WO2020108932A1 - Procédé de production d'une structure hydroformée à haute énergie à partir d'un alliage d'al-mg-sc - Google Patents

Procédé de production d'une structure hydroformée à haute énergie à partir d'un alliage d'al-mg-sc Download PDF

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Publication number
WO2020108932A1
WO2020108932A1 PCT/EP2019/080345 EP2019080345W WO2020108932A1 WO 2020108932 A1 WO2020108932 A1 WO 2020108932A1 EP 2019080345 W EP2019080345 W EP 2019080345W WO 2020108932 A1 WO2020108932 A1 WO 2020108932A1
Authority
WO
WIPO (PCT)
Prior art keywords
energy
aluminium
final
aluminium alloy
machining
Prior art date
Application number
PCT/EP2019/080345
Other languages
English (en)
Inventor
Achim BÜRGER
Philippe Meyer
Andreas Harald BACH
Philipp Daniel RUMPF
Sabine Maria Spangel
Original Assignee
Aleris Rolled Products Germany Gmbh
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Aleris Rolled Products Germany Gmbh filed Critical Aleris Rolled Products Germany Gmbh
Priority to EP19797293.8A priority Critical patent/EP3887073B1/fr
Publication of WO2020108932A1 publication Critical patent/WO2020108932A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/053—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure characterised by the material of the blanks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
    • B21D26/06—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure by shock waves
    • 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
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/92—Making other particular articles other parts for aircraft

Definitions

  • the invention relates to a method of producing an integrated monolithic alu minium alloy structure, and can have a complex configuration, that is machined to near-net-shape out of a plate material. More specifically, the invention relates to a method of producing an integrated monolithic aluminium alloy structure made from an AIMgSc-series alloy, and can have a complex configuration, that is machined to near-net-shape out of a plate material. The invention relates also to an integrated monolithic aluminium alloy structure produced by the method of this invention and to several intermediate semi-finished products obtained by said method.
  • aluminium alloy designations and temper designations refer to the Aluminium Association designa tions in Aluminium Standards and Data and the Registration Records, as published by the Aluminium Association in 2018 and are well known to the person skilled in the art.
  • the temper designations are laid down in European standard EN515.
  • the term "about” when used to describe a compositional range or amount of an alloying addition means that the actual amount of the alloying addi tion may vary from the nominal intended amount due to factors such as standard processing variations as understood by those skilled in the art.
  • the term“up to” and“up to about”, as employed herein, explicitly includes, but is not limited to, the possibility of zero weight-percent of the particular alloying com ponent to which it refers. For example, up to 0.1 % Cu may include an aluminium alloy having no Cu.
  • “Monolithic” is a term known in the art meaning comprising a substantially sin gle unit which may be a single piece formed or created without joint or seams and comprising a substantially uniform whole.
  • an aluminium alloy rolled product with a predetermined thickness of at least 2 mm (0.0787 inches), wherein the aluminium alloy rolled product is an AIMgSc-series alloy;
  • the AIMgSc-series aluminium alloy rolled product is cast, rolled to final gauge and optionally annealed.
  • the rolling process applied comprises hot roll ing, and optionally comprises hot rolling followed by cold rolling to final gauge, and where applicable intermediate annealing is applied.
  • the alloy product Prior to hot rolling the alloy product is homogenised or pre-heated for up to about 50 hours, preferably up to about 24 hours, at a temperature in a range of about 320°C to 470°C.
  • the hot rolled product re ceives a very mild cold rolling step (skin rolling or skin pass) with a reduction of less than about 1 %, preferably less than about 0.5%, to improve the flatness of the rolled product.
  • the hot rolled product can be stretched. This stretching step can be carried out with a reduction of up to 3%, preferably between about 0.5% to 1 %, to improve the flatness of the hot rolled product.
  • the AIMgSc-series plate material is pre-ma- chined, such as by turning, milling, and drilling, to an intermediate machined struc ture.
  • the ultra-sonic dead-zone is removed from a thick plate product.
  • some material can be removed to create one or more pockets in the plate ma terial and a more near-net-shape to the forming die. This may facilitate the shaping during the subsequent high-energy hydroforming operation.
  • an aluminium plate up to several inches thick, is placed over or proximate to a die, with the intervening space, or cavity, optionally evacuated by a vacuum pump.
  • the entire apparatus is submerged into an underwater basin or tank, with a charge having a predetermined force potential detonated at a predetermined dis tance from the metal workpiece to generate a predetermined shockwave in the wa ter.
  • the water then exerts a predetermined dynamic pressure on the workpiece against the die at a rate on the order of milliseconds.
  • the die can be made from any material of suitable strength to withstand the force of the detonated charge such as, for example, concrete, ductile iron, etc.
  • the tooling should have higher yield strength than the metal workpiece being formed.
  • the high-energy hydroforming step is by means of electrohydraulic forming.
  • the electrohydraulic forming process is a high-energy-rate plastic deformation process preferably per formed in water or another suitable liquid environment, e.g. an oil, to allow ambient temperature forming of the aluminium alloy plate.
  • An electric arc discharge is used to convert electrical energy to mechanical energy and change the shape of the rolled product.
  • a capacitor bank delivers a pulse of high current across two electrodes, which are positioned a short distance apart while submerged in a fluid.
  • the electric arc discharge rapidly vaporizes the surrounding fluid creating a shock wave.
  • the rolled product is placed over a die and preferably clamped at the edges. In an em bodiment the space between the rolled product and the die may be vacuumed be fore the forming process.
  • a coolant is preferably used during the various pre-machining and machining or mechanical milling processes steps to allow for ambient temperature machining of the aluminium alloy rolled product or an intermediate product.
  • the pre-machining and the machining to near-final or final machined structure com prises high-speed machining, preferably comprises numerically-controlled (NC) ma chining.
  • the resultant structure is an nealed and cooled to ambient temperature.
  • One of the objects is to heat the struc ture to a temperature in the range of 200°C to 400°C for a time in the range of up to about 20 hours, and preferably for about 0.5 hours to 10 hours.
  • the annealing fol lowed by cooling is important because of obtaining an optimum recovered micro structure and a reduction of internal stresses.
  • the intermediate product is further stress relieved, preferably by an operation including a cold compression type of operation, else there will be too much residual stress impacting a subsequent machining operation.
  • the stress relieve via a cold compression of operation is by performing one or more next high-energy hydroforming steps.
  • the annealed high-energy formed intermediate structure, and optionally also stress relieved is, in that order, next machined or mechanically milled to a near-final or final machined integrated monolithic aluminium structure and followed by annealing to a desired temper to achieve final mechanical proper ties.
  • the annealing is to a temperature in the range of 200°C to 400°C for a time in the range of up to about 20 hours, and preferably for about 0.5 hours to 10 hours.
  • the final machined formed integrated monolithic aluminium structure has a tensile strength of at least 200 MPa. In an embodiment the tensile strength is at least 250 MPa, and more preferably at least 300 MPa.
  • the predetermined thickness of the aluminium alloy rolled product is a plate product of at least 5 mm (0.2 inches), and more preferably at least 12.7 mm (0.5 inches).
  • the predetermined thickness of the aluminium alloy rolled product is a plate product of at least 38.1 (1 .5 inches), and preferably at least 50.8 mm (2.0 inches), and more preferably at least 63.5 mm (2.5 inches).
  • the predetermined thickness of the aluminium alloy rolled product is a plate product of at most 127 mm (5 inches), and preferably at most 1 14.3 mm (4.5 inches).
  • the AIMgSc-series aluminium alloy has a composition com prising, in wt.%:
  • Mn up to 1 %, preferably 0.3% to 1 .0%, more preferably 0.3% to 0.8%,
  • Cu up to 0.2%, preferably up to 0.1 %, more preferably up to 0.05%,
  • Zn up to 1 .5%, preferably up to 0.8%, more preferably 0.1 % to 0.8%,
  • Fe up to 0.4%, preferably up to 0.3%, more preferably up to 0.20%,
  • Si up to 0.3%, preferably up to 0.2%, more preferably up to 0.1 %, impurities and balance aluminium. Typically, such impurities are present each ⁇ 0.05% and total ⁇ 0.15%.
  • the Mg is the main alloying element in the AIMgSc-series alloys, and for the method according to this invention it should be in a range of 3.0% to 6.0%.
  • a pre ferred lower-limit for the Mg-content is about 3.2%, more preferably about 3.8%.
  • a preferred upper-limit for the Mg-content is about 4.8%. In an embodiment the upper- limit for the Mg-content is about 4.5%.
  • Sc is another important alloying element and should be present in a range of 0.02% to 0.5%.
  • a preferred lower-limit for the Sc-content is about 0.1 %.
  • the Sc-content is up to about 0.4%, and preferably up to about 0.3%.
  • Zr in a range of up to 0.3%, and preferably is present in a range of 0.05% to 0.20%, and more preferably is present in a range of about 0.07% to 0.15%.
  • Ti may be added up to about 0.2% to the AIMgSc alloy as strengthening ele ment or for improving the corrosion resistance or for grain refiner purposes.
  • a pre ferred addition of Ti is in a range of about 0.01 % to 0.2%, and preferably in a range of about 0.01 % to 0.10%.
  • the combined addition is at least 0.15% to achieve sufficient strength, and preferably does not exceed 0.30% to avoid the formation of too large precipi tates.
  • the combined addition of Zr+Ti is at least 0.08%, and preferably does not exceed 0.25%, and wherein Cr is up to 0.02%, and preferably only up to 0.01 %.
  • Cu can be present in the AIMgSc-alloy as strengthening element in a range up to about 2%. However, in applications of the product where the corrosion resistance is a very critical engineering property, it is preferred to maintain the Cu at a low level of 0.2% or less, and preferably at a level of 0.1 % or less, and more preferably at a level of 0.05% or less.
  • Fe is a regular impurity in aluminium alloys and can be tolerated up to 0.4%. Preferably it is kept to a level of up to about 0.3%, and more preferably up to about 0.20%.
  • Si is also a regular impurity in aluminium alloys and can be tolerated up to 0.3%. Preferably it is kept to a level of up to 0.2%, and more preferably up to 0.10%.
  • the invention relates to an intermediate semi-finished prod uct formed by the intermediate machined structure prior to the high-energy hydro forming operation.
  • the invention relates to an intermediate semi-finished prod uct formed by the intermediate, and optionally pre-machined, structure having been high-energy hydroformed formed and having at least one of a uniaxial curvature and a biaxial curvature by the method according to this invention.
  • the annealed and machined final integrated monolithic aluminium structure can be part of a structure like a fuselage panel with integrated stringers, cockpit of an aircraft, lateral windshield of a cockpit, integral lateral windshield of a cockpit, an integral frontal windshield of a cockpit, pressure bulkhead, door surround, nose landing gear bay, nose fuselage, and part of a wing structure. It can also be part of a structure like an underbody structure of an armoured vehicle providing mine blast resistance, the door of an armoured vehicle, the engine hood or front fender of an armoured vehicle, a turret.
  • the invention relates to the use of a AIMgSc-series alumin ium alloy rolled product having a composition of, in wt.%, Mg 3.0% to 6.0%, Sc 0.02% to 0.5%, Mn up to 1 %, Zr up to 0.3%, Cr up to 0.3%, Ti up to 0.2%, Cu up to 0.2%, Zn up to 1 .5%, Fe up to 0.4%, Si up to 0.3%, balance aluminium and impuri ties each ⁇ 0.05% and total ⁇ 0.15%, and with preferred narrower compositional ranges as herein described and claimed, and a thickness of at least 2 mm, prefera bly of 5 mm to 127 mm, in a high-energy hydroforming operation according to this invention, and preferably to produce an aircraft structural part.
  • Fig. 1 shows a flow chart illustrating one embodiment of the method according to this invention.
  • Fig. 2 shows a flow chart illustrating another embodiment of the method ac cording to this invention.
  • Figs. 3A, 3B and 3C show cross-sectional side-views of an aluminium plate progressing through stages of a forming process from a rough-shaped metal plate into a shaped, near-finally shaped and finally-shaped workpiece, according to as pects of the present invention.
  • the method comprises, in that order, a first process step of providing an AIMgSc-series aluminium alloy rolled product having a predetermined thickness of at least 2 mm, with preferred thicker gauges.
  • the aluminium alloy rolled product prior to the high-energy hydroforming operation can be in various conditions, in par ticular advantageous are:
  • the rolled product can be a solely hot rolled product
  • the rolled product can be a hot rolled product and having been annealed to recover the microstructure
  • the rolled product can be a hot rolled product and then cold rolled to final gauge; the rolled product can be a hot rolled product and then cold rolled to final gauge and having been annealed to recover the microstructure.
  • the hot rolled product can be further very mild cold rolled or stretched to improve the flatness of the rolled product.
  • the rolled product is pre-machined (this is an optional process step) into an intermediate machined structure and subsequently high-en ergy hydroformed, preferably by means of explosive forming or electrohydraulic forming, into a high-energy hydroformed structure with least one of a uniaxial cur vature and a biaxial curvature.
  • a next process step there is annealing and cooling of said high-energy hydroformed structure.
  • the intermediate product is stress relieved, more preferably in an operation including a cold compression type of operation.
  • machining or mechanical milling of said annealing high-energy formed structure to a near-final or final machined integrated monolithic aluminium structure optionally followed by a final annealing of said machined integrated monolithic aluminium structure to a desired temper to develop the required strength and other engineering properties relevant for the intended application of the integrated monolithic alumin ium structure.
  • the method illustrated in Fig. 2 is closely related to the method illustrated in Fig. 1 , except that in this embodiment there is a first high-energy hydroforming step, followed by annealing and cooling. Then at least one second high-energy hydro forming step is performed the purpose of which is at least stress relief, followed by the annealing and machining as in the method illustrated in Fig. 1.
  • Figs. 3A, 3B and 3C show a series in progression of exemplary drawings illus trating how an aluminium plate may be formed during an explosive forming process that can be used in the forming processes according to this invention.
  • a tank 82 contains an amount of water 83.
  • a die 84 defines a cavity 85 and a vacuum line 87 extends from the cavity 85 through the die 84 to a vacuum (not shown).
  • Aluminium plate 86a is held in position in the die 84 via a hold-down ring or other retaining device (not shown).
  • An explosive charge 88 is shown suspended in the water 83 via a charge detonation line 89, with charge detonation line 19a connected to a detonator (not shown).
  • the charge 88 (shown in Fig. 3A ) has been detonated in explosive forming assembly 80b creating a shock wave“A” emanating from a gas bubble“B”, with the shock wave“A” causing the deformation of the aluminium plate 86b into cavity 85 until the aluminium plate 86c is driven against (e.g., immediately proximate to and in contact with) the inner surface of die 84 as shown in Fig. 3C.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Fluid Mechanics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)

Abstract

L'invention concerne un procédé de production d'une structure en aluminium monolithique intégrée, le procédé comprenant les étapes consistant à : (a) utiliser un produit laminé en alliage d'aluminium de type Al-Mg-Sc présentant une épaisseur prédéterminée d'au moins 2 mm; (b) éventuellement, pré-usiner le produit laminé en alliage d'aluminium en une structure usinée intermédiaire; (c) hydroformer à haute énergie la plaque ou la structure usinée intermédiaire éventuelle contre une surface de formage d'une matrice rigide présentant un contour conformément à une courbure souhaitée de la structure d'aluminium monollithique intégrée, le formage à haute énergie amenant la plaque ou la structure usinée intermédiaire à épouser le contour de la surface de formage selon au moins une courbure uniaxiale et une courbure biaxiale; (d) recuire et refroidir la structure hydroformée à haute énergie; (e) usiner en une structure d'aluminium monolithique intégrée finale ou quasi-finale.
PCT/EP2019/080345 2018-11-26 2019-11-06 Procédé de production d'une structure hydroformée à haute énergie à partir d'un alliage d'al-mg-sc WO2020108932A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP19797293.8A EP3887073B1 (fr) 2018-11-26 2019-11-06 Procédé de production d'une structure hydroformée à haute énergie à partir d'un alliage al-mg-sc

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP18208368 2018-11-26
EP18208368.3 2018-11-26

Publications (1)

Publication Number Publication Date
WO2020108932A1 true WO2020108932A1 (fr) 2020-06-04

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PCT/EP2019/080345 WO2020108932A1 (fr) 2018-11-26 2019-11-06 Procédé de production d'une structure hydroformée à haute énergie à partir d'un alliage d'al-mg-sc

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EP (1) EP3887073B1 (fr)
NL (1) NL2024300B1 (fr)
WO (1) WO2020108932A1 (fr)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7610669B2 (en) 2003-03-17 2009-11-03 Aleris Aluminum Koblenz Gmbh Method for producing an integrated monolithic aluminum structure and aluminum product machined from that structure
EP2546373A1 (fr) * 2011-07-13 2013-01-16 Aleris Aluminum Koblenz GmbH Procédé de fabrication d'un produit de feuille d'alliage AI-Mg
EP2948571B1 (fr) * 2013-01-25 2018-09-12 Aleris Rolled Products Germany GmbH Procédé de fabrication d'un produit de feuille d'alliage ai-mg

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7610669B2 (en) 2003-03-17 2009-11-03 Aleris Aluminum Koblenz Gmbh Method for producing an integrated monolithic aluminum structure and aluminum product machined from that structure
EP2546373A1 (fr) * 2011-07-13 2013-01-16 Aleris Aluminum Koblenz GmbH Procédé de fabrication d'un produit de feuille d'alliage AI-Mg
EP2948571B1 (fr) * 2013-01-25 2018-09-12 Aleris Rolled Products Germany GmbH Procédé de fabrication d'un produit de feuille d'alliage ai-mg

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
STUCKENBRUCK L C ET AL: "Explosive Forming of Missile Components", MACHINERY,, vol. 98, no. 2520, 1 March 1961 (1961-03-01), pages 486 - 490, XP001335799 *

Also Published As

Publication number Publication date
EP3887073A1 (fr) 2021-10-06
NL2024300B1 (en) 2020-06-09
EP3887073B1 (fr) 2024-08-28

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