7000 Series Aluminum Wheels With Spray-Formed Forging Flow Control
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Solution Overview
Problem
The challenge lies in manufacturing high-strength aluminum alloy wheels for special purpose vehicles using 7000 series alloys, as they have poor forging formability and complex composition, leading to difficulties in controlling microstructure and achieving the required strength and durability.
Innovation Solution
A method involving smelting 7000 series aluminum alloys, followed by spraying and forming into ingots, extrusion, sawing, rolling, initial and final forging, trimming, reaming, and solid solution treatment to produce wheels with enhanced strength and fatigue performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If 7000 series aluminum alloy is used to manufacture forged wheels, then the strength and weight reduction requirements are met, but the forging formability deteriorates and metal flow control becomes difficult
Solution Approach 1:
The patent applies parameter changes by precisely controlling the chemical composition parameters of the 7000 series aluminum alloy, specifically limiting Zn to 3.0-5.0%, Cu to 2.0-4.0%, and Mg to 1.8-2.5%, while adjusting auxiliary elements like Cr, Mn, and Ti. These parameter optimizations balance the strength requirements with forging formability, resolving the contradiction between high strength and ease of manufacture.
2Ease of manufacture
If traditional casting process is used for 7000 series alloy, then the manufacturing process is simple, but composition segregation occurs and precipitated phase distribution becomes uneven
Solution Approach 1:
The patent replaces the traditional mechanical casting process with a semi-solid forming process. This substitution eliminates the composition segregation and uneven precipitated phase distribution inherent in traditional casting, while maintaining manufacturing efficiency. The semi-solid state forming allows for more uniform material distribution and microstructure control.
3Ease of manufacture
If 6000 series aluminum alloy is used for forged wheels, then the forging process is mature and formability is good, but the strength improvement room is limited
Solution Approach 1:
The patent utilizes the composite nature of 7000 series aluminum alloy, combining Al-Mg-Zn-Cu system with controlled auxiliary elements (Cr, Mn, Ti, Zr). This composite material approach achieves superior strength properties compared to 6000 series alloys, while the controlled composition ensures the alloy remains forgeable through the optimized processing parameters.
4Strength
If complex composition of 7000 series alloy is used, then the strength potential is increased, but the microstructure control becomes challenging
Solution Approach 1:
The patent applies comprehensive parameter changes including chemical composition parameters (Zn: 3.0-5.0%, Cu: 2.0-4.0%, Mg: 1.8-2.5%, Cr: 0.10-0.30%, Mn: 0.10-0.30%, Ti: 0.05-0.15%), processing temperature parameters, and heat treatment parameters. These coordinated parameter optimizations enable precise microstructure control despite the complex alloy composition, achieving both high strength and manufacturing precision.
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 wheels with strengths over 500 MPa, high elongation, improved electrical conductivity, and excellent corrosion resistance, meeting the requirements for weight reduction and performance in special vehicles.
Implementation Method 1
Spraying and forming is a new generation of rapid solidification technology of alloys
Implementation Method 2
solid solution treatment
Data Source
AI summary
The disclosure discloses a method for manufacturing special purpose vehicle wheels by using 7000 series aluminum alloys, comprising the following steps: step 1, smelting 7000 series aluminum alloys in a smelting furnace; step 2, making the solution obtained in step 1 into an aluminum alloy ingot blank through a spraying and forming process; step 3, extruding the aluminum alloy ingot blank of step 2 to obtain an extrusion bar; step 4, sawing the extrusion bar into blanks and heating them; step 5, rolling the blank into a cake; step 6, putting the cake into a press for forging and forming; step 7, spinning and forming the wheel rim. The wheel manufactured by the method for manufacturing special vehicle wheels with 7000 series aluminum alloys in the present disclosure has high and stable conductivity, qualified impact test and good bending and radial fatigue performance.