Classifications

• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
  • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
  • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
  • C22F1/057—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with copper as the next major constituent
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
  • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
  • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
  • C22F1/047—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with magnesium as the next major constituent
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
  • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
  • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
  • C22F1/053—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with zinc as the next major constituent

Definitions

• the present invention relates to the manufacture of structural elements from a heat-treated alloy, in particular from an aluminum alloy, by machining thick sheets. These structural elements can be used in aeronautical construction.
• sheets of thickness typically between 10 mm and 40 mm are used (here called “medium sheet”), which are in the metallurgical state corresponding to the final use of the structural element, and stiffens them by fixing, for example by riveting, stiffeners constituted by extruded profiles, for example profiles of section "T”.
• the stiffeners are machined directly into a sheet of greater thickness, typically between 30 mm and 200 mm, which is also in a metallurgical state corresponding to the final use of the structural element.
• the second approach suffers from other drawbacks.
• the thick sheet is found before machining in the metallurgical state corresponding to its final use, because according to the state of the art, no thermomechanical treatment is carried out after machining. More particularly, this final metallurgical state was obtained by dissolution and quenching.
• two physical mechanisms limit the rate of quenching in a thick sheet: the thermal conductivity of the material which constitutes said thick sheet, and the heat exchange between the surface and of the sheet and the quenching medium.
• the mechanical properties of the toughened thick sheet vary depending on the thickness. As a result, certain mechanical characteristics become worse when moving away from the surface of the sheet.
• machining therefore removes the zones in which the hardened sheet shows the best mechanical characteristics, and the stress on the structural element under service conditions involves zones of metal whose mechanical properties can be fairly variable depending on the depth from the area near the initial surface of the sheet.
• the calculation of the structures is, as a precaution, carried out on the basis of models which are fairly conservative of the real performance of the part, said models being typically based on the mechanical characteristics of the zones of the sheet which are distant from the surface and therefore have the mechanical characteristics the weakest. This prevents, when sizing the parts, from making the most of the real properties of the material.
• Patent EP 578 607 seeks to optimize the process for quenching extruded profiles by individual or group control of water spray nozzles; such a device, controlled by computer, makes it possible in principle to adapt the positions of the nozzles to each profile, but the development remains empirical.
• Patent EP 695 590 develops a similar idea for the quenching of sheets.
• Patent application WO 98/42885 (Aluminum Company of America) describes a combined process of water quenching and air quenching to reduce the deformation of thin sheets during quenching, and to improve their static mechanical characteristics.
• French patent 1.503835 (Atomic Energy Commission) proposes to increase the quenching speed when the part is immersed in a cold liquid by the application of a thin layer with low thermal conductivity which limits the vaporization of the quenching medium.
• French patent 2,524,001 Patent Rhenalu proposes to apply to certain faces of the product a coating which conducts heat less well than the underlying metal. By this improved control of the cooling rate, one would be able to avoid altering the properties of use of the product.
• This fairly cumbersome process has several drawbacks. It is limited to sheets or profiles of substantially constant thickness; in the case of aluminum alloys, this thickness should not exceed approximately 15 mm.
• the coatings proposed in this patent risk polluting the quenching liquid tank.
• the object of the invention is to present a new method of manufacturing machined metal parts suitable for use as structural elements, or of blanks for such parts, which makes it possible to improve the compromise between the static mechanical characteristics (limit of elasticity, tensile strength, elongation at break) and tolerance to damage (especially toughness) in the volume of the part and to minimize the distortions induced during quenching, and which can be implemented with a cost of particularly advantageous operation.
• the applicant has invented a new integrated process which makes it possible to manufacture, from thick sheets, machined structural elements of large dimension, with excellent dimensional tolerances, and having improved mechanical characteristics.
• the present invention provides a new manufacturing method which makes it possible to obtain machined parts having a better compromise between the minimum values of static mechanical characteristics (conventional yield strength, elongation at break, tensile strength) and the tolerance for damage. , compared to similar shaped parts produced by a process according to the state of the art.
• the variation of the mechanical characteristics within the part is smaller, compared to a machined part of analogous shape produced by a method according to the prior art.
• a first object of the invention is a process for manufacturing a machined metal part, comprising a) the manufacture of a metal sheet by a process comprising, a1) the casting of a rolling plate, optionally followed by a homogenization, a2) one or more hot or cold rolling operations, possibly separated from one or more reheating operations, to obtain a sheet, a3) possibly one or more sheet cutting or finishing operations, b) the pre-machining of said sheet on one or both sides to obtain a pre-machined blank, c) a solution treatment of said pre-machined blank, d) a quenching treatment.
• This process can optionally be followed by one or more of the following steps e) controlled traction, f) tempering, g) cutting.
• a second object is the use of a metal part obtained by said process as a structural element in aeronautical construction.
• a third object is an aluminum alloy structural element for aeronautical construction obtained by said method. Description of the figures
• FIG. 1 shows the dimensions and the sampling plan for pre-machined thick sheets according to the invention, as explained in Example 1.
• FIG. 2 shows the test tube used for the characterization of the mechanical properties of the product.
• Figures 3 and 4 schematically show a pre-machined blank according to the invention.
• FIG. 5 schematically shows the shape of a pre-machined thick sheet and the sampling plan of pre-machined thick sheet (fig. 5a) or not (fig. 5b), as explained in example 2.
• FIG. 6 schematically shows the shape of a pre-machined thick sheet and the sampling plan for pre-machined thick sheets (FIG. 6a) or not (FIG. 6b), as explained in Example 3.
• the static mechanical characteristics that is to say the tensile strength R m , the elastic limit R p o, 2 , and the elongation at break A, are determined by a tensile test according to standard EN 10002-1, the place and direction of specimen collection being defined in standard EN 485-1.
• the tenacity Kic was measured according to standard ASTM E 399.
• the curve R is determined according to standard ASTM 561-98. From the curve R, one calculates the critical stress intensity factor Kc, ie the intensity factor which causes the instability of the crack. We also calculate the intensity factor of stress Kc D , by assigning to the critical load the initial length of the crack, at the beginning of the monotonous loading.
• Ka PP designates the Kco corresponding to the test piece which was used to make the R curve test.
• the resistance to exfoliating corrosion was determined according to the EXCO test described in standard ASTM G34-72.
• machining includes any material removal process such as turning, milling, drilling, reaming, tapping, EDM, grinding, polishing.
• structural element refers to an element used in mechanical construction for which the static and / or dynamic mechanical characteristics are of particular importance for the performance and integrity of the structure, and for which a calculation of the structure is generally prescribed or performed. It is typically a mechanical part, the failure of which is likely to endanger the safety of said construction, of its users, of its users or of others.
• these structural elements include in particular the elements that make up the fuselage (such as the fuselage skin), the stiffeners or bulkheads, bulkheads, fuselage (circumferential frames), the wings (such as the wing skin), the stiffeners (stringers or stiffeners), the ribs (ribs) and spars (spars)) and the empennage composed in particular of horizontal and vertical stabilizers (horizontal or vertical stabilizers), as well as the floor profiles (floor beams), the seat rails (seat tracks) and the doors.
• this pre-machined blank has a profile consisting of one or more channels. These channels can be parallel to the rolling direction, but other orientations are possible, for example a diagonal orientation. If consideration is given to pulling after quenching, this profile is advantageously parallel to the rolling direction and substantially constant over its length, but other types of profiles are possible.
• the blank can be in a horizontal position, in a vertical position, or in any other position.
• the quenching can be carried out by immersion in a quenching medium, by spraying, or by any other suitable means.
• Said soaking medium can be water or another medium such as glycol; its temperature can be chosen between its solidification point and its boiling point, knowing that the ambient temperature (around 20 ° C) may be suitable.
• the process according to the invention comprises a) the manufacture of a metal sheet by a process comprising a) casting a rolling plate, optionally followed by homogenization, a2) one or more hot or cold rolling operations cold, possibly separated from one or more reheating operations, to obtain a sheet, a3) optionally one or more operations for cutting or finishing the sheet, b) pre-machining said sheet on one or both sides to obtain a pre-machined blank, c) a solution treatment for said pre-machined blank, d) a quenching treatment.
• the blank thus obtained can be subjected to one or more of the following steps: e) controlled traction, f) tempering, g) cutting.
• steps a) to d) that is to say after quenching, and advantageously after controlled traction (if there is one) and after tempering (s' there is one)
• the pre-machined blank can be subjected to other machining operations to obtain a machined metal part, it being understood that the shape of the blank must be compatible with that of the target machined part.
• the shape of said channels of the blank must be chosen so as to minimize the deformation on quenching of the blank, and to optimize the mechanical characteristics of the final machined part. It is preferred that one of the two faces of the blank is flat. In this case, it is preferred that during the horizontal quenching, the machined channels of the sheet are oriented downwards.
• a length between 50 mm and 1000 mm, and preferably between 50 mm and 500 mm at the start and at the end of the sheet does not include machined channels and has a substantially constant thickness (this part devoid of machined channels being called "heel"), in order to allow correct grip of the traction jaws.
• Said traction is advantageously carried out so as to lead to a permanent elongation of between 0.5% and 5%. A minimum value greater than 1.0 or even greater than 1.5% is preferred for this permanent elongation.
• said blank advantageously comprises between the heels and the central zone having machined channels a transition zone whose thickness decreases from the heel towards the central zone having machined channels. It is advantageous that this heel as well as the transition zone are trimmed after the controlled traction, either mechanically, for example by sawing or shearing, or by other known means such as the laser beam or the liquid jet. However, this heel can also be kept at least partially, for example to facilitate the assembly of the structural elements.
• the method according to the invention can be advantageously applied to sheets of metal alloys with structural hardening, in particular to aluminum alloys with structural hardening, and more particularly to alloys of the 2xxx, 6xxx and
• the sheets include the following alloying elements (in% by mass): Zn 5.5 - 11 Mg 1.5 - 3 Cu 1.0 - 3.0.
• the zinc content is between 8 and 11%.
• the alloy also comprises elements which can form dispersoids, that is to say one or more elements selected from the group consisting of Zr, Se, Hf, La, Ti, Ce, Nd, Eu, Gd, Tb, Dy, Ho, Er, Y, Yb, the content of each of the said elements, if selected, being between 0.02 and 0.7
• alloys of the 7xxx series the alloys 7449, 7349, 7049, 7050, 7055, 7040 and 7150 are particularly preferred.
• the sheets are advantageously large, that is to say a length greater than 2000 mm and preferably greater than 5000 mm, a width greater than 600 mm and preferably greater than 1200 mm. They advantageously have, before machining, a thickness greater than 15 mm, preferably greater than 30 mm and even more preferably greater than 50 mm.
• a thick sheet of 7449 aluminum alloy with a thickness of the order of 100 to 110 mm, leading to a pre-machined blank with a maximum thickness of the order of 90 to 100 mm.
• a thick sheet with a thickness of the order of 30 to 60 mm is used for the manufacture of a structural element for wing skin with integrated stiffener, leading to a pre-machined blank of a maximum thickness of the order of 25 to 55 mm.
• the problem linked to the gradients of the mechanical properties hardly arises below a thickness of about fifteen to twenty millimeters.
• the advantages provided by the present invention are therefore significant for thicknesses greater than approximately 30 to 40 mm, that is to say in particular for the manufacture of structural wing elements.
• the machining operations for forming the blank from the thick sheet and for manufacturing the finished part from the blank can be carried out at high speed, i.e. with a speed of at least 5000 revolutions per minute, and preferably greater than 10,000 revolutions per minute.
• the method according to the invention makes it possible to make the most of the chips and scraps generated during machining. To this end, their mixing with other metallic or non-metallic materials should be avoided, including with other alloys of the same type.
• the method according to the invention in order to be able to be operated with the lowest possible cost, encourages machining to be carried out in the factory of the sheet metal manufacturer or under its industrial control, and the availability of scrap and chips , in particular in 2xxx and 7xxx alloys, perfectly identified and resulting from a known process, leads to the possibility of being able to recycle larger fractions of the chips in the manufacture of heavy sheets in 2xxx and 7xxx alloys for aeronautical application.
• the applicant has thus been able to incorporate up to 40% of machining chips in the process according to the invention, using methods of processing the collected chips and the liquid metal which are known to man. of career.
• the incorporation of at least 5% of selectively collected chips has been found to be possible in almost all cases, and a level of at least 15% is preferred.
• the metal parts obtained by the process according to the invention can be used as a structural element in aeronautical construction.
• the invention makes it possible to produce wing panels, fuselage elements, side members, ribs or central wing boxes.
• the method according to the invention has many advantages over known methods. In particular, it allows the manufacture of parts having an improved compromise between tolerance to damage and static mechanical characteristics.
• a person skilled in the art can adapt the metallurgical state of the pre-machined blank to the targeted properties of the finished part, in order to favor gain in static mechanical characteristics or in damage tolerance, or to improve both types of characteristics at the same time. For example, the applicant was able to obtain with the 7449 alloy finished parts having an improvement of 20 to 25% in the Kic toughness, without any degradation of the static mechanical characteristics.
• Block 3 has not been prefabricated.
• the three blocks were dissolved for 4 hours at 472 ° C with a temperature rise of 4 hours, and quenched by vertical immersion in stirred cold water, the ribs being oriented perpendicular to the surface of the water.
• the blocks were then cut according to the cutting plan shown in Figure 2.
• Some of the specimens thus obtained were subjected to a tempering treatment of 48 h at 120 ° C to bring them to the T6 state.
• Other specimens were subjected to a controlled traction with a permanent elongation of 2%, and then to the same treatment of income as the other specimens, to put them in the state T651.
• the toughness in the pre-machined blank according to the invention increases by approximately 10 MPa m compared to a part according to the prior art, which corresponds to a gain of approximately 20 to 25%, without any degradation on static mechanical characteristics.
• the sheet was dissolved and then quenched by vertical immersion in agitated cold water, the ribs being oriented parallel to the surface of the water.
• the sheet was then subjected to controlled traction with a permanent elongation of 2% observed in the pre-machined area and zero elongation in the solid areas.
• a block was then taken from the pre-machined area as well as a block from the non-machined area for characterization. Drafts were taken from the non-machined block and subjected to controlled traction with a permanent elongation of 2 to 2.5%.
• the toughness in plane stress Ka Pp (L . ⁇ ) in the pre-machined blank according to the invention increases by approximately 14 MPaVm compared to a part according to the prior art, which corresponds to a gain of approximately 20 to 25%, without any degradation on the static mechanical characteristics.
• Example 3 In a 7449 alloy sheet (composition: Zn 8.8%, Cu 1.8%, Mg 1.8%, Zr 0.12%, Si 0.04%, Fe 0.06%, Mn 0, 01%, Ti 0.03%) with a thickness of 90 mm gross hot rolling, but riveted and trimmed, a sheet of dimensions 9,950 mm (L direction) x 2,000 mm (TL direction) was cut into the full thickness ). This sheet was cut lengthwise (direction L) so as to obtain a first sheet of dimensions 9950 mm (direction L) x 775 mm (direction TL) and a second sheet of dimensions 9950 mm (direction L) x 1225 mm ( sense TL).
• the full thickness sheet and the pre-machined sheet were dissolved and then quenched by vertical immersion in agitated cold water, the ribs being oriented parallel to the surface of the water.
• the two sheets were then subjected to controlled traction with a permanent elongation of 2 to 2.5% (observed in the pre-machined zone for the pre-machined sheet).
• a block was then taken from the pre-machined sheet as well as a block from the full thickness sheet for characterization. Samples were taken according to the cutting plan in Figure 6. Several incomes were applied in order to assess the gains linked to pre-machining.
• the characterizations carried out in the pre-machined web and at 1/8 of a thickness below the surface of the full sheet are listed in Table 6.
• the toughness in plane stress according to the orientation LT (K aPP ( - ⁇ )) in the pre-machined blank according to the invention increases between 8 and 18 MPaVm according to the income practiced compared to a part according to the prior art , which corresponds to a gain of approximately 10 to 25%, without any degradation on the static mechanical characteristics and the exfoliating corrosion.

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• 2003
  • 2003-12-17 BR BRPI0317336-4B1A patent/BR0317336B1/pt not_active IP Right Cessation
  • 2003-12-17 RU RU2005122471/02A patent/RU2341585C2/ru not_active IP Right Cessation
  • 2003-12-17 AU AU2003300632A patent/AU2003300632A1/en not_active Abandoned
  • 2003-12-17 JP JP2005502575A patent/JP2006510808A/ja active Pending
  • 2003-12-17 WO PCT/FR2003/003753 patent/WO2004056501A2/fr not_active Ceased
  • 2003-12-17 CA CA2508534A patent/CA2508534C/fr not_active Expired - Fee Related
  • 2003-12-17 EP EP03813619A patent/EP1573080B1/de not_active Expired - Lifetime

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