High-strength mechanical and structural components, and methods of making high-strength components

a technology of mechanical and structural components and high-strength components, which is applied in the field of high-strength engine components and vehicle structural components, can solve the problems of many available lightweight materials that lack sufficient strength for many structural and engine components, and many of the available lightweight materials and lower volume medium weight materials that lack sufficient strength to meet engine and/or vehicle performance standards and safety goals

Inactive Publication Date: 2007-04-19
HONEYWELL INT INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0004] In one aspect the invention encompasses a high-strength engine component comprising an alloy which contains a base metal alloyed with less than or equal to 30% by weight of alloying elements, where the material has an average grain size of less than or equal to about 30 microns. The material has an absence of voids and inclusions of a size greater than 1 micron. The material also has a yield strength (YS) at least 50% greater than the yield strength of the identical alloy composition in an annealed 0 temper condition.
[0005] In one aspect the invention includes high-strength engine components comprising a material consisting of an alloy having a base metal alloyed with less than or equal to 30% by weight of alloying elements. The material has an average grain size of less than or equal to about 30 microns, an absence of voids and inclusions of a size greater than 1 micron and contains soluble second phase precipitates having an average size of less than 30 microns. The material has a yield strength at least 10% greater than the yield strength of the identical alloy composition in the T6 temper condition.
[0006] In one aspect the invention includes a vehicle structural component comprising a material consisting of an alloy comprising at least two elements selected from Al, Ti, Mg, Be, Ni, Fe, Cu, Co, W, Ta, Zn, Ag, Sn, Pb, In, Au, Si, Sb, Mo, V, Sc, Cr, Y, B, Mn, C, Li, P, S, Nb, Zr, Pd, and Cd. The alloy contains a base metal alloyed with less than or equal to 30% of additional alloying elements by weight. The material has an average grain size of less than or equal to about 30 microns, an absence of voids and inclusions having a size greater than 1 micron, and has a yield strength at least 50% greater than the yield strength of the identical alloy composition in the annealed 0 temper condition.
[0007] In one aspect the invention includes a vehicle structu

Problems solved by technology

Many of the available lightweight materials lack sufficient strength for many structural and engine components.
Additionally, many of the available light

Method used

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  • High-strength mechanical and structural components, and methods of making high-strength components
  • High-strength mechanical and structural components, and methods of making high-strength components
  • High-strength mechanical and structural components, and methods of making high-strength components

Examples

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example 1

Heat-Treatable Al 6061

[0075] The aluminum alloy designated as Al 6061 is widely used for structural applications including various aerospace applications. Conventional Al 6061 T6 temper is produced by solutionizing, quenching and artificial peak aging at 175° C. for 8 hours. Such is the strongest temper of this alloy obtainable by precipitation treatment alone. Standard Al 6061 0 temper is obtained by fully annealing of the alloy at a temperature of 400-450° C. for several hours. It is the lowest strength commercially available 6061 material. The yield strength and ultimate tensile strength of 0 temper and T6 6061 alloys is presented in FIG. 6 for comparison purposes relative to yield strength and ultimate tensile strength achieved utilizing methodology in accordance with the invention.

[0076] Three samples were prepared by processing in accordance with the invention. The ultimate tensile strength and yield strength of each of the three samples are presented in FIG. 6. Sample 1 was...

example 3

Heat-Treatable Al 2219

[0088] The aluminum alloy material designated Al 2219 is a more heavily alloyed material than either Al 2618 or Al 6061. Copper is its principle alloying element and has a nominal presence of 6.3%, which is greater than the standard solubility limit of copper in pure aluminum (around 4.5%). For this alloy, treatment in accordance with the invention was found to be most beneficial when hot ECAE step(s) were conducted before solutionizing and quenching thereby increasing the amount of copper in solution prior to precipitation as explained above. Referring to FIG. 12, such presents results of processing of this alloy in accordance with the invention. FIG. 12 shows the results of equal channel angular extrusion alone, or as combined with solutionizing and post deformation annealing, on the yield strength and ultimate tensile strength relative to standard Al 2219 in the 0 temper condition and peak aged (T6) condition. As shown, a significant strength increase is ob...

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Abstract

The invention includes components comprising an alloy containing a base metal and less than or equal to 30% alloying elements. The material has a grain size of less than or equal to about 30 microns and an absence of voids and inclusions of a size greater than 1 micron. The components have a yield strength at least 50% greater than the identical alloy composition in the 0 temper condition. Where the material is heat treatable, the yield strength is at least 10% greater than the identical composition in the T6 temper condition. The invention includes a method of producing components by casting and initial treatment to form a billet. The billet is subjected to equal channel angular extrusion and subsequent annealing at a temperature of less than or equal to 0.85 times the minimum temperature for inducing growth of submicron grains to over 1 micron.

Description

TECHNICAL FIELD [0001] The invention pertains to high-strength engine components, vehicle structural components, methods of producing engine components and methods of forming vehicle structural components. BACKGROUND OF THE INVENTION [0002] Development of lightweight materials which can contribute to weight reduction of land, air and space vehicles has become increasingly important. Vehicle weight reduction can result in increased fuel efficiency and reduced emissions. Lighter weight materials also offer improved maneuverability and can additionally reduce manufacturing costs. [0003] Many of the available lightweight materials lack sufficient strength for many structural and engine components. Current materials which are considered to be “lightweight” materials for use in engine or body components of vehicles include, for example, magnesium, aluminum, titanium and beryllium metals and alloys. Optionally, medium-weight materials such as steels are used due to their relatively high-st...

Claims

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Application Information

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IPC IPC(8): C22C21/00C22F1/04
CPCC22F1/00C22F1/04
Inventor FERRASSE, STEPHANEALFORD, FRANKKARDOKUS, JANINE K.STROTHERS, SUSAN D.CHADDA, SAKET
Owner HONEYWELL INT INC
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