Aluminum alloy added with magnesium and at least one of chromium, manganese and zirconium, and method for manufacturing same
By adding chromium, manganese, zirconium and calcium to the aluminum alloy and adopting specific manufacturing methods, the problem of metal inclusion in high-magnesium content aluminum-magnesium alloys during casting is solved, ductility and strength are improved, and aluminum is improved Overall performance of the alloy.
Patent Information
- Application Number
- CN202411188911.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2017-04-15
- Filing Date
- 2018-04-13
- Publication Date
- 2024-12-27
AI Technical Summary
High magnesium content aluminum-magnesium alloys are difficult to control during casting, resulting in an increase in intermetallic inclusions and reducing ductility and fatigue properties.
By adding elements such as chromium, manganese, zirconium and calcium, the alloy composition is adjusted to inhibit grain growth and recrystallization, improve ductility and strength, and cast under vacuum or surface flux using specific manufacturing methods such as melting and cooling steps. .
It significantly improves the tensile elongation of aluminum alloy, improves formability and strain hardening performance, and improves the overall performance of aluminum alloy.
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Abstract
Description
[0001] This application is a divisional application. The application date of the original application is April 13, 2018, the application number is 2018103308614, and the name of the invention is "Aluminum alloy containing at least one of magnesium, chromium, manganese and zirconium and its manufacturing method". Technical Field
[0002] The present application relates to aluminum alloys and methods of making aluminum alloys. Background Art
[0003] Aluminum alloys have a relatively high strength-to-weight ratio. Therefore, aluminum alloys have been very important in aerospace manufacturing since the introduction of metal skin aircraft. Various types of aluminum alloys have been developed. For example, the Aluminum Association of America classifies aluminum alloys containing magnesium as 5000 series aluminum alloys.
[0004] Aluminum-magnesium alloys offer certain advantages (e.g., light weight) over other conventional aluminum alloys. The addition of magnesium increases the strength of aluminum alloys, makes the alloys more amenable to surface treatment, and improves corrosion resistance. However, when the magnesium content of an aluminum-magnesium alloy is increased, such as to 5% by weight or more, the alloy becomes difficult to cast. In addition, large intermetallic inclusions have been observed in high magnesium content aluminum-magnesium alloys, which tend to result in low ductility and reduced fatigue performance.
[0005] Therefore, those skilled in the art will continue research and development work in the field of aluminum alloys. Summary of the invention
[0006] In one embodiment, the disclosed aluminum alloy includes aluminum, from about 6% to about 17.4% by weight magnesium, and up to about 0.2% by weight chromium.
[0007] In another embodiment, a disclosed aluminum alloy includes aluminum, from about 6% to about 17.4% by weight magnesium, and up to about 0.3% by weight manganese.
[0008] In another embodiment, an aluminum alloy is disclosed including aluminum, from about 6% to about 17.4% by weight magnesium, and up to about 0.2% by weight zirconium.
[0009] In another embodiment, the disclosed aluminum alloy includes aluminum, approximately 6% to approximately 17.4% by weight magnesium, and at least one of up to approximately 0.2% by weight chromium, up to approximately 0.3% by weight manganese, and up to approximately 0.2% by weight zirconium.
[0010] In another embodiment, a disclosed aluminum alloy includes aluminum, about 2.5% to about 17.4% by weight magnesium, about 50 to about 3000 ppm calcium, and up to about 0.2% by weight chromium.
[0011] In another embodiment, a disclosed aluminum alloy includes aluminum, about 2.5% to about 17.4% by weight magnesium, about 50 to about 3000 ppm calcium, and up to about 0.3% by weight manganese.
[0012] In another embodiment, a disclosed aluminum alloy includes aluminum, about 2.5% to about 17.4% by weight magnesium, about 50 to about 3000 ppm calcium, and up to about 0.2% by weight zirconium.
[0013] In yet another embodiment, the disclosed aluminum alloy includes aluminum, approximately 2.5% to approximately 17.4% by weight magnesium, approximately 50 to approximately 3000 ppm calcium, and at least one of up to approximately 0.2% by weight chromium, up to approximately 0.3% by weight manganese, and up to approximately 0.2% by weight zirconium.
[0014] In one embodiment, the disclosed method for making an aluminum alloy includes the steps of preparing a magnesium master alloy containing calcium and adding the magnesium master alloy containing calcium to aluminum. The magnesium master alloy containing calcium can be prepared by the steps of forming a molten matrix material by melting the matrix material, and adding a calcium-based compound to the molten matrix material. The calcium-based compound may include calcium and at least one of magnesium, chromium, zirconium, titanium, and aluminum. In an optional scheme, the calcium-based compound may include calcium and at least one of oxygen, cyanide, carbide, hydroxide, and carbonate. The amount of calcium added may be proportional to the magnesium content.
[0015] In another embodiment, a method of making an aluminum alloy is disclosed including the steps of alloying beryllium and magnesium together to form a beryllium and magnesium alloy and subsequently adding the beryllium and magnesium alloy to aluminum.
[0016] In yet another embodiment, the disclosed method of manufacturing an aluminum alloy includes the steps of melting aluminum, magnesium, and at least one of chromium, manganese, and zirconium to produce a molten substance, wherein the melting is performed under at least one of a vacuum and a surface flux, and cooling the molten substance to produce a solid substance.
[0017] Other embodiments of the disclosed aluminum alloys and methods of making the same will become apparent from the following detailed description, the accompanying drawings, and the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Figure 1 is a flow chart depicting one embodiment of the disclosed method of making an aluminum alloy;
[0019] Figure 2 is a flow chart depicting another embodiment of the disclosed method of making an aluminum alloy;
[0020] Figure 3 is a flow chart depicting yet another embodiment of the disclosed method of making an aluminum alloy;
[0021] Figure 4 is a flow chart of the aircraft manufacturing and servicing methodology; and
[0022] Figure 5 This is a block diagram of an aircraft. DETAILED DESCRIPTION
[0023] Disclosed are aluminum alloys, particularly aluminum-magnesium alloys, with additions of at least one of chromium, manganese and zirconium, and optionally calcium. Various other elements commonly used in aluminum alloys may also be present in the disclosed aluminum alloys.
[0024] The disclosed aluminum alloys may include magnesium at levels of about 2.5 to about 17.4 weight percent, such as about 6 to about 17.4 weight percent. Compared to conventional 5000 series alloys, which typically have magnesium weight percentages of 5.0% or less for commercial products, the relatively high magnesium may result in enhanced properties, such as increased ductility and strength. Additions of chromium and / or manganese and / or zirconium may inhibit grain growth and recrystallization in the disclosed aluminum alloys.
[0025] In the disclosed aluminum alloys, the amounts of chromium, manganese, and zirconium can be specifically adjusted relative to the magnesium content of the aluminum alloy. In addition to chromium, manganese, and zirconium, calcium can also be present in certain embodiments and can also help inhibit grain growth and recrystallization. The amount of calcium used can be specifically adjusted relative to the magnesium content.
[0026] The disclosed aluminum alloys can exhibit enhanced properties, such as improved tensile elongation. For example, the tensile elongation of the disclosed aluminum alloys can be at least about 10% higher than that of conventional 5000 series aluminum alloys, which can be a significant performance improvement for aluminum-magnesium alloys in terms of formability, strain hardening, and damage tolerance.
[0027] As a first general example, the disclosed aluminum alloys may have the compositions shown in Table 1.
[0028] Table 1
[0029] element quantity magnesium 2.5-17.4wt% calcium 50-3000ppm chromium Up to 0.2 wt% Other Elements Zero to 20wt% aluminum margin
[0030] Thus, the aluminum alloy of Table 1 may include aluminum, about 2.5 to about 17.4 weight percent magnesium, about 50 to about 3000 ppm calcium, and a non-zero amount of chromium up to about 0.2% by weight. In addition, the aluminum alloy of Table 1 may include up to about 1.4% silicon by weight; up to about 1.2% iron by weight; up to about 0.8% copper by weight; up to about 0.1% nickel by weight; up to about 2.8% zinc by weight; up to about 0.05% gallium by weight; up to about 0.05% vanadium by weight; up to about 0.05% scandium by weight; and / or up to about 0.20% titanium by weight.
[0031] In one variation of the aluminum alloy in Table 1, the disclosed aluminum alloy may include aluminum, about 6 to about 17.4 weight percent magnesium, about 50 to about 3000 ppm calcium, and a non-zero amount of chromium up to about 0.2% by weight. In addition, the disclosed aluminum alloy may include up to about 1.4% silicon by weight; up to about 1.2% iron by weight; up to about 0.8% copper by weight; up to about 0.1% nickel by weight; up to about 2.8% zinc by weight; up to about 0.05% gallium by weight; up to about 0.05% vanadium by weight; up to about 0.05% scandium by weight; and / or up to about 0.20% titanium by weight.
[0032] As a second general example, the disclosed aluminum alloys may have the compositions shown in Table 2.
[0033] Table 2
[0034] element quantity magnesium 2.5-17.4wt% calcium 50-3000ppm manganese Up to 0.3 wt% Other Elements Zero to 20wt% aluminum margin
[0035] Thus, the aluminum alloy in Table 2 may include aluminum, about 2.5 to about 17.4 weight percent magnesium, about 50 to about 3000 ppm calcium, and a non-zero amount of manganese up to about 0.3% by weight. In addition, the aluminum alloy in Table 2 may include up to about 1.4% silicon by weight; up to about 1.2% iron by weight; up to about 0.8% copper by weight; up to about 0.1% nickel by weight; up to about 2.8% zinc by weight; up to about 0.05% gallium by weight; up to about 0.05% vanadium by weight; up to about 0.05% scandium by weight; and / or up to about 0.20% titanium by weight.
[0036] In one variation of the aluminum alloy in Table 2, the disclosed aluminum alloy may include aluminum, about 6 to about 17.4 weight percent magnesium, about 50 to about 3000 ppm calcium, and a non-zero amount of manganese up to about 0.3% by weight. In addition, the disclosed aluminum alloy may include up to about 1.4% silicon by weight; up to about 1.2% iron by weight; up to about 0.8% copper by weight; up to about 0.1% nickel by weight; up to about 2.8% zinc by weight; up to about 0.05% gallium by weight; up to about 0.05% vanadium by weight; up to about 0.05% scandium by weight; and / or up to about 0.20% titanium by weight.
[0037] As a third general example, the disclosed aluminum alloys can have the composition shown in Table 3.
[0038] Table 3
[0039] element quantity magnesium 2.5-17.4wt% calcium 50-3000ppm zirconium Up to 0.2 wt% Other Elements Zero to 20wt% aluminum margin
[0040] Thus, the aluminum alloy in Table 3 may include aluminum, about 2.5 to about 17.4 weight percent magnesium, about 50 to about 3000 ppm calcium, and a non-zero amount of zirconium up to about 0.2% by weight. In addition, the aluminum alloy in Table 3 may include up to about 1.4% silicon by weight; up to about 1.2% iron by weight; up to about 0.8% copper by weight; up to about 0.1% nickel by weight; up to about 2.8% zinc by weight; up to about 0.05% gallium by weight; up to about 0.05% vanadium by weight; up to about 0.05% scandium by weight; and / or up to about 0.20% titanium by weight.
[0041] In one variation of the aluminum alloy in Table 3, the disclosed aluminum alloy may include aluminum, about 6 to about 17.4 weight percent magnesium, about 50 to about 3000 ppm calcium, and a non-zero amount of zirconium up to about 0.2% by weight. In addition, the disclosed aluminum alloy may include up to about 1.4% silicon by weight; up to about 1.2% iron by weight; up to about 0.8% copper by weight; up to about 0.1% nickel by weight; up to about 2.8% zinc by weight; up to about 0.05% gallium by weight; up to about 0.05% vanadium by weight; up to about 0.05% scandium by weight; and / or up to about 0.20% titanium by weight.
[0042] As a fourth general example, the disclosed aluminum alloys can have the compositions shown in Table 4.
[0043] Table 4
[0044] element quantity magnesium 2.5-17.4wt% calcium 50-3000ppm chromium Up to 0.2 wt% zirconium Up to 0.2 wt% manganese Up to 0.3 wt% Other Elements Zero to 20wt% aluminum margin
[0045] Thus, the aluminum alloy of Table 4 may include aluminum, about 2.5 to about 17.4 weight percent magnesium, about 50 to about 3000 ppm calcium, and at least one of a non-zero amount of up to about 0.2% by weight chromium, a non-zero amount of up to about 0.2% by weight zirconium, and a non-zero amount of up to about 0.3% by weight manganese. In addition, the aluminum alloy of Table 4 may include up to about 1.4% by weight silicon; up to about 1.2% by weight iron; up to about 0.8% by weight copper; up to about 0.1% by weight nickel; up to about 2.8% by weight zinc; up to about 0.05% by weight gallium; up to about 0.05% by weight vanadium; up to about 0.05% by weight scandium; and / or up to about 0.20% by weight titanium.
[0046] In one variation of the aluminum alloy in Table 4, the disclosed aluminum alloy may include aluminum, about 6 to about 17.4 weight percent magnesium, about 50 to about 3000 ppm calcium, and at least one of a non-zero amount of up to about 0.2% by weight chromium, a non-zero amount of up to about 0.2% by weight zirconium, and a non-zero amount of up to about 0.3% by weight manganese. In addition, the disclosed aluminum alloy may include up to about 1.4% by weight silicon; up to about 1.2% by weight iron; up to about 0.8% by weight copper; up to about 0.1% by weight nickel; up to about 2.8% by weight zinc; up to about 0.05% by weight gallium; up to about 0.05% by weight vanadium; up to about 0.05% by weight scandium; and / or up to about 0.20% by weight titanium.
[0047] As a fifth general example, the disclosed aluminum alloys can have the composition shown in Table 5.
[0048] Table 5
[0049]
[0050]
[0051] Thus, the aluminum alloy of Table 5 may include aluminum, about 6 to about 17.4 weight percent magnesium, a non-zero amount of up to about 0.2% by weight chromium, and optionally beryllium. In addition, the aluminum alloy of Table 5 may include up to about 1.4% by weight silicon; up to about 1.2% by weight iron; up to about 0.8% by weight copper; up to about 0.1% by weight nickel; up to about 2.8% by weight zinc; up to about 0.05% by weight gallium; up to about 0.05% by weight vanadium; up to about 0.05% by weight scandium; and / or up to about 0.20% by weight titanium.
[0052] As a sixth general example, the disclosed aluminum alloys may have the composition shown in Table 6.
[0053] Table 6
[0054] element quantity magnesium 6-17.4wt% manganese Up to 0.3 wt% beryllium 0-100ppm Other Elements Zero to 20wt% aluminum margin
[0055] Thus, the aluminum alloys of Table 6 may include aluminum, about 6 to about 17.4 weight percent magnesium, a non-zero amount of manganese up to about 0.3% by weight, and optionally beryllium. In addition, the aluminum alloys of Table 6 may include up to about 1.4% silicon by weight; up to about 1.2% iron by weight; up to about 0.8% copper by weight; up to about 0.1% nickel by weight; up to about 2.8% zinc by weight; up to about 0.05% gallium by weight; up to about 0.05% vanadium by weight; up to about 0.05% scandium by weight; and / or up to about 0.20% titanium by weight.
[0056] As a seventh general example, the disclosed aluminum alloy may have the composition shown in Table 7.
[0057] Table 7
[0058]
[0059]
[0060] Thus, the aluminum alloy of Table 7 may include aluminum, about 6 to about 17.4 weight percent magnesium, a non-zero amount of up to about 0.2% by weight zirconium, and optionally beryllium. In addition, the aluminum alloy of Table 7 may include up to about 1.4% by weight silicon; up to about 1.2% by weight iron; up to about 0.8% by weight copper; up to about 0.1% by weight nickel; up to about 2.8% by weight zinc; up to about 0.05% by weight gallium; up to about 0.05% by weight vanadium; up to about 0.05% by weight scandium; and / or up to about 0.20% by weight titanium.
[0061] As an eighth general example, the disclosed aluminum alloy may have the composition shown in Table 8.
[0062] Table 8
[0063] element quantity magnesium 6-17.4wt% chromium Up to 0.2 wt% zirconium Up to 0.2 wt% manganese Up to 0.3 wt% beryllium 0-100ppm Other Elements Zero to 20wt% aluminum margin
[0064] Thus, the aluminum alloys of Table 8 may include aluminum, about 6 to about 17.4 weight percent magnesium, at least one of a non-zero amount of up to about 0.2% by weight chromium, a non-zero amount of up to about 0.2% by weight zirconium, and a non-zero amount of up to about 0.3% by weight manganese, and optionally beryllium. In addition, the aluminum alloys of Table 8 may include up to about 1.4% by weight silicon; up to about 1.2% by weight iron; up to about 0.8% by weight copper; up to about 0.1% by weight nickel; up to about 2.8% by weight zinc; up to about 0.05% by weight gallium; up to about 0.05% by weight vanadium; up to about 0.05% by weight scandium; and / or up to about 0.20% by weight titanium.
[0065] As a ninth general example, the disclosed aluminum alloy may have the composition shown in Table 9.
[0066] Table 9
[0067]
[0068]
[0069] In the typical examples in Table 9, at least one of Cr, Zr, and Mn is present in a non-zero amount up to the specified limit.
[0070] Various impurities that do not substantially affect the physical properties may also be present in the disclosed aluminum alloys. Those skilled in the art will appreciate that the presence of such impurities will not result in a departure from the scope of the present disclosure.
[0071] Also disclosed are methods for making the disclosed aluminum alloys.The final composition of the aluminum alloy made can depend on the manufacturing method used.
[0072] In a first embodiment, a disclosed method for making an aluminum alloy produces an aluminum alloy comprising aluminum, about 2.5% to about 17.4% by weight magnesium, about 50 to about 3000 ppm calcium, and at least one of up to about 0.2% by weight chromium, up to about 0.2% by weight zirconium, and up to about 0.3% by weight manganese. The disclosed method comprises the steps of: (1) preparing a magnesium master alloy comprising calcium and (2) adding the magnesium master alloy to aluminum (pure or alloyed).
[0073] refer to Figure 1 , a method for making an aluminum alloy according to a first embodiment, which is generally designated 10, may begin at box 12 with the step of preparing molten magnesium. Magnesium (pure or alloyed) may be placed in a crucible and heated to a temperature in the range of about 400° C. to about 800° C. The melting temperature may vary depending on the composition.
[0074] At box 14, the molten magnesium is combined with a calcium-based compound. Various calcium-based compounds can be used. As a general, non-limiting example, the calcium-based compound can include calcium and aluminum. As another general, non-limiting example, the calcium-based compound can include calcium and magnesium. Specific non-limiting examples of suitable calcium-based compounds include CaO, CaCN2, CaC2, Ca(OH)2, CaCO3, Mg2Ca, Al2Ca, Al4Ca, (Mg,Al)2Ca, and combinations thereof.
[0075] At box 16, the mixture of molten magnesium and calcium-based compound may be stirred to promote the reaction between magnesium and calcium-based compound and ultimately produce magnesium master alloy 18. Stirring (box 16) may be performed by generating an electromagnetic field around a furnace containing molten magnesium using a device capable of applying an electromagnetic field, thereby inducing convection of the molten magnesium. Also, the molten magnesium may be manually stirred (mechanically stirred) from the outside.
[0076] At box 20, a magnesium master alloy is added to aluminum (pure or alloyed) to produce the disclosed aluminum alloy 22. At box 24, the aluminum alloy 22 can be cast by pouring it into a mold at room temperature or in a preheated state. The mold can be a metal mold, a ceramic mold, a graphite mold, etc. Moreover, the casting can include gravity casting, continuous casting, and their equivalents. In the box 26 solidification step, the mold can be cooled to room temperature, and thereafter, the solidified aluminum alloy can be removed from the mold. Subsequently, although optionally, the solidified aluminum alloy can undergo further processing, such as heat treatment and / or forming (e.g., hot / warm forming).
[0077] In a second embodiment, a disclosed method for making an aluminum alloy produces an aluminum alloy comprising aluminum, about 6% to about 17.4% by weight magnesium, beryllium, and at least one of up to about 0.2% by weight chromium, up to about 0.2% by weight zirconium, and up to about 0.3% by weight manganese. The disclosed method includes the steps of: (1) alloying beryllium and magnesium together to form a beryllium and magnesium alloy and (2) adding the beryllium and magnesium alloy to the aluminum. The beryllium may be present at 5 ppm to 100 ppm.
[0078] refer to Figure 2, a method for making an aluminum alloy according to a second embodiment, which is generally designated 40, may begin at box 42 with a step of alloying magnesium (e.g., pure magnesium) with beryllium (e.g., pure beryllium) to produce a beryllium and magnesium alloy 44. For example, the alloying step (box 42) may include melting the magnesium and beryllium at a temperature in the range of about 400° C. to about 800° C.
[0079] At box 46, beryllium and magnesium alloy 44 are added to aluminum (pure or alloyed) to produce the disclosed aluminum alloy 48. At box 50, the aluminum alloy 48 can be cast by pouring it into a mold at room temperature or in a preheated state. The mold can be a metal mold, a ceramic mold, a graphite mold, etc. Moreover, casting can include gravity casting, continuous casting, and equivalent methods thereof. In the box 52 solidification step, the mold can be cooled to room temperature, and then, the solidified aluminum alloy can be removed from the mold. Subsequently, although optionally, the solidified aluminum alloy can undergo further treatment, such as hot / warm forming (box 54) and / or heat treatment (box 56), such as homogenization, etc. Optional forming (box 54) and heat treatment (box 56) steps can be performed under a protective layer of SO2 gas.
[0080] In a third embodiment, a method for making an aluminum alloy is disclosed that produces an aluminum alloy including aluminum, about 6% to about 17.4% by weight magnesium, and at least one of up to about 0.2% by weight chromium, up to about 0.2% by weight zirconium, and up to about 0.3% by weight manganese. The disclosed method includes the steps of: (1) melting the aluminum, magnesium, and at least one of chromium, zirconium, and manganese to produce a molten substance and (2) cooling the molten substance to produce a solid substance.
[0081] refer to Figure 3 According to a third embodiment of the method for manufacturing an aluminum alloy, generally designated 70, may begin at block 72 with the step of preparing a molten material including aluminum and at least one of chromium, zirconium, and manganese. The molten material may be heated to a temperature in the range of about 400°C to about 800°C.
[0082] At box 74, magnesium (e.g., pure magnesium) may be added to a molten mass of aluminum and at least one of chromium, zirconium, and manganese to produce the disclosed aluminum alloy 76. In one implementation, adding magnesium to the molten mass (box 74) may be performed under vacuum. In another implementation, a surface flux may be used prior to adding magnesium to the molten mass (box 74).
[0083] At box 78, the aluminum alloy 76 can be cast by pouring it into a mold at room temperature or in a preheated state. The mold can be a metal mold, a ceramic mold, a graphite mold, etc. Moreover, casting can include gravity casting, continuous casting, and equivalent methods thereof. In the box 80 solidification step, the mold can be cooled to room temperature, and thereafter, the solidified aluminum alloy can be removed from the mold. Subsequently, although optionally, the solidified aluminum alloy can undergo further processing, such as hot / warm forming (box 82) and / or heat treatment (box 84), such as homogenization, etc. Optional forming (box 82) and heat treatment (box 84) steps can be performed under a protective layer of SO2 gas.
[0084] Example
[0085] Examples 1-13
[0086] Presented in Table 10 are ten specific, non-limiting examples of the disclosed aluminum alloys, specifically, Al—Mg—Cr—Ca alloys.
[0087] Table 10
[0088]
[0089]
[0090] Examples 14-26
[0091] Presented in Table 11 are ten specific, non-limiting examples of the disclosed aluminum alloys, specifically, Al—Mg—Mn—Ca alloys.
[0092] Table 11
[0093] alloy# Mg Mn Ca Al 14 3 0.2 300 margin 15 4 0.2 400 margin 16 5 0.2 500 margin 17 6 0.2 600 margin 18 7 0.2 700 margin 19 8 0.15 800 margin 20 9 0.15 900 margin 21 10 0.1 1000 margin 22 11 0.1 1100 margin 23 12 0.1 1200 margin 24 13 0.08 1300 margin 25 14 0.05 1400 margin 26 15 0.05 1500 margin
[0094] Examples 27-39
[0095] Presented in Table 12 are ten specific, non-limiting examples of the disclosed aluminum alloys, specifically, Al—Mg—Cr—Mn—Ca alloys.
[0096] Table 12
[0097]
[0098]
[0099] Examples 40–52
[0100] Presented in Table 13 are ten specific, non-limiting examples of the disclosed aluminum alloys, specifically, Al—Mg—Zr—Ca alloys.
[0101] Table 13
[0102] alloy# Mg Zr Ca Al 40 3 0.06 300 margin 41 4 0.05 400 margin 42 5 0.04 500 margin 43 6 0.03 600 margin 44 7 0.025 700 margin 45 8 0.02 800 margin 46 9 0.015 900 margin 47 10 0.015 1000 margin 48 11 0.01 1100 margin 49 12 0.01 1200 margin 50 13 0.01 1300 margin 51 14 0.01 1400 margin 52 15 0.01 1500 margin
[0103] Table 14 below shows the mechanical properties of certain Al-Mg-Cr-Mn-Ca alloys of Table 12. The levels of Cr and Mn are optimized relative to Mg, combined in the presence of optimized Ca to produce alloys with improved ductility and elongation relative to non-optimized alloys.
[0104] Table 14 Mechanical properties of Al-Mg-Cr-Mn-Ca alloys with 6% to 9% Mg, optimized Cr and Mn levels
[0105]
[0106] Comparative Examples C1-C3
[0107] Table 15 shows examples of Al-Mg-Ca alloy compositions with 5 wt% magnesium (Example C1), 7 wt% magnesium (Example C2), and 9 wt% magnesium (Example C3). The same general method as the examples of Table 10 (see Figure 1 ) produced Examples C1-C3, but without disclosed amounts of chromium, manganese and / or zirconium.
[0108] Table 15 Mechanical properties of Al-Mg-Ca alloys with 5% to 9% Mg, unoptimized Cr, Mn and / or Zr levels
[0109]
[0110] It is apparent after reviewing Tables 14 and 15 that the property improvements from the non-optimized alloys to the optimized alloys are exemplified in the improved values of tensile elongation. In this regard, the tensile elongation of the optimized alloys as shown in Table 14 is at least about 10% higher as compared to the non-optimized alloys of Table 15. In the disclosed aluminum alloys of Table 14, the tensile elongation is at least 35%, whereas the non-optimized alloys of Table 15 have an elongation of less than 28%.
[0111] For example, Example 30 in Table 14 includes 6 wt% magnesium and calcium (600 ppm), and optimized amounts of chromium (0.06 wt%) and manganese (0.125 wt%) and has an elongation of 36.2%, whereas Example C1 in Table 15 includes 6 wt% magnesium and calcium, but no optimized amounts of chromium and manganese, yielding an elongation of 25%. This is a difference of over 11%. Example 31 in Table 14 includes 7 wt% magnesium and calcium (700 ppm), and optimized amounts of chromium (0.05 wt%) and manganese (0.125 wt%), and has an elongation of 35.7%, whereas Example C2 in Table 15 includes 7 wt% magnesium and calcium, but no optimized amounts of chromium and manganese, yielding an elongation of 23%. This is a difference of over 12%. Example 33 in Table 14 includes 9 wt% magnesium and calcium (900 ppm), and optimized amounts of chromium (0.03 wt%) and manganese (0.1 wt%), and has an elongation of 36.9%, whereas Example C3 in Table 15 includes 9 wt% magnesium and calcium, but no optimized amounts of chromium and manganese, yielding an elongation of 27.3%. This is a difference of almost 10%. These elongation differences show improvements in the properties of the disclosed aluminum alloys, particularly with respect to formability, strain hardening, and damage tolerance.
[0112] You can Figure 4 The aircraft manufacturing and service method 100 shown in Figure 5 Embodiments of the present disclosure are described in the context of an aircraft 102 shown in FIG. During pre-production, aircraft manufacturing and service method 100 includes, for example, specification and design 104 of the aircraft 102 and material procurement 106. During production, component / subassembly manufacturing 108 and system integration 110 of the aircraft 102 takes place. Thereafter, the aircraft 102 may be certified and delivered 112 for entry into service 114. While in service with a customer, the aircraft 102 is scheduled for routine maintenance and service 116, which may also include modification, reconfiguration, refurbishment, and the like.
[0113] Each process of method 100 may be performed or executed by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this description, a system integrator includes, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party includes, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, a leasing company, a military entity, a service organization, and the like.
[0114] like Figure 5, an aircraft 102 produced by example method 100 includes, for example, an airframe 118 having a plurality of systems 120 and an interior 122. Examples of plurality of systems 120 include one or more of propulsion system 124, electrical system 126, hydraulic system 128, and environmental system 130. Any number of other systems may be included.
[0115] The disclosed aluminum alloys may be employed during any one or more stages of the aircraft manufacturing and service method 100. As an example, the disclosed aluminum alloys may be used to assemble or manufacture components or subassemblies corresponding to component / subassembly manufacturing 108, system integration 110, and / or maintenance and service 116. As another example, the disclosed aluminum alloys may be used to construct the airframe 118. Moreover, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during component / subassembly manufacturing 108 and / or system integration 110, for example, by significantly speeding up or reducing the cost of assembling the aircraft 102, such as the airframe 118 and / or the interior 122. Similarly, one or more system embodiments, method embodiments, or a combination thereof may be utilized when the aircraft 102 is placed in service, such as, but not limited to, maintenance and service 116.
[0116] Further aspects are described according to the following clauses:
[0117] Clause 1. An aluminum alloy comprising:
[0118] aluminum;
[0119] From about 6% to about 17.4% by weight magnesium; and
[0120] At least one of the following:
[0121] Up to about 0.2% by weight chromium;
[0122] Up to about 0.3% by weight manganese; and
[0123] Up to about 0.2% by weight zirconium.
[0124] Item 2. The aluminum alloy described in Item 1, comprising the chromium.
[0125] The aluminum alloy of clause 3, clause 1, or 2, wherein the chromium is present at about 0.01% to about 0.1% by weight.
[0126] Item 4. The aluminum alloy of any one of Items 1-3, comprising the manganese.
[0127] Clause 5. The aluminum alloy of any one of clauses 1-4, wherein the manganese is approximately 0.01% by weight.
[0128] to about 0.2% present.
[0129] Clause 6. The aluminum alloy of any one of clauses 1-5, comprising both the chromium and the manganese. Clause 7. The aluminum alloy of any one of clauses 1-6, comprising the zirconium.
[0130] Clause 8, the aluminum alloy of any of clauses 1-7, wherein the zirconium is approximately 0.01% by weight
[0131] to about 0.1% present.
[0132] Item 9. The aluminum alloy of any one of Items 1-8, further comprising beryllium.
[0133] Clause 10. The aluminum alloy of any of clauses 1-9, wherein the beryllium is present at up to about 100 ppm.
[0134] Clause 11. The aluminum alloy of any of clauses 1-10, wherein the magnesium is approximately 7% by weight.
[0135] to about 15% present.
[0136] Clause 12. The aluminum alloy of any of clauses 1-11, wherein the magnesium is approximately 10% by weight.
[0137] to about 17.4% present.
[0138] Clause 13. The aluminum alloy of any of clauses 1-12, wherein the magnesium is approximately 8% by weight.
[0139] to about 13% present.
[0140] Clause 14. The aluminum alloy of Clause 1, further comprising at least one of the following:
[0141] Up to about 1.4% by weight silicon;
[0142] Up to about 1.2% by weight iron;
[0143] Up to about 0.8% by weight copper;
[0144] Up to about 0.1% by weight nickel;
[0145] Up to about 2.8% by weight zinc;
[0146] Up to about 0.05% by weight gallium;
[0147] Up to about 0.05% by weight vanadium;
[0148] Up to about 0.05% by weight scandium; and
[0149] Up to about 0.20% by weight titanium.
[0150] Clause 15. The aluminum alloy of any one of clauses 1-14, wherein the aluminum alloy consists essentially of the aluminum,
[0151] The magnesium and at least one of the chromium, manganese and zirconium and optionally beryllium. Clause 16. The aluminum alloy of any one of clauses 1-15, having a tensile elongation of at least 30%. Clause 17. A method of making the aluminum alloy of clause 1, comprising:
[0152] melting the aluminum, the magnesium, and at least one of the chromium, the manganese, and the zirconium to produce a molten mass, wherein the melting is performed under at least one of a vacuum and a surface flux; and
[0153] The molten material is cooled to produce a solid material.
[0154] The method of clause 18 and clause 17 further comprises performing at least one of the following steps under a SO2 gas layer:
[0155] forming said solid matter; and
[0156] The solid material is heat treated.
[0157] Clause 19. A method of manufacturing the aluminum alloy of Clause 9, comprising:
[0158] alloying the beryllium and the magnesium together to form a beryllium and magnesium alloy;
[0159] adding the beryllium and magnesium alloy to aluminum to produce a molten mass;
[0160] and
[0161] The molten material is cooled to produce a solid material.
[0162] The method of any one of clauses 20 and clauses 17-19, further comprising performing at least one of the following steps under a SO2 gas layer:
[0163] forming said solid matter; and
[0164] The solid material is heat treated.
[0165] The disclosed aluminum alloys are described in the context of aircraft; however, one of ordinary skill in the art will readily recognize that the disclosed aluminum alloys can be used in a variety of applications. For example, the disclosed aluminum alloys can be implemented in various types of vehicles, including, for example, helicopters, passenger ships, automobiles, marine products (boats, motors, etc.), etc.
[0166] Although various embodiments of the disclosed aluminum alloy and method of making the same have been shown and described, modifications will occur to those skilled in the art after reading the specification. The present application includes such modifications and is limited only by the scope of the claims.
Claims
1. A method for manufacturing an aluminum alloy, the aluminum alloy comprising: aluminum; from about 6% to about 17.4% by weight magnesium; up to about 0.2% by weight chromium; up to about 0.3% by weight manganese; and up to about 0.2% by weight zirconium, wherein at least one of the chromium, the manganese, and the zirconium is present in a non-zero amount, the method comprising: melting the aluminum, the magnesium, and at least one of the chromium, the manganese, and the zirconium to produce a molten substance; and cooling the molten material to produce a solid material; and The following steps are carried out under a SO2 gas layer: subjecting the solid mass to at least one of a warm forming process and a hot forming process; and The solid material is heat treated.
2. The method according to claim 1, wherein the melting is performed under vacuum.
3. The method of claim 2, wherein the melting comprises adding magnesium to a molten mass of aluminum and at least one of chromium, zirconium, and manganese, wherein adding magnesium to the molten mass is performed under vacuum. The method of claim 1 , wherein the melting is performed under surface flux.
5. The method of claim 4, wherein the melting comprises adding magnesium to a molten mass of aluminum and at least one of chromium, zirconium, and manganese, wherein the adding of magnesium to the molten mass is performed under surface flux.
6. The method of claim 1, wherein the magnesium is present at 12% to about 17.4% by weight.
7. The method of claim 1, wherein the magnesium is present at 13% to about 17.4% by weight.
8. The method of claim 1, wherein the aluminum alloy consists essentially of the aluminum; the magnesium; at least one of the chromium, the manganese, and the zirconium, and optionally beryllium.
9. The method of claim 8, wherein the magnesium is present at 12% to about 17.4% by weight.
10. The method of claim 8, wherein the magnesium is present at 13% to about 17.4% by weight.
11. The method of claim 1, wherein the aluminum alloy has a yield strength of at least 145 MPa.
12. The method of claim 8, wherein the aluminum alloy has a yield strength of at least 145 MPa.
13. The method of claim 1, wherein the aluminum alloy has a tensile elongation of at least 30%.
14. The method of claim 8, wherein the aluminum alloy has a tensile elongation of at least 30%.
15. The method of claim 1, wherein the aluminum alloy further comprises beryllium.
16. The method of claim 8, wherein the aluminum alloy further comprises beryllium.
17. The method of claim 1, wherein the chromium is present at about 0.008% to about 0.2% by weight.
18. The method of claim 1, wherein the manganese is present at about 0.03% to about 0.3% by weight.
19. The method of claim 1, wherein the manganese is present at about 0.05% to about 0.3% by weight.
20. The method of claim 1, wherein the manganese is present at about 0.08% to about 0.3% by weight.