WO2014014795A1 - Improved 6xxx aluminum alloys, and methods for producing the same - Google Patents

Improved 6xxx aluminum alloys, and methods for producing the same Download PDF

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Publication number
WO2014014795A1
WO2014014795A1 PCT/US2013/050433 US2013050433W WO2014014795A1 WO 2014014795 A1 WO2014014795 A1 WO 2014014795A1 US 2013050433 W US2013050433 W US 2013050433W WO 2014014795 A1 WO2014014795 A1 WO 2014014795A1
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Prior art keywords
6xxx aluminum
aluminum alloy
alloy
new
6xxx
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PCT/US2013/050433
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English (en)
French (fr)
Inventor
Jen C. Lin
Anton J. ROVITO
Timothy P. DOYLE
Shawn P. Sullivan
Gabriele F. CICCOLA
Christopher J. Tan
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Alcoa Corp
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Alcoa Corp
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Application filed by Alcoa Corp filed Critical Alcoa Corp
Priority to MX2015000665A priority Critical patent/MX362963B/es
Priority to BR112015000878-0A priority patent/BR112015000878B1/pt
Priority to ES13819452.7T priority patent/ES2691304T3/es
Priority to AU2013290484A priority patent/AU2013290484C1/en
Priority to EP13819452.7A priority patent/EP2872662B1/en
Priority to RU2015105005A priority patent/RU2662758C2/ru
Priority to CA2877781A priority patent/CA2877781C/en
Priority to JP2015523149A priority patent/JP6445432B2/ja
Priority to EP17201025.8A priority patent/EP3299483B1/en
Priority to KR1020157003645A priority patent/KR102176996B1/ko
Priority to CN201380036638.4A priority patent/CN104428434A/zh
Publication of WO2014014795A1 publication Critical patent/WO2014014795A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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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
    • 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
    • C22F1/05—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 of the Al-Si-Mg type, i.e. containing silicon and magnesium in approximately equal proportions

Definitions

  • Aluminum alloys are useful in a variety of applications. However, improving one property of an aluminum a!loy without degrading another property is elusive. For example, it is difficult to increase the strength of an alloy without decreasing the toughness of an alloy. Other properties of interest for aluminum alloys include corrosion resistance and fatigue resistance, to name two,
  • the present patent application relates to new 6xxx aluminum alloys, and methods for producing the same.
  • the new 6xxx aluminum alloy products achieve an improved combination of properties due to, for example, the amount of al loying elements, as described in further detail below.
  • the new 6xxx aluminum alloys may realize an improved combination of two or more of strength, toughness, fatigue resistance, and corrosion resistance, among others, as shown by the below examples.
  • the new 6xxx aluminum alloys may be produced in wrought form, such as an in rolled form (e.g., as sheet or plate), as an extrusion, or as a forging, among others, in one embodiment, the new 6xxx aluminum alloy is in the form of a forged wheel product.
  • the 6xxx forged wheel product is a die-forged wheel product.
  • the new 6xxx aluminum alloys generally comprises (and some instances consist essentially of, or consist of) magnesium (Mg), silicon (Si), and copper (Cu) as primary alloying elements and at least one secondary element selected from the group consisting of vanadium (V), manganese (Mn), iron (Fe), chromium (Cr), zirconium (Zr), and titanium (Ti), the balance being aluminum and other impurities, as defined below.
  • the new ⁇ aluminum alloys generally include from L05 wt, % to 1.50 wt. % Mg.
  • the new 6xxx aluminum alloys include at least 1.10 wt. % Mg.
  • the new 6xxx aluminum alloys include at least 1.15 wt. % Mg.
  • the new 6xxx aluminum alloys include at least 1 .20 wt. % Mg.
  • the new ⁇ aluminum alloys include not greater than 1.45 wt. % Mg
  • the new 6xxx aluminum alloys include not greater than 1.40 wt. % Mg.
  • the new ⁇ aluminum alloys include not greater than 1.35 wt. % Mg, [005]
  • the new 6xxx aluminum alloys generally include silicon and in the range of from 0,60 wt. % to 0.95 wt, % Si. in one embodiment, the new ⁇ aluminum alloys include at least 0.65 wt. % Si. in another embodiment, the new 6xxx aluminum alloys include at least 0.70 wt. % Si. In one embodiment, the new 6xxx aluminum alloys include not greater than 0.90 wt. % Si. In another embodiment, the new 6xxx aluminum alloys include not greater than 0.85 wt. % Si. In yet another embodiment, the new 6xxx aluminum alloys include not greater than 0.80 wt. % Si.
  • the new 6xxx aluminum alloys generally include magnesium and silicon in a ratio of from 1.30 to 1.90 (Mg/Si). in one embodiment, the new ⁇ aluminum alloys have a Mg/Si ratio of at least 1.35. In another embodiment, the new ⁇ aluminum alloys have a Mg/Si ratio of at least 1 ,40. In yet another embodiment, the new 6xxx aluminum alloys have a Mg/Si ratio of at least 1 ,45. In one embodiment, the new 6xxx aluminum alloys have a Mg/Si ratio of not greater than 1 ,85.
  • the new 6xxx aluminum alloys have a Mg/Si ratio of not greater than 1.80, In yet another embodiment, the new 6xxx aluminum alloys have a Mg/Si ratio of not greater than 1.75. .In another embodiment, the new 6xxx aluminum alloys have a Mg/Si ratio of not greater than 1.70. In yet another embodiment, the new 6xxx aluminum alloys have a Mg/Si ratio of not greater than 1.65. In some embodiments, the new 6xxx aluminum alloys have a Mg/Si ratio of from 1.35 to 1.85. In other embodiments, the new 6xxx aluminum alloys have a Mg/Si ratio of from 1.35 to 1.80.
  • the new 6xxx aluminum alloys have a Mg/Si ratio of from 1.40 to 1.75. In other embodiments, the new 6xxx aluminum alloys have a Mg/Si ratio of from 1.40 to 1.70. In yet other embodiments, the new 6xxx aluminum alloys have a Mg/Si ratio of from 1 ,45 to 1.65. Other combinations of the above-described limits may be used. Using the above described amounts of Mg and Si may facilitate, among other things, improved strength and/or fatigue resistance properties,
  • the new 6xxx aluminum alloys generally include copper and in the range of from 0.275 wt, % to 0.50 wt, % Cu. in one embodiment, the new ⁇ ⁇ aluminum alloys include at least 0.30 wl. % Cu. In another embodiment, the new 6xxx aluminum alloys include at least 0.325 wt. % Cu, In yet another embodiment, the new 6xxx aluminum alloys include at least 0.35 wt. % Cu. In one embodiment, the new 6xxx aluminum alloys include not greater than 0.45 wt. % Cu, In another embodiment, the new 6xxx aluminum alloys include not greater than 0,425 wt. % Cu.
  • the new 6xxx aluminum alloys include not greater than 0.40 wt, % Cu. Using the above described amounts of Cu may facilitate improved strength and with good corrosion resistance. As described in further detail below, when the new 6xxx aluminum alloy is substantially free of vanadium (i.e., includes less than 0.05 wt. % V), the new 6xxx aluminum alloy should include at least 035 wt. % Cu.
  • the new ⁇ ⁇ aluminum alloys include 0.05 to 1.0 wt. % of secondary elements, wherein the secondary elements are selected from the group consisting of vanadium, manganese, chromium, iron, zirconium, titanium, and combinations thereof.
  • the new ⁇ aluminum alloys include 0.10 to 0.80 wt. % of secondary elements.
  • the new 6xxx aluminum alloys include 0.15 to 0.60 wt. % of secondary elements.
  • the new 6xxx aluminum alloys include 0.20 to 0.45 wt. % of secondary elements.
  • the secondary elements at least include vanadium, and in these embodiments the new 6xxx aluminum alloy includes at least 0.05 wt. % V.
  • the secondary elements at least include vanadium and iron.
  • the secondary elements at least include vanadium, iron and titanium.
  • the secondary elements at. least include vanadium, iron, titanium and chromium.
  • the secondary elements at least include vanadium, iron, titanium and manganese, in yet another embodiment, the secondary elements include all of vanadium, iron, titanium, manganese, and chromium.
  • the secondary elements are substantially free of vanadium (i.e., include less than 0.05 wt. % V), and, in these embodiments, the secondary elements are selected from the group consisting of vanadium, manganese, chromium, iron, zirconium, titanium, and combinations thereof, and wherein at least one of manganese, chromium and zirconium is present. In one embodiment, at least chromium is present. In one embodiment, at least chromium and zirconium are present. In one embodiment, at least chromium and manganese are present. In one embodiment, at least zirconium is present. In one embodiment, at least zirconium and manganese are present. In one embodiment, at least manganese is present.
  • the new 6xxx aluminum alloys include from 0.05 to 0.25 wt. % V.
  • the new ⁇ aluminum alloys include not greater than 0.20 wt. % V.
  • the new ⁇ aluminum alloys include not greater than 0.18 wt. % V.
  • the new 6xxx aluminum alloys include not greater than 0.16 wt. % V.
  • the new ⁇ aluminum alloys include not greater than 0,14 wt. % V.
  • the new 6xxx aluminum alloys include not greater than 0.13 wt. % V. in one embodiment, the new ⁇ aluminum alloys include at least 0.06 wt. % V. in another embodiment, the new 6xxx aluminum alloys include at least 0.07 wt. % V, In some embodiments, the new 6xxx aluminum alloys include from 0.05 to 0.16 wt. % V. In other embodiments, the new 6 ' xxx aluminum alloys include from 0.06 to 0.14 wt. % V, in yet other embodiments, the new 6xxx aluminum alloys include from 0.07 to 0.13 wt. % V. Other combinations of the above-described limits may be used.
  • the new ⁇ aluminum alloys are substantially free of vanadium, and, in these embodiments, the new 6xxx aluminum alloys contain less than 0.05 wt. %. V.
  • chromium, manganese, and/or zirconium may be used as a substitute for the vanadium.
  • the new 6xxx aluminum alloys contain less than 0.05 wt. % V, but contam a total of from 0.15 to 0.60 wt. % of chromium, manganese, and/or zirconium (i.e., Cr + Mn + Zr is from 0.15 wt. % to 0.60 wt. %).
  • the new ⁇ aluminum alloys contain less than 0.05 wt. % V, but contain from 0.20 to 0.45 wt. % of chromium, manganese, and/or zirconium.
  • the amount of copper in the new ⁇ aluminum alloys should be at least 0.35 wt. % Cu
  • the new 6xxx aluminum alloys include at least 0.375 wt. % Cu.
  • the new 6xxx aluminum alloys include at least 0.40 wt. % Cu.
  • the new 6xxx aluminum alloys generally include from 0.05 to 0.40 wt. % Cr. In one embodiment, the new 6xxx aluminum alloys include not greater than 0.35 wt. % Cr. In another embodiment, the new 6xxx aluminum alloys include not greater than 0.30 wt. % Cr, In yet another embodiment, the new 6xxx aluminum alloys include not greater than 0.25 wt. % Cr. In another embodiment, the new ⁇ aluminum alloys include not greater than 0.20 wt. % Cr. In one embodiment, the new 6xxx aluminum alloys include at least 0.08 wt. % Cr.
  • the new 6xxx aluminum alloys include from 0.05 to 0,25 wt. % Cr. In other embodiments, the new ⁇ aluminum alloys include from 0.08 to 0.20 wt. % Cr. Other combinations of the above-described limits may be used. In some embodiments, the new 6xxx aluminum alloys are substantially free of chromium, and, in these embodiments, contain less than 0.05 wt. %. Cr.
  • the new ⁇ aluminum alloys generally include from 0.05 to 0.50 wt. % Mn. In some embodiments, the new 6xxx aluminum alloys include not greater than 0.25 wt. % Mn. In other embodiments, the new 6xxx aluminum alloys include not greater than 0.20 wt. % Mn. In yet other embodiments, the new 6xxx aluminum alloys include not greater than 0,15 wt. % Mn. In some embodiments, the new ⁇ aluminum alloys include from 0,05 to 0.25 wt. % Mn. In other embodiments, the new 6xxx aluminum alloys include from 0.05 to 0.20 wt. % Mn.
  • the new ⁇ aluminum alloys include from 0.05 to 0.15 wt. % Mn. Other combinations of the above-described limits may be used. In some embodiments, the new 6xxx aluminum alloys are substantially free of manganese, and, in these embodiments, contains less than 0.05 wt. %. Mn.
  • the new 6xxx aluminum alloys generally include from 0.05 to 0,25 wt, % Zr. In some embodiments, the new 6xxx aluminum alloys include not greater than 0.20 wt. % Zr, In other embodiments, the new ⁇ aluminum alloys include not greater than 0.18 wt. % Zr. in yet other embodiments, the new 6xxx aluminum alloys include not greater than 0.15 wt. % Zr. In one embodiment, the new 6xxx aluminum alloys include at least 0,06 wt. % Zr. In yet other embodiments, the new 6xxx aluminum alloys include at least 0.07 wt. % Zr.
  • the new 6xxx aluminum alloys include from 0.05 to 0.20 wt. % Zr. In other embodiments, the new ⁇ aluminum alloys include from 0.06 to 0.18 wt. % Zr. In yet other embodiments, the new 6xxx aluminum alloys include from 0,07 to 0.15 wt. % Zr. Other combinations of the above-described limits may be used. In some embodiments, the aluminum alloys are substantially free of zirconium, and, in these embodiments, contain less than 0.05 wt. %. Zr,
  • Iron is generally present in the alloy, and may be present in the range of from 0.01 wt. % to 0.80 wt. % Fe.
  • the new 6xxx aluminum alloys include not greater than 0.50 wt. % Fe.
  • the new ⁇ aluminum alloys include not greater than 0.40 wt. % Fe.
  • the new r 6xxx aluminum alloys include not greater than 0.30 wt. % Fe.
  • the new 6xxx aluminum alloys include at least 0.08 wt. % Fe.
  • the new 6xxx aluminum alloys include at least 0.10 wt, % Fe.
  • the new 6xxx aluminum alloys include from 0.05 to 0.50 wt. % Fe. In other embodiments, the new 6xxx aluminum alloys include from 0.08 to 0.40 wt. % Fe. In yet other embodiments, the new r ⁇ aluminum alloys include from 0.10 to 0.30 wt. % Fe. In yet other embodiments, the new ⁇ aluminum alloys include from 0.10 to 0.25 wt. % Fe. Other combinations of the above-described limits may be used. Higher iron levels may be tolerable in new 6xxx aluminum alloy products when lower fatigue resistance properties are tolerable. In some embodiments, the new 6xxx aluminum alloys are substantially free of iron, and, in these embodiments, contain less than 0.01 wt. %. Fe,
  • the new 6xxx aluminum alloys generally include from 0.001 to 0.10 wt. % Ti. In some embodiments, the new 6xxx aluminum alloys include not greater than 0.05 wt. % Ti. In other embodiments, the new 6xxx aluminum alloys include not greater than 0.04 wt. % Ti. In yet other embodiments, the new 6xxx aluminum alloys include not greater than 0.03 wt. % Ti. In one embodiment, the new 6xxx aluminum alloys include at least 0.005 wt. % Ti. In yet other embodiments, the new ⁇ aluminum alloys include at least 0.01 wt. % Ti.
  • the new 6xxx aluminum alloys include from 0.005 to 0.05 wt. % Ti, In other embodiments, the new ⁇ aluminum alloys include from 0.01 to 0.04 wt. % Ti. in yet other embodiments, the new 6xxx aluminum alloys include from 0,01 to 0.03 wt. % Ti. Other combinations of the above-described limits may be used, in some embodiments, the new ⁇ aluminum alloys are substantially free of titanium, and, in these embodiments, contain less than 0.001 wt. %. Ti.
  • the new 6xxx aluminum alloys may be substantially free of other elements.
  • other elements means any other elements of the periodic table other than the above-listed magnesium, silicon, copper, vanadium, iron, chromium, titanium, zirconium, and iron, as described above.
  • the phrase "substantially free” means that the new 6xxx aluminum alloys contain not more than 0.10 wt. % each of any element of the other elements, with the total combined amount of these other elements not exceeding 0.35 wt. % in the new 6xxx aluminum alloys. In another embodiment, each one of these other elements, individually, does not exceed 0.05 wt.
  • each one of these other elements individually, does not exceed 0.03 wt. % in the 6xxx aluminum alloys, and the total combined amount of these other elements does not exceed 0.10 wt. % in the 6xxx aluminum alloys.
  • the new 6xxx aluminum alloys may achieve high strength.
  • a wrought product made from the new 6xxx aluminum alloys (“new wrought 6xxx aluminum alloy product") realizes a tensile yield strength in the L (longitudinal) direction of at least 45 ksi.
  • a new wrought 6xxx aluminum alloy product realizes a tensile yield strength in the L direction of at least 46 ksi.
  • a new wrought 6xxx aluminum alloy product realizes a tensile yield strength in the L direction of at least 47 ksi, or at least 48 ksi, or at least 49 ksi, or at least about 50 ksi, or at least about 51 ksi, or at least about 52 ksi, or at least about 53 ksi, or at least about 54 ksi, or at least about 55 ksi, or more.
  • the new 6xxx aluminum alloys may achieve good elongation.
  • a new wrought 6xxx aluminum alloy product realizes an elongation of at least 6% in the L direction.
  • a new wrought 6xxx aluminum alloy product realizes an elongation in the L direction of at least 8%.
  • a new wrought 6xxx aluminum alloy product realizes an elongation in the L direction of at least 1.0%, or at least 12%, or at least 14%, or more.
  • Strength and elongation properties are measured in accordance with ASTM E8 and B557.
  • the new 6xxx aluminum alloys may achieve good toughness.
  • a new wrought 6xxx aluminum al!oy product realizes a toughness of at least 35 ft, -lbs. as measured by a Charpy impact test, wherein the Charpy impact test is performed according to ASTM E23-07a
  • a new wrought 6xxx aluminum alloy product realizes a toughness of at least 40 ft. -lbs. as measured by a Charpy impact test.
  • a new wrought ⁇ aluminum alloy product realizes a toughness of at least 45 ft.-lbs., or at least 50 ft.-lbs., or at least 55 ft.-lbs., or at least 60 ft.-lbs., or at least 65 ft.-lbs., or at least 70 ft.-lbs., or at least 75 ft. -lbs., or at least 80 ft.-lbs., or at least 85 ft.-lbs., or more, as measured by a Charpy impact test.
  • the new 6xxx aluminum alloys may achieve good fatigue resistance.
  • a new wrought ⁇ aluminum alloy product realizes an average rotary fatigue life that is at least 10% better than the average rotary fatigue life of the same wrought product (e.g., the same product form, dimensions, geometry, temper) but made from conventional alloy 6061, wherein the average rotary fatigue life is the average of the rotary fatigue life of at least 5 specimens of the wrought 6xxx aluminum alloy product as tested in accordance with ISO 1143 (2010) ("Metallic materials - Rotating bar bending fatigue testing"), i.e., rotating beam fatigue.
  • a new wrought 6xxx aluminum alloy product realizes an average rotary fatigue life that is at least 20% better than the average rotary fatigue life of the same wrought product made from conventional alloy 6061. In other embodiments, a new wrought 6xxx aluminum alloy product realizes an average rotary fatigue life that is at least 25% better, or at least 30% better, or at least 40% better, or at least 45% better, or more, than the average rotary fatigue life of the same wrought product made from conventional alloy 6061.
  • the new wrought 6xxx aluminum alloy product is a forged wheel product, and the forged 6xxx aluminum alloy wheel product realizes an average radial fatigue life of at least 1,000,000 cycles as tested in accordance with SAE J267 (2007), with a 2.8X load factor applied.
  • the forged 6xxx aluminum alloy wheel product realizes an average radial fatigue life of at least 1 ,050,000 cycles.
  • the forged 6xxx aluminum alloy wheel product realizes an average radial fatigue life of at least 1,100,000 cycles, or at least 1,150,000 cycles, or at least 1,200,000 cycles, or at least 1,250,000 cycles, or at least 1,300,000 cycles, or at least 1,350,000 cycles, or more.
  • a new wrought 6xxx aluminum alloy product realizes an average radial fatigue life that is at least 10% better than the average radial fatigue life of the same wrought product (e.g., the same product form, dimensions, geometry, temper) but made from conventional alloy 6061 as tested in accordance with SAE J267 (2007), with a 2.8X load factor applied.
  • a new wrought 6xxx aluminum alloy product realizes an average radial fatigue life that is at least 20% better than the average radial fatigue life of the same wrought product made from conventional alloy 6061.
  • a new wrought 6xxx aluminum alloy product realizes an average radial fatigue life that is at least 25% better, or at least 30% better, or at least 40% better, or at least 45% better, or more, than the average radial fatigue life of the same wrought product made from conventional alloy 6061.
  • the new 6xxx aluminum alloys may achieve good corrosion resistance.
  • a new wrought 6xxx aluminum alloy product realizes an average depth of attack of not greater than 0,008 inch at the T/10 location when measured in accordance with ASTM G1 10 (24 hours of exposure; minimum of 5 samples).
  • a new wrought 6xxx aluminum alloy product realizes an average depth of attack of not greater than 0,006 inch at the T/10 location.
  • a new wrought 6xxx aluminum alloy product realizes an average depth of attack of not greater than 0.004 inch, or not greater than 0.002 inch, or not greater than 0.001 inch, or less at the T/10 location.
  • a new wrought 6xxx aluminum alloy product realizes a maximum depth of attack of not greater than 0.01 1 inch at the T/10 location when measured in accordance with ASTM G110 (24 hours of exposure; minimum of 5 samples).
  • a new wrought 6xxx aluminum alloy product realizes a maximum depth of attack of not greater than 0.009 inch at the T/10 location.
  • a new wrought 6xxx aluminum alloy product realizes a maximum depth of attack of not greater than 0,007 inch, or not greater than 0.005 inch, or not greater than 0.003 inch, or less at the T/10 location.
  • a new wrought 6xxx aluminum alloy product realizes an average depth of attack of not greater than 0.008 inch at the surface when measured in accordance with ASTM G110 (24 hours of exposure; minimum of 5 samples).
  • a new wrought ⁇ aluminum alloy product realizes an average depth of attack of not greater than 0.007 inch at the surface.
  • a new wrought 6xxx aluminum ahoy product realizes an average depth of attack of not greater than 0,006 inch, or not greater than 0.005 inch, or not greater than 0.004 inch, or less at the surface.
  • a new wrought 6xxx aluminum alloy product realizes a maximum depth of attack of not greater than 0,010 inch at the surface when measured in accordance with ASTM G1 10 (24 hours of exposure; minimum of 5 samples).
  • a new wrought ⁇ aluminum alloy product realizes a maximum depth of attack of not greater than 0.009 inch at the surface.
  • a new wrought 6xxx aluminum alloy product realizes a maximum depth of attack of not greater than 0,008 inch, or not greater than 0.007 inch, or not greater than 0.006 inch, or less at the surface.
  • FIGS, la-lf are graphs showing results from Example 1.
  • FIGS, lg-1 to lg ⁇ 4 are micrographs from Example 1. DETAILED DESCRIPTION
  • Alloys 6061 and 6069 are conventional 6xxx aluminum alloys. All alloys contained the listed elements, the balance being aluminum and other impurities, where the other impurities did not exceed more than 0.05 wt. % each, and not more than 0.15 wt. % total of the other impurities.
  • the invention alloys have a Mg/Si ratio of from 1.46 to 1.59.
  • the alloys were cast as 2.875 inch (ST) x 4.75 inch (LT) x 37 inch (L) ingots that were scalped to 2 inches thick and then homogenized. The ingots were then hot rolled to about 0.5 inch plates, corresponding to approximately a 75% reduction. The plates were subsequently solution heat-treated and cold water quenched (100°F). The plates were then aged at 385°F and 35()°F for different times, and aging curves were generated. Based on the aging curve results, two aging conditions (385°F for 2 hours, and 350°F for 8 hours) were selected for testing of various properties.
  • the aging condition of 385°F for 2 hours generally represents about peak strength, and the aging condition of 350°F for 8 hours generally represents an underaged condition.
  • the test results are illustrated in FIGS, la- If and provided in Tables 2-7, below.
  • Strength and elongation properties were measured in accordance with ASTM E8 and B557.
  • Charpy impact tests were measured in accordance with ASTM 1323- 07a.
  • Rotary fatigue life tests were conducted in accordance with ISO 1 143 (2010) at a stress of 15 ksi, with R :::: - I and with t - 3, Corrosion resistance was tested in accordance with ASTM Gl 10 for 24 hours.
  • FIGS, la-lc illustrates the tensile properties of the alloys. All the tested alloys have a higher near peak strength than conventional alloy 6061.
  • FIG. Id illustrates the rotary fatigue life of the alloys.
  • Alloys having high more than 0.7 wt. % Fe i.e., alloys 6xxx-8 and 6xxx-9) realize lower fatigue life.
  • Alloys 6xxx-8 and 6xxx-9 also contain more than 1.0 wt. % of the secondary elements of vanadium (V), manganese (Mn), iron (Fe), chromium (Cr), zirconium (Zr), and titanium (11), which contributes to their low fatigue performance.
  • Alloys 6 and 8, having about 0,7 wt. % Cu realize worse fatigue performance than their counterpart alloys, illustrating the importance of maintaining copper below about 0.55 wt. %.
  • FIG. le illustrates the un-notched charpy impact energy of the alloys.
  • Charpy impact energy is an indicator of fracture toughness.
  • the charpy impact energy increased with increasing constituent forming elements (e.g., Fe, Cr, and V).
  • a correlation plot is given in FIG. I f. This trend is inverse to the normal trend, where charpy impact energy generally decreases with increasing constituent particle concentration in aluminum alloys,
  • Tables 4 and 5 pro vide corrosion data relating to depth of attack testing per A STM Gl lO (24 hours test). Ail the alloys show better or similar corrosion resistance compared to the conventional alloy 6061.
  • Example 2 alloys Seven additional book mold ingots were produced per the procedure of Example 1 , except the alloys were all aged at 385°F for 2 hours.
  • the compositions of the Example 2 alloys are provided in Table 6, below (all values in weight percent).
  • All alloys contained the listed elements, the balance being aluminum and other impurities, where the other impurities did not exceed more than 0.05 wt. % each, and not more than 0.15 wt, % total of the other impurities. These alloys have a Mg/Si ratio of from 1.64 to 1 ,75.
  • the alloys generally have negligible amounts of excess Si and Mg, helping the alloys to achieve the improved properties; all alloys achieved improved properties over alloy 6061 (6xxx-l from Example 1 ) due to, at least in part, the amount of Si, Mg and the Si/Mg ratio, and irrespective of the amount of Mn, Cr, and V used. It is observed, however, that alloys having vanadium with at least one of manganese and chromium generally achieved high strength in combination with improved resistance to fatigue.
  • All alloys contained the listed elements and about 0,02 wt. % Ti, the balance being aluminum and other impurities, where the other impurities did not exceed more than 0.05 wt. % each, and not more than 0.15 wt. % total of the other impurities.
  • the invention alloys have a Mg/Si ratio of from 1 .43 to 1.63.
  • Example 4 alloys Ten additional book mold ingots were produced per the procedure of Example 1 , except the alloys were all aged at 385°F for 2 hours.
  • the compositions of the Example 4 alloys are provided in Table 10, below (all values in weight percent).
  • All alloys contained the listed elements and about 0.02 wt. % Ti, the balance being aluminum and other impurities, where the other impurities did not exceed more than 0.05 wt. % each, and not more than 0, 15 wt, % total of the other impurities.
  • the invention alloys have a Mg/Si ratio of from 1.52 to 1.62. [0050] The alloys were cast as 2.875 inc (ST) x 4.75 inch (LT) x 17 inch (L) ingots that were scalped to 2 inches thick and then homogenized. The ingots were then machined into about 1.5 inch diameter cylinders (3 inches in height) and then deformed into disks having a final thickness of about 0.52 inch.
  • the invention alloys realize improved properties over non-invention alloy 33 (6061 -type).
  • Alloys 24-26, 28-29 and 31 having vanadium realized about equivalent or improved strength over non-invention alloy 33 (6061 -type) and with improved rotary fatigue life and good elongation.
  • Non-invention alloy 32 having 1.14 Si and a Mg/Si ratio of 1.07 realizes poor elongation.
  • All alloys contained the listed elements and about 0.01-0.02 wt. % Ti, the balance being aluminum and other impurities, where the other impurities did not exceed more than 0.05 wt. % each, and not more than 0.15 wt. % total of the other impurities.
  • the invention a!loys have a Mg/Si ratio of from 1.55 to 1.58.
  • the alloys were processed the same as Example L except they were only aged at 385°F for 2 hours. Strength and elongation properties were measured in accordance with ASTM E8 and B557. Results are provided in Table 14, below.
  • the invention alloys realize improved properties over non-invention alloy 40 (6061 -type). Specifically, alloys 34-35 achieved improved tensile yield strength (TYS) over non-invention alloy 40 (60 1 -type) and with good elongation, although Alloy 34 with vanadium achieved higher strength.
  • Non-invention alloy 36 with 0.62 wt. % Si, 0.96 wt. % Mg, 0.28 wt. % Cu, and no vanadium achieved about the same tensile yield strength and elongation as non-invention alloy non-invention alloy 40 (6061 -type).
  • Non-invention alloy 37 with 0.92 wt.
  • the above results indicate that alloys with at least 0,05 wt, % vanadium may achieve improved properties when employing, among other things, at least 0.275 wt. % Cu and the appropriate amount of Si and Mg, as shown above.
  • alloys without at least 0,05 wt. % vanadium may achieve improved properties by employing at least 0,35 wt. % Cu, and with the appropriate amount of Si, Mg and by using Cr, Mn and/or Zr as a substitute for V.

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