Aluminum Bottle Alloy Control for Expansion and Necking Reliability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The container industry faces challenges in expanding and necking metal beverage containers without causing metal failures such as curl splits, fracture, or collapse, due to the need for multiple operations with different dies, which affects the formability and reject rates of aluminum alloy sheets used in manufacturing.
Innovation Solution
A method of manufacturing an aluminum bottle using a 3XXX or 5XXX alloy with a specific tensile yield strength and ultimate tensile strength difference, involving forming, necking, and expanding processes to reduce the diameter by at least 26%, and optimizing the aluminum sheet's properties through adjustments in Ti levels and preheat soak times to minimize reject rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If multiple operations with several different expansion dies are used to expand the container diameter, then the container can be shaped and enlarged, but metal failures such as curl splits, fracture, and collapse occur
Solution Approach 1:
The patent applies parameter changes by precisely controlling the aluminum alloy composition (specific elements and their ranges) and mechanical properties (tensile yield strength, ultimate tensile strength, and their difference). This material parameter optimization enables the metal to withstand multiple expansion and necking operations without failure, resolving the contradiction between achieving desired container shapes and preventing metal failures.
2Shape
If several different necking dies are used to narrow the container diameter, then the container can be necked and shaped, but metal failures such as curl splits, fracture, and collapse occur
Solution Approach 1:
The patent optimizes the aluminum alloy's mechanical parameters, specifically controlling the difference between ultimate tensile strength and tensile yield strength to be within a specific range. This parameter control allows the material to undergo repeated necking operations with multiple dies while maintaining structural integrity and preventing failures like curl splits and fractures.
3Reliability
If the aluminum sheet's tensile strength properties are increased to prevent metal failures, then the formability and reject rates improve, but the manufacturing process becomes more complex
Solution Approach 1:
The patent establishes specific parameter ranges for aluminum alloy composition and mechanical properties that balance formability and reliability. By defining precise ranges for element content and strength properties, the patent simplifies the manufacturing process while maintaining high quality standards, avoiding the need for overly complex alloy formulations.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An aluminum sheet comprises a 3XXX or a 5xxx alloy having a tensile yield strength as measured m the longitudinal direction of 27-33 ksi and an ultimate tensile strength; wherein the ultimate tensile strength minus the tensile yield strength is less than 3.30 ksi (UTS-TYS < 3,30 ksi). An aluminum container has a dome, wherein the dome comprises a AA 3XXX or a 5xxx having a tensile yield strength as measured in the longitudinal direction of 27-33 ksi and an ultimate tensile strength; wherein the ultimate tensile strength minus the tensile yield strength is less than 3,30 ksi (UTS-TYS < 3.30 ksi).