WO2011040453A1 - 曲げ圧壊性と耐食性に優れたアルミニウム合金押出材 - Google Patents
曲げ圧壊性と耐食性に優れたアルミニウム合金押出材 Download PDFInfo
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- WO2011040453A1 WO2011040453A1 PCT/JP2010/066931 JP2010066931W WO2011040453A1 WO 2011040453 A1 WO2011040453 A1 WO 2011040453A1 JP 2010066931 W JP2010066931 W JP 2010066931W WO 2011040453 A1 WO2011040453 A1 WO 2011040453A1
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- aluminum alloy
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- extruded material
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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
- C22C21/06—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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C23/00—Extruding metal; Impact extrusion
- B21C23/002—Extruding materials of special alloys so far as the composition of the alloy requires or permits special extruding methods of sequences
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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
Definitions
- the present invention relates to an Al—Mg—Si-based aluminum alloy extruded material excellent in bending crushability and a manufacturing method thereof (hereinafter, aluminum is also simply referred to as Al).
- Al aluminum alloy extruded material
- the Al—Mg—Si system is also referred to as 6000 system.
- Patent Document 1 it is proposed to improve the bending workability by making the structure of a 6000 series aluminum alloy extruded material an equiaxed grain structure.
- the contents of Mg and Si are stoichiometrically equivalent, and transition elements such as Mn, Cr, Zr, etc. that promote the fibrous structure are used as the example level.
- the total amount is regulated to 0.1% or less, extruded at an extrusion temperature of 500 ° C. or higher, and subjected to water quenching (forced cooling) immediately after the extrusion.
- an equiaxed grain structure having an average crystal grain size of 100 ⁇ m or less and an aspect ratio of the crystal grains (ratio between the length of the crystal grains in the extrusion direction and the length in the thickness direction) of 2 or less is obtained.
- Patent Document 2 conversely, the structure is not the equiaxed grain structure but a fibrous crystal grain structure (fibrous structure) elongated in the extrusion direction to improve the bending workability of the hollow extruded shape. It has been proposed.
- transition elements such as Mn, Cr, Zr and the like are included in a comparatively large amount of 0.45 to 0.53% in total at an example level, extruded at an extrusion temperature of 500 ° C. or higher, and extruded.
- water quenching forced cooling
- transition elements such as Mn, Cr, and Zr are added at a total amount of 0.5 at an example level. %, And is extruded at an extrusion temperature of 500 ° C. or higher, and water-quenched immediately after extrusion to form a fibrous structure.
- the composition of the extruded material is an excess Si type and transition elements such as Mn, Cr, Zr and the like are included in a comparatively large amount of 0.25 to 0.48% in a total amount at an example level.
- the aluminum alloy composition is included in a comparatively large amount of 0.25 to 0.48% in a total amount at an example level.
- the aluminum alloy composition is included in a comparatively large amount of 0.25 to 0.48% in a total amount at an example level.
- extrusion is performed at the extrusion temperature of 500 degreeC, and it is set as the fibrous structure which controlled the thickness and crystal grain size of the surface recrystallized layer (GG layer).
- the extruded material is excellent not only in vertical crushing but also in lateral crushing.
- patent document 5 in order to combine bending workability as a reinforcing material of a 6000 series aluminum alloy extruded material and pressure cracking resistance, it is a fibrous structure and further has a structure having anisotropy of elongation. It has been proposed.
- the composition of the extruded material is an excess Si type, and transition elements such as Mn, Cr, Zr and the like are included in a comparatively large amount of 0.15 to 0.30% in a total amount at an example level.
- the aluminum alloy composition. Extrusion is also performed at a relatively low extrusion temperature of less than 500 ° C.
- the extruded material has a structure having elongation anisotropy in which the elongation ⁇ 1 in the direction of 45 ° with respect to the extrusion direction is larger than the elongations ⁇ 2 and ⁇ 3 in the direction perpendicular to the other parallel directions.
- Patent Document 6 in order to combine the bending workability and shock absorption of the 6000 series aluminum alloy extruded material as a side member or a bumper reinforcing material, not the fibrous structure but the aspect ratio of the crystal grains (of the crystal grains) It has been proposed to have a fine equiaxed grain structure in which the ratio of the major axis to the minor axis is 3 or less. In this patent document, the elongation and bending workability are improved by using such a fine equiaxed grain structure. In addition, the amount and size of the grain boundary precipitates are controlled to suppress fine fragmentation starting from the grain boundary precipitates at the time of impact.
- the cross-sectional shape is not only a rectangular hollow cross-section (“mouth” shape), but also the cross-sectional shape is a daily shape (“day” shape), or an eye shape (“eye” shape), Bumper reinforcements with a rectangular hollow cross-section of a type reinforced by providing a medium rib such as a rice field ("field" shape) also have a great potential for lack of bending crushability, which is important for improving lateral crushability.
- the present invention has been made paying attention to such circumstances, and its purpose is to provide both bending crushability and corrosion resistance, which are required as a vehicle body reinforcement material even when the collision condition of the vehicle becomes severe. It is an object of the present invention to provide an excellent 6000 series aluminum alloy extruded material and a method for producing the same.
- the gist of the aluminum alloy extruded material excellent in bending crushability and corrosion resistance of the present invention is, by mass, Mg: 0.60 to 1.20%, Si: 0.30 to 0.00. 95%, Fe: 0.01-0.40%, Mn: 0.30-0.52%, Cu: 0.001-0.65%, Ti: 0.001-0.10%, Extrusion of Al—Mg—Si based aluminum alloy in which the content of Mg and Si satisfies Mg (%) ⁇ (1.73 ⁇ Si (%) ⁇ 0.25) ⁇ 0, and the balance is made of Al and inevitable impurities Grain boundary having an equiaxed recrystallized grain structure with a recrystallization area ratio of 65% or more in the cross section in the thickness direction and having a size of the center of gravity diameter of 1 ⁇ m or more observed by a TEM of 5000 times in the same structure The average distance between the precipitates exceeds 25 ⁇ m, and the thickness of this extruded material Glenn gloss of
- the aluminum alloy extruded material replaces a part of Mn, and one or two of Cr: 0.001 to 0.18% and Zr: 0.001 to 0.18% are replaced with Mn, Cr, Zr. These may be selectively included in the range of 0.30 to 0.52%.
- the bending line of the plate-like specimen obtained by the push bending method defined in JIS Z2248 is the extrusion direction as the bending crushability.
- the aluminum alloy extruded material is preferably used for an energy absorbing member that receives a load in a direction perpendicular to the extrusion direction and collapses.
- An aluminum alloy extruded material having the above equiaxed recrystallized structure, grain boundary precipitate distribution, and texture, and having excellent bending crushability and corrosion resistance is obtained by using an Al-Mg-Si-based aluminum alloy cast billet having the above composition, After homogenization heat treatment at a temperature of 560 ° C. or higher, forcibly cool to a temperature of 400 ° C. or lower at an average cooling rate of 100 ° C./hr or higher, and further, the extrusion material temperature on the extrusion outlet side becomes a solution temperature range of 575 ° C. or higher.
- the cast billet is reheated to perform hot extrusion, and the extruded material on the extrusion outlet side is forcibly cooled at an average cooling rate of 5 ° C./second or more immediately after the extrusion processing, and then the extruded material is further cooled.
- It can be manufactured by aging treatment. It is desirable to perform the aging treatment under the condition that the 0.2% proof stress after the aging treatment is 280 MPa or more.
- the present inventors have re-examined the influence of the texture on the bending crushability by paying attention to the texture of the 6000 series (Al-Mg-Si series) aluminum alloy extruded material, which has not been attracting much attention so far. did. As a result, it was found that an equiaxed recrystallized grain structure with few Goss orientations in the texture has a great effect of improving the bending crushability.
- these 6000 series aluminum alloy rolled plates are different from extruded materials (reinforcing materials) and are used as automobile body panels, so that the plates have an extremely thin thickness of about 1 mm or less for weight reduction. It is.
- the bending load applied to the thin plate is different from the collision load applied to the extruded material (reinforcing material) described above. It is a load that is almost uniformly applied over a wide area of the plate by a mold or punch.
- the strength of the rolled sheet when being formed is relatively low strength of 150 MPa or less with 0.2% proof stress even in the case of T4 material in consideration of the formability to an automobile body panel.
- the extruded material targeted by the present invention is an extruded material (reinforcing material) having a rectangular hollow cross section that is thicker than the plate of about 1 mm or less.
- the strength of the extruded material is 0.2% proof stress and high strength of 280 MPa or more. Therefore, hemming (hem workability) in the case of the above-described rolled plate is caused by a vehicle collision such as a pole collision or an offset collision that is locally added to the extruded material (reinforcing material) targeted by the present invention.
- the bending mechanism is basically different in deformation mechanism and deformation form.
- the axial (longitudinal) direction of the extruded hollow profile has a crushing characteristic (longitudinal collapse) and the extruded hollow profile has a cross-sectional direction.
- the characteristics (lateral crushing) excellent it is mainstream to make the structure a fibrous structure elongated in the extrusion direction, and the texture itself has never attracted attention. From this point as well, it is similarly difficult to predict the relationship between Goss orientation and bending crushability in the 6000 series aluminum alloy extruded material.
- the bending crushability is improved as an equiaxed recrystallized grain structure in which the development of Goss orientation (crystal grains having Goss orientation) is suppressed.
- the 6000 series aluminum alloy extruded material is equivalent to the higher strength 7000 series aluminum alloy extruded material and more excellent in corrosion resistance, and is crushed by receiving lateral loads such as bumper reinforcements and door guard bars. It can be used as an energy absorbing member.
- the structure in the cross section in the thickness direction of this extruded material is first an equiaxed recrystallized grain structure as a premise, and characteristically,
- the average area ratio of Goss orientation over the entire thickness region including the outermost glen loss layer in the cross section in the thickness direction of the extruded material is set to less than 8%.
- the average area ratio of Goss orientation is desirably less than 5%.
- the relationship between Goss orientation and bending crushability can be explained as follows.
- the Taylor factor M is a constant corresponding to the crystal orientation. When the tensile axis is parallel to [110] and [111], the maximum value is 3.674. When the tensile axis is parallel to [100], the minimum is 2.449. The value is close to 2.300.
- the critical decomposition shear stress ⁇ CRSS takes a constant value. It is pointed out that the bendability is correlated with this Taylor factor.
- the average area ratio of Goss orientation is the average area ratio over the entire thickness region including the outermost glen loss layer in the cross section in the thickness direction (cross section perpendicular to the extrusion direction, perpendicular cross section) of the extruded material. It prescribes.
- both outermost surfaces usually have a glen loss layer (GG layer, coarse recrystallized grains having a thickness of several hundred ⁇ m by contacting the outermost surfaces with the extrusion die. Tissue layer).
- This outermost GG layer may have a different orientation distribution from the equiaxed recrystallized grain structure other than the inner GG layer. Therefore, in the present invention, the average area ratio of the Goss orientation is defined by the average area ratio over the entire thickness region of the extruded material including the outermost glen loss layer in the cross section in the thickness direction of the extruded material.
- the Goss orientation in the entire thickness region of the extruded material stipulated by the present invention is substantially.
- the average area ratio cannot be measured.
- the structure of the extruded material is the equiaxed recrystallized grain structure as described in Patent Documents 2 to 5, in which the crystal grain aspect ratio exceeds 5, and the crystal grains are elongated in the extrusion direction.
- the equiaxed recrystallized grain structure referred to in the present invention is, as a premise, an equiaxed grain structure in which the average aspect ratio of the crystal grains is less than 5 even if it extends in the extrusion direction.
- the aspect ratio of the crystal grain is a ratio of the major axis to the minor axis.
- the major axis is the length in the extrusion direction of the crystal grain, and the minor axis is the length in the thickness direction.
- the equiaxed recrystallized grain structure has a recrystallization area ratio of 65% or more in the cross section in the thickness direction. If the recrystallization area ratio is lower than this, the bending crushability is lowered. Desirably, it is 80% or more.
- Patent Documents 1 and 6 described above the structure of the 6000 series aluminum alloy extruded material is the equiaxed recrystallized grain structure.
- these Patent Documents 1 and 6 also have an equiaxed recrystallized grain structure, but the Goss orientation cannot be less than 8% over the entire thickness direction of the extruded material cross section.
- the contents of Mg and Si are stoichiometrically equivalent, and transition elements such as Mn, Cr, and Zr that promote the fibrous structure are used in the example level.
- the total amount is regulated to 0.1% or less, extruded at an extrusion temperature of 500 ° C.
- the composition of an extrusion material is made into excess Si type, and although it is selective, it contains transition elements, such as Mn, Cr, and Zr, in a comparatively large amount of 0.34% in total.
- the composition is a 6000 series aluminum alloy. And there is no forced cooling such as online water cooling immediately after extrusion at 500 ° C., and solution treatment and quenching treatment are separately performed off-line.
- the extrudate composition is not made into an excessive excess Si type, and Mn, Cr, and Zr are restricted to a predetermined content range, as described later, a premise for suppressing the development of Goss orientation. As necessary conditions.
- the area ratio (existence ratio) of Goss orientation is determined by scanning the cross section (thickness direction cross section) of the extruded material, for example, the flange (front wall) with a scanning electron microscope SEM (Scanning Electron Microscope). It is measured by a crystal orientation analysis method (SEM / EBSP method) using a scattered electron diffraction image EBSP (Electron Backscatter Diffraction Pattern).
- the crystal orientation analysis method using EBSP projects an EBSP on a screen by irradiating an electron beam onto a sample surface set in an SEM column. This is taken with a high-sensitivity camera and captured as an image on a computer. In the computer, the orientation of the crystal is determined by analyzing this image and comparing it with a pattern obtained by simulation using a known crystal system.
- the crystal orientation analysis method using the EBSP is not a measurement for each crystal grain, but is performed by scanning a specified sample region at an arbitrary fixed interval, and the above process is automatically performed for all measurement points. Therefore, tens of thousands to hundreds of thousands of crystal orientation data can be obtained at the end of measurement. For this reason, there is an advantage that the observation field of view is wide, and the average crystal grain size, the standard deviation of the average crystal grain size, or the information of orientation analysis can be obtained within a few hours for a large number of crystal grains. Therefore, when the texture is measured over a wide area of the cross section of the extruded material including the outermost GG layer as in the present invention, for example, over a wide area having a thickness of 2 mm or more. Ideal for.
- the crystal orientation analysis method using the above EBSP is performed by mechanical polishing and buffing on the surface of the cross-sectional specimen of the extruded material for structure observation (the entire thickness direction of the extruded material cross section including the outermost GG layer). Then, adjust by electropolishing.
- SEM JEOL JSM5410
- EBSP measurement / analysis system manufactured by TSL (Tex SEM Laboratories, Inc.): OIM (Orientation Imaging Macrograph, analysis software name “OIMA Analysis”) is used to determine whether each crystal grain is the target orientation (within 15 ° from the ideal orientation), and the orientation density in the measurement field (area of the orientation) Rate).
- the measurement step interval is, for example, 3 ⁇ m or less, and measurements are taken at several appropriate cross-sectional locations of the extruded material and averaged.
- the measurement area of the material to be measured is usually divided into hexagonal areas, and a Kikuchi pattern is obtained from the reflected electrons of the electron beam incident on the sample surface for each divided area.
- the orientation distribution on the sample surface can be measured.
- the obtained Kikuchi pattern is analyzed to know the crystal orientation at the electron beam incident position. That is, the obtained Kikuchi pattern is compared with data of a known crystal structure, the crystal orientation at the measurement point is obtained, and the average area ratio of Goss orientation is obtained based on the crystal orientation.
- the measurement site of the extruded material is regarded as a plate and conforms to the rules and measurement procedures of the texture in the rolled plate.
- Cube orientation (Cube orientation): ⁇ 001 ⁇ ⁇ 100> Goss orientation: ⁇ 011 ⁇ ⁇ 100> CR orientation: ⁇ 001 ⁇ ⁇ 520> RW orientation: ⁇ 001 ⁇ ⁇ 110> [Cube orientation rotated on (100) plane Orientation] Brass orientation: ⁇ 011 ⁇ ⁇ 211> S orientation: ⁇ 123 ⁇ ⁇ 634> Cu orientation: ⁇ 112 ⁇ ⁇ 111> (or D orientation: ⁇ 4411 ⁇ ⁇ 11118>) SB orientation: ⁇ 681 ⁇ ⁇ 112>.
- the centroid diameter observed by a 5,000 times magnification of the 6000 series aluminum alloy extruded material is 1 ⁇ m or more in size in order to improve the texture.
- the average interval between the grain boundary precipitates is increased to 25 ⁇ m or more. A larger average interval between the grain boundary precipitates is preferable.
- the grain boundary precipitates (precipitates existing at the grain boundaries) referred to in the present invention are mainly compounds such as MgSi and simple substance Si based on the composition of the 6000 series aluminum alloy.
- MgSi is precipitated in the crystal grains as a ⁇ 'phase or the like, and imparts high strength (high proof stress) as a reinforcing material.
- these precipitates precipitate coarsely and densely (largely) at the grain boundaries, they become the starting point of fracture, promote the propagation of the grain boundaries of the fracture, and even if the texture is controlled, the reinforcing material for automobiles As the bending crushability and corrosion resistance are reduced. Therefore, it can be said that the regulation of the interval between the grain boundary precipitates in the present invention is a precondition for exerting the effect of improving the bending crushability and corrosion resistance of the extruded material of 6000 series aluminum alloy.
- Measurement of the average interval and size between the grain boundary precipitates is a cross section of the extruded material, and, unlike the texture observation, the innermost surface of the extruded material, for example, the thickness, except the outermost GG layer.
- the equiaxed recrystallized grain structure at the center is the measurement target.
- the test piece of this equiaxed recrystallized grain structure is processed into a thin film for TEM observation, and the test piece thus obtained is measured by observing the structure with a 5,000-fold TEM.
- the center-of-gravity diameter of the grain boundary precipitate is a size (circle diameter: equivalent circle diameter) when converted into an equivalent circle diameter of the grain boundary precipitate per grain boundary precipitate.
- this equivalent circle diameter (center of gravity diameter) is measured, and only the grain boundary precipitate having a size of the center of gravity diameter of 1 ⁇ m or more is selected.
- the average interval between grain boundary precipitates is comprehensively measured and averaged.
- the chemical composition of the 6000 series aluminum alloy targeted by the present invention will be described.
- the 6000 series aluminum alloy targeted by the present invention is required to have excellent properties such as bending crushability and corrosion resistance as an extruded material for the above-mentioned automobile body reinforcement.
- the composition of the extruded material of the 6000 series aluminum alloy (or the cast billet that is the material) targeted by the present invention is, by mass, Mg: 0.60 to 1.20%, Si: 0.30 to 0.95%, Fe: 0.01 to 0.40%, Mn: 0.30 to 0.52%, Cu: 0.001 to 0.65%, Ti: 0.001 to Each containing 0.10%, the content of Mg and Si satisfying Mg (%) ⁇ (1.73 ⁇ Si (%) ⁇ 0.25) ⁇ 0, and the balance is Al consisting of Al and inevitable impurities —Mg—Si based aluminum alloy.
- Mn of this composition is replaced with one or two of Cr: 0.001 to 0.18% and Zr: 0.001 to 0.18%, and the total of Mn, Cr and Zr is 0. It may be included in the range of 30 to 0.52%.
- % display of content of each element means the mass% altogether.
- the Si content is set in the range of 0.30 to 0.95%.
- the preferable content range of Si is 0.40 to 0.70%, more preferably 0.40 to 0.60%.
- the said compound phase cannot be formed at the time of artificial aging treatment, and the said age-hardening ability and required intensity
- Mg Assuming that the quantitative relationship with Si is satisfied, the Mg content is set to a range of 0.60 to 1.20%. A more preferable content range of Mg for obtaining the above-described balance alloy is 0.70 to 1.1%. Mg forms an aging precipitate that contributes to strength improvement together with Si during solid solution strengthening and artificial aging treatment, exhibits age hardening ability, and has a required strength of 280 MPa or more necessary as a reinforcing material It is an essential element for obtaining (yield strength). If the Mg content is too small, the compound phase cannot be formed during the artificial aging treatment, the age-hardening ability and the required strength cannot be satisfied, and the age-hardening ability cannot be exhibited. On the other hand, when there is too much Mg content, it cannot be set as the above-mentioned balance alloy. In addition, bending workability also decreases.
- the extruded material of the 6000 series aluminum alloy has an equiaxed recrystallized grain structure having a Goss orientation of less than 8% in average area ratio, and an average interval between grain boundary precipitates having a centroid diameter of 1 ⁇ m or more is 25 ⁇ m or more.
- the contents of Mg and Si are made to satisfy the relationship Mg (%) ⁇ (1.73 ⁇ Si (%) ⁇ 0.25) ⁇ 0.
- This relationship rule is that the alloy of the present invention is a balanced alloy in which the contents of Mg and Si are stoichiometrically equivalent to each other among the 6000 series aluminum alloys, or the Si content in the excess Si type composition. Is to make a relatively small alloy.
- the 6000 series aluminum alloy in which the Si content exceeds Mg ⁇ 1.73Si and the excess Si type composition is more excessive, the 6000 series aluminum alloy is more age-hardened by artificial aging treatment at a relatively low temperature. Is improved, and the age-hardening ability (BH property) capable of ensuring the required strength is excellent. For this reason, it is widely used in the field of 6000 series aluminum alloy plates, which are press-formed or bent into the above-mentioned automobile panel and require high formability and high strength after forming.
- BH property age-hardening ability
- the 6000 series aluminum alloy extruded material of the present invention is made into such an excessive Si type, Si remains undissolved during extrusion, becomes a nucleus of various crystal orientations, becomes a texture of random orientation, Goss orientation may develop.
- the structure also tends to be a fibrous structure elongated in the above-described extrusion direction.
- the Si content is too large, grain boundary precipitates due to Si are coarsened, and the number thereof is increased, along with the texture, to improve the bending crushability and corrosion resistance as a reinforcing material,
- the average interval between grain boundary precipitates having a centroid diameter of 1 ⁇ m or more cannot be made 25 ⁇ m or more. Therefore, if the Si content increases beyond the relationship Mg (%) ⁇ (1.73 ⁇ Si (%) ⁇ 0.25) ⁇ 0, the reinforcing material depends on the manufacturing method such as the extrusion conditions. As a result, there is a possibility that the bending crushability and corrosion resistance of the extruded material cannot be improved.
- Fe has the same function as Mn, Cr, Zr, etc., generates dispersed particles (dispersed phase), prevents grain boundary movement after recrystallization, prevents coarsening of crystal grains, and refines crystal grains. There is an effect to make it. Fe is an element that inevitably tends to be mixed in a certain amount (substantial amount) from scrap as a melting raw material. For this reason, the Fe content is in the range of 0.01 to 0.40%. If the Fe content is too small, these effects are not obtained. On the other hand, if the content of Fe is too large, coarse crystallized products such as Al-Fe-Si crystallized products are likely to be generated, and these crystallized products deteriorate the bending crushability, and fracture toughness and fatigue characteristics. Deteriorate etc. A more desirable range is 0.1 to 0.3%.
- Mn is a transition element, like Cr and Zr, and is necessary for preventing coarsening of crystal grains.
- These generate dispersed particles (dispersed phase) made of an intermetallic compound such as an Al—Mn system selectively bonded to other alloy elements during the homogenization heat treatment and the subsequent hot extrusion.
- these dispersed particles are dispersed finely, densely and uniformly, and have the effect of preventing grain boundary movement after recrystallization (pinning effect), preventing coarsening of crystal grains.
- the effect of miniaturizing crystal grains is high.
- Mn content is too small, the pinning force at the grain boundaries is low, and growth in the Goss orientation is allowed, and the average area ratio in the Goss orientation becomes 8% or more, and the bending workability tends to be lowered. Mn can also be expected to increase in strength due to solid solution in the matrix.
- the structure of the extruded material tends to be a fibrous structure elongated in the extrusion direction. For this reason, an equiaxed recrystallized grain structure having an average area ratio of Goss orientation of less than 8% cannot be obtained. Further, excessive inclusion of Mn tends to generate coarse intermetallic compounds and crystallized products during melting and casting, which is a starting point of fracture, required characteristics such as bending crushability and corrosion resistance as a reinforcing material, and extruded materials. This causes a decrease in the bending workability of the steel. Therefore, the Mn content is set to a range of 0.3 to 0.52% (in the case where Cr and Zr are not added).
- Cu contributes to improvement of strength by solid solution strengthening, and also has an effect of significantly accelerating age hardening of the final product during aging treatment. Therefore, 0.001 to 0.65% is contained. If the Cu content is too small, these effects are not obtained. On the other hand, when there is too much content of Cu, the sensitivity of the stress corrosion cracking and intergranular corrosion of an extrusion material structure will be raised remarkably, and corrosion resistance and durability will be reduced. Therefore, the Cu content is within the above range. A more desirable range is 0.2 to 0.5%.
- Ti has the effect of refining the crystal grains of the ingot to make the extruded material structure fine crystal grains. Therefore, Ti is contained in the range of 0.001 to 0.10%. Further, when containing B which is easily mixed when Ti is contained, the content is set to B: 1 to 300 ppm. If the Ti content is too small, this effect cannot be exhibited. However, when there is too much content of Ti, a coarse crystal precipitate will be formed and it will cause the required characteristics, such as the bending crushability and corrosion resistance as a reinforcing material, and the bending workability of an extrusion material to fall. Therefore, the Ti content is within the above range.
- One or two of Cr and Zr Cr and Zr, like Mn, are effective in producing dispersed particles (dispersed phase) composed of intermetallic compounds such as Al—Cr and Al—Zr, and preventing coarsening of the crystal grains (pinning) Effect).
- Cr and Zr are contained excessively, the structure of the extruded material tends to be a fibrous structure elongated in the extrusion direction, like Mn. Therefore, when these effects are required, a part of Mn is selectively replaced with one or two of Cr: 0.001 to 0.18% and Zr: 0.001 to 0.18%.
- Mn, Cr and Zr are contained in a total amount of 0.30 to 0.52%.
- Mn is desirably 0.13% or more. In this range, particularly when 0.1 to 0.18% of Zr is contained, high temperature soaking is performed according to the production method of the present invention, the billet heating temperature is increased, the extrusion speed is increased, and the extrusion outlet temperature is increased.
- the average area ratio of Goss orientation is less than 5%, and the bending workability is further improved (even if the same limit bending R is used, cracking (cracking) ) Is small when cracks occur).
- Zn is contained as an impurity in the 6000 series aluminum alloy. At 0.001% or more, like Cu, it has the effect of improving strength by solid solution strengthening and promoting age hardening. On the other hand, if the content is too large, the susceptibility to stress corrosion cracking and intergranular corrosion of the extruded material structure is remarkably increased and the corrosion resistance and durability are lowered. Therefore, the allowable content is 0.25 as in JIS standard 6061 alloy. % Or less.
- the cross-sectional shape of the 6000 series aluminum alloy extruded material As the cross-sectional shape of the 6000 series aluminum alloy extruded material, a cross-sectional shape capable of enhancing the bending crushability as a reinforcing material is appropriately selected.
- the cross-sectional shape is preferably a hollow shape.
- a typical (basic) shape of this hollow cross-sectional shape is a rectangular hollow cross-section with a substantially cross-sectional shape, and both flanges (front wall and rear wall) and both webs (up and down connecting both flanges) constituting the mouth shape. Side wall).
- the cross-sectional shape is a Japanese shape (one intermediate rib parallel to the upper and lower side walls is provided in the center of the cross section. ), Or a rectangular hollow cross section such as an eye shape (two middle ribs parallel to the upper and lower side walls are provided in the cross section at intervals), and a square shape (a cross middle rib is provided in the cross section).
- the length of both ends of the flange is made longer than the width between the webs, and the flanges and webs bulge outward in addition to the straight shape, or the flanges and webs bulge outward. Or it is good also as circular arc shape dented inward.
- the cross-sectional shape of the extruded material (reinforcing material) in the longitudinal direction is not necessarily the same, but a hollow shape in which the cross-sectional shape changes partially or sequentially can be freely selected from the design side of the reinforcing material.
- the hollow cross section of the bumper reinforcing material in the present invention may be a hollow cross section in which any one of the walls or sides is opened, instead of the complete closed cross section hollow shape as described above. Since it is inferior to the closed cross-section hollow shape in terms of strength, it is disadvantageous in terms of weight reduction and bending crushability.
- the thickness of the extruded material As the thickness of the extruded material, a thickness capable of enhancing the bending crushability as the reinforcing material is appropriately selected in relation to the above-described cross-sectional shape.
- the object of the present invention is a reinforcing material that absorbs energy against the collision of the vehicle body, and in order to enhance the bending crushability as the reinforcing material, it is not as thin as a vehicle body panel made of the above-described rolled thin plate. However, it is necessary to increase the thickness. In order to improve the bending crushability, it is better that the wall thickness is thick, but even if it is too thick, the weight increases and the weight cannot be reduced.
- the thickness is preferably selected from the range of 2 to 7 mm. Further, in each of the cross-sectional shapes described above, it is not necessary that the thicknesses of both flanges, both webs, and intermediate ribs are all the same, the flanges and other impacting (loading) side walls are thickened, and the others are thinned. You can devise such as doing.
- the extruded material of the present invention refers to an extruded material that has been subjected to appropriate tempering such as quenching or artificial age hardening after hot extrusion, and the manufacturing process itself is excluding the control conditions of the texture to be described later.
- the conventional method or a known method is used.
- an aluminum alloy ingot having the above-described 6000 series component composition is cast into a billet.
- the billet is once cooled to a temperature near room temperature after the homogenization heat treatment. And it reheats to solution treatment temperature, it extrudes hot, and forcibly cools online to the temperature of 190 degrees C or less including immediately after extrusion to room temperature, It is set as the extruded material of the above-mentioned predetermined cross-sectional shape.
- This extruded material was also subjected to a solution treatment and a quenching process through a series of hot extrusion processes.
- this artificial age hardening treatment may not be performed in advance at the stage of the extruded material, but may be performed by baking and curing the paint after painting the automobile body after assembling to the automobile body as an automobile reinforcing material.
- the molten aluminum alloy melt-adjusted within the above-mentioned 6000 series component composition range is cast by appropriately selecting a normal melting casting method such as a continuous casting method or a semi-continuous casting method (DC casting method). .
- Homogenization heat treatment Next, the cast aluminum alloy ingot (billet) is subjected to a homogenization heat treatment.
- the temperature of the homogenization heat treatment itself is selected from a high temperature of 560 ° C. or higher, a homogenization temperature range below the melting point, and optimally a temperature range of 560 to 590 ° C.
- the purpose of this homogenization heat treatment (soaking) is to homogenize the structure, that is, to eliminate segregation in the crystal grains in the ingot structure and to sufficiently dissolve the alloy elements and coarse compounds. If the homogenization temperature is low, the segregation in the crystal grains cannot be sufficiently eliminated, and this acts as a starting point of fracture.
- the soaking temperature is less than 560 ° C.
- an equiaxed recrystallized structure cannot be obtained (particularly when 0.1 to 0.18% of Zr is contained), or the Goss orientation is obtained even if an equiaxed recrystallized structure is obtained.
- the area ratio increases, and the bending crushability decreases.
- the cast billet is forcibly cooled to a temperature of 400 ° C. or lower, including room temperature, at an average cooling rate of 100 ° C./hr or higher.
- the cooling rate of this forced cooling is preferably large (fast), and is performed by forced cooling using a fan or water cooling. If forced cooling to a temperature of 400 ° C. or lower after soaking is performed, thereafter, forced cooling is stopped at this temperature, or after the forced cooling is stopped at this temperature, it is allowed to cool to room temperature, or it is continuously forced to room temperature.
- the cooling can be freely selected.
- the ingot (billet) is allowed to cool outside the soaking furnace (natural cooling), for example, depending on the size of the billet, the normal size is homogenized heat treatment.
- the subsequent cooling rate is about 40 ° C./hr at the highest, and does not increase to the above 100 ° C./hr or more.
- the MgSi compound that is once dissolved in the high-temperature homogenization heat treatment is combined with the FeAl compound that remains undissolved because of its high melting point during this cooling to form a new composite compound (precipitate).
- Hot extrusion Next, the cast billet is reheated and subjected to hot extrusion so that the extrusion material temperature on the extrusion outlet side is a solution temperature range of 575 ° C. or higher, and the extrusion material on the extrusion outlet side is immediately after extrusion. Forcibly cool down to 190 ° C or lower including room temperature at an average cooling rate of 5 ° C / second or more to prepare a tempered material for T5, or T6 (aging) or T7 in combination with artificial aging treatment thereafter It is preferable to use a tempered treatment material of (overaging).
- the Cube orientation is more likely to accumulate at a lower temperature, and the Cube orientation is dominant in the texture of the extruded material, and the average area of the Goss orientation is the average area ratio over the entire thickness direction of the extruded material cross section.
- An equiaxed recrystallized grain structure with a rate of less than 8% can be obtained.
- the reheating temperature of the cast billet is not necessarily set to 500 ° C. or higher. Not a problem.
- the extrusion speed is low, the extruded material temperature may not be in the solution temperature range.
- the Cube orientation is likely to be accumulated at the low speed, and the Goss orientation is likely to be accumulated at a high speed. For this reason, it is preferable to select an extrusion speed that can raise the temperature to the solution temperature range without reducing the Cube orientation and without increasing the Goss orientation.
- the temperature of the extruded material on the extrusion outlet side is the material surface temperature immediately after the die outlet (distance 0 mm from the outlet). If it is difficult to measure immediately after the die exit, the surface temperature of the material is measured with a contact thermometer at a certain distance from the die exit (the position where the temperature can be measured differs depending on the extrusion press). Using the cooling curve, the temperature immediately after the die exit can be calculated by back calculation.
- the quenching treatment by forced cooling at an average cooling rate of 5 ° C./second or more from immediately after extrusion to 190 ° C. including room temperature is performed in order to improve the bending crushability as a reinforcing material.
- the texture is an equiaxed recrystallized grain structure having a Goss orientation of less than 8%.
- the average distance between grain boundary precipitates having a gravity center diameter of 1 ⁇ m or more is increased to 25 ⁇ m or more to improve the bending crushability and corrosion resistance.
- Forcible cooling immediately after extrusion is preferably water cooling.
- a forced cooling means such as a spray or shower of mist, water, or a water tank is provided or combined on the line on the exit side of the extruder, and is performed online.
- the cooling rate in the case of the forced cooling means by water cooling depends on the specifications of the equipment, but in the case of the forced cooling means by water cooling, a cooling rate of 10 ° C./second or more is usually obtained.
- T5 tempering process after the extrusion process, the process of solution heating and quenching process by separately reheating the extruded material can be omitted.
- the extruded material is separately reheated to a solution temperature range of 500 ° C. or more, and solution treatment and quenching treatment are performed. It is good also as a tempering treatment material of T6 which performs artificial aging treatment.
- the extruded material is subjected to artificial age hardening after cutting or straightening to a predetermined length.
- This artificial age hardening treatment is preferably held in a temperature range of 150 to 250 ° C. for a necessary time.
- the age hardening of the extruded material is adjusted by this holding time, and is appropriately selected from the time for peak aging to maximize the strength and the time for overaging to improve the corrosion resistance for a longer time.
- billets were cast from the molten aluminum alloys having the respective component compositions shown in Tables 1 and 2.
- the billet was subjected to homogenization heat treatment at each temperature shown in Tables 3 and 4, and then cooled to room temperature at an average cooling rate (° C./hr) shown in Tables 3 and 4 by forced air cooling with a fan.
- the billet after this homogenization heat treatment was reheated to the temperatures shown in Tables 3 and 4, and immediately hot extruded at the extrusion speed (m / min) shown in Tables 3 and 4.
- Tables 3 and 4 show the extrusion outlet temperature (die outlet arrival temperature) (° C).
- the outer shape of the extruded material of the cross-section of the mold is the size for the bumper reinforcement, and in each example, each flange (front wall, rear wall) is 40 mm long, 2.3 mm thick, each web The length of the (side wall) and the middle rib was 40 mm, each thickness was 2.0 mm, and the length after cutting was 1300 mm.
- Specimens (plate-shaped test pieces) were cut out from the web (side wall) portions of the extruded materials after the artificial age hardening treatment, and the structure and characteristics of the specimens were measured and evaluated. These results are shown in Tables 5 and 6.
- the average aspect ratio of the crystal grains in the recrystallized grain structure of each example was simultaneously measured, and the structure morphology of the recrystallized grains was evaluated and discriminated. That is, an equiaxed grain structure having an average aspect ratio of 5 or less as crystal grains and a fibrous structure having an average aspect ratio exceeding 5 were used.
- columns of Tables 5 and 6 those having an equiaxed grain structure of 50% or more are described as equiaxed recrystallized structures, and those having an equiaxed grain structure of less than 50% are designated as fibrous structures. Described. In all Examples and Comparative Examples, the recrystallized portion was all composed of an equiaxed grain structure.
- test material properties As the characteristics of the test material after standing at room temperature for 30 days after the tempering treatment, 0.2% yield strength (As yield strength: MPa) and elongation (%) were measured, respectively. Also, bending crushability and corrosion resistance were measured and evaluated. These results are also shown in Tables 5 and 6.
- Tensile test In the tensile test, a No. 13 B test piece (width: 12.5 mm, rating distance: 50 mm, thickness: extruded material thickness) was sampled from the test material and subjected to room temperature tension. At this time, the specimen was collected and the tensile direction was taken as the extrusion direction. The tensile speed was 5 mm / min up to 0.2% proof stress and 20 mm / min after proof stress. The measured N number was 5, and each mechanical property was an average of these values.
- Bending crushability (bending workability) test The specimen (plate-shaped test piece) was subjected to a 180 ° bending test (in a direction perpendicular to the extrusion direction) by a bending method defined in JIS Z2248 so that the bending line is in the extrusion direction (10 times).
- the limit bend R (mm) at which breakage due to cracks did not occur outside the bending corner (tensile side portion) was obtained 10 times. It was evaluated that the smaller the limit bending R, the better the bending crushability. If this limit bending R is 3.0 mm or less, it is excellent in bending crushability and can be used as a reinforcing material for automobiles.
- Corrosion resistance test The specimen was subjected to a corrosion test by an immersion method defined in the ISO / DIS11846B method. The test condition was that the extruded material was immersed in an aqueous solution in which NaCl was dissolved at a concentration of 30 g / l and HCl was dissolved at a concentration of 10 ml / l for 24 hours at room temperature. Were examined to determine whether intergranular corrosion cracking occurred. And when the intergranular corrosion cracking has occurred x, not the intergranular corrosion cracking, but when the intergranular corrosion has occurred ⁇ , when the intergranular corrosion cracking or intergranular corrosion has not occurred ( A case where superficial front corrosion occurred) was evaluated as ⁇ .
- each of Invention Examples 1 to 10 includes a homogenization heat treatment (homogenization) within the composition range of the present invention including the above-described relationship between the contents of Mg and Si and within a preferable condition range. (Thermal temperature, forced cooling) and hot extrusion (billet heating temperature, extrusion outlet temperature, forced cooling immediately after extrusion). For this reason, as shown in Table 5, it has an equiaxed recrystallized grain structure (Recrystallized area ratio of 65% or more) having the Goss orientation area ratio defined in the present invention, and the grain boundary precipitate average defined in the present invention. Have an interval. As a result, each invention example is excellent in bending crushability and corrosion resistance.
- Comparative Examples 1, 5 and 6 have a low soaking temperature, an equiaxed recrystallized structure (a recrystallization area ratio of 65% or more) is obtained in Comparative Examples 1 and 5 (composition containing a predetermined amount of Zr).
- Comparative Example 6 composition not containing Zr
- many Goss orientations were accumulated due to insufficient pinning force, and all were inferior in bending crushability.
- Comparative Examples 2 to 4 since the total content of Mn + Cr + Zr was small, an equiaxed recrystallization structure (recrystallization area ratio of 65% or more) was obtained, but growth of Goss orientation was allowed due to insufficient pinning force. Also, the bending crushability is inferior.
- Comparative Examples 7 and 8 have a large total content of Mn + Cr + Zr, the fibrous structure (recrystallization) was observed both when the method of the present invention (Comparative Example 7) and when the soaking temperature was low (Comparative Example 8).
- the area ratio is less than 50%) and the bending crushability is inferior.
- Comparative Example 9 since the extrusion temperature was low and the extrusion speed was low, the extrusion outlet side temperature was low, the fibrous structure (recrystallization area ratio was less than 65%), and the proof stress was lowered. Since Comparative Example 10 had an excess Si composition, an equiaxed recrystallized structure was obtained, but the Goss orientation was developed, the bending crushability was inferior, and coarse grain boundary precipitates were increased to reduce the corrosion resistance. In Comparative Example 11, the cooling rate of forced cooling immediately after extrusion was small and the quenching was delayed, coarse grain boundary precipitates increased, and the corrosion resistance decreased.
- Comparative Examples 12 to 14 since the extrusion outlet side temperature is low, coarse grain boundary precipitates increase, and Comparative Example 12 in which an equiaxed recrystallized structure having a recrystallization area ratio of 65% or more is not obtained has poor strength.
- the comparative example 13 of the fibrous structure and the comparative example 14 of the equiaxed recrystallized structure (recrystallized area ratio of 65% or more) are inferior in bending crushability.
- Comparative Example 15 has an excessive Si content
- Comparative Example 16 has an excessive Fe content
- Comparative Example 18 has an excessive Mn content
- Comparative Example 19 has an excessive Mg content
- Comparative Example 20 has an Cr, Zr content.
- Excessive and Comparative Example 22 have an excessive Ti content and are inferior in bending crushability.
- Comparative Example 17 has an excessive Cu content
- Comparative Example 21 has an excessive Zn content, both of which have poor corrosion resistance.
- the Si and Mg contents are insufficient and the strength (yield strength) is low.
- the cooling rate after soaking is low, and a coarse MgSi compound is produced, so that the bending crushability is inferior.
- the results of the above examples support the critical significance or effect for combining the bending crushability and mechanical properties of the requirements of the components and structures in the present invention, or preferable manufacturing conditions.
- the present invention it is possible to provide a 6000 series aluminum alloy extruded material excellent in both bending crushability and corrosion resistance, which is required as a vehicle body reinforcing material, and a method for producing the same, even when the collision condition of the automobile becomes severe. That is, it is suitable as a vehicle body reinforcing material such as a bumper reinforcing material or a door guard bar that requires excellent lateral crushability.
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Abstract
Description
上記組成及び組織形態をとることにより、本発明に係るアルミニウム合金押出材では、前記曲げ圧壊性として、JIS Z2248に規定された押し曲げ法による、板状採取試験片の曲げ線が押出方向となる180°曲げ試験にて、割れが発生しない限界曲げRが3.0mm以下の性能が得られ、前記耐食性として、ISO/DIS11846B法に規定された交互浸漬法による腐食試験にて粒界腐食が発生しない性能が得られる。前記アルミニウム合金押出材は、押出方向と直角方向に荷重を受けて圧壊するエネルギー吸収部材に用いられることが好ましい。
補強材としての曲げ圧壊性に対しては、6000系アルミニウム合金押出材の集合組織について、Goss方位を有する結晶粒の平均面積率が少ないほど向上する。
Goss方位の平均面積率が8%以上では、高強度域において曲げ圧壊性が向上せず、自動車用補強材としての要求特性(仕様)を満足できない。
多結晶体の降伏応力σyは、テイラー(Taylor)因子M、結晶の臨界分解せん断応力τCRSSにより、σy=M・τCRSSと表される。テイラー因子Mは結晶方位に対応した定数で、引張軸が[110]及び[111]と平行である場合に最大値3.674となり、[100]と平行である場合は2.449と、最小値2.300に近い値となる。臨界分解せん断応力τCRSSは一定値をとる。曲げ加工性はこのテイラー因子との相関が指摘されている。
本発明で、押出材の組織を等軸再結晶粒組織とするのは、前記特許文献2~5のような、結晶粒のアスペクト比が5を超える、押出方向に結晶粒が伸長したような繊維状組織では、高強度でかつ曲げ圧壊性に優れた押出材が得られにくいからである。ここで、本発明で言う等軸再結晶粒組織とは、前提として、結晶粒の平均アスペクト比が、押出方向に伸長したとしても5未満の等軸粒組織である。また、この結晶粒のアスペクト比とは、長軸と短軸との比であり、通常は長軸が結晶粒の押出方向の長さで、短軸が厚さ方向の長さである。
等軸再結晶粒組織は、厚み方向断面における再結晶面積率が65%以上とする。再結晶面積率がこれより低いと曲げ圧壊性が低下する。望ましくは80%以上である。
特許文献1では、等軸粒組織とするために、MgとSiとの含有量が化学量論的に当量であり、繊維状組織を促進するMn、Cr、Zrなどの遷移元素を実施例レベルでは合計量で0.1%以下と規制し、500℃以上の押出温度で押出して、押出直後に水焼入れ(強制冷却)を行って製造している。これによって、平均結晶粒径が100μm以下で、かつ結晶粒のアスペクト比が2以下である等軸粒組織としている。また、特許文献6では、実施例において、押出材の組成を過剰Si型とし、かつ、選択的ではあるがMn、Cr、Zrなどの遷移元素を合計で0.34%と比較的多量に含む6000系アルミニウム合金組成としている。そして、500℃での押出直後からのオンラインでの水冷などの強制冷却は無く、別途オフラインにて溶体化および焼入れ処理を行っている。
Goss方位(各結晶方位成分)の面積率(存在率)は、押出材の例えばフランジ(前面壁)の前記した断面(厚み方向断面)を、走査型電子顕微鏡SEM(Scanning Electron Microscope)による、後方散乱電子回折像EBSP(Electron Backscatter Diffraction Pattern)を用いた結晶方位解析方法(SEM/EBSP法)により測定する。
なお、押出材のGoss方位を含めた集合組織については、押出材の測定部位を板と見なして、圧延板における集合組織の規定や測定要領に準じる。
本発明では、6000系アルミニウム合金押出材の組織について、上記集合組織とともに、補強材としての曲げ圧壊性や耐食性を向上させるために,5000倍のTEMにより観察される重心直径が1μm以上のサイズを有する粒界析出物同士の平均間隔を25μm以上に大きくする。この粒界析出物同士の平均間隔は大きい方が好ましい。
粒界析出物同士の平均間隔とサイズの測定は前記した押出材の断面であって、前記集合組織観察とは違い、前記最表面のGG層を除き、押出材の厚み方向内側の、例えば厚み中心部の等軸再結晶粒組織部分を測定対象とする。この等軸再結晶粒組織の試験片をTEM観察用に薄膜加工し、このように得られた試験片について、5000倍のTEMにより組織観察して測定する。
本発明が対象とする6000系アルミニウム合金の化学成分組成について説明する。本発明が対象とする6000系アルミニウム合金は、前記した自動車車体補強材用の押出材として、優れた曲げ圧壊性や耐食性などの諸特性が要求される。
Mgとの前記量的関係を満足することを前提として、Si含有量は0.30~0.95%の範囲とする。前記したバランス合金とするための、Siの好ましい含有量範囲は0.40~0.70%、更に好ましくは0.40~0.60%である。SiはMgとともに、固溶強化と、低温での人工時効処理時に、強度向上に寄与する時効析出物を結晶粒内に形成して、時効硬化能を発揮し、補強材として必要な280MPa以上の必要強度(耐力)を得るための必須の元素である。Si含有量が少なすぎると、人工時効処理時に前記化合物相を形成できず、前記時効硬化能や必要強度を満たすことができない。一方、Si含有量が多すぎると、前記したバランス合金とすることができず、本発明の集合組織とできない。粒界析出物が増加して曲げ加工性なども低下し、更に、溶接性も阻害される。
Siとの前記量的関係を満足することを前提として、Mg含有量は0.60~1.20%の範囲とする。前記したバランス合金とするための、Mgの更に好ましい含有量範囲は0.70~1.1%である。Mgは、固溶強化と、前記人工時効処理時に、Siとともに強度向上に寄与する時効析出物を結晶粒内に形成して、時効硬化能を発揮し、補強材として必要な280MPa以上の必要強度(耐力)を得るための必須の元素である。Mg含有量が少なすぎると、人工時効処理時に前記化合物相を形成できず、前記時効硬化能や必要強度を満たすことができないし、時効硬化能を発揮できない。一方、Mg含有量が多すぎると、前記したバランス合金とすることができない。また、曲げ加工性も低下する。
ここで、6000系アルミニウム合金押出材を、Goss方位が平均面積率で8%未満の等軸再結晶粒組織とし、また、重心直径が1μm以上の粒界析出物同士の平均間隔を25μm以上とするためには、MgとSiとの含有量が、Mg(%)-(1.73×Si(%)-0.25)≧0の関係を満たすようにする。この関係規定は、本発明合金を、6000系アルミニウム合金の中でも、MgとSiとの含有量が互いに化学量論的に当量であるようなバランス合金、あるいは過剰Si型組成の中でもSiの含有量が比較的少なめの合金とするためのものである。
Feは、Mn、Cr、Zrなどと同じ働きをして、分散粒子(分散相)を生成し、再結晶後の粒界移動を妨げ、結晶粒の粗大化を防止するとともに、結晶粒を微細化させる効果がある。また、Feは溶解原料としてのスクラップなどから一定量(実質量)が必然的に混入しやすい元素である。このため、Feの含有量は0.01~0.40%の範囲とする。Feの含有量が少な過ぎると、これらの効果が無い。一方、Feの含有量が多過ぎると、Al-Fe-Si晶出物などの粗大な晶出物を生成しやすくなり、これらの晶出物は曲げ圧壊性を劣化させ、破壊靱性および疲労特性などを劣化させる。より望ましい範囲は0.1~0.3%である。
Mnは、Cr、Zrと同じく遷移元素であり、結晶粒の粗大化を防止するために必要である。これらは、均質化熱処理時およびその後の熱間押出加工時に、他の合金元素と選択的に結合したAl-Mn系などの金属間化合物からなる分散粒子(分散相)を生成する。これらの分散粒子は、製造条件にもよるが、微細で高密度、均一に分散して、再結晶後の粒界移動を妨げる効果(ピン止め効果)があるため、結晶粒の粗大化を防止するとともに、結晶粒を微細化させる効果が高い。Mnの含有量が少なすぎると、粒界のピン止め力が低く、Goss方位の成長も許してしまい、Goss方位の平均面積率が8%以上となって、曲げ加工性を低下させやすい。また、Mnはマトリックスへの固溶による強度の増大も見込める。
Cuは固溶強化にて強度の向上に寄与する他、時効処理に際して、最終製品の時効硬化を著しく促進する効果も有する。したがって、0.001~0.65%を含有させる。Cuの含有量が少な過ぎると、これらの効果が無い。一方、Cuの含有量が多過ぎると、押出材組織の応力腐食割れや粒界腐食の感受性を著しく高め、耐食性や耐久性を低下させる。したがって、Cuの含有量は前記範囲とする。より望ましい範囲は0.2~0.5%である。
Tiは、鋳塊の結晶粒を微細化し、押出材組織を微細な結晶粒とする効果がある。したがって、Tiは0.001~0.10%の範囲で含有させる。また、Tiを含有させる際に混入しやすいBを含有する場合には、B:1~300ppmの範囲とする。Tiの含有量が少な過ぎるとこの効果が発揮されない。しかし、Tiの含有量が多過ぎると、粗大な晶析出物を形成し、補強材としての前記曲げ圧壊性や耐食性などの要求特性や、押出材の曲げ加工性などを低下させる原因となる。したがってTiの含有量は前記範囲とする。
Cr、Zrは、Mnと同じく、Al-Cr系、Al-Zr系などの金属間化合物からなる分散粒子(分散相)を生成して、結晶粒の粗大化を防止するために有効(ピン止め効果)である。但し、これらの元素を過剰に含有すると、Mnと同じく、押出材の組織が押出方向に伸長した繊維状組織となりやすくなる。したがって、これらの効果が必要な場合には、Mnの一部を、Cr:0.001~0.18%、Zr:0.001~0.18%の1種または2種で選択的に置き換え、Mn,Cr,Zrの合計で0.30~0.52%含有させる。Cube方位を優先的に成長させ、相対的にGoss方位の成長を抑制するには、Mnは0.13%以上であることが望ましい。この範囲で、特にZrを0.1~0.18%含有する場合、本発明の製造方法に従って高温均熱し、ビレット加熱温度を高く、押出速度を大きくし、押出出口温度を高温にすることにより(高温加熱によりAl-Zr系金属間化合物粒子によるピン止め力を少し弱め、成長速度が大きいCube方位を優先的に成長させ、相対的にGoss方位が成長しないようにする)、再結晶率65%以上を得た上で、Goss方位の平均面積率をより少ない5%未満とし、曲げ加工性をより向上(仮に同じ限界曲げRであっても、限界曲げRを超える曲げ加工で割れ(亀裂)が発生したときの亀裂が小さい)させることができる。
Znは、6000系アルミニウム合金に不純物として含有される。0.001%以上で、Cuと同様に、固溶強化による強度の向上、および時効硬化を促進する効果を有する。一方、含有量が多過ぎると、押出材組織の応力腐食割れや粒界腐食の感受性を著しく高め、耐食性や耐久性を低下させるので、許容される含有量はJIS規格6061合金と同じく0.25%以下とする。
6000系アルミニウム合金押出材の断面形状は、補強材としての曲げ圧壊性を高めることができる断面形状が、適宜選択される。軽量化と補強材としての曲げ圧壊性とを兼備するためには、断面形状が中空形状であることが好ましい。この中空断面形状の代表的な(基本的な)形状は、断面形状が略口形の矩形中空断面であり、口形を構成する両フランジ(前壁、後壁)と両ウエブ(両フランジをつなぐ上下側壁)とからなる。この口形中空断面の基本形に対して、曲げ圧壊性を高めるに、更に中リブを設けて補強した、断面形状が日形(上下側壁と平行な1本の中リブを断面内の中央部に設ける)、あるいは目形(上下側壁と平行な2本の中リブを断面内に間隔を開けて設ける)、田形(十字の中リブを断面内に設ける)等の矩形中空断面としても良い。
押出材の肉厚は、上記した断面形状との関係で、補強材としての曲げ圧壊性を高めることができる肉厚が適宜選択される。ただ、本発明が対象とするのは、車体の衝突に対するエネルギーを吸収する補強材であり、補強材としての曲げ圧壊性を高めるためにも、前記した圧延薄板からなる車体パネルのように薄くはなく、厚みを厚くする必要がある。曲げ圧壊性を高めるためには、肉厚が厚い方が良いが、あまり厚くしても、重量が増加して、軽量化が図れない。この点、肉厚は2~7mmの範囲から選択することが好ましい。また、前記した各断面形状において、両フランジ、両ウエブ、中リブなどの肉厚を、全て同じとする必要はなく、フランジなど衝突する(荷重を受ける)側の壁を厚くし、その他を薄くするなどの工夫ができる。
次ぎに、本発明に係る6000系アルミニウム合金押出材の製造方法について以下に説明する。本発明押出材は、熱間押出後に、焼入れ処理、あるいは人工時効硬化処理などの適宜の調質が施された押出材を言い、後述する集合組織の制御条件などを除けば、製造工程自体は常法あるいは公知の方法で行う。
溶解、鋳造工程では、上記6000系成分組成範囲内に溶解調整されたアルミニウム合金溶湯を、連続鋳造法、半連続鋳造法(DC鋳造法)等の通常の溶解鋳造法を適宜選択して鋳造する。
次いで、前記鋳造されたアルミニウム合金鋳塊(ビレット)に均質化熱処理を施す。均質化熱処理の温度自体は、560℃以上の高温、融点未満での均質化温度範囲、最適には560~590℃の温度範囲から選択される。この均質化熱処理(均熱処理)は、組織の均質化、すなわち、鋳塊組織中の結晶粒内の偏析をなくし、合金元素や粗大な化合物を十分に固溶させることを目的とする。この均質化温度が低いと結晶粒内の偏析を十分に無くすことができず、これが破壊の起点として作用する。また均熱温度が560℃未満であると、等軸再結晶組織が得られないか(特にZrを0.1~0.18%含むとき)、等軸再結晶組織が得られてもGoss方位の面積率が増加し、曲げ圧壊性が低下する。
次に、押出出口側の押出材温度が575℃以上の溶体化温度域になるように、前記鋳造ビレットを再加熱して熱間押出を行い、この押出出口側の押出材を押出加工直後から室温までを含む190℃以下までを5℃/秒以上の平均冷却速度で強制冷却し、T5の調質処理材とするか、あるいは、その後の人工の時効処理と併せてT6(時効)あるいはT7(過時効)の調質処理材とすることが好ましい。この押出直後の冷却は、押出材の温度が190℃以下になるまで強制冷却を行えば、それ以降は、この温度で強制冷却を停止するか、この温度で強制冷却停止後は室温まで放冷するか、室温まで引き続き強制冷却するか、は自由に選択できる。このT5の調質処理においては、押出出口側の押出材の温度を575℃以上の溶体化温度域の温度として、オンライン(押出加工)にて溶体化処理し、引き続き、押出直後から押出材を室温近傍の温度まで、オンライン(押出機出口側)にて強制冷却する焼入れ処理を行う。
なお、押出出口側の押出材の温度は、ダイス出口直後(出口からの距離0mm)における材料表面温度である。ダイス出口直後で測定することが困難な場合、ダイス出口からある距離(押出プレスによって温度測定ができる位置が異なる)において材料表面温度を接触式温度計で測定し、予め測定したおいた押出材の冷却曲線を用い、ダイス出口直後の温度を逆算して求めることができる。
押出材は、所定の長さに切断あるいは矯正処理後に、人工時効硬化処理が施される。この人工時効硬化処理は、好ましくは150~250℃の温度範囲に必要時間保持する。この保持時間によって、押出材の時効硬化は調節され、強度を最大にするピーク時効とする時間や、これより長時間として耐食性を向上させる過時効とする時間から適宜選択される。
Goss方位の平均面積率:
前記調質処理後15日間の室温放置後の供試材の集合組織を、前記SEM-EBSPを用いて、測定・解析し、供試材の、最表面のグレングロス層を含めた、断面の厚み方向全域に亙るGoss方位の平均面積率(%)を求めた。
前記調質処理後30日間の室温放置後の供試材の特性として、0.2%耐力(As耐力: MPa)、伸び(%)を各々測定した。また、曲げ圧壊性および耐食性を測定、評価した。これらの結果も表5,6に示す。
引張試験は、前記供試材から13号B試験片(幅:12.5mm、評点距離:50mm、厚さ:押出材厚さ)を採取し、室温引張りを行った。このときの試験片の採取、引張方向を押出方向とした。引張り速度は、0.2%耐力までは5mm/分、耐力以降は20mm/分とした。測定N数は5として、各機械的性質は、これらの平均値とした。
前記供試材(板状試験片)を、JIS Z2248に規定された押し曲げ法により、曲げ線が押出方向となるように(押出方向と直角方向に)180°曲げ試験し、10回試験して10回とも曲げコーナーの外側(引張側部位)に割れによる破断が発生しない限界曲げR(mm)を求めた。この限界曲げRが小さいほど、曲げ圧壊性に優れると評価した。この限界曲げRが3.0mm以下であれば、曲げ圧壊性に優れ、自動車用の補強材として使用可能である。
前記供試材を、ISO/DIS11846B法に規定された浸漬法により腐食試験を行った。試験条件は、押出材を、NaClを30g/lの濃度およびHClを10ml/lの濃度で各々溶解させた水溶液に、室温で24時間浸漬した後の、押出材の断面観察を行って腐食形態を調査し、粒界腐食割れ発生の有無を判定した。そして、粒界腐食割れが発生している場合を×、粒界腐食割れではないが、粒界腐食が発生している場合を△、粒界腐食割れや粒界腐食が発生していない場合(表面的な前面腐食が発生している場合を含む)を○として評価した。
比較例2~4はMn+Cr+Zrの合計含有量が少ないため、等軸再結晶組織(再結晶面積率65%以上)が得られたが、ピン止め力不足によりGoss方位の成長を許してしまい、いずれも曲げ圧壊性が劣る。
比較例7,8はMn+Cr+Zrの合計含有量が多いため、本発明の方法に従った場合(比較例7)および均熱温度が低い場合(比較例8)のいずれも、繊維状組織(再結晶面積率50%未満)となり、曲げ圧壊性が劣る。
比較例10は過剰Si組成であるため、等軸再結晶組織が得られたが、Goss方位が発達して曲げ圧壊性が劣り、また粗大な粒界析出物が増えて耐食性が低下した。
比較例11は押出直後からの強制冷却の冷却速度が小さく焼き入れ遅れとなり、粗大な粒界析出物が増えて耐食性が低下した。
比較例12~14はいずれも押出出口側温度が低いため粗大な粒界析出物が増えて、再結晶面積率65%以上の等軸再結晶組織が得られていない比較例12は強度が劣り、繊維状組織の比較例13および等軸再結晶組織(再結晶面積率65%以上)の比較例14は、曲げ圧壊性が劣る。
Claims (4)
- 質量%で、Mg:0.60~1.20%、Si:0.30~0.95%、Fe:0.01~0.40%、Mn:0.30~0.52%、Cu:0.001~0.65%、Ti:0.001~0.10%を各々含み、MgとSiとの含有量がMg(%)-(1.73×Si(%)-0.25)≧0を満たし、残部がAlおよび不可避的不純物からなるAl-Mg-Si系アルミニウム合金押出材であって、厚み方向断面において再結晶面積率が65%以上の等軸再結晶粒組織を有し、同組織において5000倍のTEMにより観察される重心直径が1μm以上のサイズを有する粒界析出物同士の平均間隔が25μmを超え、この押出材の厚み方向断面における最表面のグレングロス層を含めた厚み領域全域に亙るGoss方位の平均面積率が8%未満であることを特徴とする曲げ圧壊性と耐食性に優れたアルミニウム合金押出材。
- Mnの一部がCr:0.001~0.18%、Zr:0.001~0.18%の1種または2種で置き換えられ、Mn,Cr,Zrの合計が0.30~0.52%である請求項1に記載の曲げ圧壊性と耐食性に優れたアルミニウム合金押出材。
- 前記アルミニウム合金押出材の前記曲げ圧壊性が、JISZ2248に規定された押し曲げ法による、板状採取試験片の曲げ線が押出方向となる180°曲げ試験にて、割れが発生しない限界曲げRが3.0mm以下の性能である請求項1に記載の曲げ圧壊性と耐食性に優れたアルミニウム合金押出材。
- 請求項1に記載された組成を有するAl-Mg-Si系アルミニウム合金鋳造ビレットを、560℃以上の温度で均質化熱処理後に、100℃/hr以上の平均冷却速度で400℃以下の温度まで強制冷却し、更に、押出出口側の押出材温度が575℃以上の溶体化温度域になるように、前記鋳造ビレットを500℃以上に再加熱して熱間押出を行い、この押出出口側の押出材を押出加工直後から5℃/秒以上の平均冷却速度で強制冷却し、その後、押出材を更に時効処理して0.2%耐力を280MPa以上とすることを特徴とする曲げ圧壊性と耐食性に優れたアルミニウム合金押出材の製造方法。
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Also Published As
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JP2011074471A (ja) | 2011-04-14 |
US20120168045A1 (en) | 2012-07-05 |
JP5366748B2 (ja) | 2013-12-11 |
CN102549185A (zh) | 2012-07-04 |
CN102549185B (zh) | 2014-02-19 |
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