Single-Layer Aluminum Alloy Sheet for Heat Joining Shape Stability
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Solution Overview
Problem
Conventional aluminum alloy materials with single-layer heat joining function have insufficient deformation resistance during heat joining.
Innovation Solution
An aluminum alloy sheet with specific composition and microstructure, including Si, Fe, and Mn, and optional additives, is developed to enhance deformation resistance by controlling grain size and number after heating, ensuring an average grain size of 370 μm or more in the plane parallel to the rolled surface and 1.5 grains or more in the sheet thickness direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional aluminum alloy material with single-layer heat joining function is used, then joining without additional materials is achieved, but deformation resistance during heat joining is insufficient
Solution Approach 1:
The invention changes the material parameters by specifying precise compositional ranges (Si: 1.50-5.00 mass%, Fe: 0.01-2.00 mass%, Mn: 0.50-2.00 mass%) and microstructural parameters (grain size ≥370 μm, number of grains ≥1.5 pieces) to simultaneously achieve heat joining capability and deformation resistance
Solution Approach 2:
The invention creates a composite microstructure within the aluminum alloy by combining specific alloying elements (Si, Fe, Mn) with controlled grain structure, where the interaction between these components produces both the liquid phase for joining and the grain boundary structure for deformation resistance
2Strength
If grain size is increased to improve deformation resistance, then resistance to grain boundary sliding increases, but manufacturing precision of metal structure may be affected
Solution Approach 1:
The invention transforms the grain structure from a fine-grained state to a coarse-grained state (average grain size ≥370 μm) through controlled heating, which fundamentally changes the deformation behavior by reducing grain boundary sliding while maintaining manufacturing precision through specified compositional and microstructural parameters
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 solution provides an aluminum alloy sheet with high deformation resistance during heat joining, preventing grain boundary sliding and maintaining shape integrity, which is essential for high-precision product design and manufacturing.
Implementation Method 1
the liquid phase generated inside the alloy material by heating is used for joining
Implementation Method 2
a metal structure that allows grains to become coarse after heating for brazing
Data Source
AI summary
An aluminum alloy sheet includes a function of heat joining in a single layer. The aluminum alloy sheet is formed of an aluminum alloy comprising: Si of 1.50 to 5.00 mass %; Fe of 0.01 to 2.00 mass %; and Mn of 0.50 to 2.00 mass %, with the balance being Al and inevitable impurities. In a heating test in which a temperature is raised from 300° C. to 400° C. at an average temperature rising rate of 60° C./min or less and held at 600±3° C. for 5±3 minutes, average grain size in a plane parallel to a rolled surface after the heating test is 370 μm or more, and an average number of grains in a sheet thickness direction after the heating test is 1.5 pieces or more.