6000-Series Aluminum Sheet Processing for Flanging and Low Roping
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Solution Overview
Problem
Existing 6000 series aluminum alloy sheets suffer from poor flanging performance and obvious roping defects, limiting their large-scale application in automobile body coverings.
Innovation Solution
A manufacturing method involving homogenization, hot rolling, coiling, intermediate annealing, and cold rolling processes, followed by a pre-aging treatment, to regulate the size and quantity of second phase particles, stimulate recrystallization nucleation, and adjust texture and grain size, thereby enhancing formability and flanging performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional 6000 series aluminum alloy sheet is used, then high strength and good corrosion resistance are achieved, but poor flanging performance and obvious roping defects occur
Solution Approach 1:
The patent applies parameter changes by precisely controlling the chemical composition parameters (Si: 0.2-0.6 wt%, Mg: 0.25-0.55 wt%, Mn: 0.05-0.20 wt%, Cu: 0.05-0.25 wt%, Fe: 0.10-0.40 wt%) and processing parameters (homogenization temperature 530-580°C, hot rolling temperature 400-480°C, cold rolling reduction rate 50-85%) to optimize the balance between strength and flanging performance, eliminating roping defects while maintaining high strength properties
Solution Approach 2:
The patent applies local quality by creating a controlled distribution of second phase particles (Mg2Si, Al-Fe-Si intermetallic compounds) with specific size ranges (0.5-2.0 μm) and areal density (≥55000 pieces/mm2) within the aluminum matrix, rather than uniform distribution, to locally enhance formability and flanging performance while maintaining overall strength
2Strength
If conventional 6000 series aluminum alloy sheet is used, then high strength is achieved, but obvious roping defects appear on the surface after stamping
Solution Approach 1:
The patent applies parameter changes by optimizing the cold rolling reduction rate to 50-85% and controlling the second phase particle size to 0.5-2.0 μm, which effectively suppresses the formation of roping defects during stamping while maintaining the high strength characteristics of 6000 series aluminum alloy
Solution Approach 2:
The patent applies preliminary action by performing homogenization treatment at 530-580°C before hot rolling to uniformly distribute alloying elements and control the formation of second phase particles, and by conducting pre-aging treatment after cold rolling to prepare the material structure in advance, preventing roping defects before final forming operations
3Shape
If conventional 6000 series aluminum alloy sheet is used, then good surface quality after baking is achieved, but poor flanging performance occurs due to stress concentrations at intermetallic compound interfaces
Solution Approach 1:
The patent applies parameter changes by controlling the size of intermetallic compounds to 0.5-2.0 μm and their areal density to ≥55000 pieces/mm2, which reduces stress concentration at interfaces during flanging operations while maintaining good surface quality after baking and overall structural strength
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 produces a 6000 series aluminum alloy sheet with high formability, high flanging performance, and low roping defects, suitable for vehicle manufacturing, meeting lightweight vehicle requirements.
Implementation Method 1
subjecting an ingot to a homogenization treatment, wherein the temperature of the homogenization treatment is 530 ̃580° C.
Implementation Method 2
subjecting the homogenized ingot to hot rough rolling, hot finish rolling and hot final rolling and coiling directly
Implementation Method 3
stimulate the recrystallization nucleation (PSN) effect in the subsequent solution pre-aging treatment
Implementation Method 4
the temperature of hot final rolling and coiling is controlled to be 250° C. or higher
Implementation Method 5
pre-aging treatment, followed by air cooling
Implementation Method 6
cold rolling: wherein the total deformation rate of cold rolling is controlled to be 50-85%
Implementation Method 7
stimulate the recrystallization nucleation (PSN) effect in the subsequent solution pre-aging treatment
Data Source
AI summary
Disclosed are a 6000-series aluminum alloy sheet having high formability, high flangeability and few roping line defects, and a manufacturing method therefor. The sheet has an average grain size of 20-32 μm, a recrystallization texture density of 6.5-10.0, a cubic texture component content of less than or equal to 8%, and a Gaussian texture component content of less than or equal to 7%. The method comprises: (1) homogenizing a cast ingot, the temperature of homogenization being 530-580° C.; (2) directly performing hot rough rolling, hot finish rolling, and hot final rolling and coiling on the homogenized cast ingot, controlling the initial rolling temperature of the hot finish rolling to be 400-480° C., and controlling the temperature of the hot final rolling and coiling to be above 250° C.; (3) cold rolling: controlling the total deformation of the cold rolling to be 50-85%; (4) solution treatment; and (5) performing pre-aging treatment, and then performing air cooling, so as to obtain the 6000-series aluminum alloy sheet.