Tailored aging response through rapid local heating for high strength automotive components

Abstract

A method of obtaining tailored properties in a metal product includes modifying the artificial aging response in the metal product. In certain embodiments, the method includes selectively applying a thermal spike to one or more localized areas of the metal product prior to artificial aging treatment of the entire metal product.

Description

TAILORED AGING RESPONSE THROUGH RAPID LOCAL HEATING FOR HIGH STRENGTH AUTOMOTIVE COMPONENTSREFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 604,931, filed on December 1, 2023, and entitled TAILORED AGING RESPONSE THROUGH RAPID LOCAL HEATING FOR HIGH STRENGTH AUTOMOTIVE COMPONENTS, the content of which is hereby incorporated by reference in its entirety.FIELD OF THE INVENTION

[0002] This application relates to aluminum alloys and products prepared therefrom, and more specifically to methods of processing aluminum alloy products.BACKGROUND

[0003] Aluminum alloys with high strength are desirable for improved product performance in many applications, including automotive and other transportation (including, for example and without limitation, trucks, trailers, trains, aerospace, and marine) applications and electronics applications. Achieving such high strength aluminum alloy products often requires costly processing steps and generally produces a component with uniform properties. Traditionally, a product with varied properties has been achieved by joining sheets with different alloys, thicknesses, coatings, and / or material properties using a joining process such as laser welding, electron beam welding, or friction stir welding. Such processes are time-consuming and may cause surface (and other) modifications due to the joining process.SUMMARY

[0004] Embodiments covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to beused in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings, and each claim.

[0005] According to certain embodiments, a method of modifying an artificial aging response in a metal product includes rapidly heating a section of the metal product for a spike duration and to a spike temperature before artificially aging the entire metal product to an artificial aging temperature.

[0006] According to some embodiments, a method of processing an aluminum alloy product includes solutionizing and quenching the aluminum alloy product to produce a W temper aluminum alloy product, applying a thermal spike to a localized area of the W temper aluminum alloy product to produce an intermediate aluminum alloy product, and artificially aging the intermediate aluminum alloy product.

[0007] According to various embodiments, a method includes rapidly heating a localized area of a starting metal product to a spike temperature before performing artificial aging on the entire metal product to an artificial aging temperature. In some embodiments, the spike temperature is greater than the artificial aging temperature.

[0008] A metal product formed by the methods described herein may be various metal products as desired, and in some non-limiting examples, the metal product may be an automotive component.

[0009] According to certain embodiments, a system for forming the metal product described herein and / or performing the methods described herein includes a rapid heating unit for rapidly heating a localized area of the metal product.

[0010] Various implementations described herein can include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The specification makes reference to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components.

[0012] FIG. 1 illustrates a processing system for forming a metal product with tailored properties according to embodiments.

[0013] FIG. 2 illustrates a rapid heating system of the processing system of FIG. 1 according to embodiments.

[0014] FIG. 3 illustrates a portion of the rapid heating system of FIG. 2.

[0015] FIG. 4 illustrates a portion of a rapid heating system of the processing system of FIG. 1 according to embodiments.

[0016] FIG. 5 illustrates the rapid heating system of FIG. 4.

[0017] FIG. 6 illustrates a rapid heating system for the processing system of FIG. 1 according to embodiments.

[0018] FIG. 7 illustrates a method of processing a metal product using the processing system of FIG. 1 according to embodiments.

[0019] FIG. 8 illustrates an example of a metal product formed by the method of FIG. 7 according to embodiments.

[0020] FIG. 9 illustrates a thermal history of a first portion of the metal product of FIG. 8 according to embodiments.

[0021] FIG. 10 illustrates a thermal history of a second portion of the metal product of FIG. 8 according to embodiments.

[0022] FIG. 11 illustrates an example of a system for forming a metal product according to embodiments.DETAILED DESCRIPTION

[0023] Described herein are systems and methods for processing metal products, such as aluminum or aluminum alloy products, to obtain tailored properties in the metal products. Incertain embodiments, the systems and methods described herein obtain tailored properties in the metal products by selectively applying a thermal spike to a localized area prior to artificial aging treatment of the entire metal product. In certain embodiments, the peak metal temperature of the thermal spike is less than a solutionizing temperature of the metal product during hot forming and greater than an artificial aging temperature of the metal product during artificial aging. The thermal spike may be applied for various durations, and in some embodiments, the duration of the thermal spike is less than a duration of artificial aging. Applying the thermal spike to one or more localized areas locally modifies the microstructure of the metal product in those localized areas, which in turn may respond differently to subsequent artificial aging treatment. The location, size, and number of localized areas to which a thermal spike is applied may be controlled based on desired properties of the metal product. Moreover, a plurality of thermal spikes may be applied to a particular metal product, and each thermal spike may be individually controlled (e.g., by controlling temperature, duration, etc.) to provide desired properties in the metal product.

[0024] The systems and methods described herein may be suitable for various aluminum alloys, and may be particularly suitable for heat treatable aluminum alloys. As non-limiting examples, the metal products described herein may include 2xxx series aluminum alloys, 6xxx series aluminum alloys, 7xxx series aluminum alloys, and / or 8xxx series aluminum alloys.

[0025] The systems and methods described herein may process various types of metal products, including flat metal products (e.g., sheets, blanks, etc.) or shaped metal products (e.g., stamped, roll-formed, etc.). The systems and methods used to apply the thermal spike may be various suitable systems as desired. In one non-limiting example, a rapid heating system or unit for applying the thermal spike may include one or more inducting heaters, such as but not limited to one or more magnetic rotors, discs, arrays, etc. Optionally, a rapid heating system may include one or more flux concentrators, thereby allowing for higher heating rates in the metal product. In some embodiments, the rapid heating unit may be integrated with a processing or forming line (e.g., the thermal spike may be applied using a rapid heating unit integrated into the forming die, trimming die, piercing die, stamping die, roll forming line, bending station, etc.) and / or the rapid heating unit may apply the thermal spike in a separate operation and / or station. Various other benefits and advantages may be realized with the systems and methods described herein, and the aforementioned benefits and advantages should not be considered limiting.

[0026] Referring to FIGS. 1 and 2, a method includes subjecting a metal product 201 to a heat treatment process 102 (e.g., a solutionizing step and / or a deforming step at an elevated temperature followed by quenching), a localized heating process 104, and an artificial aging process 106.

[0027] As best illustrated in FIG. 2, the metal product 201 generally includes at least two localized areas 203A-B. As discussed in detail below, at least one of the localized areas (e.g., localized area 203A) may be subjected to the localized heating process 104. The other localized area (e.g., localized area 203B) may not be subjected to the localized heating process 104 and / or subjected to a different localized heating process 104.

[0028] The metal products 201 processed by the methods descried herein may be various metal products 201 as desired, and in certain examples, the metal product 201 may be an aluminum alloy product, such as but not limited to a rolled aluminum alloy product. In certain embodiments, the metal product 201 may be a heat treatable aluminum alloy, such as but not limited to a 2xxx series aluminum alloy, a 6xxx series aluminum alloy, a 7xxx series aluminum alloy, and / or an 8xxx series aluminum alloy.

[0029] Optionally, the metal product 201 may be a 2xxx series aluminum alloy according to one of the following aluminum alloy designations: AA2001, A2002, AA2004, AA2005, AA2006, AA2007, AA2007A, AA2007B, AA2008, AA2009, AA2010, AA2011, AA2011A, AA2111, AA2111A, AA2111B, AA2012, AA2013, AA2014, AA2014A, AA2214, AA2015, AA2016, AA2017, AA2017A, AA2117, AA2018, AA2218, AA2618, AA2618A, AA2219, AA2319, AA2419, AA2519, AA2021, AA2022, AA2023, AA2024, AA2024A, AA2124, AA2224, AA2224A, AA2324, AA2424, AA2524, AA2624, AA2724, AA2824, AA2025, AA2026, AA2027, AA2028, AA2028A, AA2028B, AA2028C, AA2029, AA2030, AA2031, AA2032, AA2034, AA2036, AA2037, AA2038, AA2039, AA2139, AA2040, AA2041, AA2044, AA2045, AA2050, AA2055, AA2056, AA2060, AA2065, AA2070, AA2076, AA2090, AA2091, AA2094, AA2095, AA2195, AA2295, AA2196, AA2296, AA2097, AA2197, AA2297, AA2397, AA2098, AA2198, AA2099, or AA2199.

[0030] Optionally, the metal product 201 may be a 6xxx series aluminum alloy according to one of the following aluminum alloy designations: AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA6206, AA6306, AA6008,AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, AA6016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027, AA6028, AA6031, AA6032, AA6033, AA6040, AA6041, AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA6053, AA6055, AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560, AA6660, AA6061, AA6061A, AA6261, AA6361, AA6162, AA6262, AA6262A, AA6063, AA6063A, AA6463, AA6463A, AA6763, A6963, AA6064, AA6064A, AA6065, AA6066, AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A, AA6182, AA6091, or AA6092.

[0031] Optionally, the metal product 201 may be a 7xxx series aluminum alloy according to one of the following aluminum alloy designations: AA7019, AA7020, AA7021, AA7039, AA7072, AA7075, AA7085, AA7108, AA7108A, AA7015, AA7017, AA7018, AA7019A, AA7024, AA7025, AA7028, AA7030, AA7031, AA7033, AA7035, AA7035A, AA7046, AA7046A, AA7003, AA7004, AA7005, AA7009, AA7010, AA7011, AA7012, AA7014, AA7016, AA7116, AA7122, AA7023, AA7026, AA7029, AA7129, AA7229, AA7032, AA7033, AA7034, AA7036, AA7136, AA7037, AA7040, AA7140, AA7041, AA7049, AA7049A, AA7149, AA7249, AA7349, AA7449, AA7050, AA7050A, AA7150, AA7250, AA7055, AA7155, AA7255, AA7056, AA7060, AA7064, AA7065, AA7068, AA7168, AA7175, AA7475, AA7076, AA7178, AA7278, AA7278A, AA7081, AA7181, AA7185, AA7090, AA7093, AA7095, or AA7099.

[0032] Optionally, the metal product 201 may be an 8xxx series aluminum alloy according to one of the following aluminum alloy designations: AA8024, AA8090, AA8091, or AA809.

[0033] In some examples, the metal products 201 may be prepared from monolithic alloys. In other examples, the metal products 201 described herein are clad metal products, having a core layer and one or two cladding layers. In some cases, the core layer and / or the cladding layer(s) may be a 7xxx series aluminum alloy. In some cases, the core layer has a different composition from one or both of the cladding layers. In some non-limiting examples, the clad metal products may include a 6xxx series aluminum alloy core layer with a 7xxx series aluminum alloy cladding layer, a 2xxx series aluminum alloy core layer with a 6xxx series aluminum alloy cladding layer, or a 2xxx series aluminum alloy core layer with a 7xxx series aluminum alloy cladding layer.

[0034] The metal products 201 may be prepared by various processes as desired, including by casting a metal such as an aluminum alloy using any suitable casting process. As non-limiting examples, the metal product 201 may be cast using a continuous casting process that may include, but is not limited to, the use of twin belt casters, twin roll casters, or block casters. In some examples, the casting process is performed by a continuous casting process to form a cast product such as a billet, slab, strip, or the like. In some examples, the casting process is performed by a direct chill casting process to form a cast product such as an ingot. Optionally, the cast product may be subjected to further processing steps. In one non-limiting example, the processing method may include one or more of the following steps: homogenizing, hot rolling, cold rolling, and / or annealing to produce a metal product. Optionally, the gauge of the metal product for use in the methods described herein may be about 15 mm or less (e.g., about 14 mm or less, about 13 mm or less, about 12 mm or less, about 11 mm or less, about 10 mm or less, about 9 mm or less, about 8 mm or less, about 7 mm or less, about 6 mm or less, about 5 mm or less, about 4 mm or less, about 3 mm or less, about 2 mm or less, about 1 mm or less, about 0.9 mm or less, about 0.8 mm or less, about 0.7 mm or less, about 0.6 mm or less, about 0.5 mm or less, about 0.4 mm or less, about 0.3 mm or less, about 0.2 mm or less, or about 0.1 mm or less). The temper of the as-rolled aluminum alloy product is referred to as F temper.

[0035] Referring to FIG. 11, a system 1100 for forming a metal product generally includes a heat treatment system 1102, a rapid heating system 1104, and an artificial aging system 1106. One or more control systems (e.g., processor and / or memory) optionally may be included with the system 1100 for controlling equipment and / or processes of one or more systems 1102, 1104, 1106. Each of these systems 1102, 1104, 1106 are described in greater detail below and with reference to the various processes performed by each system.Heat Treatment Process

[0036] The heat treatment system 1102 may by various devices or systems suitable for performing the heat treatment process 102 on the metal product 102. In certain embodiments, the heat treatment system 1102 includes various devices (e.g., heaters or heating systems) suitable for heating the metal product 201. Optionally, the heat treatment system 1102 includes a quenching system configured to rapidly reduce the temperature of the metal product 201 using varioustechniques as desired, such as but not limited to using a coolant, liquid (e.g., water), gas, and / or other medium as desired. Optionally, the heat treatment system includes various devices or systems for forming, shaping, and / or deforming the metal product 201. As non-limiting examples, the heat treatment system 1102 may include devices or systems suitable for cutting, stamping, pressing, roll-forming, press-forming, drawing, shaping, straining, and / or other processes that can create two- or three-dimensional shapes as known to one of ordinary skill in the art. In one non-limiting example, the heat treatment system 1102 includes a roll-forming device or system.

[0037] In certain embodiments, the heat treatment process 102 performed by the heat treatment system 1102 on the metal product 201 may include subjecting the metal product 201 to a heat treatment step, such as a solutionizing or solution heat treatment step. The solutionizing step may include heating the metal product 201 from room temperature to a solutionizing temperature of at least about 400 °C. In some cases, the solutionizing temperature may be from about 400 °C to about 500 °C (e.g., such as from about 410 °C to about 490 °C, such as from about 420 °C to about 480 °C, such as from about 430 °C to about 470 °C, and / or such as from about 440 °C to about 460 °C). As non-limiting examples, the solutionizing temperature may be about 400 °C, about 405 °C, about 410 °C, about 415 °C, about 420 °C, about 425 °C, about 430 °C, about 435 °C, about 440 °C, about 445 °C, about 450 °C, about 455 °C, about 460 °C, about 465 °C, about 470 °C, about 475 °C, about 480 °C, about 485 °C, about 490 °C, about 495 °C, and / or about 500 °C.

[0038] The metal product 201 may be maintained at the solutionizing temperature (i.e., soaked at the solutionizing temperature) for a desired period of time. In certain aspects, the metal product 201 is allowed to soak for at least about 30 seconds (e.g., from about 60 seconds to about 120 minutes, inclusively). For example, the metal product 201 may be soaked at the solutionizing temperature for about 30 seconds, about 35 seconds, about 40 seconds, about 45 seconds, about 50 seconds, about 55 seconds, about 60 seconds, about 65 seconds, about 70 seconds, about 75 seconds, about 80 seconds, about 85 seconds, about 90 seconds, about 95 seconds, about 100 seconds, about 105 seconds, about 110 seconds, about 115 seconds, about 120 seconds, about 125 seconds, about 130 seconds, about 135 seconds, about 140 seconds, about 145 seconds, about 150 seconds, about 5 minutes, about 10 minutes, about 15 minutes, about 20 minutes, about 25 minutes, about 30 minutes, about 35 minutes, about 40 minutes, about 45 minutes, about 50 minutes, about 55 minutes, about 60 minutes, about 65 minutes, about 70 minutes, about 75 minutes, about 80minutes, about 85 minutes, about 90 minutes, about 95 minutes, about 100 minutes, about 105 minutes, about 110 minutes, about 115 minutes, and / or about 120 minutes or greater, or anywhere in between.

[0039] The solutionizing step may be following by a quenching step. The term “quenching,” as used herein, refers to rapidly reducing a temperature of the metal product 201. As one non-limiting example, the quenching step following the solutionizing step includes reducing the temperature of a metal product 201 that has been solutionized as described above. The quenching may be performed using a liquid (e.g., water), gas, and / or other medium as desired. In certain aspects, the metal product 201 may be quenched using water at a temperature between about 40 °C and about 75 °C In certain aspects, the metal product 201 is quenched using forced air. In some embodiments, die quenching may be utilized to rapidly reduce the temperature of the metal product 201.

[0040] A quench rate of the quenching step may be from about 5 °C / s to about 1000 °C / s. The quench rate and other conditions may be selected based on a variety of factors, such as a desired combination of properties to be exhibited by the metal product 201 and / or the gauge of the metal product 201. In some cases, the quench rate may be from about 5 °C / s to about 975 °C / s, such as from about 10 °C / s to about 950 °C / s, such as from about 25 °C / s to about 800 °C / s, such as from about 50 °C / s to about 700 °C / s, such as from about 75 °C / s to about 600 °C / s, such as from about 100 °C / s to about 500 °C / s, such as from about 200 °C / s to about 400 °C / s, and / or anywhere in between. As a non-limiting example, the quench rate may be about 5 °C / s, about 10 °C / s, about 15 °C / s, about 20 °C / s, about 25 °C / s, about 30 °C / s, about 35 °C / s, about 40 °C / s, about 45 °C / s, about 50 °C / s, about 55 °C / s, about 60 °C / s, about 65 °C / s, about 70 °C / s, about 75 °C / s, about 80 °C / s, about 85 °C / s, about 90 °C / s, about 95 °C / s, about 100 °C / s, about 200 °C / s, about 300 °C / s, about 400 °C / s, about 500 °C / s, about 600 °C / s, about 700 °C / s, about 800 °C / s, about 900 °C / s, and / or about 1000 °C / s.

[0041] In certain embodiments, the heat treatment process 102 includes at least one deforming step. As used herein, “deforming” may include cutting, stamping, pressing, roll-forming, pressforming, drawing, shaping, straining, or other processes that can create two- or three-dimensional shapes as known to one of ordinary skill in the art. For example, in a stamping or pressing step, a metal product is deformed by pressing it between two dies of desired shapes. As such, in certain embodiments, the heat treatment process 102 may utilize various equipment such as but not limitedto dies, bending stations, etc. suitable for deforming the metal product. The deforming step may be performed on the metal product 201 after the quenching step and / or on a metal product at an elevated temperature.

[0042] In some examples, the deforming step may be performed on the metal product 201 at an elevated temperature (e.g., greater than room temperature to about 550 °C). As non-limiting examples, the deforming step may be performed on the metal product 201 at a temperature of from about 40 °C to about 550 °C, such as from about 100 °C to about 500 °C, and / or such as from about 150 °C to about 440 °C. In non-limiting examples, the deforming step may be performed at a temperature such as about 40 °C, about 50 °C, about 60 °C, about 70 °C, about 80 °C, about 90 °C, about 100 °C, about 110 °C, about 120 °C, about 130 °C, about 140 °C, about 150 °C, about 160 °C, about 170 °C, about 180 °C, about 190 °C, about 200 °C, about 210 °C, about 220 °C, about 230 °C, about 240 °C, about 250 °C, about 260 °C, about 270 °C, about 280 °C, about 290 °C, about 300 °C, about 310 °C, about 320 °C, about 330 °C, about 340 °C, about 350 °C, about 360 °C, about 370 °C, about 380 °C, about 390 °C, about 400 °C, about 410 °C, about 420 °C, about 430 °C, about 440 °C, about 450 °C, about 460 °C, about 470 °C, about 480 °C, about 490 °C, about 500 °C, about 510 °C, about 520 °C, about 530 °C, about 540 °C, and / or about 550 °C.

[0043] In some cases, the deforming step may be a warm forming process. As used herein, warm forming refers to a deforming step that is performed at a temperature greater than room temperature up to about 250 °C. In some cases, the warm forming may be performed at a temperature of from about 40 °C to about 250 °C, such as from about 50 °C to about 240 °C, such from about 75 °C to about 200 °C, and / or such as from about 100 °C to about 175 °C. As non-limiting examples, the warm forming may be performed at a temperature of about 40 °C, about 50 °C, about 60 °C, about 70 °C, about 80 °C, about 90 °C, about 100 °C, about 110 °C, about 120 °C, about 130 °C, about 140 °C, about 150 °C, about 160 °C, about 170 °C, about 180 °C, about 190 °C, about 200 °C, about 210 °C, about 220 °C, about 230 °C, about 240 °C, and / or about 250 °C.

[0044] In some cases, the deforming step may be a hot forming process. As used herein, hot forming refers to a deforming step that is performed at a temperature from about 255 °C to about 550 °C. In some cases, the hot forming may be performed at a temperature of from about 260 °C to about 500 °C, such as from about 275 °C to about 475 °C, such as from about 300 °C to about 450 °C, and / or such as from about 325 °C to about 400 °C. For example, the hot forming may beperformed at a temperature of about 255 °C, about 260 °C, about 270 °C, about 280 °C, about 290 °C, about 300 °C, about 310 °C, about 320 °C, about 330 °C, about 340 °C, about 350 °C, about 360 °C, about 370 °C, about 380 °C, about 390 °C, about 400 °C, about 410 °C, about 420 °C, about 430 °C, about 440 °C, about 450 °C, about 460 °C, about 470 °C, about 480 °C, about 490 °C, about 500 °C, about 510 °C, about 520 °C, about 530 °C, about 540 °C, and / or about 550 °C. In some cases, the deforming step may be followed by a quenching step, as described above.

[0045] In some cases, the deforming step may be performed on the metal product 201 at a temperature below 125 °C (e.g., from room temperature to a temperature lower than 125 °C.'). For example, the deforming step may be performed on the metal product 201 at a temperature of from about 15 °C to about 120 °C, such as from about 30 °C to about 110 °C, and / or such as from about 50 °C to about 90 °C. Optionally, the warm forming may be performed at a temperature of about 20 °C, about 30 °C, about 40 °C, about 50 °C, about 60 °C, about 70 °C, about 80 °C, about 90 °C, about 100 °C, about 110 °C, and / or about 120 °C.

[0046] In certain embodiments, the metal product 201 prepared by the heat treatment process 102 may be in a W temper.Localized Heating Process

[0047] The rapid heating system 1104 may be various devices or systems suitable for heating localized areas 203 on the metal product 201 via a localized heating process 104. In some embodiments, the rapid heating system 1104 includes one or more rapid heating units 308 ad discussed in detail below.

[0048] The localized heating process 104 performed on the metal product may include subjecting one or more localized areas 203 of the metal product 201 to a thermal spike (e.g., rapid heating). In the embodiment illustrated in FIG. 2, the localized area 203A is subjected to the localized heating process 104 while the localized area 203B is not subjected to the localized heating process 104.

[0049] The localized heating process 104 may include rapidly heating the localized area of the metal product for a spike duration and to a spike temperature. While a two localized areas 203 A- B are illustrated in FIG. 2, in other embodiments, the metal product 201 may include any numberof localized areas subjected to athermal spike. In such embodiments, a characteristic of the thermal spike (e.g., spike duration and / or spike temperature) in one localized area 103 may be the same as or different from the characteristic of the thermal spike in another localized area 203. Moreover, the relative size of the localized areas 203 should not be considered limiting and need not be the same when a plurality of localized areas 203 are utilized.

[0050] The spike duration of the thermal spike may be various durations as desired. In some embodiments, the thermal spike may be applied for less than about 100 seconds, such as from greater than 0 seconds to about 100 seconds. In certain embodiments, the spike duration may be less than about 30 seconds, such as less than about 25 seconds, such as less than about 20 seconds, such as less than about 15 seconds, such as less than about 10 seconds. In non-limiting examples, the spike duration may be about 5 seconds, about 10 seconds, about 15 seconds, about 20 seconds, about 25 seconds, about 30 seconds, about 35 seconds, about 40 seconds, about 45 seconds, about 50 seconds, about 55 seconds, about 60 seconds, about 65 seconds, about 70 seconds, about 75 seconds, about 80 seconds, about 85 seconds, about 90 seconds, about 95 seconds, and / or about 100 seconds. In certain embodiments, the spike duration may be less than a duration of the heat treatment process 102. In various embodiments, the spike duration may be less than a duration of the artificial aging process 106.

[0051] The spike temperature of the localized heating process 104 may be a temperature that is greater than an artificial aging temperature of the artificial aging process 106. In certain embodiments, the spike temperature of the localized heating process 104 is less than the peak metal temperature of the heat treatment process 102. In certain embodiments, the spike temperature may be a temperature from about 200 °C to about 400 °C. In some cases, the spike temperature may be from about 225 °C to about 400 °C, such as from about 250 °C to about 375 °C, such as from about 250 °C to about 300 °C. For example, the spike temperature about 200 °C, about 205 °C, about 210 °C, about 215 °C, about 225 °C, about 230 °C, about 235 °C, about 240 °C, about 245 °C, about 250 °C, about 255 °C, about 260 °C, about 265 °C, about 270 °C, about 275 °C, about 280°C, about 285 °C, about 290 °C, about 295 °C, about 300 °C, about 305 °C, about 310 °C, about315 °C, about 320 °C, about 325 °C, about 330 °C, about 335 °C, about 340 °C, about 345 °C, about 350 °C, about 355 °C, about 360 °C, about 365 °C, about 370 °C, about 375 °C, about 380°C, about 385 °C, about 390 °C, about 395 °C, and / or about 400 °C.

[0052] The localized heating process 104 may be performed using one or more rapid heating units, which may be various heating systems as desired, such as but not limited to a rotating magnet, hot air, heated fluid, electrical resistance, direct flame impingement, infrared heating, induction heating, combinations thereof, and / or as otherwise desired. In some nonlimiting examples, the one or more rapid heating units may be configured to heat the localized area by induction heating and may include a magnetic rotor, array of magnets, such as a Halbach array, a rotating magnet on a disk, and / or other arrangements of magnets as desired. FIGS. 3-7 illustrate non-limiting examples of rapid heating units 308 configured for induction heating.

[0053] As mentioned, the rapid heating system 1104 may include one or more rapid heating units 308. Referring to FIGS. 3-7, in some embodiments, the rapid heating unit 308 includes one or more magnetic rotors 310, and in certain examples, the rapid heating unit 308 includes a plurality of magnetic rotors 310. As non-limiting examples, the rapid heating unit 308 may include one magnetic rotor 310, two magnetic rotors 310, three magnetic rotors 310, four magnetic rotors 310, five magnetic rotors 310, six magnetic rotors 310, and / or more than six magnetic rotors 310. As such, the number of magnetic rotors 310 should not be considered limiting. In FIGS. 3 and 4, the rapid heating unit 308 includes two magnetic rotors 310, in FIGS 5 and 6, the rapid heating unit 308 includes one magnetic rotor 310, and in FIG. 7, the rapid heating unit 308 includes six magnetic rotors 310.

[0054] As best illustrated in FIG. 4, each magnetic rotor 310 includes one or more magnet sources 312, which may be permanent magnets and / or electromagnets. In various embodiments, permanent magnet rotors may be preferable in some cases and may be able to achieve more efficient results than rotors having internal electromagnets. Each magnetic rotor 310 can rotate about an axis of rotation that is perpendicular or approximately perpendicular to a surface of the metal product. As non-limiting examples, and as best illustrated in FIGS. 3, 6, and 7, the axis of rotation of the magnetic rotors 310 may be perpendicular to an upper surface 205 and / or a lower surface 207 of the metal product 201. In various embodiments, the magnetic rotors 310 may be provided on one side of the metal product 201 (see, e.g., FIGS. 6 and 7), while in other embodiments, the magnetic rotors 310 may be provided on both sides of the metal product 201 (see, e g., FIG. 3).

[0055] In certain embodiments, the magnetic rotors 310 may be rotatable in either direction about the axis of rotation. In various examples, the magnetic rotors 310 may be rotated through various suitable means or methods, including but not limited to electric motors, pneumatic motors, another magnetic rotor 310, and / or as otherwise desired. Rotating magnetic rotors 310 with associated magnets can induce moving or time varying magnetic fields within the metal product. The changing magnetic fields can create currents (e.g., eddy currents) within the metal product, thus heating the metal product.

[0056] In some embodiments, a relative location of a magnetic rotor 310 along the metal product 201 may be unchanging. However, in other embodiments, the relative location of a magnetic rotor 310 along the metal product 201 may be adjustable by changing a position of the magnetic rotor 310 and / or changing a position of the metal product 201. In such embodiments, the position of the magnetic rotor 310 and / or the metal product 201 may be achieved via various actuators and / or mechanisms as desired. In one non-limiting example, at least one magnetic rotor 310 may be supported by an actuated arm.

[0057] Optionally, and as illustrated in FIGS. 5 and 6, the rapid heating unit 308 may include one or more flux directors 314 for focusing, concentrating, and / or otherwise directing flux towards the metal product 201 being processed. The flux directors 314 may be provided at various locations as desired. When the flux directors 314 are included, the flux directors 314 may allow for higher heating rates in the metal product 201.

[0058] In certain embodiments, rapid heating using one or more magnetic rotors 310 may allow for desired localized areas of the metal product 201 to be heated without heating other portions of the metal product 201. Various characteristics of one or more magnetic rotors 310 may be controlled to provide desired rapid heating during the localized heating process 104. Non-limiting examples of characteristics that may be controlled include but are not limited to a size of the magnetic rotor 310, a number of magnet sources 312 on the magnetic rotor 310, an arrangement of the magnet sources 312 on the magnetic rotor, a number of magnetic rotors 310, a direction of rotation, a rotational speed, a distance or gap between the magnetic rotor 310 and the metal product 201, a duration of rotation, a location of the magnetic rotor 310 along the metal product 201, combinations thereof, and / or other characteristics as desired.

[0059] In some embodiments, the localized heating process 104 may be implemented utilizing equipment integrated with equipment for other processes. As a non-limiting example, a rapid heating unit 308 such as but not limited to one or more magnetic rotors 310 may be integrated into a forming line such that the localized heating process 104 may be performed on the metal product 201 while the metal product 201 is on a forming die, trim or piercing die, bending station, etc. As a non-limiting example, the rapid heating system 1104 may be integrated into the heat treatment system 1102. In other embodiments, the localized heating process 104 may be implemented as a separate operation. As a non-limiting example, the rapid heating system 1104 may be separate from the heat treatment system 1102.

[0060] The localized heating process 104 may modify the microstructure of the localized areas 203 through the thermal spike, which in turn may respond differently to the subsequent artificial aging process 106. Accordingly, the localized heating process 104 may be used to tailor the response of the metal product 201 to the artificial aging process 106, thereby forming the metal product 201 with tailored properties.

[0061] In certain embodiments, after being subjected to the localized heating process 104 (e.g., the metal product 201 includes locally heated areas 203) and before the artificial aging process 106, the metal product 201 may be considered an intermediate metal product.Artificial Aging Process

[0062] The artificial aging system 1106 includes various devices or systems suitable for performing the artificial aging process 106. The artificial aging process 106 performed on the metal product may include subjecting the entire metal product 201 (i.e., the entire intermediate metal product) to an artificial aging process that can result in the age-hardening of the metal product 201.

[0063] The artificial aging process 106 may be for various durations as desired. In certain embodiments, the duration of the artificial aging process 106 is greater than the duration of the localized heating process 104. In some non-limiting examples, the artificial aging process 106 may be performed for a period of up to about 8 hours (e.g., up to about 7 hours, up to about 6 hours, up to about 5 hours, up to about 4 hours, up to about 3 hours, up to about 2 hours, up to about 1 hour, and / or up to about 30 minutes, or any period in between).

[0064] In various embodiments, the artificial aging process 106 may heat the metal product 201 to an artificial aging temperature. In certain embodiments, the artificial aging temperature is less than the spike temperature. In some embodiments, the artificial aging temperature is less than the peak metal temperature of the heat treatment process 102.

[0065] In certain embodiments, the artificial aging temperature may be from about 50 °C to about 300 °C. As non-limiting examples, the artificial aging temperature may be about 50 °C, about 60 °C, about 70 °C, about 80 °C, about 90 °C, about 100 °C, about 110 °C, about 120 °C, about 130 °C, about 140 °C, about 150 °C, about 160 °C, about 170 °C, about 180 °C, about 190 °C, about 200 °C, about 210 °C, about 220 °C, about 230 °C, about 240 °C, about 250 °C, about 260 °C, about 270 °C, about 280 °C, about 290 °C, and / or about 300 °C. In one non-limiting example, the artificial aging temperature may be from about 90 °C to about 220 °C, such as from about 90 °C to about 140 °C, such as from about 140 °C to about 220 °C.

[0066] In various embodiments, because the localized area 203A was subjected to the localized heating process 104 and thus has a different microstructure than the rest of the metal product 201, the artificial aging response of the localized area 203 A will be different from the artificial aging response of the localized area 203B or other portions of the metal product 201. Accordingly, tailored properties (e.g., strength) can be achieved in a single, monolithic metal product.

[0067] FIG. 8 depicts an exemplary thermal history 800 of the localized area 203A and FIG. 9 depicts an exemplary thermal history 900 of the localized area 203B.

[0068] In certain embodiments, and as illustrated in FIGS. 8 and 9, both areas 203A-B of the metal product 201 may be subjected to a solutionizing and quenching and / or a hot forming and quenching step 802. In various embodiments, both areas 203 A-B may be heated to a peak metal temperature 808. In some embodiments, at the beginning of step 802, both areas 203 A-B of the metal product may be in an F temper, and at the end of step 802, both areas 203 A-B of the metal product may be in a W temper.

[0069] As illustrated by comparing FIGS. 8 and 9, following step 802, localized area 203A may be subjected to localized heating step 804 by the application of the thermal spike whereas localized area 203B is not subjected to the localized heating step 804. In step 804, the localized area 203 A may be heated to a spike temperature 810, which may be less than the peak metal temperature 808 and greater than an artificial aging temperature 812.

[0070] Following the localized heating step 804, both localized areas 203A-B (i.e., the entire metal product 201) may be subjected to an artificial aging step 806. As illustrated in FIGS. 8 and 9, both areas 203 A-B may be heated to the artificial aging temperature 812 during the step 806. In certain embodiments, a duration of step 806 may be greater than a duration of step 804.Example

[0071] FIG. 10 is a graph illustrating an example of tailored properties that may be obtained in a single, monolithic metal product using the methods described herein.

[0072] In this example, the single metal product was a 7xxx series aluminum alloy and included four localized areas A-D. Areas A-D were subjected to the same heat treatment process to produce the metal product in a W temper. Area A was not locally heated with a thermal spike and was artificially aged to a T6 temper. Area B was locally heated with a thermal spike having a spike temperature of 200 °C for a spike duration of 10 seconds with a magnetic rotor offset 0.25 inches vertically from the sample and running at 4000 RPM with four magnet sources before being subjected to the same artificial aging treatment as Area A such that Area B was artificially aged to a T6 temper. Area C was locally heated with a thermal spike having a spike temperature of 225 °C for a spike duration of 10 seconds with a magnetic rotor offset 0.25 inches vertically from the sample and running at 4000 RPM with four magnet sources before being subjected to the same artificial aging treatment as Area A such that Area C was artificially aged to a T6 temper. Area D was locally heated with a thermal spike having a spike temperature of 300 °C for a spike duration of 10 seconds with a magnetic rotor offset 0.25 inches vertically from the sample and running at 4000 RPM with four magnet sources before being subjected to the same artificial aging treatment as Area A such that Area D was artificially aged to a T6 temper.

[0073] The yield strength (“YS”) of each Area A-D of the single metal product was measured and is illustrated in FIG. 10. As shown in FIG. 10, the YS of Area A was 514 MPa, the YS of Area B was 494 MPa, the YS of Area C was 335 MPa, and the YS of Area D was 183 MPa. As illustrated, in areas where the heat was applied locally (e.g., Areas B-D), the strength was observed as tied to the temperature applied. Within the single metal product, tailored metal properties were achieved with a range in strength from 514 MPa to 183 MPa (a spread of 331 MPa). As illustrated by these results, a single metal product may thus be produced by the methods described hereinwith areas having tailored properties such as desired strengths, thereby enabling the efficient use of material, and providing enhanced performance.Methods of Using

[0074] The products and methods described herein can be used in automotive and / or transportation applications, including motor vehicle, aircraft, marine, and railway applications, or any other desired application. In some examples, the products and methods can be used to prepare motor vehicle body part products, such as bumpers, side beams, roof beams, cross beams, pillar reinforcements (e.g., A-pillars, B-pillars, and C-pillars), inner panels, outer panels, side panels, inner hoods, outer hoods, or trunk lid panels. The rolled aluminum alloy products and methods described herein can also be used in aircraft or railway vehicle applications, to prepare, for example, external and internal panels.

[0075] The products and methods described herein can also be used in electronics applications, to prepare, for example, external and internal encasements. For example, the products and methods described herein can also be used to prepare housings for electronic devices, including mobile phones and tablet computers. In some examples, the products can be used to prepare housings for the outer casing of mobile phones (e.g., smart phones) and tablet bottom chassis.

[0076] In certain aspects, the products and methods can be used to prepare aerospace vehicle body part products. For example, the disclosed products and methods can be used to prepare airplane body parts, such as skin alloys.Illustrations

[0077] A collection of exemplary embodiments is provided below, including at least some explicitly enumerated as an “Illustration” providing additional description of a variety of example embodiments in accordance with the concepts described herein. These illustrations are not meant to be mutually exclusive, exhaustive, or restrictive; and the disclosure not limited to these example illustrations but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.

[0078] Illustration 1. A method of modifying an artificial aging response in a metal product, the method comprising rapidly heating a section of the metal product for a spike duration and to a spike temperature before artificially aging the entire metal product to an artificial aging temperature.

[0079] Illustration 2. The method of any preceding or subsequent illustration or combination of illustrations, wherein the spike duration is less than a duration of artificial aging treatment.

[0080] Illustration 3. The method of any preceding or subsequent illustration or combination of illustrations, wherein the spike temperature is greater than the artificial aging temperature and less than a peak metal temperature during a heat treatment step performed before rapidly heating the section of the metal product.

[0081] Illustration 4. The method of any preceding or subsequent illustration or combination of illustrations, further comprising, before rapidly heating the section of the metal product, solutionizing a starting metal product at a solutionizing temperature and / or deforming the starting metal product at an elevated temperature to form the metal product, wherein the spike temperature is less than the solutionizing temperature and the elevated temperature and greater than the artificial aging temperature.

[0082] Illustration 5. The method of any preceding or subsequent illustration or combination of illustrations, wherein further comprising deforming the metal product by hot stamping the metal product or roll forming the metal product.

[0083] Illustration 6. The method of any preceding or subsequent illustration or combination of illustrations, wherein rapidly heating the section of the metal product comprises rapidly heating the metal product having a W temper microstructure.

[0084] Illustration 7. The method of any preceding or subsequent illustration or combination of illustrations, wherein the spike duration is from greater than 0 seconds to 30 seconds.

[0085] Illustration 8. The method of any preceding or subsequent illustration or combination of illustrations, wherein the spike temperature is from 200 °C to 300 °C.

[0086] Illustration 9. The method of any preceding or subsequent illustration or combination of illustrations, wherein rapidly heating the section of the metal product comprises heating the sectionby rotating a magnetic rotor having an axis of rotation extending perpendicular to a surface of the metal product.

[0087] Illustration 10. The method of any preceding or subsequent illustration or combination of illustrations, wherein the metal product comprises at least one of a 2xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy.

[0088] Illustration 11. A method of processing an aluminum alloy product, the method comprising: solutionizing and quenching the aluminum alloy product to produce a W temper aluminum alloy product; applying a thermal spike to a localized area of the W temper aluminum alloy product to produce an intermediate aluminum alloy product; and artificially aging the intermediate aluminum alloy product.

[0089] Illustration 12. The method of any preceding or subsequent illustration or combination of illustrations, wherein solutionizing is at a first peak metal temperature, applying the thermal spike is at a second peak metal temperature, and artificial aging is at a third peak metal temperature, and wherein the second peak metal temperature is less than the first peak metal temperature and greater than the third peak metal temperature.

[0090] Illustration 13. The method of any preceding or subsequent illustration or combination of illustrations, wherein applying the thermal spike comprises heating the localized area with a magnetic rotor having an axis of rotation extending perpendicular to a surface of the metal product.

[0091] Illustration 14. The method of any preceding or subsequent illustration or combination of illustrations, wherein solutionizing is at a solutionizing temperature of at least about 400 °C.

[0092] Illustration 15. The method of any preceding or subsequent illustration or combination of illustrations, wherein the aluminum alloy product comprises at least one of a 2xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy.

[0093] Illustration 16. A method comprising rapidly heating a localized area of a starting metal product to a spike temperature before performing artificial aging on the entire metal product to an artificial aging temperature, wherein the spike temperature is greater than the artificial aging temperature.

[0094] Illustration 17. The method of any preceding or subsequent illustration or combination of illustrations, wherein the metal product comprises a heat-treatable aluminum alloy.

[0095] Illustration 18. The method of any preceding or subsequent illustration or combination of illustrations, wherein rapidly heating the localized area of the metal product comprises heating the localized area with a magnetic rotor having an axis of rotation extending perpendicular to a surface of the metal product.

[0096] Illustration 19. The method of any preceding or subsequent illustration or combination of illustrations, wherein rapidly heating the localized area of the metal product comprises changing a position of the magnetic rotor relative to the metal product.

[0097] Illustration 20. The method of any preceding or subsequent illustration or combination of illustrations, wherein a duration of rapidly heating the localized area of the metal product is less than a duration of performing artificial aging treatment to the entire metal product.

[0098] Illustration 21. The method of any preceding or subsequent illustration or combination of illustrations, wherein rapidly heating the metal product is after subjecting the metal product to a solutionizing step and / or deforming step at an elevated temperature.

[0099] Illustration 22. A metal product formed by the method of any preceding or subsequent illustration or combination of illustrations.

[0100] Illustration 23. The metal product of any preceding or subsequent illustration or combination of illustrations, wherein the metal product comprises an automotive component.

[0101] Illustration 24. A system for forming the metal product of any preceding or subsequent illustration or combination of illustrations, the system comprising a rapid heating unit for rapidly heating a localized area of the metal product.

[0102] Illustration 25. A system for forming a metal product, the system comprising: a heat treatment system configured to subject the metal product to a heat treatment process; a rapid heating system configured to rapidly heating a localized area of the metal product without heating other portions of the metal product for a spike duration and to a spike temperature; and an artificial aging system for artificially aging the entire metal product to an artificial aging temperature.

[0103] Illustration 26. The system of any preceding or subsequent illustration or combination of illustrations, wherein the rapid heating system comprises at least one rapid heating unit.

[0104] Illustration 27. The system of any preceding or subsequent illustration or combination of illustrations, wherein the spike duration is less than a duration of artificial aging treatment.

[0105] Illustration 28. The system of any preceding or subsequent illustration or combination of illustrations, wherein the heat treatment system is configured to perform a forming process on the metal product.

[0106] Illustration 29. The system of any preceding or subsequent illustration or combination of illustrations, wherein the forming process comprises at least one of cutting, stamping, pressing, roll-forming, press-forming, drawing, shaping, and / or straining.

[0107] Illustration 30. The system of any preceding or subsequent illustration or combination of illustrations, wherein the spike temperature is greater than the artificial aging temperature and less than a peak metal temperature during a heat treatment step performed before rapidly heating the section of the metal product.

[0108] Illustration 31. The system of any preceding or subsequent illustration or combination of illustrations, wherein the heat treatment system comprises a hot stamping system or a roll forming system.

[0109] Illustration 32. The system of any preceding or subsequent illustration or combination of illustrations, wherein the spike duration is from greater than 0 seconds to 30 seconds and the spike temperature is from 200 °C to 300 °C.

[0110] Illustration 33. The system of any preceding or subsequent illustration or combination of illustrations, wherein the heat treatment system further comprises a quenching system.[0U1] Illustration 34. The system of any preceding or subsequent illustration or combination of illustrations, wherein the rapid heating system is integrated into the heat treatment system.

[0112] As used herein, the terms “invention,” “the invention,” “this invention,” and “the present invention” are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.

[0113] In this description, reference is made to alloys identified by AA numbers and other related designations, such as “series” or “5xxx.” For an understanding of the number designation systemmost commonly used in naming and identifying aluminum and its alloys, see “International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys” or “Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot,” both published by The Aluminum Association.

[0114] Reference is made in this application to alloy temper or condition. For an understanding of the alloy temper descriptions most commonly used, see “American National Standards (ANSI) H35 on Alloy and Temper Designation Systems.” An F condition or temper refers to an aluminum alloy as fabricated. As used herein, an F* temper refers to a heat treatable aluminum alloy that is hot worked (e.g., hot rolled, extruded, forged, or drawn) and immediately quenched while still in a solutionized state, and optionally cold worked. A W condition or temper refers to an aluminum alloy solution heat treated at a temperature greater than a solvus temperature of the aluminum alloy and then quenched. An O condition or temper refers to an aluminum alloy after annealing. An Hxx condition or temper, also referred to herein as an H temper, refers to a non-heat treatable aluminum alloy after cold rolling with or without thermal treatment (e.g., annealing). Suitable H tempers include HX1, HX2, HX3 HX4, HX5, HX6, HX7, HX8, or HX9 tempers. A T1 condition or temper refers to an aluminum alloy cooled from hot working and naturally aged (e.g., at room temperature). A T2 condition or temper refers to an aluminum alloy cooled from hot working, cold worked, and naturally aged. A T3 condition or temper refers to an aluminum alloy solution heat treated, cold worked, and naturally aged. A T4 condition or temper refers to an aluminum alloy solution heat treated and naturally aged. A T5 condition or temper refers to an aluminum alloy cooled from hot working and artificially aged (at elevated temperatures). A T6 condition or temper refers to an aluminum alloy solution heat treated and artificially aged. A T7 condition or temper refers to an aluminum alloy solution heat treated and artificially overaged. A T8x condition or temper refers to an aluminum alloy solution heat treated, cold worked, and artificially aged. A T9 condition or temper refers to an aluminum alloy solution heat treated, artificially aged, and cold worked. A W condition or temper refers to an aluminum alloy after solution heat treatment.

[0115] As used herein, a sheet generally refers to an aluminum product having a thickness of less than about 4 mm. For example, a sheet may have a thickness of less than about 4 mm, less thanabout 3 mm, less than about 2 mm, less than about 1 mm, less than about 0.5 mm, or less than about 0.3 mm (e.g., about 0.2 mm).

[0116] As used herein, the meaning of “room temperature” can include a temperature of from about 15 °C to about 30 °C, for example about 15 °C, about 16 °C, about 17 °C, about 18 °C, about 19 °C, about 20 °C, about 21 °C, about 22 °C, about 23 °C, about 24 °C, about 25 °C, about 26 °C, about 27 °C, about 28 °C, about 29 °C, or about 30 °C

[0117] All ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, e.g., 1 to 6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10.

[0118] As used herein, terms such as “cast metal product,” “cast product,” “cast aluminum alloy product,” and the like are interchangeable and refer to a product produced by direct chill casting (including direct chill co-casting) or semi-continuous casting, continuous casting (including, for example, by use of a twin belt caster, a twin roll caster, a twin block caster, or any other continuous caster), electromagnetic casting, hot top casting, or any other casting method

[0119] As used herein, the meaning of “a,” “an,” and “the” includes singular and plural references unless the context clearly dictates otherwise.

[0120] The elements included in the illustrations herein may not be drawn to scale. For example, figures depicting metal sumps may include exaggerated features for illustrative purposes.

[0121] The subject matter of embodiments of the present disclosure is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. Directional references such as “up,” “down,” “top,” “bottom,” “left,” “right,” “vertical,” “horizontal,” “lateral,” “longitudinal,” “front,” and“back,” among others, are intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing.

[0122] The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. All methods described herein may be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention, and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0123] The above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. Moreover, although specific terms are employed herein, as well as in the claims that follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described embodiments, nor the claims that follow.

Claims

CLAIMSThat which is claimed:

1. A method of modifying an artificial aging response in a metal product, the method comprising rapidly heating a section of the metal product for a spike duration and to a spike temperature before artificially aging the entire metal product to an artificial aging temperature.

2. The method of claim 1, wherein the spike duration is less than a duration of artificial aging treatment.

3. The method of claim 1, wherein the spike temperature is greater than the artificial aging temperature and less than a peak metal temperature during a heat treatment step performed before rapidly heating the section of the metal product.

4. The method of claim 1, further comprising: before rapidly heating the section of the metal product, solutionizing a starting metal product at a solutionizing temperature and / or deforming the starting metal product at an elevated temperature to form the metal product, wherein the spike temperature is less than the solutionizing temperature and the elevated temperature and greater than the artificial aging temperature.

5. The method of claim 1, further comprising deforming the metal product by hot stamping the metal product or roll forming the metal product.

6. The method of claim 1, wherein rapidly heating the section of the metal product comprises rapidly heating the metal product having a W temper microstructure.

7. The method of claim 1, wherein the spike duration is from greater than 0 seconds to 30 seconds.

8. The method of claim 1, wherein the spike temperature is from 200 °C to 300 °C.

9. The method of claim 1, wherein rapidly heating the section of the metal product comprises heating the section by rotating a magnetic rotor having an axis of rotation extending perpendicular to a surface of the metal product.

10. The method of claim 1, wherein the metal product comprises at least one of a 2xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy.

11. A method of processing an aluminum alloy product, the method comprising: solutionizing and quenching the aluminum alloy product to produce a W temper aluminum alloy product; applying a thermal spike to a localized area of the W temper aluminum alloy product to produce an intermediate aluminum alloy product; and artificially aging the intermediate aluminum alloy product.

12. The method of claim 11, wherein solutionizing is at a first peak metal temperature, applying the thermal spike is at a second peak metal temperature, and artificial aging is at a third peak metal temperature, and wherein the second peak metal temperature is less than the first peak metal temperature and greater than the third peak metal temperature.

13. The method of claim 11, wherein applying the thermal spike comprises heating the localized area with a magnetic rotor having an axis of rotation extending perpendicular to a surface of the aluminum alloy product.

14. The method of claim 11, wherein solutionizing is at a solutionizing temperature of at least about 400 °C.

15. The method of claim 11, wherein the aluminum alloy product comprises at least one of a 2xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy.

16. A method comprising rapidly heating a localized area of a metal product to a spike temperature before performing artificial aging on the entire metal product to an artificial aging temperature, wherein the spike temperature is greater than the artificial aging temperature.

17. The method of claim 16, wherein the metal product comprises a heat-treatable aluminum alloy.

18. The method of claim 16, wherein rapidly heating the localized area of the metal product comprises heating the localized area with a magnetic rotor having an axis of rotation extending perpendicular to a surface of the metal product.

19. The method of claim 18, wherein rapidly heating the localized area of the metal product comprises changing a position of the magnetic rotor relative to the metal product.

20. The method of claim 16, wherein a duration of rapidly heating the localized area of the metal product is less than a duration of performing artificial aging treatment to the entire metal product.

21. The method of claim 16, wherein rapidly heating the metal product occurs after subjecting the metal product to a solutionizing step and / or deforming step at an elevated temperature.

22. A metal product formed by the method of claim 1, 11, or 16.

23. The metal product of claim 22, wherein the metal product comprises an automotive component.

24. A system for forming a metal product, the system comprising: a heat treatment system configured to subject the metal product to a heat treatment process; a rapid heating system configured to rapidly heating a localized area of the metal product without heating other portions of the metal product for a spike duration and to a spike temperature; and an artificial aging system for artificially aging the entire metal product to an artificial aging temperature.

25. The system of claim 24, wherein the rapid heating system is integrated into the heat treatment system.

26. The system of claim 24, wherein the rapid heating system comprises at least one rapid heating unit.

27. The system of claim 24, wherein the spike duration is less than a duration of artificial aging treatment.

28. The system of claim 24, wherein the heat treatment system is configured to perform a forming process on the metal product.

29. The system of claim 28, wherein the forming process comprises at least one of cutting, stamping, pressing, roll-forming, press-forming, drawing, shaping, and / or straining.

30. The system of claim 24, wherein the spike temperature is greater than the artificial aging temperature and less than a peak metal temperature during a heat treatment step performed before rapidly heating the section of the metal product.

31. The system of claim 24, wherein the heat treatment system comprises a hot stamping system or a roll forming system.

32. The system of claim 24, wherein the spike duration is from greater than 0 seconds to 30 seconds and the spike temperature is from 200 °C to 300 °C.

33. The system of claim 24, wherein the heat treatment system further comprises a quenching system.

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