阅读说明：本技术 一种高强度铝合金性能冲压件 (High strength aluminum alloy performance stamping workpiece ) 是由 陆潇 于 2019-10-10 设计创作，主要内容包括：本发明公开了一种高强度铝合金量身定制的性能冲压件,包括将铝合金坯料加热到固溶温度以上；将铝合金坯料淬火；以及在模具中冲压铝合金坯料以形成具有预定形状的铝部件。引入多个局部塑性变形以选择铝部件的区域,并且对铝部件进行一种或多种时效处理,包括加热铝。组分温度低于固溶温度。局部塑性变形充当一种或多种时效处理期间沉淀硬化的成核部位,以在铝部件中形成多个强化区域。(The invention discloses a high-strength aluminum alloy tailored performance stamping part, which comprises the steps of heating an aluminum alloy blank to a temperature above a solid solution temperature; quenching the aluminum alloy blank; and stamping the aluminum alloy blank in a die to form an aluminum part having a predetermined shape. A plurality of localized plastic deformations are introduced to select regions of the aluminum component and the aluminum component is subjected to one or more aging processes, including heating the aluminum. The component temperature is lower than the solid solution temperature. The localized plastic deformation acts as a nucleation site for precipitation hardening during one or more aging treatments to form a plurality of strengthened regions in the aluminum component.)

1. A high strength aluminum alloy performance stamping comprising heating an aluminum alloy blank to greater than or equal to about 400 ℃ to less than or equal to about 600 ℃ and quenching the aluminum alloy blank to less than or equal to about 40 ℃, stamping the aluminum alloy blank in a die to form an aluminum component having a predetermined shape; introducing one or more localized plastic deformations into one or more selected regions of the aluminum component; and aging the aluminum composition at a temperature of greater than or equal to about 100 ℃ to less than or equal to about 200 ℃, wherein the localized plastic deformation serves as a nucleation site for precipitation hardening during aging to form a region in the one or more strengthened aluminum components.

2. The high strength aluminum alloy performance stamping of claim 1, wherein the first yield strength of the one or more strengthened regions is greater than or equal to about 20% greater than the second yield strength of the region of the aluminum component lacking the one or more strengthened regions.

3. The high strength aluminum alloy performance stamping of claim 1, wherein the first yield strength of the one or more strengthened regions is greater than or equal to about 600MPa and the second yield strength of the region of the aluminum component lacking the one or more strengthened regions is greater than or equal to about 480MPa to less than or equal to about 520 MPa.

4. The high strength aluminum alloy performance stamping of claim 1, wherein aging comprises a first temperature aging treatment comprising aging the aluminum composition to less than or equal to about 200 ℃ at a first temperature selected from a temperature of greater than or equal to about 100 ℃ and a second temperature aging treatment comprising aging the aluminum composition at a second temperature selected from a temperature of greater than or equal to about 100 ℃ to less than or equal to about 200 ℃.

5. A high strength aluminum alloy performance stamping according to claim 4, further comprising: localized plastic deformation is introduced between the first temperature aging and the second temperature aging.

6. A high strength aluminum alloy performance stamping according to claim 5, further comprising: local plastic deformation is introduced after the second temperature aging treatment.

7. The high strength aluminum alloy performance stamping of claim 4, wherein the aging further comprises a third temperature aging treatment, and the third temperature aging treatment comprises aging the aluminum component at a third temperature selected from a temperature of greater than or equal to about 100 ℃ to less than or equal to 100 ℃.

8. A high strength aluminum alloy performance stamping according to claim 7, further comprising: localized plastic deformation is introduced between the second temperature aging and the third temperature aging.

9. The high strength aluminum alloy performance stamping of claim 1, wherein the one or more localized plastic deformations are formed in a linear pattern on the aluminum component to enhance the strength of the aluminum component in a direction parallel to the linear pattern.

10. The high strength aluminum alloy performance stamping of claim 1, wherein the one or more localized plastic deformations are discrete from one another and are formed on the aluminum component in a distributed pattern to prevent localized bending of the aluminum component.

Technical Field

The invention relates to the technical field of aluminum alloy stamping parts, in particular to a high-strength aluminum alloy stamping part.

Background

Components formed using aluminum alloys are becoming increasingly popular in a variety of industries and applications, including general manufacturing, construction equipment, automotive or other transportation industries, domestic or industrial structures, aerospace, and the like. For example, aluminum alloys are commonly used in the manufacturing industry for die cast parts, such as engine blocks and transmissions in the automotive industry. It is worth noting that aluminum alloys are commonly used to die cast parts with thin walls that require high strength and high ductility and are lightweight. While many shaped aluminum alloy parts have sufficient strength for many applications, there is still a need to produce aluminum alloy parts with increased yield strength.

Disclosure of Invention

The invention relates to a high strength aluminum stamping with tailored mechanical properties.

In various aspects, the present disclosure provides an example method of a high strength aluminum alloy performance stamping. The method can include heating an aluminum alloy blank to a temperature of greater than or equal to about 400 ℃ to less than or equal to about 600 ℃, and quenching the aluminum alloy blank to a temperature of less than or equal to about 400 ℃. At 40 ℃. The aluminum alloy blank may be stamped in a die to form an aluminum component having a predetermined shape. After removing the formed part from the stamping die, one or more localized plastic deformations (e.g., permanent deformations) may be introduced into one or more selected regions of the aluminum part. The aluminum component may be subsequently aged at a temperature of greater than or equal to about 100 ℃ to less than or equal to about 200 ℃.

In one variation, the first yield strength of the one or more reinforced regions may be greater than or greater than about 20% greater than the tensile strength at yield of the region of the aluminum component lacking the one or more reinforced regions.

In one variation, the one or more strengthened regions can have a first yield strength greater than or equal to about 600MPa, and the second yield strength of a region of the aluminum component lacking the one or more strengthened regions can be greater than or equal to. To about 480MPa to less than or equal to about 520 MPa.

In one variation, the aging includes a first temperature aging process and a second temperature aging process. The first temperature aging treatment may include aging the aluminum component at a first temperature selected from the group consisting of temperatures greater than or equal to about 100 ℃ to less than or equal to about 200 ℃. The second temperature aging may include aging the aluminum composition. The aluminum component is at a second temperature selected from a temperature of greater than or equal to about 100 ℃ to less than or equal to about 200 ℃.

In one variation, localized plastic deformation may be introduced between the first temperature aging and the second temperature aging.

In one variation, the localized plastic deformation may be introduced after the second temperature aging treatment.

In one variation, the aging may further include a third temperature aging process. The third temperature aging treatment may include aging the aluminum component at a third temperature selected from a temperature of greater than or equal to about 100 ℃ to less than or equal to about 200 ℃.

In one variation, localized plastic deformation may be introduced between the second temperature aging and the third temperature aging.

In one variation, one or more localized plastic deformations are formed in a linear pattern on the aluminum part to enhance the strength of the aluminum part in a direction parallel to the linear pattern.

In one variation, one or more localized plastic deformations are discrete from each other and formed on the aluminum component in a distributed pattern to prevent localized bending of the aluminum component.

In one variation, the aluminum alloy blank is a 7000 series aluminum alloy including greater than or equal to about 1.2 wt.% to less than or equal to about 2.0 wt.% copper (Cu), greater than or equal to about 2.1 wt.% to less. Less than or equal to about 2.9 wt.% magnesium (Mg), less than or equal to about 0.30 wt.% manganese (Mn), less than or equal to about 0.40 wt.% silicon (Si), less than or equal to about 0.50 wt.% iron (Fe), greater than or equal to about 0.18 wt.% to less than or equal to about 0.28 wt.% chromium (Cr), greater than or equal to about 5.1 wt.% to less than or equal to about 6.1 wt.% zinc (less than or equal to about 0.20 wt.% titanium (Ti), less than or equal to about 0.15 wt.% of other elements, each less than or equal to about 0.05 wt.%, and the balance aluminum (Al).

In one variant, the local plastic deformation may be introduced using a method selected from: redraw, friction stir processing, shot peening, roll burnishing, and combinations thereof.

In one variation, the heating, quenching, and stamping of the aluminum alloy blank may occur simultaneously.

In one variation, the stamping of the aluminum alloy blank to form the aluminum component may occur at a temperature of less than or equal to about 26 ℃.

In other aspects, the present disclosure provides another exemplary method for making a high strength aluminum component. The method optionally comprises: heating the aluminum alloy blank in the die to a temperature of greater than or equal to about 400 ℃ to less than or equal to about 600 ℃ to form an aluminum part having a predetermined shape, and quenching the aluminum part. Heated in a mold to a temperature of less than or equal to about 40 ℃. The local plastic deformation may be introduced to select the region of the aluminum component by a process selected from the group consisting of: redraw, friction stir process, shot peening, barrel polishing, and combinations thereof. The aluminum component can be aged at a temperature of greater than or equal to about 100 ℃ to less than or equal to about 200 ℃. As the aluminum component ages, the localized plastic deformation may act as nucleation sites for precipitates that cause hardening and form one or more strengthening regions in the aluminum component. The first yield strength of the strengthened region of the aluminum component may be greater than or equal to about 20% greater than the second yield strength of the region of the aluminum component lacking the one or more strengthened regions.

In one variation, the aging may include a first temperature aging process and a second temperature aging process. The first temperature aging treatment may include aging the aluminum component at a first temperature selected from the group consisting of temperatures greater than or equal to about 100 ℃ to less than or equal to about 200 ℃. The second temperature aging may include aging the aluminum composition. The aluminum component is at a second temperature selected from a temperature of greater than or equal to about 100 ℃ to less than or equal to about 200 ℃.

In one variation, localized plastic deformation may be introduced between the first temperature aging and the second temperature aging.

In one variation, the aging may further include a third temperature aging process. The third temperature aging treatment may include aging the aluminum component at a third temperature selected from a temperature of greater than or equal to about 100 ℃ to less than or equal to about 200 ℃. Local plastic deformation may be introduced between the second temperatures. A temperature aging treatment and a third temperature aging treatment.

In other aspects, the present disclosure provides another exemplary method for making a high strength aluminum component. The method optionally comprises: the aluminum alloy blank is heated to a temperature of greater than or equal to about 400 ℃ to less than or equal to about 600 ℃, and the aluminum alloy blank is quenched to a temperature of less than or equal to about 40 ℃. The aluminum alloy blank may be stamped in a die to form an aluminum component having a predetermined shape. The aluminum component may be subjected to a first process selected from the group consisting of: redraw, friction stir processing, shot peening, roll polishing, and combinations thereof. The aluminum part may then be aged at a first temperature selected from a temperature of greater than or equal to about 100 ℃ to less than or equal to about 200 ℃. After the first temperature aging treatment, the aluminum component may be subjected to a second treatment selected from the group consisting of: redraw, friction stir processing, shot peening, roller burnishing or combinations thereof. The aluminum part may then be aged at a second temperature selected from a temperature of greater than or equal to about 100 ℃ to less than or equal to about 200 ℃. The first and second processes may introduce a plurality of local plastic deformations. A region of the aluminum component is selected. The localized plastic deformation may serve as a nucleation site for precipitation hardening during the first and second aging treatments to form a plurality of strengthened regions in the aluminum component. The aluminum component may be subjected to a second process selected from the group consisting of: re-stretching, friction stir process, shot peening, roller burnishing or combinations thereof. The aluminum part may then be aged at a second temperature selected from a temperature of greater than or equal to about 100 ℃ to less than or equal to about 200 ℃. The first and second processes may introduce a plurality of local plastic deformations. A region of the aluminum component is selected. The localized plastic deformation may serve as a nucleation site for precipitation hardening during the first and second aging treatments to form a plurality of strengthened regions in the aluminum component. The aluminum component may be subjected to a second process selected from the group consisting of: re-stretching, friction stir process, shot peening, roller burnishing or combinations thereof. The aluminum part may then be aged at a second temperature selected from a temperature of greater than or equal to about 100 ℃ to less than or equal to about 200 ℃. The first and second processes may introduce a plurality of local plastic deformations. A region of the aluminum component is selected. The localized plastic deformation may serve as a nucleation site for precipitation hardening during the first and second aging treatments to form a plurality of strengthened regions in the aluminum component. Or a combination thereof. The aluminum part may then be aged at a second temperature selected from a temperature of greater than or equal to about 100 ℃ to less than or equal to about 200 ℃. The first and second processes may introduce a plurality of local plastic deformations. A region of the aluminum component is selected. The localized plastic deformation may serve as a nucleation site for precipitation hardening during the first and second aging treatments to form a plurality of strengthened regions in the aluminum component. Or a combination thereof. The aluminum part may then be aged at a second temperature selected from a temperature of greater than or equal to about 100 ℃ to less than or equal to about 200 ℃. The first and second processes may introduce a plurality of local plastic deformations. A region of the aluminum component is selected. The localized plastic deformation may serve as a nucleation site for precipitation hardening during the first and second aging treatments to form a plurality of strengthened regions in the aluminum component. The first and second processes may introduce a plurality of localized plastic deformations to select regions of the aluminum component. The localized plastic deformation may serve as a nucleation site for precipitation hardening during the first and second aging treatments to form a plurality of strengthened regions in the aluminum component. The first and second processes may introduce a plurality of localized plastic deformations to select regions of the aluminum component. The localized plastic deformation may serve as a nucleation site for precipitation hardening during the first and second aging treatments to form a plurality of strengthened regions in the aluminum component.

In one variation, the twice aged aluminum component may be subjected to a third process selected from the group consisting of: redrawing, friction stir processing, shot blasting, roll polishing, and combinations thereof. The aluminum part may then be aged at a third temperature selected from a temperature of greater than or equal to about 100 ℃ to less than or equal to about 200 ℃.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

Drawings

1A-1C are perspective views of an exemplary door beam for an automobile having one or more localized plastic deformations;

Fig. 2 is a diagram of an exemplary method for making a high strength aluminum component.

Detailed Description

Example embodiments are provided so that this disclosure will be thorough and will fully convey the scope of the invention to those skilled in the art. Numerous specific details are set forth such as examples of specific components, parts, devices, and methods in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having," are inclusive and therefore specify the presence of stated features, elements, components, steps, integers, operations, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Although the open-ended term "comprising" should be understood as a non-limiting term used to describe and claim the various embodiments set forth herein, in certain aspects, the term may instead be understood as a more limiting and limiting term, such as "consisting of or" consisting essentially of. Thus, for any given embodiment, the compositions, materials, components, elements, features, integers, operations, and/or process steps are listed as embodiments that consist of, or consist essentially of such compositions, materials, components, elements, features, integers, operations, and/or process steps. In the case of "consisting of", alternative embodiments do not include any other components, materials, components, elements, features, integers, operations, and/or process steps, while in the case of "consisting essentially of", any other components, materials, components, elements, features, integers, operations, unless explicitly identified as an order of execution, any method steps, processes, and operations described herein should not be construed as necessarily requiring their execution in the particular order discussed or illustrated. It should also be understood that additional or alternative steps may be employed unless otherwise indicated.

When a component, element or layer is referred to as being "on," "engaged to," "connected to" or "coupled to" another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer. Other components, elements or layers, or intermediate elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly engaged with," "directly connected to" or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements (e.g., "between" and "directly between," "adjacent" and "directly adjacent," etc.) should be interpreted in a similar manner. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various steps, elements, components, regions, layers and/or sections, these steps, elements, components, regions, layers and/or sections should not be limited. Unless otherwise indicated, these terms shall control. These terms may be only used to distinguish one step, element, component, region, layer or section from another step, element, component, region, layer or section. Terms such as "first," "second," and other numerical terms used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first step, element, component, region, layer or section discussed below could be termed a second step, element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially and temporally relative terms, such as "before", "after", "inside", "outside", "below", "lower", "above", and the like, may be used for convenience in the description and the term "is used herein to describe one element or feature's relationship to another element or feature or elements as illustrated in the figures. Spatially and temporally relative terms may be intended to encompass different orientations of the device or system in use or operation in addition to the orientation depicted in the figures.

Throughout this disclosure, numerical values represent approximate measures of ranges or ranges, to encompass minor deviations from the given values, as well as embodiments having about the mentioned values and exactly the mentioned values. Other than the working examples provided at the end of the detailed description, in this specification the numerical values of all parameters (e.g., quantities or conditions) including the appended claims are to be understood as modified in all instances by the term. Whether "about" actually occurs before the numerical value. "about" means that the numerical value allows some slight imprecision (with some approach to exactness in the value; approximately or reasonably close to the value; close). As used herein, "about" means a change that can be caused at least by ordinary methods of measuring and using such parameters, provided that the imprecision provided by "about" is not otherwise understood in the art with this ordinary meaning. For example, "about" can include a variation of less than or equal to 5%, alternatively less than or equal to 4%, alternatively less than or equal to 3%, alternatively less than or equal to 2%, alternatively less than or equal to 5%. Equal to 1%, alternatively less than or equal to 0.5%, and in certain aspects, alternatively less than or equal to 0.1%.

In addition, the disclosure of a range includes the disclosure of all values and further divided ranges within the entire range, including the endpoints and sub-ranges given for that range. As referred to herein, unless otherwise indicated, ranges are inclusive of the endpoints and include ranges disclosing all different values and further divisions throughout the ranges. Thus, for example, a range of "from a to B" or "from about a to about B" includes a and B.

Example embodiments will now be described more fully with reference to the accompanying drawings.

Age hardening (i.e., precipitation hardening) processes are commonly used to increase the strength of metal alloys, including aluminum alloys. For example, as the aluminum component ages, the aluminum component is strengthened (e.g., hardened) by the formation of micro and sub-microscopic precipitate particles. Precipitation hardening involves heating the metal alloy to uniformly distribute the alloying elements throughout the base metal to form a solid solution. As the alloy cools, solutes (e.g., dissolved alloying elements) may migrate out of solution (e.g., precipitate) over time. The rate of precipitation may be controlled by environmental factors, including temperature and pressure. The precipitated alloying elements may nucleate to form a second phase that may strengthen and strengthen the crystal matrix structure. Grain boundaries of the crystal matrix are common nucleation sites. However, precipitation within the particles provides enhanced strengthening as compared to precipitation on the particles. The present technique provides a method of promoting intragranular precipitate formation, thereby further increasing the strength of the part formed in selected regions of the part.

Accordingly, in various aspects, the present techniques provide a method for manufacturing a component (e.g., an automotive component) having improved strength. The method includes stamping the aluminum alloy and thereafter introducing one or more localized deformations followed by subsequent aging. The localized plastic deformation may act as a nucleation site for precipitation hardening.

The method includes annealing the aluminum alloy blank to reduce the number of dislocations in the crystal lattice (e.g., line defects in the crystal structure of the alloy) and to improve the machinability of the aluminum alloy blank. Annealing includes rapidly heating the aluminum alloy ingot above the solutionizing temperature and maintaining the temperature until the alloying elements are substantially uniformly distributed throughout the aluminum and a solid solution is obtained. For example only, annealing may include heating the aluminum alloy blank to a temperature of greater than or equal to about 400 ℃ to less than or equal to about 600 ℃ at a rate of greater than or equal to about 1.0 ℃. (ii) a/s of less than or equal to about 100 ℃, and maintaining the temperature for a time of greater than or equal to about 0. 01 hours to less than or equal to 1.0 hour. The annealing time and temperature may depend on the thickness of the aluminum alloy blank.

In some cases, the method includes annealing an aluminum alloy including greater than or equal to about 0.4 wt.% silicon (Si), and less than or equal to about 0.7 wt.% iron (Si). Fe), from greater than or equal to about 0.15 wt% to less than or equal to about 4.9 wt% copper (Cu), less than or equal to about 0.9 wt% manganese (Mn), greater than or equal to about 0.8 wt% to less than or equal to about 2.9 wt% magnesium (Mg), less than or equal to about 0.35 wt% chromium (Cr), less than or equal to about 6.1 zinc (Zn), less than or equal to about 0.20 wt% titanium (Ti), less than or equal to about 0.15 wt% of other elements present alone in an amount less than or equal to about 0.05 wt%, and the balance aluminum (Al).

In some cases, the method includes annealing an aluminum alloy blank selected from the group consisting of: a 2xxx series aluminum alloy (e.g., a two thousand series aluminum alloy), a 6xxx series aluminum alloy (e.g., a six thousand series aluminum alloy), a 7xxx series aluminum alloy (e.g., a seven thousand series aluminum alloy), and combinations thereof. Copper (Cu) is the main alloying element of 2xxx series aluminum alloys. However, other elements, such as magnesium (Mg), may also be specified. Magnesium (Mg) and silicon (Si) are the main alloying elements of 6xxx series aluminum alloys. Zinc (Zn) is the main alloying element of 7xxx series aluminum alloys; however, other elements may also be specified, such as copper (Cu), magnesium (Mg), chromium (Cr), zirconium (Zr), and combinations thereof.

Non-limiting examples of suitable aluminum alloys include aluminum alloy 2024, aluminum alloy 6061, aluminum 7075, and the like.

Aluminum alloy 2024 includes about 0.5 wt.% silicon (Si), about 0.5 wt.% iron (Fe), greater than or equal to about 3.8 wt.% to less than or equal to about 4.9 wt.% copper (Cu), and greater. Less than or equal to about 0.3 wt% to less than or equal to about 0.9 wt% manganese (Mn), greater than or equal to about 1.2 wt% to less than or equal to about 1.8 wt% magnesium (Mg), less than or equal to about 0.1 wt% chromium (Cr), less than or equal to about 0.25 wt% zinc (Zn), less than or equal to about 0.15 wt% titanium (Ti), less than or equal to about 0.15 wt% of other elements present alone less than or equal to about 0.05 wt%, with the balance aluminum (Al). For example only, the other elements may include zirconium (Zr), vanadium (V), and combinations thereof.

Aluminum alloy 6061 includes greater than or equal to about 0.4 wt.% to less than or equal to about 0.8 wt.% silicon (Si), less than or equal to about 0.7 wt.% iron (Fe), greater than or equal to about 0.8 wt.%. 0.15 to less than or equal to about 0.40 weight percent copper (Cu), less than or equal to about 0.15 weight percent manganese (Mn), greater than or equal to about 0.8 to less than or equal to about 0.8 weight percent 1.2 weight percent magnesium (Mg), greater than or equal to about 0.04 weight percent chromium (Cr), less than or equal to about 0.35 weight percent zinc (Zn), less than or equal to about 0.15 weight percent titanium (Ti), less than or equal to about 0.15 weight percent of other elements present alone in an amount less than or equal to about 0.05 weight percent, and the balance aluminum (Al).

Aluminum alloy 7075 includes greater than or equal to about 1.2 wt.% to less than or equal to about 2.0 wt.% copper (Cu), greater than or equal to about 2.1 wt.% to less than or equal to 2.9 wt.% magnesium (Mg less than or equal to about 0.30 wt.% manganese (Mn), less than or equal to about 0.40 wt.% silicon (Si), less than or equal to about 0.50 wt.% iron (Fe), greater than or equal to about 0.18 wt.% to less than or equal to about 0.28 wt.% chromium (Cr), greater than or equal to about 5.1 wt.% to less than or equal to about 6.1 wt.% zinc (Zn), less than or equal to about 0.20 wt.% to less than or equal to about 0.15 wt.% titanium (Ti) as another element, in an amount of less than or equal to about 0.05 wt.%, and the balance aluminum (Al).

In some cases, the aluminum alloy 2024 blank can be heated to a temperature of greater than or equal to about 488 ℃ to less than or equal to about 499 ℃ for a time period of greater than or equal to about 0.1 hour. In other cases, the aluminum alloy 6061 blank can be heated to a temperature of greater than or equal to about 525 ℃ to less than or equal to about 535 ℃ for a time of greater than or equal to about 0.1 hour. In still other cases, the aluminum alloy 7075 billet can be heated to a temperature of greater than or equal to about 485 ℃ to less than or equal to about 495 ℃ for a time period of greater than or equal to about 0.1 hour.

After annealing, the solid solution may then be quenched. Quenching includes cooling the aluminum alloy to a temperature of less than or equal to about 40 ℃ at a rate of greater than or equal to about 450 ℃/s. The solute elements are frozen in place, thereby substantially preventing diffusion of the alloy. And (4) alloying elements. The quenched aluminum alloy may be relatively soft and may be pressed or drawn to form the desired aluminum composition. For example, a quenched aluminum alloy may be stamped in a die having a predetermined shape to form a desired aluminum component. For an automobile, for example only, the mold may be shaped to form an a-pillar or B-pillar, roof bow or rail or hinge pillar. In other cases, the solid solution may be simultaneously compression molded and quenched to a temperature of less than or equal to about 40 ℃.

One or more plastic deformations may be introduced into one or more selected regions of the aluminum component. In some cases, one or more plastic deformations may be introduced into one or more selected regions of the aluminum part after the formed part is removed from the die. As described above, in various aspects, as the aluminum composition ages, the localized plastic deformation may act as a nucleation site for precipitation (e.g., heterogeneous nucleation) of the alloying element. As the aluminum composition ages, the alloying elements diffuse (e.g., precipitate) to the respective nucleation sites, thereby forming one or more strengthened regions of the aluminum composition. The nucleation sites promote the formation of a second phase because the surface energy is lower and the free energy barrier is reduced. The selected regions (e.g., nucleation sites for the aluminum component are selected to allow the formation of a second phase that provides the aluminum component with enhanced strength because localized plastic deformation may act as nucleation sites for precipitates, the subsequent amount of age hardening in the selected regions is greater than in surrounding regions.

The nucleation sites (e.g., strengthened regions) may have a tensile strength greater than or equal to about 20% of the tensile strength of regions that do not include the aluminum component of the second phase after precipitation. For example only, where the aluminum composition includes an aluminum alloy 2024, the one or more strengthened regions may have a yield strength of greater than or equal to about 450MPa, while the region of the aluminum composition lacking the one or more strengthens may have a yield strength. The yield strength is about 380 MPa. In the case where the aluminum composition includes aluminum alloy 6061, the yield strength of the one or more strengthened regions may be greater than or equal to about 370MPa, and the yield strength of the region of the aluminum composition lacking the one or more strengthened regions may be.

Plastic deformation may be introduced to select regions of the aluminum component to improve energy management during impact. In some cases, the plastic deformation may be located along the convex and concave surfaces of the aluminum component, alone or in combination. In other cases, plastic deformation may be introduced in a discontinuous linear manner. Such as a graph. FIG. 1A shows an automotive vehicle 12 with an exemplary door beam 10 having a first end and a second end 14 and a plurality of ridges 16 extending therebetween and creating a plurality of concave and convex surfaces 18, 20 wherein plastic deformation 22 is introduced in a linear pattern of discrete areas on at least one convex (convex) surface 20 of a first ridge of the plurality of ridges 16. It should be noted that the placement of such plastic deformation 22 is representative, but may in fact be placed on other areas of the door beam 10. Further, FIG. 1B illustrates an exemplary door beam 30 of an automobile having a first end 32 and a second end 34 and a plurality of ridges 36. Extending between them and creating a plurality of concave and convex surfaces 38, 40, wherein the plastic deformation 28 is introduced into the first ridges 36 of the at least one protruding (convex) surface 40 in a continuous linear pattern. Again, this placement of plastic deformation 28 is representative, but may in fact be placed on other areas of the door beam 30 that require reinforcement.

In other cases, the plastic deformation may be distributed throughout the aluminum component to resist local bending of the aluminum component. Such as a graph. FIG. 1C illustrates an automotive vehicle door 48 having a first end portion and a second end 50 and a plurality of ridges 52 extending therebetween and creating a plurality of concave and convex surfaces 54, 56, wherein the plastic deformation 58 is throughout the distributed door beam 46. Thus, each of the plurality of localized plastic deformations 58 is discrete from one another. A plurality of plastic deformations 58 are formed in a distributed pattern on door beam 46 to prevent high localized bending of the aluminum component.

In other cases (not shown), plastic deformation may be introduced at various angles (e.g., non-parallel fashion) relative to the length of the exemplary door beam. In other cases (not shown), plastic deformation may be introduced on a surface of the exemplary door beam that is substantially perpendicular to the primary plane of the exemplary beam.

The application of a sufficient load or force will permanently deform the assembly and may occur in various processes, resulting in plastic deformation. In some cases, plastic deformation may be introduced using a process selected from the group consisting of: heavy stretching, friction stir processing, shot blasting, roll polishing, and combinations thereof. By way of example only, redrawing includes stamping the aluminum part into a second die having a plurality of anomalies that are selectively placed. For example, the second mold may include a plurality of indentations, protrusions, or nubs of sufficient depth or length to cause plastic deformation at room temperature. The friction stir process includes forcibly inserting a blunt object coupled with a rotating tool into a selected region of the aluminum assembly. Friction between the blunt object and the aluminum component results in localized heating sufficient to soften and deform the solid aluminum component without altering the macroscopic geometry of the aluminum component. Shot peening involves bombarding the aluminum assembly with high speed steel balls having a predetermined angle using precision equipment. Roll finishing involves pressing and rolling a hard ball or cylinder against a suitably supported workpiece (e.g., a stamped aluminum part) to plastically deform a surface area of the workpiece. Shot peening involves bombarding the aluminum assembly with high speed steel balls having a predetermined angle using precision equipment. Roll finishing involves pressing and rolling a hard ball or cylinder against a suitably supported workpiece (e.g., a stamped aluminum part) to plastically deform a surface area of the workpiece. Shot peening involves bombarding the aluminum assembly with high speed steel balls having a predetermined angle using precision equipment. Roll finishing involves pressing and rolling a hard ball or cylinder against a suitably supported workpiece (e.g., a stamped aluminum part) to plastically deform a surface area of the workpiece.

In some cases, one or more localized plastic deformations may be introduced into one or more selected regions of the formed aluminum component after quenching and prior to aging of the formed aluminum component (e.g., T-type designation: T8 or T3). In other cases, the formed aluminum component is aged and subsequently deformed (e.g., T-shaped name: T9). In other cases, the formed aluminum part may be aged multiple times and plastic deformation may be introduced between aging cycles (see fig. 2).

As the aluminum composition ages, the alloying elements diffuse to many nucleation sites to form precipitates (e.g., second phases). In some cases, aluminum parts may be artificially aged. Artificial aging increases the precipitation rate of the alloying elements compared to natural aging that occurs at room temperature (26 ℃). Aging occurs at a temperature below the equilibrium solvus temperature and below the metastable miscibility gap (Guinier-Preston ("GP") region solvus). By way of non-limiting example, the aluminum part may be aged by heating the aluminum part at a greater rate to a selected temperature of greater than or equal to about 100 ℃ to less than or equal to about 200 ℃. Less than or equal to about 0.1 ℃/s to less than or equal to about 10 ℃/s. The selected temperature may be maintained for a predetermined period of time greater than or equal to about 0.1 hour to less than or equal to 48 hours. After a predetermined period of time, the aluminum composition may be returned to a temperature of less than or equal to about 40 ℃ at a rate of greater than or equal to about 1.0 ℃/s to less than or equal to about 1000 °.

In various instances, the aluminum component can be artificially aged using one or more heat treatments (i.e., a dual aging heat treatment cycle). For example, in some cases, the aluminum component may be artificially aged using a first temperature aging treatment and a second temperature aging treatment. In this case, the first temperature aging may include aging the aluminum component at a first temperature selected from a temperature range of greater than or equal to about 100 ℃ to less than or equal to about 200 ℃; the second temperature aging may include aging the aluminum component at a second temperature selected from a temperature range of greater than or equal to about 100 ℃ to less than or equal to about 200 ℃.

The aluminum component can be heated to the first temperature at a rate of greater than or equal to about 0.1 ℃/s to less than or equal to about 10 ℃/s. The aluminum component may be maintained at the first temperature for a first predetermined period of time greater than or equal to about 0.1 hours to less than or equal to 48 hours. After expiration of the first predetermined time period, the aluminum composition may return to a temperature of less than or equal to about 40 ℃ at a rate of greater than or equal to about 1.0 ℃/s to less than or equal to about 120 ℃. About 1000 deg.c/s. The aluminum component may be maintained at a temperature of less than or equal to about 40 ℃ for a second predetermined period of time that is greater than or equal to about 0.1 hours to less than or equal to 1000 hours.

After the second predetermined period of time expires, the aluminum component may be heated to the second temperature at a rate of greater than or equal to about 0.1 ℃/s to less than or equal to about 10 ℃/s. The aluminum component may be maintained at the second temperature for a third predetermined period of time greater than or equal to about 0.1 hours to less than or equal to 48 hours. After the third predetermined period of time has expired, the aluminum composition may return to a temperature of less than or equal to about 40 ℃ at a rate of greater than or equal to about 1.0 ℃/s to less than or equal to about 120 ℃.

In other cases, the aluminum component may be artificially aged using three aging processes. In this case, the first temperature aging may include aging the aluminum component at a first temperature selected from a temperature range of greater than or equal to about 100 ℃ to less than or equal to about 200 ℃; the second temperature aging treatment may include aging the aluminum component at a second temperature selected from a temperature range of greater than or equal to about 100 ℃ to less than or equal to about 200 ℃; the third temperature aging treatment may include aging the aluminum component at a third temperature selected from a temperature range of greater than or equal to about 100 ℃ to less than or equal to about 200 ℃.

In such a case, the aluminum component can be heated to the first temperature at a rate of greater than or equal to about 0.1 ℃/s to less than or equal to about 10 ℃/s. The aluminum component may be maintained at the first temperature for a first predetermined period of time greater than or equal to about 0.1 hours to less than or equal to 48 hours. After expiration of the first predetermined time period, the aluminum composition may return to a temperature of less than or equal to about 40 ℃ at a rate of greater than or equal to about 1.0 ℃/s to less than or equal to about 120 ℃. About 1000 deg.c/s. The aluminum component may be maintained at a temperature of less than or equal to about 40 ℃ for a second predetermined period of time that is greater than or equal to about 0.1 hours to less than or equal to 1000 hours.

After the second predetermined period of time expires, the aluminum component may be heated to the second temperature at a rate of greater than or equal to about 0.1 ℃/s to less than or equal to about 10 ℃/s. The aluminum component may be maintained at the second temperature for a third predetermined period of time greater than or equal to about 0.1 hours to less than or equal to 48 hours. After the third predetermined period of time has expired, the aluminum composition may return to a temperature of less than or equal to about 40 ℃ at a rate of greater than or equal to about 1.0 ℃/s to less than or equal to about 120 ℃. About 1000 deg.c/s. The aluminum component may be maintained at a temperature of less than or equal to about 40 ℃ for a fourth predetermined period of time that is greater than or equal to about 0.1 hours to less than or equal to 1000 hours.

After expiration of the fourth predetermined period of time, the aluminum composition may be heated to the third temperature at a rate of greater than or equal to about 0.1 ℃/s to less than or equal to about 10 ℃/s. The aluminum composition may be maintained at the third temperature for a fifth predetermined period of time that is greater than or equal to about 0.1 hours to less than or equal to 48 hours. After expiration of the fifth predetermined time period, the aluminum composition may return to a temperature of less than or equal to about 40 ℃ at a rate of greater than or equal to about 1.0 ℃/s to less than or equal to about 120 ℃.

In some cases, the aluminum parts may be accidentally aged (e.g., heat treated) as the aluminum parts are further processed. For example, in the case of automobiles, the aluminum composition may further age during painting and finishing.

Embodiments of the present technology are further illustrated by the following non-limiting examples.

Example 1

Fig. 2 provides an illustration of an exemplary method for making a high strength aluminum component. The y-axis 60 is in degrees celsius and the x-axis 62 is in hours. The exemplary method has two stages. First stage 64 illustrates annealing, quenching, stamping, deforming, and optionally aging of the formed aluminum component. The second stage 66 illustrates incidental aging of the aluminum component, including localized plastic deformation.

First, the aluminum alloy billet is heated to about 490 ℃ at a rate of about 1.0 ℃/s. The aluminum alloy billet is held at about 490 c for about 0.1 hours. The homogenized aluminum alloy is quenched at a rate of about 1000 ℃/s to a temperature of less than or equal to about 40 ℃, and the soft aluminum alloy is stamped 68 to form an aluminum composition having a predetermined shape. After stamping 68, the aluminum component is subjected to a first deformation process 70 and then aged. The aluminum composition is artificially aged by heating the aluminum composition to a temperature of about 120 ℃ at a rate of about 1.0 ℃/s. The aluminum component is maintained at about 120 c for about 5 hours before returning to a temperature of less than or equal to about 40 c at a rate of about 1.0 c/s.

After the first aging process, a second deformation process 72 is performed on the aluminum component. After the second deformation process 72, the aluminum component is again artificially aged by heating the aluminum component to a temperature of about 160 ℃ at a rate of about 1.0 ℃/s. The aluminum component is maintained at about 160 c for about 2 hours before returning to a temperature of less than or equal to about 40 c at a rate of about 1.0 c/s.

After the second ageing process, the aluminium component is subjected to a third deformation process 74. After the third deformation process 74, the aluminum part may be incidentally aged by heating the aluminum part to a temperature of about 180 ℃ at a rate of about 1.0 ℃/s. The aluminum component is maintained at about 180 c for about 0.3 hours and then returned to a temperature of less than or equal to about 40 c at a rate of about 1.0 c/s.

The aluminum composition may be held at about 40 c for about 10 hours and then subjected to an occasional second aging again by heating the aluminum composition to a temperature of about 140 c at a rate of about 1.0 c/s. The aluminum component is maintained at about 140 c for about 0.3 hours and then returned to a temperature of less than or equal to about 40 c at a rate of about 1.0 c/s.

The aluminum composition may be held at about 40 c for about 1 hour and then subjected again to a third occasional aging by heating the aluminum composition to a temperature of about 130 c at a rate of about 1.0 c/s. The aluminum component is maintained at about 130 c for about 0.3 hours and then returned to a temperature of less than or equal to about 40 c at a rate of about 1.0 c/s.

example 2

The aluminum alloy blank may be heated to about 495 ℃ at a rate of about 1.0 ℃/s. The aluminum alloy billet is held at about 495 ℃ for about 0.1 hour. The homogeneous aluminum alloy is quenched to about room temperature at a rate of about 1000 ℃/s and the soft aluminum alloy is stamped to form an aluminum composition having a predetermined shape. After stamping, one or more localized deformations are introduced into one or more selected regions of the aluminum component. The aluminum component having one or more localized deformations is then subjected to various subsequent aging treatments.