Aluminum Alloy Blank Partial Heating for Dual Yield Strength
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Solution Overview
Problem
Current methods for producing motor vehicle components from light metal alloys struggle to achieve different strength ranges economically and cost-effectively, while also meeting the requirements of lightweight construction and crash resistance.
Innovation Solution
A method involving a work-hardened 5000 aluminum alloy blank, where specific areas are partially heated and tempered to achieve distinct yield points, followed by rapid forming and cooling to produce components with varying strengths, utilizing a combination of tools for precise temperature control and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-strength steel materials are used to achieve high-strength properties in vehicle components, then the strength and crash resistance are improved, but the vehicle weight increases
Solution Approach 1:
The patent applies parameter changes by controlling the temperature history of the aluminum alloy blank through partial heating and tempering processes. By heating specific areas to different temperatures and maintaining other areas at lower temperatures, the material's microstructure and mechanical properties are altered to achieve high strength (450-500 MPa) in the second region while keeping the overall weight low due to aluminum's lower density compared to steel
Solution Approach 2:
The patent implements local quality by creating different strength zones within the same component. The first region is heated to produce a yield strength of 120-250 MPa, while the second region is maintained at lower temperature to achieve 200-450 MPa yield strength. This allows selective application of high-strength properties to specific parts of the component, optimizing both weight and strength requirements
2Weight of moving object
If aluminum alloy components are used for lightweight construction, then the vehicle weight is reduced, but the strength and crash resistance are insufficient compared to steel
Solution Approach 1:
The patent overcomes the inherent strength limitation of aluminum alloys by applying controlled thermal parameters. The tempering process at 150-350°C after partial heating transforms the microstructure of the 5000 series aluminum alloy, enabling the material to achieve yield strengths of 200-450 MPa in the second region, which is comparable to high-strength steels, while maintaining the weight advantage of aluminum
Solution Approach 2:
The patent creates a composite-like structure within a single aluminum alloy blank by producing regions with different thermal histories and microstructures. The combination of cold-worked base material, heated zones, and tempered zones creates a multi-phase microstructure that delivers both lightweight properties and high strength, effectively combining the advantages of different materials
3Manufacturing precision
If selective heating and tempering processes are applied to achieve different strength ranges in different regions, then the manufacturing precision and strength distribution are improved, but the process complexity and production time increase
Solution Approach 1:
The patent applies segmentation by dividing the heating and tempering processes into distinct stages and zones. The blank is partially heated in specific first regions while second regions are maintained at lower temperatures, followed by a tempering step that affects the entire blank. This segmented approach allows precise control over the microstructure and strength distribution in different areas of the component
Solution Approach 2:
The patent implements preliminary action by performing partial heating of specific regions before the tempering process. This pre-heating step creates the necessary temperature gradient and microstructural conditions in the first regions, which then respond differently during the subsequent tempering step, enabling the final component to have the desired dual-zone strength distribution
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
This method allows for the economical and cost-effective production of motor vehicle components with tailored strength properties, enhancing both formability and strength, while reducing production time and increasing precision, thus addressing the need for diverse strength ranges in vehicle components.
Implementation Method 1
partially heating the blank in at least a first area to a temperature greater than 350°C, in particular to 400°C, wherein the blank is maintained in at least a second area at a temperature between 15°C and 30°C, preferably at 20°C
Implementation Method 2
tempering the entire blank to a temperature between 150 and 350°C, in particular 300°C, in less than 20 s
Implementation Method 3
cooling of the automotive component, wherein the method establishes a yield strength in the first region less than 250 MPa and greater than 120 MPa and in the second region less than or equal to 450 MPa and greater than 200 MPa
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3c
AI summary
The present invention relates to a method for manufacturing a motor vehicle component (1) comprising the following process steps: - providing a cold-worked blank made of a 5000 series aluminum alloy, - partially heating the blank in a first area (5) to a temperature greater than 350°C, in particular to 400°C, wherein the blank is maintained in a second area (6) at a temperature between 15°C and 30°C, preferably at 20°C, and the partial heating is carried out in less than 20 s, preferably less than 10 s and in particular in 2 to 5 s, - tempering the entire blank to a temperature between 150 and 350°C in less than 20 s, preferably less than 10 s and in particular in 2 to 5 s, - forming the blank into the motor vehicle component (1) in less than 20 s, preferably less than 10 s and in particular in 2 to 5 s and Cooling of the motor vehicle component (1),- Setting a yield strength in the first range (5) less than 250 MPa and greater than 120 MPa and in the second range (6) less than 450 MPa and greater than 200 MPa.