2XXX Aluminum Hydroformed Structure With Uniform Strength
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Solution Overview
Problem
There is a demand for producing integrated monolithic aluminum structures with complex configurations from thick plate materials, where existing methods struggle to maintain consistent mechanical properties across varying deformation degrees.
Innovation Solution
A method involving a 2xxx-series aluminum alloy plate in T3-temper, processed through high-energy hydroforming and subsequent machining, followed by ageing to achieve a T8 temper, ensuring consistent mechanical properties and cost-effectiveness by avoiding silver additions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If high-energy hydroforming is used to produce complex integrated monolithic aluminum structures from thick plate material, then manufacturing capability for complex configurations is improved, but maintaining consistent mechanical properties across varying deformation degrees becomes difficult
Solution Approach 1:
The patent applies parameter changes by carefully controlling the starting temper (T3) and final temper (T8) of the aluminum alloy, adjusting the composition parameters (Cu: 3.8-4.5%, Mn: 0.3-0.8%, Mg: 0.9-1.6%), and controlling the deformation degree during hydroforming to maintain consistent mechanical properties across varying deformation zones
Solution Approach 2:
The patent applies preliminary action by performing pre-machining operations before hydroforming to create a near-net-shape intermediate structure, which reduces the deformation degree variability during the subsequent hydroforming process and helps maintain consistent mechanical properties in the final product
2Strength
If silver is added to the aluminum alloy composition to improve mechanical properties, then strength and ductility are enhanced, but manufacturing cost increases
Solution Approach 1:
The patent applies this principle by replacing expensive silver additions with a cost-effective aluminum alloy composition that uses readily available elements (Cu, Mn, Mg) in optimized proportions, achieving the required mechanical properties without the high cost of silver
Solution Approach 2:
The patent changes the compositional parameters by eliminating silver and optimizing the ranges of Cu (3.8-4.5%), Mn (0.3-0.8%), and Mg (0.9-1.6%) to achieve the desired tensile yield strength of at least 390 MPa at a lower manufacturing cost
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in an integrated monolithic aluminum structure with consistent mechanical properties across different directions, achieving tensile yield strengths of at least 390 MPa, and is cost-effective due to the absence of silver in the alloy composition.
Implementation Method 1
high-energy hydroforming of the plate or the intermediate machined structure against a forming surface of a rigid die
Implementation Method 2
ageing of the integrated monolithic aluminum structure to a desired temper to develop the required strength and other engineering properties
Data Source
AI summary
A method of producing an integrated monolithic aluminum structure, comprising: providing an aluminum alloy plate with a thickness of at least 38.1 mm, wherein the plate is a 2xxx-series alloy in a T3-temper and has a composition comprising, in wt. %: Cu 3.8-4.5, Mn 0.3-0.8, Mg 1.1-1.6, Si up to 0.15, Fe up to 0.20, Cr up to 0.10, Zn up to 0.25, Ti up to 0.15, Ag up to 0.10, balance aluminum; optionally pre-machining the plate to an intermediate machined structure; high-energy hydroforming the plate or intermediate structure against a rigid die forming surface having a desired curvature contour of the integrated monolithic aluminum structure, causing the plate or the intermediate structure to conform to the forming surface contour; machining or mechanical milling the high-energy formed structure to a near-final or final machined integrated monolithic aluminum structure; ageing the final integrated monolithic aluminum structure to a desired temper.