Functionally graded aluminum alloy products and manufacturing methods

Abstract

The present disclosure generally provides aluminum alloy products having a functional gradient across at least one dimension of the aluminum alloy product. The disclosure also provides articles made from such products, as well as methods for making such products, for example, by casting and rolling. The disclosure also provides various end uses for such products, such as automotive, aerospace, marine, defense, transportation, electronics, and industrial applications.

Claims

1. A method for preparing a functionally graded aluminum alloy product, wherein the aluminum alloy product is functionally graded over the thickness and / or width of the product. The process of forming a casting by casting an ingot into a mold or by pouring a molten metal into a casting cavity, wherein the casting comprises an aluminum alloy, and the casting comprises at least one peritecto-forming element and at least one eutecto-forming element, a) To form primary crystal grains that are rich in at least one peritecto-forming element and depleted of at least one eutecto-forming element, and b) Controlling the movement and accumulation of the primary crystal grains. Including the formation of the above; Homogenizing the casting, wherein the primary crystal grains precipitate during the homogenization process; The homogenized casting is rolled to form the functionally graded aluminum alloy product. The method, including the method described above.

2. The method according to claim 1, wherein the aluminum alloy is a 2xxx-type aluminum alloy, a 5xxx-type aluminum alloy, a 6xxx-type aluminum alloy, or a 7xxx-type aluminum alloy.

3. The method according to claim 1 or claim 2, wherein the at least one peritecto-forming element is present in an amount of 0.2% by weight or less.

4. The method according to any one of claims 1 to 3, wherein the at least one eutectic-forming element is present in an amount greater than 0.2% by weight.

5. The method according to any one of claims 1 to 4, wherein casting an ingot into the mold includes a direct chill casting process.

6. The method according to any one of claims 1 to 5, wherein casting involves pouring molten metal into the casting cavity, and the process includes a continuous casting process.

7. The aforementioned continuous casting process, Twin-belt casting machines, twin-roll casting machines, block casting machines, or any other continuous casting machines The method according to claim 6, comprising casting by at least one of the following.

8. The method according to any one of claims 1 to 7, wherein the rolling includes hot rolling.

9. The method according to any one of claims 1 to 8, wherein the precipitated primary crystal grains suppress recrystallization during rolling.

10. The method according to any one of claims 1 to 9, wherein the primary crystal grains have a maximum dimension of 25 to 250 microns.

11. The method according to any one of claims 1 to 10, wherein the aluminum alloy comprises the at least one peritecto-forming element and the at least one eutecto-forming element.

12. The method according to any one of claims 1 to 11, wherein during the casting process, the at least one peritecto-forming element, the at least one eutecto-forming element, or a combination thereof is added to the ingot or liquid metal.

13. Forming the aforementioned primary crystal grains Solute elements, intermetallic compound particles, solute-rich crystal grains, reinforcing particles, or combinations thereof. The method according to any one of claims 1 to 12, further comprising forming at least one of the following.

14. An aluminum alloy product comprising a functional gradient over the thickness and / or width of the product, wherein the functional gradient is Non-recrystallized centers and recrystallized planes, and Changes in the proportion of reinforcing particles from the center to the surface The aluminum alloy product, including the aluminum alloy product.

15. The aluminum alloy product according to claim 14, wherein the product contains at least one peritectic-forming element in the non-recrystallized center.

16. The at least one peritecto-forming element is Ti, Zr, V, Hf, Nb, Ta, Cr, or combinations thereof. The aluminum alloy product according to claim 15, comprising at least one of the above.

17. The aluminum alloy product according to claim 15 or claim 16, wherein the at least one peritecto-forming element is present in an amount of 0.2% by weight or less.

18. The aluminum alloy product according to any one of claims 14 to 17, wherein the product contains at least one eutectic-forming element on the recrystallized plane.

19. The aforementioned eutectic-forming element is Si, Cu, Fe, Zn, Mg, Sc, Ni, Mn, Ce, and Y, and combinations thereof. The aluminum alloy product according to claim 18, comprising at least one of the following.

20. The aluminum alloy product according to claim 18 or claim 19, wherein the eutectic-forming element is present in an amount greater than 0.2% by weight.

21. The aluminum alloy product according to any one of claims 14 to 17, wherein the product may contain at least one reinforcing particle.

22. The aforementioned reinforcing particles TiB ２ 、TiC、NbB ２ 、Al ２ O ３ 、SiC、ZrB ２ 、AlB ２ 、Al ３ Ti、Al ７ Cr、Al ３ Zr、Al ３ Nb、Al ３ Ta、Al ３ V、AlN、Al ３ Ni、Al ３ Hf、Al ３ HfO, and combinations thereof The aluminum alloy product according to claim 21, comprising at least one of the above.

23. The aforementioned reinforcing particles It is added to the molten metal, or During the casting process, the following is formed in the system: The aluminum alloy product according to claim 21 or claim 22.

24. The aluminum alloy product according to any one of claims 21 to 23, wherein the reinforcing particles are present in an amount exceeding 0.1% by weight.

25. An aluminum alloy article comprising an aluminum alloy product according to any one of claims 14 to 24.