WO2020097169A1 - 2xxx aluminum lithium alloys - Google Patents

2xxx aluminum lithium alloys Download PDF

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Publication number
WO2020097169A1
WO2020097169A1 PCT/US2019/060016 US2019060016W WO2020097169A1 WO 2020097169 A1 WO2020097169 A1 WO 2020097169A1 US 2019060016 W US2019060016 W US 2019060016W WO 2020097169 A1 WO2020097169 A1 WO 2020097169A1
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WO
WIPO (PCT)
Prior art keywords
aluminum alloy
2xxx aluminum
alloy
another embodiment
2xxx
Prior art date
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Ceased
Application number
PCT/US2019/060016
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English (en)
French (fr)
Inventor
Julien Boselli
Jen C. Lin
Lynette M. Karabin
Wei Wen
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Howmet Aerospace Inc
Original Assignee
Arconic Inc
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First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=70612347&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=WO2020097169(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Arconic Inc filed Critical Arconic Inc
Priority to JP2021523951A priority Critical patent/JP7621248B2/ja
Priority to CN201980071897.8A priority patent/CN113039303A/zh
Priority to EP19882996.2A priority patent/EP3877562B1/en
Priority to BR112021008230-1A priority patent/BR112021008230B1/pt
Priority to CA3117862A priority patent/CA3117862C/en
Publication of WO2020097169A1 publication Critical patent/WO2020097169A1/en
Priority to US17/307,453 priority patent/US12194529B2/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002—Castings of light metals
    • B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • 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
    • C22C21/12—Alloys based on aluminium with copper as the next major constituent
    • C22C21/14—Alloys based on aluminium with copper as the next major constituent with silicon
    • 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
    • C22C21/12—Alloys based on aluminium with copper as the next major constituent
    • C22C21/16—Alloys based on aluminium with copper as the next major constituent with magnesium
    • 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
    • C22C21/12—Alloys based on aluminium with copper as the next major constituent
    • C22C21/18—Alloys based on aluminium with copper as the next major constituent with zinc
    • 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
    • C22F1/057—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 copper as the next major constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the present disclosure relates to 2xxx aluminum lithium alloys and products made therefrom.
  • Aluminum alloys are useful in a variety of applications. However, improving one property of an aluminum alloy without degrading another property often proves 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 crack growth rate resistance, to name two.
  • the present patent application relates to new 2xxx aluminum lithium alloys.
  • the new 2xxx aluminum lithium alloys comprise (and some instances consist essentially of or consist of) from 2.5 to 3.9 wt. % Cu, from 0.82 to 1.20 wt. % Li, from 0.5 to 2.0 wt. % Zn, from 0.10 to 0.60 wt. % Mn, from 0.05 to 0.35 wt. % Mg; from 0.05 to 0.50 wt. % of at least one grain structure control element, wherein the at least one grain structure control element is selected from the group consisting of Zr, Sc, Cr, V, Hf, other rare earth elements, and combinations thereof, up to 0.22 wt.
  • Products incorporating such alloy compositions may achieve an improved combination of, for instance, two or more of strength, elongation, fracture toughness and stress corrosion cracking resistance.
  • copper (Cu) is included in the alloy, and generally in the range of from 2.5 wt. % to 3.9 wt. % Cu. More specific embodiments relating to copper are provided near the end of this section.
  • lithium (Li) is included in the new alloy, and generally in the range of from 0.82 wt. % to 1.20 wt. %.
  • a new alloy includes at least 0.85 wt. % Li.
  • a new alloy includes at least 0.875 wt. % Li.
  • a new alloy includes at least 0.90 wt. % Li.
  • a new alloy includes at least 0.925 wt. % Li.
  • a new alloy includes at least 0.95 wt. % Li.
  • a new alloy includes not greater than 1.15 wt. % Li.
  • a new alloy includes not greater than 1.10 wt.
  • a new alloy includes not greater than 1.075 wt. % Li. In another embodiment, a new alloy includes not greater than 1.050 wt. % Li. In yet another embodiment, a new alloy includes not greater than 1.025 wt. % Li. In another embodiment, a new alloy includes not greater than 1.000 wt. % Li. In yet another embodiment, a new alloy includes not greater than 0.980 wt. % Li.
  • Zinc (Zn) is generally included in the new alloy, and generally in the range of from 0.50 wt. % Zn to 2.0 wt. % Zn. More specific embodiments relating to zinc are provided near the end of this section.
  • the weight ratio of copper-to-zinc in the alloy may be related to its improved properties (e.g., its quench sensitivity).
  • a new 2xxx aluminum alloy realizes a copper-to-zinc weight ratio of not greater than 4.25: 1 (Cu:Zn).
  • Mn Manganese
  • a new alloy includes at least 0.125 wt. % Mn. In another embodiment, a new alloy includes at least 0.15 wt. % Mn. In yet another embodiment, a new alloy includes at least 0.175 wt. % Mn. In another embodiment, a new alloy includes at least 0.20 wt. % Mn. In another embodiment, a new alloy includes at least 0.225 wt. % Mn. In yet another embodiment, a new alloy includes at least 0.25 wt. % Mn.
  • a new alloy includes at least 0.27 wt. % Mn. In one embodiment, a new alloy includes not greater than 0.55 wt. % Mn. In another embodiment, a new alloy includes not greater than 0.50 wt. % Mn. In yet another embodiment, a new alloy includes not greater than 0.45 wt. % Mn. In another embodiment, a new alloy includes not greater than 0.425 wt. % Mn. In yet another embodiment, a new alloy includes not greater than 0.40 wt. % Mn. In another embodiment, a new alloy includes not greater than 0.375 wt. % Mn. In yet another embodiment, a new alloy includes not greater than 0.35 wt. % Mn.
  • a new alloy includes not greater than 0.325 wt. % Mn. In another embodiment, a new alloy includes not greater than 0.30 wt. % Mn.
  • manganese may be considered both an alloying ingredient and a grain structure control element—the manganese retained in solid solution may enhance a mechanical property of the alloy (e.g., strength and/or toughness), while the manganese in particulate form (e.g., as Al 6 Mn, Al l2 Mn 3 Si 2 , Al 20 Cu 2 Mn 3 — sometimes referred to as dispersoids) may assist with grain structure control and may also improve damage tolerance properties, such as fracture toughness.
  • Mn is separately defined with its own composition limits in the present patent application, it is not within the definition of“grain structure control element” (described below) for the purposes of the present patent application.
  • Magnesium (Mg) is included in the new alloy, and generally in the range of from 0.05 wt. % to 0.35 wt. % Mg. More specific embodiments relating to magnesium are provided near the end of this section.
  • the alloy may include 0.05 to 0.50 wt. % of at least one grain structure control element selected from the group consisting of zirconium (Zr), scandium (Sc), chromium (Cr), vanadium (V) and/or hafnium (Hf), and/or other rare earth elements, and such that the utilized grain structure control element(s) is/are maintained below maximum solubility.
  • grain structure control element means elements or compounds that are deliberate alloying additions with the goal of forming second phase particles, usually in the solid state, to control solid state grain structure changes during thermal processes, such as recovery and recrystallization.
  • grain structure control elements include Zr, Sc, Cr, V, Hf, and other rare earth elements, to name a few, but excludes Mn.
  • the amount of grain structure control material utilized in an alloy is generally dependent on the type of material utilized for grain structure control and/or the alloy production process.
  • the grain structure control element is Zr
  • the alloy includes from 0.05 wt. % to 0.20 wt. % Zr.
  • the aluminum alloy includes at least 0.06 wt. % Zr.
  • the aluminum alloy includes at least 0.07 wt. % Zr.
  • the aluminum alloy includes at least 0.08 wt. % Zr.
  • the aluminum alloy includes not greater than 0.18 wt. % Zr.
  • the aluminum alloy includes not greater than 0.16 wt. % Zr.
  • the aluminum alloy includes not greater than 0.15 wt. % Zr. In yet another embodiment, the aluminum alloy includes not greater than 0.14 wt. % Zr. In another embodiment, the aluminum alloy includes not greater than 0.13 wt. % Zr. In one embodiment, the alloy includes from 0.05 wt. % to 0.15 wt. % Zr. In another embodiment, the alloy includes from 0.07 wt. % to 0.14 wt. % Zr. In another embodiment, the alloy includes from 0.08 wt. % to 0.13 wt. % Zr.
  • the alloy may include up to 0.15 wt. % Ti cumulatively for grain refining and/or other purposes.
  • Grain refiners are inoculants or nuclei to seed new grains during solidification of the alloy.
  • An example of a grain refiner is a 9.525 mm rod comprising 96% aluminum, 3% titanium (Ti) and 1% boron (B) (all in weight percent), where virtually all boron is present as finely dispersed TiB 2 particles.
  • a grain refining rod may be fed in-line into the molten alloy flowing into the casting pit at a controlled rate.
  • the amount of grain refiner included in the alloy is generally dependent on the type of material utilized for grain refining and the alloy production process.
  • grain refiners examples include Ti combined with B (e.g., TiB 2 ) or carbon (TiC), although other grain refiners, such as Al-Ti master alloys may be utilized.
  • B e.g., TiB 2
  • TiC carbon
  • grain refiners are added in an amount ranging from 0.0003 wt. % to 0.005 wt. % to the alloy, depending on the desired as-cast grain size.
  • Ti may be separately added to the alloy in an amount up to 0.15 wt. %, depending on product form, to increase the effectiveness of grain refiner, and typically in the range of 0.005 to 0.15 wt. % Ti.
  • Ti is included in the alloy, it is generally present in an amount of from 0.01 to 0.10 wt. %.
  • a new alloy includes at least 0.005 wt. % Ti. In another embodiment, a new alloy includes at least 0.01 wt. % Ti. In yet another embodiment, a new alloy includes at least 0.015 wt. % Ti. In another embodiment, a new alloy includes at least 0.020 wt. % Ti. In one embodiment, a new alloy includes not greater than 0.10 wt. % Ti. In another embodiment, a new alloy includes not greater than 0.08 wt. % Ti. In yet another embodiment, a new alloy includes not greater than 0.07 wt. % Ti. In another embodiment, a new alloy includes not greater than 0.06 wt. % Ti.
  • a new alloy includes not greater than 0.05 wt. % Ti.
  • the aluminum alloy includes a grain refiner, and the grain refiner is at least one of TiB 2 and TiC, where the wt. % of Ti in the alloy is from 0.01 to 0.06 wt. %, or from 0.01 to 0.03 wt. %.
  • the new aluminum alloy may include iron (Fe).
  • the iron content of the new alloy should generally not exceed 0.15 wt. %.
  • a new alloy may include at least 0.01 wt. % Fe.
  • a new alloy includes not greater than 0.12 wt. % Fe.
  • a new alloy includes not greater than 0.10 wt. % Fe.
  • a new alloy includes not greater than 0.08 wt. % Fe.
  • a new alloy includes not greater than 0.06 wt. % Fe.
  • a new alloy includes not greater than 0.04 wt. % Fe.
  • the new aluminum alloy may include silicon (Si).
  • the silicon content of the new alloy should generally not exceed 0.12 wt. %.
  • a new alloy may include at least 0.01 wt. % Si.
  • a new alloy includes not greater than 0.10 wt. % Si.
  • a new alloy includes not greater than 0.08 wt. % Si.
  • a new alloy includes not greater than 0.06 wt. % Si.
  • a new alloy includes not greater than 0.04 wt. % Si.
  • the new aluminum alloy may optionally include silver and in an amount of up to 0.22 wt. %.
  • a new alloy includes not greater than 0.20 wt. % Ag.
  • a new alloy includes not greater than 0.15 wt. % Ag.
  • a new alloy includes not greater than 0.10 wt. % Ag.
  • a new alloy includes not greater than 0.05 wt. % Ag.
  • a new alloy includes not greater than 0.01 wt. % Ag.
  • a new alloy includes not greater than 0.005 wt. % Ag and/or is not detectable in a new alloy.
  • the new alloys generally include the stated alloying ingredients, the balance being aluminum, optional incidental elements, and impurities.
  • incident elements means those elements or materials, other than the above listed elements, that may optionally be added to the alloy to assist in the production of the alloy. Examples of incidental elements include casting aids, such as grain refiners and deoxidizers.
  • Optional incidental elements may be included in the alloy in a cumulative amount of up to 1.0 wt. %.
  • one or more incidental elements may be added to the alloy during casting to reduce or restrict (and is some instances eliminate) ingot cracking due to, for example, oxide fold, pit and oxide patches.
  • deoxidizers These types of incidental elements are generally referred to herein as deoxidizers.
  • deoxidizers include Ca, Sr, and Be.
  • Ca calcium
  • Sr calcium
  • Be When calcium (Ca) is included in the alloy, it is generally present in an amount of up to about 0.05 wt. %, or up to about 0.03 wt. %.
  • Ca is included in the alloy in an amount of about 0.001-0.03 wt % or about 0.05 wt. %, such as 0.001-0.008 wt. % (or 10 to 80 ppm).
  • Strontium (Sr) may be included in the alloy as a substitute for Ca (in whole or in part), and thus may be included in the alloy in the same or similar amounts as Ca.
  • Be beryllium
  • some embodiments of the alloy are substantially Be-free.
  • Be is included in the alloy, it is generally present in an amount of up to about 20 ppm.
  • Incidental elements may be present in minor amounts, or may be present in significant amounts, and may add desirable or other characteristics on their own without departing from the alloy described herein, so long as the alloy retains the desirable characteristics described herein. It is to be understood, however, that the scope of this disclosure should not/cannot be avoided through the mere addition of an element or elements in quantities that would not otherwise impact on the combinations of properties desired and attained herein.
  • the new 2xxx aluminum alloys generally contain low amounts of impurities.
  • a new 2xxx aluminum alloy includes not greater than 0.15 wt. %, in total, of the impurities, and wherein the 2xxx aluminum alloy includes not greater than 0.05 wt. % of each of the impurities.
  • a new 2xxx aluminum alloy includes not greater than 0.10 wt. %, in total, of the impurities, and wherein the 2xxx aluminum alloy includes not greater than 0.03 wt. % of each of the impurities.
  • a first version of the new 2xxx aluminum alloy includes first tailored amounts of copper, magnesium and zinc.
  • the first version includes from 3.1 to 3.8 wt. % copper, from 0.5 to 2.0 wt. % Zn, and from 0.05 to 0.35 wt. % Mg.
  • the first version includes at least 3.2 wt. % Cu. In another embodiment, the first version includes at least 3.3 wt. % Cu. In one embodiment, the first version includes not greater than 3.75 wt. % Cu. In another embodiment, the first version includes not greater than 3.7 wt. % Cu. In one embodiment, the first version includes not greater than 3.65 wt. % Cu. In another embodiment, the first version includes not greater than 3.6 wt. % Cu.
  • the first version includes at least 0.6 wt. % Zn. In another embodiment, the first version includes at least 0.7 wt. % Zn. In yet another embodiment, the first version includes at least 0.75 wt. % Zn. In another embodiment, the first version includes at least 0.8 wt. % Zn. In yet another embodiment, the first version includes at least 0.85 wt. % Zn. In another embodiment, the first version includes at least 0.9 wt. % Zn. In yet another embodiment, the first version includes at least 0.95 wt. % Zn. In one embodiment, the first version includes not greater than 1.8 wt. % Zn.
  • the first version includes not greater than 1.6 wt. % Zn. In yet another embodiment, the first version includes not greater that 1.4 wt. % Zn. In another embodiment, the first version includes not greater than 1.3 wt. % Zn. In yet another embodiment, the first version includes not greater that 1.2 wt. % Zn. In another embodiment, the first version includes not greater than 1.1 wt. % Zn. In yet another embodiment, the first version includes not greater that 1.05 wt. % Zn.
  • the weight ratio of copper-to-zinc in the alloy may be related to its improved properties (e.g., its quench sensitivity).
  • the first version realizes a copper-to-zinc (weight) ratio of not greater than 4.25: 1 (Cu:Zn), i.e., (wt. % Cu) / (wt. % Zn) of the alloy is not greater than 4.25.
  • the first version realizes a copper- to-zinc (weight) ratio of not greater than 4.10: 1.
  • the first version realizes a copper-to-zinc (weight) ratio of not greater than 4.00: 1.
  • the first version realizes a copper-to-zinc (weight) ratio of not greater than 3.90: 1. In yet another embodiment, the first version realizes a copper-to-zinc (weight) ratio of not greater than 3.80: 1. In another embodiment, the first version realizes a copper-to-zinc (weight) ratio of not greater than 3.78: 1.
  • the first version includes at least 0.10 wt. % Mg. In another embodiment, the first version includes at least 0.125 wt. % Mg. In yet another embodiment, the first version includes at least 0.15 wt. % Mg. In another embodiment, the first version includes at least 0.175 wt. % Mg. In yet another embodiment, the first version includes at least 0.20 wt. % Mg. In another embodiment, the first version includes at least 0.21 wt. % Mg. In yet another embodiment, the first version includes at least 0.22 wt. % Mg. In one embodiment, the first version includes not greater than 0.325 wt. % Mg.
  • the first version includes not greater than 0.30 wt. % Mg. In yet another embodiment, the first version includes not greater than 0.29 wt. % Mg. In another embodiment, the first version includes not greater than 0.28 wt. % Mg.
  • a first version includes 3.2 - 3.7 wt. % Cu, 0.85 - 1.15 wt. % Li, 0.75 - 1.25 wt. % Zn, wherein Cu:Zn (weight ratio) is ⁇ 4.25:1, 0.15 - 0.29 wt. % Mg, (XI, X2, X3, X4 or X5) wt. % Mn, ⁇ 0.005 wt. % Ag, 0.05 - 0.15 wt. % Zr, ⁇ 0.10 wt. % Fe, ⁇ 0.08 wt. % Si, 0.01 - 0.10 wt.
  • XI is 0.15 - 0.40 (i.e., XI wt. % Mn is 0.15 - 0.40 wt. % Mn), wherein X2 is 0.15-0.30, wherein X3 is 0.15 - 0.25, wherein X4 is 0.20 - 0.40, and wherein X5 is 0.25 - 0.35.
  • a second version of the new 2xxx aluminum alloy includes second tailored amounts of copper, magnesium and zinc.
  • the second version includes from 2.5 to 3.4 wt. % copper, from 0.5 to 2.0 wt. % Zn, and from 0.05 to 0.35 wt. % Mg.
  • the second version includes at least 2.6 wt. % Cu. In another embodiment, the second version includes at least 2.7 wt. % Cu. In yet another embodiment, the second version includes at least 2.8 wt. % Cu. In another embodiment, the second version includes at least 2.85 wt. % Cu. In one embodiment, the second version includes not greater than 3.35 wt. % Cu. In another embodiment, the second version includes not greater than 3.3 wt. % Cu. In one embodiment, the second version includes not greater than 3.25 wt. % Cu. In another embodiment, the second version includes not greater than 3.2 wt. % Cu. In another embodiment, the second version includes not greater than 3.15 wt. % Cu.
  • the second version includes at least 0.6 wt. % Zn. In another embodiment, the second version includes at least 0.8 wt. % Zn. In yet another embodiment, the second version includes at least 1.0 wt. % Zn. In another embodiment, the second version includes at least 1.1 wt. % Zn. In yet another embodiment, the second version includes at least 1.2 wt. % Zn. In another embodiment, the second version includes at least 1.3 wt. % Zn. In one embodiment, the second version includes not greater than 1.9 wt. % Zn. In another embodiment, the second version includes not greater than 1.8 wt. % Zn.
  • the second version includes not greater that 1.7 wt. % Zn. In another embodiment, the second version includes not greater than 1.6 wt. % Zn. In yet another embodiment, the second version includes not greater that 1.5 wt. % Zn.
  • the weight ratio of copper-to-zinc in the alloy may be related to its improved properties (e.g., its quench sensitivity).
  • the second version realizes a copper-to-zinc (weight) ratio of not greater than 4.25: 1 (Cu:Zn), i.e., (wt. % Cu) / (wt. % Zn) of the alloy is not greater than 4.00: 1.
  • the second version realizes a copper-to-zinc (weight) ratio of not greater than 3.75 : 1.
  • the second version realizes a copper-to-zinc (weight) ratio of not greater than 3.50: 1.
  • the second version realizes a copper-to-zinc (weight) ratio of not greater than 3.30: 1. In yet another embodiment, the second version realizes a copper-to-zinc (weight) ratio of not greater than 3.10: 1. In another embodiment, the second version realizes a copper-to-zinc (weight) ratio of not greater than 2.95: 1. In yet another embodiment, the second version realizes a copper-to-zinc (weight) ratio of not greater than 2.90: 1. In another embodiment, the second version realizes a copper-to-zinc (weight) ratio of not greater than 2.75: 1. In another embodiment, the second version realizes a copper-to-zinc (weight) ratio of not greater than 2.67: 1. In another embodiment, the second version realizes a copper-to-zinc (weight) ratio of not greater than 2.50: 1. In another embodiment, the second version realizes a copper-to-zinc (weight) ratio of not greater than 2.42: 1.
  • the second version includes at least 0.10 wt. % Mg. In another embodiment, the second version includes at least 0.12 wt. % Mg. In yet another embodiment, the second version includes at least 0.13 wt. % Mg. In another embodiment, the second version includes at least 0.14 wt. % Mg. In yet another embodiment, the second version includes at least 0.15 wt. % Mg. In another embodiment, the second version includes at least 0.16 wt. % Mg. In yet another embodiment, the second version includes at least 0.17 wt. % Mg. In one embodiment, the second version includes not greater than 0.30 wt. % Mg.
  • the second version includes not greater than 0.275 wt. % Mg. In yet another embodiment, the second version includes not greater than 0.25 wt. % Mg. In another embodiment, the second version includes not greater than 0.24 wt. % Mg. In yet another embodiment, the second version includes not greater than 0.23 wt. % Mg.
  • a second version includes 2.7 - 3.3 wt. % Cu, 0.85 - 1.15 wt. % Li, 1.2 - 1.6 wt. % Zn, wherein Cu:Zn (weight ratio) is ⁇ 4.25: 1, 0.15 - 0.30 wt. % Mg, (Yl, Y2, Y3, Y4 or Y5) wt. % Mn, ⁇ 0.005 wt. % Ag, 0.05 - 0.15 wt. % Zr, ⁇ 0.10 wt. % Fe, ⁇ 0.08 wt. % Si, 0.01 - 0.10 wt.
  • Yl is 0.15 - 0.40 (i.e., Yl wt. % Mn is 0.15 - 0.40 wt. % Mn), wherein Y2 is 0.15-0.30, wherein Y3 is 0.15 - 0.25, wherein Y4 is 0.20 - 0.40, and wherein Y5 is 0.25 - 0.35.
  • the new alloys may be useful in a variety of product forms, including ingot or billet, wrought product forms (plate, forgings and extrusions), shape castings, additively manufactured products, and powder metallurgy products, for instance.
  • a new 2xxx aluminum alloy is in the form of a thick wrought product.
  • Thick wrought aluminum alloy products are those wrought products having a cross- sectional thickness of at least 12.7 mm.
  • the wrought products may be rolled products, forged products or extruded products.
  • a thick wrought aluminum alloy product has a thickness of at least 25.4 mm.
  • a thick wrought aluminum alloy product has a thickness of at least 50.8 mm.
  • a thick wrought aluminum alloy product has a thickness of at least 76.2 mm.
  • a thick wrought aluminum alloy product has a thickness of at least 101.6 mm.
  • a thick wrought aluminum alloy product has a thickness of at least 126.0 mm. In another embodiment, a thick wrought aluminum alloy product has a thickness of at least 152.4 mm. The improved properties described herein may be achieved with thick wrought products having a thickness of up to 304.8 mm. In one embodiment, a thick wrought aluminum alloy product has a thickness of not greater than 254.0 mm. In another embodiment, a thick wrought aluminum alloy product has a thickness of not greater than 203.2 mm. In yet another embodiment, a thick wrought aluminum alloy product has a thickness of not greater than 177.8 mm. As used in this paragraph, thickness refers to the minimum thickness of the product, realizing that some portions of the product may realize slightly larger thicknesses than the minimum stated.
  • the new alloy can be prepared into wrought form, and in the appropriate temper, by more or less conventional practices, including direct chill (DC) casting the aluminum alloy into ingot form.
  • DC direct chill
  • these ingots may be further processed by hot working the product.
  • the product may then be optionally cold worked, optionally annealed, solution heat treated, quenched, and final cold worked (e.g., by stretching or compression of from 0.5% to 10%).
  • final cold worked e.g., by stretching or compression of from 0.5% to 10%
  • the product may be artificially aged.
  • the products may be produced in a T3 or T8 temper.
  • other T tempers may be used (e.g., any of a Tl, T2, T4, T5, T6, T7 or T9 temper). T tempers are defined in ANSI H35.1 (2009).
  • the new 2xxx aluminum lithium alloys generally realize an improved combination of at least two of strength, elongation, fracture toughness, and stress corrosion cracking resistance.
  • a new 2xxx aluminum lithium alloy has a thickness of at least 80 mm and realizes a tensile yield strength (ST) of at least 440 MPa in the T8 temper.
  • a new 2xxx aluminum lithium alloy has a thickness of at least 80 mm and realizes a tensile yield strength (ST) of at least 450 MPa in the T8 temper.
  • a new 2xxx aluminum lithium alloy has a thickness of at least 80 mm and realizes a tensile yield strength (ST) of at least 460 MPa in the T8 temper.
  • a new 2xxx aluminum lithium alloy has a thickness of at least 80 mm and realizes a tensile yield strength (ST) of at least 470 MPa in the T8 temper.
  • a new 2xxx aluminum lithium alloy has a thickness of at least 80 mm and realizes a tensile yield strength (ST) of at least 480 MPa, or more, in the T8 temper.
  • ST tensile yield strength
  • the above strength properties may be realized in products having a thickness of at least 100 mm, or at least 125 mm, or at least 150 mm, or higher.
  • a new 2xxx aluminum lithium alloy has a thickness of at least 80 mm and realizes a plane-strain (Kic) fracture toughness (S-L) of at least 20 MPa-sqrt-m in the T8 temper.
  • a new 2xxx aluminum lithium alloy has a thickness of at least 80 mm and realizes a plane-strain (Kic) fracture toughness (S-L) of at least 21 MPa- sqrt-m in the T8 temper.
  • a new 2xxx aluminum lithium alloy has a thickness of at least 80 mm and realizes a plane-strain (Kic) fracture toughness (S-L) of at least 22 MPa-sqrt-m in the T8 temper.
  • a new 2xxx aluminum lithium alloy has a thickness of at least 80 mm and realizes a plane-strain (Kic) fracture toughness (S- L) of at least 23 MPa-sqrt-m in the T8 temper.
  • a new 2xxx aluminum lithium alloy has a thickness of at least 80 mm and realizes a plane-strain (Kic) fracture toughness (S-L) of at least 24 MPa-sqrt-m in the T8 temper.
  • a new 2xxx aluminum lithium alloy has a thickness of at least 80 mm and realizes a plane- strain (Kic) fracture toughness (S-L) of at least 25 MPa-sqrt-m in the T8 temper.
  • a new 2xxx aluminum lithium alloy has a thickness of at least 80 mm and realizes a plane-strain (Kic) fracture toughness (S-L) of at least 26 MPa-sqrt-m, or more, in the T8 temper.
  • the above fracture toughness properties may be realized in products having a thickness of at least 100 mm, or at least 125 mm, or at least 150 mm, or higher.
  • a new 2xxx aluminum lithium alloy has a thickness of at least 80 mm and realizes an elongation (ST) of at least 1.5% in the T8 temper.
  • a new 2xxx aluminum lithium alloy has a thickness of at least 80 mm and realizes an elongation (ST) of at least 2.0% in the T8 temper.
  • a new 2xxx aluminum lithium alloy has a thickness of at least 80 mm and realizes an elongation (ST) of at least 2.5% in the T8 temper.
  • a new 2xxx aluminum lithium alloy has a thickness of at least 80 mm and realizes an elongation (ST) of at least 3.0%, or more, in the T8 temper.
  • the above elongation properties may be realized in products having a thickness of at least 100 mm, or at least 125 mm, or at least 150 mm, or higher.
  • a new 2xxx aluminum lithium alloy has a thickness of at least 80 mm and is stress corrosion cracking resistant (defined below) in the T8 temper.
  • the above stress corrosion cracking resistance properties may be realized in products having a thickness of at least 100 mm, or at least 125 mm, or at least 150 mm, or higher.
  • a new 2xxx aluminum lithium alloy realizes at least 3.0 MPa-sqrt- m (MPaVm) higher plane strain (Kic) fracture toughness as compared to a standard 2070 aluminum alloy product, where both products processed to the same product form, gauge, yield strength and temper.
  • both a new 2xxx aluminum lithium alloy and a 2070 alloy are produced as 150 mm plate in the T8 temper (with the same amount of stretch or compression, e.g., within 0.5% stretch/compression of each other), and if both alloys are artificially aged to about the same tensile yield strength (e.g., within 5 MPa of one another), then, in this approach, the Kic fracture toughness of the new 2xxx aluminum lithium alloy would be at least 3 MPa-sqrt-m higher than the 2070 alloy.
  • a new 2xxx aluminum lithium alloy realizes at least 4.0 MPa-sqrt-m higher plane strain (Kic) fracture toughness as compared to a standard 2070 aluminum alloy product, where both products processed to the same product form, gauge, yield strength and temper.
  • a new 2xxx aluminum lithium alloy realizes at least 5.0 MPa-sqrt-m higher plane strain (Kic) fracture toughness as compared to a standard 2070 aluminum alloy product, where both products processed to the same product form, gauge, yield strength and temper.
  • a standard 2070 aluminum alloy product nominally includes (targets) 3.5 wt. % Cu, 0.30 wt. % Mn, 0.22 wt. % Mg, 0.30 wt.
  • % Zn 1.15 wt. % Li, 0.30 wt. % Zn, 0.11 wt. % Zr, ⁇ 0.04 wt. % Si, ⁇ 0.06 wt. % Fe, ⁇ 0.03 wt. % Ti, not greater than 0.10 wt. %, in total, of impurities, and not greater than 0.03 wt. % of each of impurities, the balance being aluminum.
  • “2xxx aluminum alloys” are aluminum alloys compositions having copper as the major alloying element as per the Aluminum Association definition provided in“ International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys,” page 28 (2015).
  • 2xxx aluminum alloy compositions may be used in non-wrought products, such as in shape castings, ingot/billet, and additively manufactured products, among others.
  • “Wrought aluminum alloy product” means an aluminum alloy product that is hot worked after casting, and includes rolled products (sheet or plate), forged products, and extruded products.
  • Formged aluminum alloy product means a wrought aluminum alloy product that is either die forged or hand forged.
  • Solution heat treating means exposure of an aluminum alloy to elevated temperature for the purpose of placing solute(s) into solid solution.
  • “Hot working” means working the aluminum alloy product at elevated temperature, generally at least 250°F.
  • Cold working means working the aluminum alloy product at temperatures that are not considered hot working temperatures, generally below about 250°F (e.g., at ambient).
  • “Artificially aging” means exposure of an aluminum alloy to elevated temperature for the purpose of precipitating solute(s). Artificial aging may occur in one or a plurality of steps, which can include varying temperatures and/or exposure times. [0050] Strength and elongation are measured in accordance with ASTM E8 and B557.
  • Fracture toughness is measured in accordance with ASTM E399.
  • Stress corrosion cracking resistant means that all specimens of a 2xxx aluminum alloy product do not fail after 30 days of alternate immersion testing at a net stress of 379 MPa in accordance with ASTM G44/G47, and with at least 5 specimens being required for testing. In one embodiment, all specimens of a 2xxx aluminum alloy product do not fail after 60 days of alternate immersion testing at a net stress of 379 MPa in accordance with ASTM G44/G47, and with at least 5 specimens being required for testing. In another embodiment, all specimens of a 2xxx aluminum alloy product do not fail after 90 days of alternate immersion testing at a net stress of 379 MPa in accordance with ASTM G44/G47, and with at least 5 specimens being required for testing. SCC test specimens are extracted so as to be centered at the mid-plane and oriented in the ST direction relative to the original alloy product.
  • additive manufacturing means“a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies”, as defined in ASTM F2792-l2a entitled “Standard Terminology for Additively Manufacturing Technologies”.
  • additive manufacturing processes useful in producing aluminum alloy products include, for instance, DMLS (direct metal laser sintering), SLM (selective laser melting), SLS (selective laser sintering), and EBM (electron beam melting), among others.
  • Any suitable feedstocks made from the above new 2xxx aluminum alloys may be used, including one or more powders, one or more wires, one or more sheets, and combinations thereof.
  • the additive manufacturing feedstock is comprised of one or more powders comprising the new 2xxx aluminum alloys. Shavings are types of particles.
  • the additive manufacturing feedstock is comprised of one or more wires comprising the new 2xxx aluminum alloys.
  • a ribbon is a type of wire.
  • the additive manufacturing feedstock is comprised of one or more sheets comprising the new 2xxx aluminum alloys. Foil is a type of sheet.
  • the term“or” is an inclusive“or” operator, and is equivalent to the term“and/or,” unless the context clearly dictates otherwise (e.g.,“XI, X2, X3, X4 or X5” does not mean“and/or” herein because all of X1-X5 are unique and distinct from one another).
  • the term“based on” is not exclusive and allows for being based on additional factors not described, unless the context clearly dictates otherwise.
  • the meaning of“a,”“an,” and“the” include plural references, unless the context clearly dictates otherwise.
  • the meaning of“in” includes“in” and“on”, unless the context clearly dictates otherwise.
  • FIGS. 1-2 are graphs illustrating the performance of various aluminum alloy products of Example 1.
  • FIG. 3 is a graph illustrating the performance of various aluminum alloys products of Example 2.
  • Al-Li alloys were cast as ingot and homogenized. The composition of each ingot is shown in Table 3a, below. Alloys A and B are invention alloys. Alloy C and the 2070 alloy are non-invention alloys. The 2070 alloy is described in, for instance, commonly-owned U.S. Patent Application Publication No. 2012/0225271.
  • each alloy was aluminum, incidental elements and impurities, with no one impurity exceeding 0.05 wt. %, and with the total amount of impurities not exceeding 0.15 wt. %.
  • the alloys were hot rolled to final gauge, solution heat treated, quenched and stretched about 6%. Approximate final gauges are provided in Table 3b, below.
  • the new alloys generally realize improved fracture toughness at equivalent strength.
  • invention alloy A-l realizes about 3 MPa-sqrt-m higher strength over the 2070 alloy at about equivalent strength (at 30 hours of aging).
  • Invention alloy A-2 also is improved over the 2070 alloy, and the A-2 alloy would be expected to achieve results similar to that of the Alloy A-l if the silicon content of the A-2 alloy were reduced to 0.02 wt. %.
  • Invention alloy B realizes very high fracture toughness at reduced strength levels, but would be expected to achieve results at least as good as A-l, if aged to equivalent strength. The improved properties are even more pronounced at 150 mm, where all of the invention alloys realized much better fracture toughness at equivalent strength.
  • the invention alloys include less magnesium than non-invention alloy C.
  • the invention alloys also have a Cu:Zn ratio (weight) of not greater than 4.25: 1, whereas the non-invention alloys realize higher Cu:Zn ratios.
  • the invention alloys also have more zinc than alloy C and non-invention alloy 2070.
  • each alloy was aluminum, incidental elements and impurities, with no one impurity exceeding 0.05 wt. %, and with the total amount of impurities not exceeding 0.15 wt. %.
  • the alloys were hot rolled to final gauge, solution heat treated, quenched and then stretched about 6%.
  • the alloys were then artificially aged at various times and temperatures. The aging conditions are shown in Table 6.
  • Alloys 1-2 having a thickness of about 60 mm, realize an excellent combination of strength and fracture toughness.
  • Alloy 3 realizes a similar strength- toughness trend as the 100 mm alloys of Example 1.

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EP19882996.2A EP3877562B1 (en) 2018-11-07 2019-11-06 2xxx aluminum lithium alloys
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