profiles having at their thickest cross sectional point a thickness in the range of up to 10 mm, and preferably in the range of 1 to 7 mm.
• the alloy product can also replace thick plate material which is conventionally machined via high-speed machining or milling techniques into a shaped structural component.
• the extruded alloy product has preferably at its thickest cross sectional point a thickness in a range of 2 inches (50.8 mm) to 6 inches (152.4 mm).
• the product is a high strength and toughness aerospace plate, such as an upper wing plate, the Mg-content of the product preferably depending on the Zn-content according to Mg >6.6 - (0.45xZn).
• the product is a high strength tooling plate, preferably having a hardness after artificial ageing of more than 185 HB, preferably of more than 190 HB, the Mg-content of the product preferably depending on the Zn- content according to Mg >6.6 - (0.45xZn), and more preferably according to Mg >10 - (0.79xZn).
• all hardness values in this description and the claims are Brinell hardness values, measured according to ASTM E10, version 2002, and whereby the hardness is being measured at mid-section thickness.
• the wrought alloy product consists of a tooling plate in a T6 or T7 temper and having a composition consisting essentially of:
• Zn 7.5 to 14.0 preferably 7.5 to 12.0, more preferably 8.5 to 11.0, or 9.5 to 12.0 Mg 1.0 to 5.0, preferably 2.0 to 4.5 or 2.5 to 4.5, and more preferably
• Mg-content depends on the Zn- content according to Mg >6.6 - (0.45xZn), and more preferably Mg >10- (0.79xZn)
• Fe ⁇ 0.30 preferably ⁇ 0.14 Si ⁇ 0.25, preferably ⁇ 0.12, remainder incidental elements and impurities, each ⁇ 0.05, total ⁇ 0.15, and balance aluminium.
• said tooling plate further consists of 0.05 to 0.40% Mn.
• the wrought alloy product consists of a tooling plate in a T6 or T7 temper and having a composition consisting essentially of:
• Zn 7.5 to 14.0 preferably 7.5 to 12.0, more preferably 8.5 to 11.0 or 9.5 to 12.0 Mg 1.0 to 5.0, preferably 2.0 to 4.5 or 2.5 to 4.5, and more preferably
• Mg-content depends on the Zn- content according to Mg >6.6 - (0.45xZn), and more preferably Mg >10- (0.79xZn)
• Fe ⁇ 0.30 preferably ⁇ 0.14 Si ⁇ 0.25, preferably ⁇ 0.12, remainder incidental elements and impurities, each ⁇ 0.05, total ⁇ 0.15, and balance aluminium.
• the wrought alloy product according to this invention consists of an aerospace product selected from the group consisting of a sheet, plate, extrusion, or a structural aircraft component made from such a sheet, plate or extrusion, and being in a T6 or T7 temper and having a composition consisting essentially of:
• Mg 1.0 to 5.0 and wherein the Mg-content depends on the Zn-content according to Mg >6.6 - (0.45xZn), and preferably Mg >10 - (0.79xZn) Cu 0.03 to 0.25
• Fe ⁇ 0.14 preferably ⁇ 0.08, Si ⁇ 0.12, preferably ⁇ 0.07, remainder incidental elements and impurities, each ⁇ 0.05, total ⁇ 0.15, the balance aluminium.
• the aerospace product has a Mg content of 2.0 to 4.5% and wherein further the Mg content depends on the Zn content according to Mg ⁇ dO - (0.79xZn).
• Mg ⁇ dO - (0.79xZn) In a further embodiment of the aerospace product it has a Zn content in a range of 7.5 to 11.0%, and preferably 8.5 to 10.0%.
• it further consists of Mn in a range of 0.05 to 0.40%, and preferably 0.05 to 0.30%.
• the invention is also embodied in a welded component comprising at least a first component part being a product according to the invention and at least a second component part, the component parts being welded together to form the welded component, preferably wherein the welded component is a welded structural aircraft component. More preferably the first and second component part comprise of a product according to the invention. Even more preferably substantially all or even all component parts forming the welded component or the welded structural aircraft component comprise of a product according to the invention. The good weldability and other favourable properties are used to provide a welded component or welded structural aircraft component with excellent strength, corrosion properties and weld quality.
• a method of producing a wrought aluminium AA7000-series alloy product comprising the processing steps of: a) casting an ingot having a composition as set out in the present description; b) homogenising and/or pre-heating the ingot after casting; c) hot working the ingot into a pre-worked product by one or more methods selected from the group consisting of: rolling, extruding and forging; d) optionally reheating the pre-worked product and either, e) hot working and/or cold working the pre-worked product to a desired workpiece shape; f) solution heat treating (SHT) the formed workpiece at a temperature and time sufficient to place into solid solution substantially all soluble constituents in the alloy; g) quenching the solution heat treated workpiece, preferably by one of spray quenching or immersion quenching in water or oil or other quenching media; h) optionally stretching or compressing of the quenched work
• the homogenising treatment also comprises at least a second homogenisation stage consecutive to the first homogenisation stage.
• the dissolving temperature is reached at an earlier time at the perimeter of the ingot or cast, and that the temperature in the cold spot slowly increases to the dissolving temperature.
• the dissolving temperature is usually called the homogenisation temperature.
• the alloy products of the present invention are conventionally prepared by melting and may be direct chill (“D. C") cast into ingots or other suitable casting techniques.
• Hot working the alloy product can be done by one or more methods selected from the group consisting of rolling, extruding and forging.
• rolling is being preferred.
• Solution heat treatment is typically carried out in the same temperature range as used for homogenisation, although the soaking times can be chosen somewhat shorter.
• a method wherein the duration of the first homogenisation stage for an ingot or a slab is chosen such that the cold spot is at a dissolving temperature for at least a dissolving time necessary to dissolve the m-phase precipitates, wherein preferably the dissolving time is at most 2 hours, preferably 1 hour, more preferably as short as possible, such as 30 minutes or 20 minutes, or even shorter.
• the dissolving temperature is about 470 c C.
• a method wherein the duration of the first homogenisation stage for an ingot or a slab is at most 24 hours, preferably at most 12 hours, preferably wherein the homogenisation temperature is 470 c C.
• a method wherein for an ingot or a slab having Cu ⁇ 0.28%, even more preferably having Cu ⁇ 0.20% the first homogenisation stage is at most 12 hours at 470 0 C and wherein there is no second homogenisation stage.
• a method wherein for an ingot or a slab having a Cu >0.20%, preferably having Cu >0.25%, more preferably having Cu of max. 0.28% the homogenising step comprises a first homogenisation stage and a second homogenisation stage, the first homogenisation stage is at most 24 hours, preferably at most 12 hours at 470 0 C and wherein the second homogenisation stage is at most 24 hours, preferably at most 12 hours at 475°C.
• a product having reduced hot crack sensitivity, also having improved strength and toughness properties, and when in artificially aged condition having a hardness of more than 180 HB is obtained.
• Cu preferably Cu ⁇ 0.25% or even Cu ⁇ 0.20%
• a homogenisation treatment of at most 24 hours preferably at most 12 hours at 470 0 C is adequate to dissolve all m-phase precipitates and yield a product having the desired properties after SHT, quenching, optionally stretching, and ageing.
• the process can be performed even more economically if the ageing treatment is a single step ageing treatment.
• the ageing treatment is a single step ageing treatment.
• a product having reduced hot crack sensitivity, also having improved strength, and when in T6 temper condition having a hardness of more than 180 HB is obtained, excellent for high strength tooling plate applications.
• a product having an advantageous combination of improved mechanical properties, hardness in artificially aged condition, toughness properties and corrosion resistance is obtained, excellent for high strength and high toughness weldable aerospace plate.
• the corrosion resistance, particularly IGC and EXCO were found to be improved.
• the m-phase precipitates dissolve rapidly for alloys according to the invention having Cu ⁇ 0.28%, and more rapidly at lower copper contents ⁇ 0.25% or ⁇ 0.20% respectively, so that the process can be made more economical by choosing the duration of the first homogenisation stage time chosen such that a cold spot, said cold spot being defined as the coldest spot in the ingot or slab, usually the centre of the ingot or slab, in the ingot or slab is at the homogenisation temperature, for instance of 470 0 C, for at least a dissolving time necessary to dissolve the m-phase precipitates, wherein preferably the dissolving time is at most 2 hours, preferably 1 hour, more preferably as short as possible.
• control means such as a mathematically or physically based computer model calculating the temperature development of the ingot or cast during the homogenisation treatment, are used for controlling the homogenisation treatment so as to determine the optimum residence time of the slab or ingot at the homogenisation temperature such that the cold spot of the ingot or slab is at the dissolving temperature of e.g.
• annealing times and temperatures are exchangeable to a certain extent by the concept of equivalent time, as defined in EP-0876514-B1 (paragraph [0028]) and incorporated herein by reference, although of course the minimum annealing temperature should be sufficiently high to enable dissolution of the precipitates. It may also be important to avoid dissolution of certain other precipitates, so that the liberty of choosing the annealing temperature is limited by a maximum and a minimum homogenisation temperature.
• the artificial ageing step i.) comprises a first ageing step at a temperature in a range of 105 0 C to 135°C preferably for 2 to 20 hours, and a second ageing step at a temperature in a range of 135°C to 210 0 C preferably for 4 to 20 hours.
• a third ageing step may be applied at a temperature in a range of 105 0 C to 135°C and preferably for 20 to 30 hours.
• the mechanical (L-direction) and corrosion (EXCO, measured according to the standard ASTM G34-97) properties of the alloys are also shown in Table 2.
• An 0.8% Cu level (see alloy B.2) does not improve the mechanical properties, but has an adverse influence on the corrosion behaviour of the alloy.
• Mg and Zn additions (see alloys B.3 and B.4) lead to better corrosion properties and to a considerable strength increase.
• Example 3 Seven alloys with compositions as given in Table 3 were investigated. Most alloys (C.1-C.5) have low Cu levels and some contain more Cu (alloy C.6, CJ). They were all processed to 3.5 mm gauge plate according to the following route:
• Hot rolling preheat @ 43O 0 C, rolled from 80 mm to 3.5 mm thickness, SHT: 1 hr @ 470 0 C, followed by quenching in water or oil, stretching: 1.5%, After SHT, all the alloys in this example were aged into T6 temper.
• the alloys were quenched in both water and oil, to investigate the quench sensitivity of the alloys.
• the oil quench is comparable to the quench rate in the core of a about 70 mm thick plate, where the plate core cannot be quenched as fast as the surface.
• the Brinell hardness was measured according to ASTM E 10, version 2002. The achieved hardness values are given in Table 3. Table 3 shows that the water quenched values are typically higher or similar to the oil quenched values. Alloys with the highest overall alloying content are most quench sensitive. Alloys C.2, C.3, C.5, C.7, which are all > 9.3% in Zn, obtain hardness values of at least 190 HB.
• the low Cu alloys even if quenched in oil, show an excellent resistance to intergranular corrosion (IGC, test performed according to the standard
• the alloy is thus less quench sensitive, which has various advantages in processing the alloy as is has a larger tolerance for fluctuations in the process.
• Hot rolling pre-heat @ 430 0 C, rolled from 80 mm to 3 mm thickness
• Table 4 the resulting average hardness values after 1- and 2-step ageing are given.
• the results in Table 4 indicate that for a HB of 190 or higher, given a Zn content of 9.47%, there is a minimum level of Mg, which lies in between 1.92% and 2.85%.
• Table 3 provides a value of 2.8.
• comparable hardness levels are obtained for 1-step and 2-step artificial ageing. This increases the applicability of this alloy for multiple product ranges, were 2-step ageing is needed (aerospace material requirements) or 1 -step is preferred (cost saving).
• Table 4 shows that the ageing time for the 145°C-step of artificial ageing is allowed to lie in a wide range for reaching hardness levels of 190 HB or higher.
• Table 4 Composition of alloys of example 2 in wt.% with balance aluminium, together with averaged hardness for 1-step and 2-step ageing.
• a compositional relationship between the Mg and the Zn content, above which a high hardness can be expected with proper processing of the alloy can be derived from Table 3 and 4.
• Mg 10 - 0.79 * Zn in wt.%.
• For a Mg content higher than that given by this relationship in dependency with the Zn content will provide a hardness of at least 185 HB, even of at least 190 HB, particularly for the alloys where the Zn-content is above 7.4%.
• Example 5 Three alloys according to the invention (E.1 to E.3) and which are particularly suitable for tooling plate application have been processed according to the process of this invention and subsequently peak-aged at 13O 0 C for 24 hours.
• the tensile properties (yield strength and tensile strength) has been determined in the L-direction and the hardness has been measured at mid-section thickness.
• the alloys have been compared against regular AA7050 and AA7075 alloys in the T651 temper.
• the weldability of three alloys processed according to the invention has been assessed using a well defined procedure used to assess the hot crack sensitivity of an aluminium alloy, and which procedure is also known as the Houldcroft test described in the paper "A simple Cracking Test for use With Argon-Arc Welding", by PT. Houldcroft, British Welding Journal, October 1955, pp.471-475, incorporated herein by reference.
• the procedure uses either a fish bone sample geometry or a tapered specimen geometry, and for laser welding the tapered specimen geometry is preferred and used for this example and having a thickness of 2 mm.
• the laser is used to create a full penetration bead-on-plate weld.
• the weld starts at the narrow end of the sample and runs the entire length of the sample.
• a hot crack is formed during solidification of the weld pool, and at a certain point the crack stops.
• the crack length is a measure of the hot crack sensitivity, such that the longer the crack, the higher the hot crack sensitivity.
• the samples were not constrained during the test and all of the welds were produced without a filler wire addition.
• a Nd:YAG laser was used with a spot size of 0.45 mm (150 mm focus lens) and with the focus position on the top surface of the plate.
• the laser processing parameters were kept constant at 4500 W laser power and 4 m/min welding speed.
• the alloys selected for investigation are given in Table 6 and also the results of the welding tests.
• the crack sensitivity is represented by %cracking being the crack length divided by the specimen length; thus a lower %cracking represents a lower hot crack sensitivity. It can clearly be seen that as the total Zn and Mg solute content is increased, so the crack sensitivity decreases leading to higher weldability.
• the aluminium AA7017 was also tested as this is accepted by the aluminium industry as a weldable alloy. It can clearly be seen that all of the alloys according to this invention were better weldable than AA7017.

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• 2006
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