WO2009130175A1 - Procédé de fabrication d'une pièce structurelle en alliage d'aluminium - Google Patents

Procédé de fabrication d'une pièce structurelle en alliage d'aluminium Download PDF

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Publication number
WO2009130175A1
WO2009130175A1 PCT/EP2009/054631 EP2009054631W WO2009130175A1 WO 2009130175 A1 WO2009130175 A1 WO 2009130175A1 EP 2009054631 W EP2009054631 W EP 2009054631W WO 2009130175 A1 WO2009130175 A1 WO 2009130175A1
Authority
WO
WIPO (PCT)
Prior art keywords
aluminium alloy
structural part
alloy sheet
temperature
7xxx
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/EP2009/054631
Other languages
English (en)
Inventor
Christiaan Theodorus Wilhelmus Lahaije
Alastair Wise
Jean Pierre Jules Baekelandt
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Aleris Aluminum Duffell BVBA
Original Assignee
Aleris Aluminum Duffell BVBA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Aleris Aluminum Duffell BVBA filed Critical Aleris Aluminum Duffell BVBA
Priority to DE112009000981T priority Critical patent/DE112009000981T5/de
Publication of WO2009130175A1 publication Critical patent/WO2009130175A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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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
    • C22F1/043—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 silicon as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
    • C22C21/04—Modified aluminium-silicon alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/12—Alloys based on aluminium 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
    • C22F1/057—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

Definitions

  • the invention relates to a method for the manufacture of forming a structural part from a high-strength 7xxx-series aluminium alloy, said structural part being formed in a shaping operation using a strip of rolled aluminium alloy sheet.
  • the invention is also directed to an automobile structural part formed by this method, in particular to a pillar reinforcement, for example to a B-pillar reinforcement or a tunnel.
  • alloy designations and temper designations refer to the Aluminum Association designations in Aluminum Standards and Data and the Registration Records, as published by the Aluminum Association in 2007.
  • alloy compositions or preferred alloy compositions all references to percentages are by weight percent unless otherwise indicated.
  • the 6xxx- and 5xxx-series alloys have been used to produce body panels, whereas the load-bearing structural parts such as door beams and pillar reinforcements are commonly made from steel due to its higher strength.
  • the B-pillar reinforcement which plays an important role in protecting the occupants of a vehicle in a side impact incident, is currently produced from ultra high-strength steel, for example boron steel.
  • Such a B-pillar is manufactured from a rolled steel sheet in a hot stamp forming operation.
  • EP-0952067-A2 disclosed a bodywork B-column or B-pillar for an automobile made from an aluminium alloy in a die-casting operation.
  • US-4,035,891 discloses a method of making a one-piece wheel starting from a blank made from an aluminium sheet product of the 6xxx-series, and wherein the blank is hot stamped at a temperature of about 475°C, which is below the solution heat treatment temperature of the subject alloy, to form the minor flange of the rim and the wheel, while the major flange of the rim is obtained by subsequently press-forming.
  • a method for the manufacture of forming a structural part from a 7xxx-series aluminium alloy sheet said structural part being formed in a shaping operation of a strip of rolled aluminium alloy sheet, typically a cold rolled aluminium alloy sheet having a gauge in the range of about 0.4 to 8 mm, and preferably about 0.5 to 5 mm, the method comprising the following sequential steps of: a.) cutting the aluminium alloy sheet to obtain an aluminium alloy sheet blank; b.) heating the aluminium alloy sheet blank to a temperature of more than 350 0 C but at a temperature lower than the solidus temperature of the subject alloy, and whereby heat-up rates can be applied that are regular in the art, and followed by transfer of the heated blank to the forming tool,
  • the shaped structural part may be trimmed from any excess material from the alloy sheet following the cooling operation and prior to any subsequent further heat treatment operation.
  • the rolled aluminium alloy sheet may be obtained by methods known in the art, and which include continuous casting or DC-casting of a rolling stock, homogenisation and/or preheating of the rolling stock, hot rolling and/or cold rolling to a final gauge typically in the range of about 0.4 to 8 mm. Depending on the alloy composition and the amount of cold work an intermediate anneal may be used before or during the cold rolling operation.
  • 7xxx-series alloys when processed according to the invention are ductile enough at higher temperatures to be shaped in a stamping, a pressing , a deep-drawing or press-forming operation.
  • the method according to the invention allows for the production of aluminium alloy structural parts having a very high strength while having equivalent or superior side impact performance compared to a structural part of similar geometry made of steel, for example a boron steel.
  • a further advantage of aluminium alloy structural parts compared to steel structural parts is the significantly reduced mass of the parts even if the thickness of the aluminium alloy structural parts is higher than the thickness of the steel structural parts.
  • a boron steel sheet of 2.0 mm thickness may be replaced by an AA7136 aluminium alloy sheet of about 3.5 mm thickness without compromising the side impact performance of a B-pillar reinforcement, and thereby realizing a weight saving of about 35% to 40%.
  • the method is applied to a 7xxx-series aluminium alloy sheet which a Cu-free, meaning for the purpose of this invention that it has a Cu-content of less than 0.3 wt.%, and preferably less than about 0.2 wt.%.
  • a particular suitable aluminium alloy for this process and the intended structural application is an aluminium alloy having a composition within the window of AA7021.
  • the AA7021 registration defines a Cu-content of maximum 0.25 wt.%, it is preferred to process aluminium alloys having a lower upper-limit, for example of less than about 0.2 wt.%, and more preferably of less than about 0.15 wt.% Cu.
  • the aluminium alloy sheet blank is heated to a temperature at which solutionizing occurs, thus the heating of the blank has the effect of a solution heat treatment to achieve the dissolving of as much as practically possible any of M- and T-phases which may have precipitated out during cooling from a homogenisation treatment or during a hot working operation or any other intermediate thermal treatment before the rolled product was rolled to final gauge.
  • a solution heat treatment is preferably carried out at a temperature of more than about 400 0 C, and more preferably to a temperature in a range of about 420 to 510 0 C.
  • a more preferred upper-limit is about 490°C.
  • the duration of this heating or the soaking time is preferably in a range of a few minutes to less than about 2 hours, and preferably less than about 1 hour.
  • the heated blank is subsequently transferred to the forming tool in which the structural part is shaped.
  • the shaping operation can be done for example by means of deep-drawing, pressing or press forming. In the transfer of the aluminium alloy sheet blank may loose some heat, but at the beginning of the shaping operation the temperature should be higher than 200 0 C, and ideally be more than 250°C.
  • the structural part is rapidly cooled for example by means water such as water quenching or water spray quenching.
  • the shaping operation and the cooling operation are combined.
  • This can be obtained for example by means of using relatively cold forming tools, e.g. dies, such that during the shaping operation the heated blank is formed while simultaneously being rapidly cooled, more in particular quenched.
  • relatively cold forming tools e.g. dies
  • This kind of combined shaping, e.g. by means of stamping, and cooling of the blank is also referred to as press-quenching.
  • An advantage of press-quenching is the reduced spring back in the structural part.
  • the Cu-free 7xxx-series aluminium alloy have a very low quench sensitivity and consequently can be quenched in the forming tool without criticality.
  • the structural part After the rapid cooling operation either by press-quenching or the use of water, the structural part is in a W-temper. Thereafter the structural part is aged to bring achieve the desired mechanical properties such as strength and physical properties in the structural part.
  • Ageing can be done by natural ageing, typically at ambient temperatures. In a preferred mode the ageing is carried out by means of artificial aging. Artificial aging can bring the structural part for example to a peak strength (T6) or to an over-aged temper (T7). Artificial ageing is preferably carried out by holding the structural part for about 3 to 20 hours at a temperature in the range of about 90 to 200 0 C.
  • Artificial ageing can also be carried out as a single ageing treatment, but also in a two-step or even three-step ageing treatment, for example by holding the structural part for about 5 hours at about 100 0 C, then for about 4 hours at about 145°C, and then for about 3 hours at about 170 0 C followed by rapid cooling.
  • a non-isothermal ageing practice as disclosed in WO- 2007/106772-A2 can be applied.
  • the structural part prior to the artificial ageing treatment can be subjected to a cold forming operation to reduce any possible distortions in the structural part introduced during the rapid cooling operation.
  • the method according to the invention it is being applied to 7xxx- series aluminium alloy sheet having a purposive addition of copper as alloying element.
  • the Cu-content is more than 0.3 wt.%, and preferably more than about 0.8 wt.%.
  • Aluminium alloys in particular suitable for this embodiment are aluminium alloys within the compositional ranges of AA7136, AA7081 , AA7085, AA7050,and AA7055-series alloys. Some of these registered aluminium alloys have very strict upper-limits for the Si and Fe-contents. However, it has been found that in the method according to this invention the Si and Fe levels are less critical and the upper-limits can be raised to about 0.25 wt.% and about 0.35 wt.% respectively.
  • the aluminium alloy sheet blank is heated to a temperature in the range of about 350 0 C to 440°C, and typically for a period of a few minutes to about 1 hour.
  • the temperature applied is below the temperature to obtain a substantial solutionizing effect.
  • the heated blank is subsequently transferred to the forming tool in which the structural part is shaped.
  • the shaping operation can be done for example by means of deep-drawing, pressing or press forming.
  • the shaping operation can be done for example by means of deep-drawing, pressing or press forming.
  • In the transfer of the aluminium alloy sheet blank may loose some heat, but at the beginning of the shaping operation the temperature should be higher than 200 0 C, and ideally be more than 250 0 C.
  • Press forming is typically applied at a strain rate of 0.01/s to 0.1/s.
  • the forming tools to shape the structural part may be heated to a temperature of about 200°C to 440°C, and preferably to about 300°C to 400°C.
  • the forming tools are about 20°C to 30°C below the heating temperature of the aluminium alloy sheet blank.
  • the heating of the forming tools is to prevent too fast cooling of the aluminium alloy sheet blank during the hot forming operation.
  • the structural part is cooled.
  • the structural part are cooled while still in the forming dies to reduce the amount of distortion in the part.
  • the cooled shaped structural part is subjected to a solution heat treatment followed by rapid cooling for example by means water such as water quenching or water spray quenching.
  • Such a solution heat treatment is preferably carried out at a temperature of more than 450 0 C but at a temperature lower than the solidus temperature of the subject alloy, and more preferably to a temperature in a range of 450 0 C to 490 0 C.
  • a typical solution heat treatment temperature would by about 475°C.
  • the duration of this heating or the soaking time is preferably in a range of about 3 to 150 min, more preferably in a range of about 5 to 40 min.
  • the structural part is aged to bring achieve the desired mechanical properties such as strength and physical properties in the structural part.
  • Ageing can be done by natural ageing, typically at ambient temperatures. In a preferred mode the ageing is carried out by means of artificial aging. Artificial aging can bring the structural part for example to a peak strength (T6) or to an over-aged temper (T7). Artificial ageing is preferably carried out by holding the structural part for about 3 to 20 hours at a temperature in the range of about 90 0 C to 200 0 C.
  • Artificial ageing can also be carried out as a single ageing treatment, but also in a two-step or even three-step ageing treatment, for example by holding the structural part for about 5 hours at about 100°C, then for about 4 hours at about 145°C, and then for about 3 hours at about 170°C followed by rapid cooling.
  • the structural part prior to the artificial ageing treatment can be subjected to a cold forming operation, e.g. a cold press forming operation, to reduce any possible distortions in the structural part introduced during the rapid cooling operation.
  • a cold forming operation e.g. a cold press forming operation
  • the method according to this invention may be used to manufacture structural parts from a
  • 7xxx-series aluminium alloy sheet is an automobile structural part. More in particular a structural part selected from the group comprising: a bumper, door beam, roof beam, side beam, instrumental panel support beam, pillar reinforcement, tunnel, and B-pillar reinforcement.
  • a structural part such as an automobile structural part formed by the method according to this invention.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)

Abstract

L'invention porte sur un procédé pour la fabrication et la formation d'une pièce structurelle à partir d'une tôle d'alliage d'aluminium série 7xxx, et sur ladite pièce structurelle formée lors d'une opération de mise en forme à l'aide d'une feuille de tôle d'alliage d'aluminium enroulée, le procédé consistant à : (i) couper la tôle d'alliage d'aluminium afin d'obtenir un flan en tôle d'alliage d'aluminium ; (ii) chauffer le flan en tôle d'alliage d'aluminium jusqu'à une température supérieure à 450°C ; (iii) mettre en forme le flan en tôle d'alliage d'aluminium chauffé de façon à obtenir la pièce structurelle ; (iv) refroidir la pièce structurelle mise en forme ; et (v) traiter thermiquement la pièce structurelle mise en forme et refroidie.
PCT/EP2009/054631 2008-04-25 2009-04-20 Procédé de fabrication d'une pièce structurelle en alliage d'aluminium Ceased WO2009130175A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
DE112009000981T DE112009000981T5 (de) 2008-04-25 2009-04-20 Verfahren zur Herstellung eines Bauteils aus einer Aluminiumlegierung

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP08008010.4 2008-04-25
EP08008010 2008-04-25

Publications (1)

Publication Number Publication Date
WO2009130175A1 true WO2009130175A1 (fr) 2009-10-29

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Application Number Title Priority Date Filing Date
PCT/EP2009/054631 Ceased WO2009130175A1 (fr) 2008-04-25 2009-04-20 Procédé de fabrication d'une pièce structurelle en alliage d'aluminium

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DE (1) DE112009000981T5 (fr)
WO (1) WO2009130175A1 (fr)

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011058332A1 (fr) * 2009-11-13 2011-05-19 Imperial Innovations Limited Procédé de formation d'un composant de forme complexe à partir d'un matériau en feuille
DE102010055095A1 (de) 2010-12-18 2011-08-25 Daimler AG, 70327 Strukturbauteil für eine Karosserie eines Kraftwagens sowie Verfahren zum Herstellen eines solchen Strukturbauteils
CN103128267A (zh) * 2011-12-01 2013-06-05 福特全球技术公司 成形f-回火铝合金的方法
GB2536193A (en) * 2014-10-31 2016-09-14 Imp Innovations Ltd A method for forming a part from aluminium alloy
US9757784B2 (en) 2015-03-10 2017-09-12 Ford Global Technologies, Llc Temperature measurement device for metal sheet
WO2020016506A1 (fr) 2018-07-17 2020-01-23 Constellium Neuf-Brisach Procede de fabrication de toles minces en alliage d'aluminium 7xxx aptes a la mise en forme et a l'assemblage
WO2020102065A2 (fr) 2018-11-12 2020-05-22 Novelis Inc. Produits en alliage d'aluminium pouvant être traités thermiquement, à haute résistance, rapidement vieillis et leurs procédés de fabrication
US11590565B2 (en) 2016-10-27 2023-02-28 Novelis Inc. Metal casting and rolling line
US11692255B2 (en) 2016-10-27 2023-07-04 Novelis Inc. High strength 7XXX series aluminum alloys and methods of making the same
US11821065B2 (en) 2016-10-27 2023-11-21 Novelis Inc. High strength 6XXX series aluminum alloys and methods of making the same

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102013021478B3 (de) * 2013-12-17 2015-05-28 Aweba Werkzeugbau Gmbh Aue Herstellverfahren für Blechteile aus Magnesium und hochfestem Aluminium

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3212941A (en) * 1960-10-26 1965-10-19 Reynolds Metals Co Method of producing a bumper
US3850763A (en) * 1973-11-14 1974-11-26 Reynolds Metals Co Method of producing a vehicle bumper
US3945861A (en) * 1975-04-21 1976-03-23 Aluminum Company Of America High strength automobile bumper alloy
EP0062469A1 (fr) * 1981-03-31 1982-10-13 Sumitomo Light Metal Industries Limited Procédé pour la fabrication de pièces en alliage d'aluminium à grain fin et à résistance élevée
GB2169617A (en) * 1984-12-18 1986-07-16 Aluminum Co Of America High strength, weldable aluminium base alloy
JP2003328031A (ja) * 2002-05-13 2003-11-19 Nissan Motor Co Ltd プレス部品の焼入れ方法および焼入れ装置およびプレス部品
WO2007084089A2 (fr) * 2006-01-18 2007-07-26 Mehmet Terziakin Outil de régulation des effets de refroidissement et de durcissement dans les opérations d'estampage à chaud

Family Cites Families (3)

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Publication number Priority date Publication date Assignee Title
FR2316017A1 (fr) 1975-07-03 1977-01-28 Forgeal Procede de fabrication de roues monoblocs pour vehicules gros porteurs
DE19818260B4 (de) 1998-04-23 2008-08-21 Volkswagen Ag Karosseriesäule, insbesondere B-Säule, für ein Kraftfahrzeug
WO2007106772A2 (fr) 2006-03-13 2007-09-20 Alcoa Inc. Méthode et procédé de vieillissement non isothermique pour alliages d'aluminium

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3212941A (en) * 1960-10-26 1965-10-19 Reynolds Metals Co Method of producing a bumper
US3850763A (en) * 1973-11-14 1974-11-26 Reynolds Metals Co Method of producing a vehicle bumper
US3945861A (en) * 1975-04-21 1976-03-23 Aluminum Company Of America High strength automobile bumper alloy
EP0062469A1 (fr) * 1981-03-31 1982-10-13 Sumitomo Light Metal Industries Limited Procédé pour la fabrication de pièces en alliage d'aluminium à grain fin et à résistance élevée
GB2169617A (en) * 1984-12-18 1986-07-16 Aluminum Co Of America High strength, weldable aluminium base alloy
JP2003328031A (ja) * 2002-05-13 2003-11-19 Nissan Motor Co Ltd プレス部品の焼入れ方法および焼入れ装置およびプレス部品
WO2007084089A2 (fr) * 2006-01-18 2007-07-26 Mehmet Terziakin Outil de régulation des effets de refroidissement et de durcissement dans les opérations d'estampage à chaud

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011058332A1 (fr) * 2009-11-13 2011-05-19 Imperial Innovations Limited Procédé de formation d'un composant de forme complexe à partir d'un matériau en feuille
US9950355B2 (en) 2009-11-13 2018-04-24 Imperial Innovations Limited Method of forming a component of complex shape from sheet material
DE102010055095A1 (de) 2010-12-18 2011-08-25 Daimler AG, 70327 Strukturbauteil für eine Karosserie eines Kraftwagens sowie Verfahren zum Herstellen eines solchen Strukturbauteils
US8496764B2 (en) 2011-12-01 2013-07-30 Ford Global Technologies, Llc System and method for manufacturing an F-temper 7xxx series aluminum alloy
CN103128267A (zh) * 2011-12-01 2013-06-05 福特全球技术公司 成形f-回火铝合金的方法
GB2536193A (en) * 2014-10-31 2016-09-14 Imp Innovations Ltd A method for forming a part from aluminium alloy
US9757784B2 (en) 2015-03-10 2017-09-12 Ford Global Technologies, Llc Temperature measurement device for metal sheet
US11590565B2 (en) 2016-10-27 2023-02-28 Novelis Inc. Metal casting and rolling line
US11692255B2 (en) 2016-10-27 2023-07-04 Novelis Inc. High strength 7XXX series aluminum alloys and methods of making the same
US11806779B2 (en) 2016-10-27 2023-11-07 Novelis Inc. Systems and methods for making thick gauge aluminum alloy articles
US11821065B2 (en) 2016-10-27 2023-11-21 Novelis Inc. High strength 6XXX series aluminum alloys and methods of making the same
WO2020016506A1 (fr) 2018-07-17 2020-01-23 Constellium Neuf-Brisach Procede de fabrication de toles minces en alliage d'aluminium 7xxx aptes a la mise en forme et a l'assemblage
FR3084087A1 (fr) 2018-07-17 2020-01-24 Constellium Neuf-Brisach Procede de fabrication de toles minces en alliage d'aluminium 7xxx aptes a la mise en forme et a l'assemblage
US12146202B2 (en) 2018-07-17 2024-11-19 Constellium Neuf-Brisach Process for manufacturing thin sheets made of 7XXX aluminum alloy suitable for shaping and assembly
WO2020102065A2 (fr) 2018-11-12 2020-05-22 Novelis Inc. Produits en alliage d'aluminium pouvant être traités thermiquement, à haute résistance, rapidement vieillis et leurs procédés de fabrication

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