Thick Al-Mg Armor Plate Processing for Strength and Corrosion Balance
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Solution Overview
Problem
Existing aluminum alloys used in armor plates and marine applications struggle to maintain mechanical strength, elongation balance, and corrosion resistance when produced in thicknesses greater than 3 inches, leading to weaknesses and corrosion issues in welded joints.
Innovation Solution
A manufacturing process involving casting, preheating, hot rolling, and specific cold rolling with stretching operations to produce Al-Mg-Mn alloys with controlled compositions, achieving a thickness of 3 inches or more, while maintaining strength and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If aluminum alloys are produced in thicknesses greater than 3 inches, then the plate thickness requirement is met, but mechanical strength and corrosion resistance deteriorate
Solution Approach 1:
The patent applies parameter changes by precisely controlling chemical composition parameters (Mg: 4.0-5.2%, Mn: 0.4-1.0%, Zn: ≤0.3%, Zr: ≤0.3%, Cr: ≤0.3%, Ti: ≤0.3%) and processing parameters (cold rolling reduction: 3-10%, stretching: 0.7-5%) to produce thick plates with improved mechanical strength and corrosion resistance
Solution Approach 2:
The patent creates a composite microstructure through controlled alloying and processing, where Mn forms strengthening precipitates and Zr/Cr/Ti form grain-refining inclusions, resulting in a composite microstructure that simultaneously improves strength and corrosion resistance in thick plates
2Length of stationary object
If aluminum alloys are produced in thicknesses greater than 3 inches, then the plate thickness requirement is met, but corrosion resistance deteriorates
Solution Approach 1:
The patent optimizes compositional parameters to balance corrosion resistance with thickness, specifically controlling Mg content (4.0-5.2%) to provide adequate corrosion protection while limiting impurities (Fe, Si, Cu, Zn) that could compromise corrosion performance in thick sections
Solution Approach 2:
The patent achieves uniform local quality throughout the thick plate by controlling composition homogeneity and applying controlled cold rolling (3-10% reduction) to ensure consistent microstructure and property distribution from surface to core
3Strength
If cold rolling reduction is increased to improve strength, then mechanical strength improves, but elongation balance deteriorates
Solution Approach 1:
The patent optimizes the cold rolling reduction parameter to a specific range (3-10%) that balances strength development through work hardening with preservation of adequate elongation, preventing excessive strain hardening that would compromise ductility
Solution Approach 2:
The patent applies partial cold rolling (3-10% reduction) rather than severe cold working, providing sufficient strength improvement through moderate work hardening while maintaining adequate elongation balance
4Stability of the object's composition
If stretching is applied to improve elongation balance, then elongation improves, but production complexity increases
Solution Approach 1:
The patent optimizes the stretching parameter to a moderate range (0.7-5% elongation) that provides sufficient improvement in elongation balance without requiring excessive complexity in the production line or specialized equipment
Solution Approach 2:
The patent combines stretching with the existing cold rolling operation in a integrated process flow, where stretching is applied directly after cold rolling to achieve elongation balance without requiring separate, complex processing stages
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 process results in thick aluminum alloy plates with improved strength-elongation balance and corrosion resistance, suitable for use as armor plates and marine structures without compromising mechanical integrity or corrosion performance.
Implementation Method 1
hot rolling
Implementation Method 2
cold rolling
Implementation Method 3
cold rolling with stretching operations
Data Source
AI summary
The disclosure relates to an aluminum alloy plate having a final thickness of 3 inch or more, and a method for manufacturing same. In the method, an aluminum alloy with a chemical composition of in weight percent: Mg 4.0 to 5.2, Mn 0.4 to 1.0, Zn≤0.3, Zr≤0.3, Cr≤0.3, Ti≤0.3, Fe<0.50, Si<0.45, Cu<0.25, other elements and unavoidable impurities each <0.05 total <0.20 balance aluminum, is cast, preheated and/or homogenized, hot rolled, cold rolled with a cold rolling reduction of 3 to 10%, and stretched directly after cold rolling with a permanent elongation of 0.7 to 5% in the direction of stretching.