Extruded Brazing Alloy Composition for Corrosion-Resistant Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The AA3003 aluminum alloy has poor corrosion resistance, limiting its applications in industries like automotive and air conditioning, where stringent corrosion resistance requirements are needed while maintaining tensile properties and appropriate grain size for extruded and brazed products.
Innovation Solution
An aluminum alloy composition with specific weight percentages of Zn, Mn, Mg, Fe, and optionally Cu and Si is developed to enhance corrosion resistance, tensile properties, and grain size, including up to 0.15% Si, 0.15-0.30% Fe, 0.9-1.2% Mn, 0.03-0.10% Mg, 0.10-0.20% Zn, and up to 0.03% Cu, with (Mg+Mn) exceeding 0.99, to create extruded and brazed products with improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If AA3003 aluminum alloy is used for making extruded and brazed products, then tensile properties and extrudability are maintained, but corrosion resistance is poor
Solution Approach 1:
The patent modifies the chemical composition parameters of the aluminum alloy by adding specific amounts of Zn (0.05-1.0%), Cu (0.05-1.0%), Mg (0.01-0.5%), and Mn (0.01-0.5%), while controlling Si (0-0.5%) and Fe (0-0.5%). This parameter change transforms the alloy from standard AA3003 to an improved composition that achieves both enhanced corrosion resistance and maintained tensile properties
Solution Approach 2:
The patent creates a composite aluminum alloy system by combining multiple alloying elements (Zn, Cu, Mg, Mn, Si, Fe) in specific proportions. This composite approach leverages the synergistic effects of different elements: Zn and Cu for corrosion resistance, Mg and Mn for tensile strength, and controlled Si and Fe for grain size control, resulting in a material that satisfies multiple competing requirements simultaneously
2Reliability
If Zn and Cu are added to improve corrosion resistance, then corrosion resistance increases, but tensile properties may deteriorate
Solution Approach 1:
The patent optimizes the concentration parameters of Zn (0.05-1.0%) and Cu (0.05-1.0%) within specific ranges to achieve corrosion resistance improvement while preventing excessive strength deterioration. Simultaneously, it adjusts Mg (0.01-0.5%) and Mn (0.01-0.5%) content to compensate for any tensile strength loss, maintaining a balanced property profile
Solution Approach 2:
The patent converts the potential harm of Zn and Cu additions (which can reduce tensile strength) into a benefit by carefully controlling their concentrations and balancing them with Mg and Mn additions. The controlled presence of these elements provides corrosion resistance while the accompanying Mg and Mn ensure tensile properties are maintained, transforming a potential disadvantage into an advantage
3Strength
If Mg and Mn are added to maintain tensile properties, then tensile strength is maintained, but corrosion resistance may decrease
Solution Approach 1:
The patent optimizes the parameter combination of Mg (0.01-0.5%) and Mn (0.01-0.5%) to maintain tensile properties while controlling their upper limits to prevent corrosion resistance deterioration. Simultaneously, it balances these with Zn (0.05-1.0%) and Cu (0.05-1.0%) additions to achieve overall corrosion resistance improvement, creating a balanced compositional profile
4Shape
If Si and Fe are added to control grain size, then formability is improved, but corrosion resistance may be affected
Solution Approach 1:
The patent严格控制Si (0-0.5%) and Fe (0-0.5%) content within low ranges to achieve grain size control and improved formability while minimizing their negative impact on corrosion resistance. This parameter control ensures that the grain-refining benefits are obtained without sacrificing the corrosion resistance provided by the Zn-Cu-Mg-Mn alloying system
Data Source
AI summary
An aluminum alloy for making an extruded and brazed aluminum product, the aluminum alloy comprising, in weight percent, 0.10-0.20 Zn to improve corrosion resistance, 0.9-1.2 Mn, 0.03-0.10 Mg, the sum of Mg and Mn being at least 0.99 to maintain or improve strength, 0.15 to 0.30 Fe to control grain size, up to 0.15 Si, up to 0.03 Cu, up to 0.04 Ti, the balance being aluminum and unavoidable impurities. The alloy may be in the form of extrusion ingots or extruded and brazed aluminum products. A process for making an extruded and brazed aluminum product from the alloy involves homogenizing, extruding, optionally working, and brazing the alloy to form the product.