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EP3521467B1 - Alliage de plaque d'aluminium-lithium à faible densité, à faible coût, essentiellement exempt d'ag et de zn, pour application aérospatiale - Google Patents

Alliage de plaque d'aluminium-lithium à faible densité, à faible coût, essentiellement exempt d'ag et de zn, pour application aérospatiale Download PDF

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Publication number
EP3521467B1
EP3521467B1 EP19155140.7A EP19155140A EP3521467B1 EP 3521467 B1 EP3521467 B1 EP 3521467B1 EP 19155140 A EP19155140 A EP 19155140A EP 3521467 B1 EP3521467 B1 EP 3521467B1
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aluminum
alloy
stock
lithium alloy
lithium
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EP3521467A1 (fr
Inventor
Zhengdong Long
Philippe Lassince
Robert A. Matuska
Florence Andrea BALDWIN
David J. Shoemaker
Ravi Rastogi
Roy A. Nash
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Kaiser Aluminum Fabricated Products LLC
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Kaiser Aluminum Fabricated Products LLC
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    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • C22C21/12Alloys based on aluminium with copper as the next major constituent
    • C22C21/16Alloys based on aluminium with copper as the next major constituent with magnesium
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • C22C21/12Alloys based on aluminium with copper as the next major constituent
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • C22C21/12Alloys based on aluminium with copper as the next major constituent
    • C22C21/14Alloys based on aluminium with copper as the next major constituent with silicon
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • C22C21/12Alloys based on aluminium with copper as the next major constituent
    • C22C21/18Alloys based on aluminium with copper as the next major constituent with zinc
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22FCHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/002Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working by rapid cooling or quenching; cooling agents used therefor
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22FCHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/057Changing 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 present invention generally relates to Aluminum-Copper-Lithium-Magnesium based alloy products.
  • Al-lithium (Al-Li) plate products that meet all above requirements.
  • Al-Li alloys capable of producing higher than 0.5" thickness plate products.
  • the examples of existing alloys are 2050 (up to 6.5" thickness), 2195 (up to 2.25" thickness), 2060 (up to 1.5" thickness), 2395 (up to 1.5" thickness) and 2196 (up to 1.0" thickness) based on “Registration Record Series - Tempers for Aluminum and Aluminum Alloys Production” published in 2011 and “Addendum to 2011 Tan Sheets of Registration Record Series - Tempers for Aluminum and Aluminum Alloys Production” published in 2017 by The Aluminum Association. It should be mentioned that all above Al-Li plate alloys are high cost Ag containing alloys. Silver (Ag) is added to many new generation Al-Li alloys in order to improve the final product properties.
  • the Li is the most critical element for Al-Li alloys. Too low of a level of Li cannot reduce the density and improve the properties enough. However, too high of a level of Li can cause undesirable performance such as low short transverse fracture toughness, and high anisotropy of tensile properties.
  • the Cu is another important element and has to be controlled within a certain range for desirable product performance.
  • the Mg is another element to be added in a certain range in order to primarily enhance the strength and secondarily reduce the density.
  • the Zn is also another element to be considered for Al-Li alloy.
  • the addition of Zn can also negatively impact the density.
  • WO2017137260 relates to an aluminium alloy wrought product for structural members having a chemical composition consisting of, in wt.%: Cu 3.2% to 4.4%, Li 0.8% to 1.4%, Mg 0.20% to 0.90%, Mn 0.10% to 0.8%, Zn 0.20% to 0.80%, one or more elements selected from the group consisting of: (Zr 0.05% to 0.25%, Cr 0.05% to 0.30%, Ti 0.01% to 0.25%, Sc 0.05% to 0.4%, Hf 0.05% to 0.4%), Ag ⁇ 0.08%, Fe ⁇ 0.15%, Si ⁇ 0.15%, unavoidable impurities and balance aluminium.
  • the present invention provides a low cost, high performance, high Mg, substantially Ag-free and Zn-free, low density Al-Li alloy suitable for making transportation components, such as aerospace structural components.
  • Aluminum-lithium alloys of the present invention comprise from 3.6 to 4.1 wt. % Cu, 0.8 to 1.05 wt. % Li, 0.6 to 1.0 wt. % Mg, 0.2 to 0.6 wt. % Mn, up to 0.12 wt. % Si, up to 0.15 wt. % Fe, from 0.03 to 0.16 wt. % of at least one grain structure control element selected from the group consisting of Zr, Sc, Cr, V, Hf, and other rare earth elements, up to 0.10 wt.
  • % Ti up to 0.15 wt. % incidental elements with the total of incidental elements not exceeding 0.35 wt. %, and the balance being aluminum.
  • Ag is not intentionally added and should not be more than 0.05 wt. % as a non-intentionally added element.
  • Zn is not intentionally added and should not be more than 0.2 wt. % as a non-intentionally added element.
  • the amount of Cu in weight percent is at least equal to or higher than 4 times the amount of Li in weight percent in the inventive alloy.
  • the inventive alloy has improved properties over the prior art.
  • the inventive alloy has a tensile yield strength (TYS) along rolling (L) direction as function of plate gage (ga) that is higher than 75.0-1.4*ga, preferably higher than 76.2-1.4*ga, and more preferably higher than 77.0-1.4*ga.
  • the inventive alloy has a tensile yield strength (TYS) along long transverse (LT) direction that is higher than 71.2-1.4*ga, preferably higher than 72.2-1.4*ga, and more preferably higher than 72.7-1.4*ga.
  • the inventive alloy has a fracture toughness (K1c) along the orientation of Long Transverse - Rolling (T-L) that is higher than 28-1.0*ga, preferably higher than 29-1.0*ga, and more preferably higher than 29.5-1.0*ga.
  • the inventive alloy has a fracture toughness (K1c) along the orientation of Rolling - Long Transverse (L-T) that is higher than 28.8-0.6*ga, preferably higher than 30.8-0.6*ga, and more preferably higher than 31.8-0.6*ga.
  • the units for gage (ga), strength, and fracture toughness are inch, ksi, and ksi*in 1/2 respectively.
  • the aluminum-lithium alloy of the present invention is a plate, extrusion or forged wrought product having a thickness of 1.27 to 20.32 cm (0.5 to 8.0 inch). It has been surprisingly discovered that the aluminum-lithium alloy of the present invention having no Ag, or very low amounts of non- intentionally added Ag, no Zn, or very low amounts of non-intentionally added Zn, and high Mg content is capable of producing 1.27 to 20.32 cm (0.5 to 8.0 inch) thickness plate products with excellent strength and fracture toughness properties and desirable corrosion resistance performance. Another aspect of the present invention is a method to manufacture aluminum-lithium alloys of the present invention, set forth in Claim 12 of the accompanying claims.
  • the present invention is directed to aluminum-lithium alloys, specifically aluminum - copper - lithium - magnesium - manganese alloys.
  • the aluminum-lithium alloy of the present invention comprises from 3.6 to 4.1 wt. % Cu, 0.8 to 1.05 wt. % Li, 0.6 to 1.0 wt. % Mg, 0.2 to 0.6 wt. % Mn, up to 0.12 wt. % Si, up to 0.15 wt. % Fe, from 0.03 to 0.16 wt. % of at least one grain structure control element selected from the group consisting of Zr, Sc, Cr, V, Hf, and other rare earth elements, up to 0.10 wt. % Ti, up to 0.15 wt.
  • % incidental elements with the total of incidental elements not exceeding 0.35 wt. %, and the balance being aluminum.
  • Ag is not intentionally added and should not be more than 0.05 wt. % as a non-intentionally added element.
  • Zn is not intentionally added and should not be more than 0.2 wt. % as a non-intentionally added element.
  • the amount of Cu in weight percent is at least equal to or higher than 4 times the amount of Li in weight percent in the inventive alloy.
  • the aluminum-lithium alloy comprises from 3.7 to 4.0 wt. % Cu, 0.9 to 1.0 wt. % Li, 0.7 to 0.9 wt. % Mg along with 0.2 to 0.6 wt. % Mn, up to 0.12 wt. % Si, up to 0.15 wt. % Fe, from 0.03 to 0.16 wt. % of at least one grain structure control element selected from the group consisting of Zr, Sc, Cr, V, Hf, and other rare earth elements, up to 0.10 wt. % Ti, up to 0.15 wt. % incidental elements with the total of incidental elements not exceeding 0.35 wt. %, and the balance being aluminum.
  • Ag is not intentionally added and should not be more than 0.05 wt. % as a non-intentionally added element.
  • Zn is not intentionally added and should not be more than 0.2 wt. % as a non-intentionally added element.
  • the amount of Cu in weight percent is at least equal to or higher than 4 times the amount of Li in weight percent in the inventive alloy.
  • the aluminum-lithium alloy of the present invention can be used to produce wrought products, having a thickness range of 1.27 to 20.32 cm (0.5 - 8.0 inch).
  • the aluminum-lithium alloys of the present invention are wrought products having high strength, stronger damage tolerance, and excellent fatigue and corrosion resistance properties.
  • Such products are suitable for use in many structural applications, especially for aerospace structural components such as spar, rib, and integrally machined structural parts.
  • the aluminum-lithium alloy of the present invention can be used for the fabrication of components using several manufacturing processes such as high speed machining.
  • Copper is added to the aluminum-lithium alloy in the present invention in the range of 3.6 to 4.1 wt. %, mainly to enhance the strength but also to improve the combination of strength and fracture toughness.
  • An excessive amount of Cu can result in unfavorable intermetallic particles which can negatively affect material properties such as ductility and fracture toughness. In these cases the interaction of Cu with other elements such as Li and Mg must also be considered.
  • the upper or lower limit for the amount of Cu may be selected from 3.6, 3.7, 3.8, 3.9, 4.0, and 4.1 wt. %.
  • the Cu is from 3.7 to 4.0 wt. % to provide compositions that enhance specific product performance while maintaining relatively high performance in the remaining attributes as compared to the prior art.
  • Lithium is added to the aluminum-lithium alloy in the present invention in the range of 0.8 to 1.05 wt. %.
  • the primary benefit for adding Li is to reduce the density and increase the elastic modulus.
  • Li is critical in improving the strength, damage tolerance and corrosion performance. Li contents that are too high, however, can negatively impact fracture toughness, and anisotropy of tensile properties.
  • the present invention includes the alternative embodiments wherein the upper or lower limit for the amount of Li may be selected from 0.8, 0.9, 1.0, and 1.05 wt. %. In one preferred embodiment, Li is in the range of 0.9 to 1.0 wt. %.
  • the Cu/Li ratio significantly affects the desirable T1 strengthening phase, which is critical for strength, fracture toughness, and anisotropy of tensile properties.
  • the present invention requires the Cu/Li ratio should be higher than 4.0 in terms of wt. % Cu / wt. % Li.
  • Mg is added to the aluminum-lithium alloy in the present invention in the range of 0.6 to 1.0 wt. %.
  • the primary purpose of adding Mg is to enhance the strength with the secondary purpose of reducing the density.
  • Mg levels that are too high can reduce Li solubility in the matrix, thus negatively impacting the aging potential for higher strength.
  • the present invention includes alternative embodiments wherein the upper or lower limit for the amount of Mg may be selected from 0.6, 0.7, 0.8, 0.9, and 1.0 wt. %.
  • Mg is in the range of 0.7 to 0.9 wt. %.
  • Ag is not intentionally added in the aluminum-lithium alloy of the present invention.
  • Ag may exist in the alloy as a result of a non-intentional addition.
  • the Ag should not be more than 0.05 wt. %.
  • the present invention includes alternate embodiments wherein the upper or limit for the amount of Ag may be selected from 0.05, 0.04, 0.03, 0.02, and 0.01 wt.%
  • the prior art teaches that Ag is necessary to improve the final product properties and is therefore included in many aluminum-lithium alloys as well as many patents and patent applications. However, Ag significantly increases the cost of the alloys.
  • the aluminum-lithium alloy of the present invention Ag is not intentionally included in order to reduce the cost. It is surprising to find that the aluminum-lithium alloy of the present invention, without the addition of Ag for providing low cost, can be used to produce high strength, high fracture toughness, and excellent corrosion resistance plate products suitable for structural applications particularly in aerospace.
  • Zn can negatively affect the density and therefore Zn is not added in the present invention.
  • Zn may exist in the alloy as a result of a non-intentional addition. In this case, the Zn should not be more than 0.2 wt. %.
  • the present invention includes alternate embodiments having less than 0.15 wt. % Zn, less than 0.10 wt.% Zn, less than 0.05 wt.% Zn.
  • Mn is intentionally added to improve the grain structure for better mechanical isotropy and formability.
  • the present invention includes alternative embodiments wherein the upper or lower limits for the amounts of Mn may be selected from 0.2, 0.3, 0.4, 0.5, and 0.6 wt. %.
  • Ti can be added up to 0.10 wt. %.
  • the purpose of adding Ti is mainly for grain refinement in casting.
  • the present invention includes alternative embodiments wherein the upper limit for the amount of Ti may be selected from 0.01, 0.02, 0.05, 0.06, 0.07, 0.08, 0.09, and 0.10 wt. % Ti.
  • Si and Fe may be present in the aluminum-lithium alloy of the present invention as impurities but are not intentionally added.
  • the present invention includes alternate embodiments wherein the alloy includes ⁇ 0.12 wt. % for Si, and ⁇ 0.15 wt. % for Fe, preferably ⁇ 0.05 wt. % for Si and ⁇ 0.08 wt. % for Fe.
  • the aluminum-lithium alloy of the present invention includes a maximum content of 0.12 wt. % for Si, and 0.15 wt. % for Fe. In one preferred embodiment, the maximum contents are 0.05 wt. % for Si and 0.08 wt. % for Fe.
  • the aluminum-lithium alloy of the present invention may also include low levels of "incidental elements” that are not included intentionally.
  • the "incidental elements” means any other elements except Al, Cu, Li, Mg, Zr, Zn, Mn, Ag, Fe, Si, and Ti.
  • the low cost, high performance, high Mg content Al-Li alloy of the present invention may be used to produce wrought products.
  • the aluminum-lithium alloy of the present invention is capable of producing rolled products, preferably, a plate product in the thickness range of 1.27 to 20.32 cm (0.5 to 8.0 inch).
  • the upper or lower limit for the thickness may be selected from 1.27, 2.54, 5.08, 7.62, 10.16, 12.7, 15.24, 17.78 and 20.32 cm (0.5, 1.0, 2.0, 3.0, 4.0, 5.0, 6.0, 7.0 and 8.0 inch).
  • the rolled products may be manufactured using known processes such as casting, homogenization, hot rolling, solution heat treating and quenching, stretching, and ageing treatments.
  • the ingot may be cast by traditional direct chill (DC) casting method.
  • the ingot may be homogenized at temperatures from 482 to 543°C (900 to 1010°F).
  • the hot rolling temperature may be from 357 to 482°C (675 to 900°F).
  • the products may be solution heat treated at temperature range of 482 to 538°C (900 to 1000°F).
  • the wrought products are cold water quenched to room temperature and may be stretched up to 15%, preferably from 2 to 8%.
  • the quenched and stretched product may be subjected to any aging practices known by those skilled in the art including, but not limited to, one-step aging practices that produce a final desirable temper, such as T8 temper, for better combination of strength, fracture toughness, and corrosion resistance which are highly desirable for aerospace members.
  • the aging temperature can be in the range of 121 to 205°C (250 to 400°F) and preferably from 149 to 182°C (300 to 360°F) and the aging time can be in the range of 2 to 60 hours, preferably from 10 to 48 hours.
  • the unique chemistry along with proper processing of present patent application results in plate products with surprising novel and basic material characteristics.
  • the tensile yield strength (TYS) along rolling (L) direction as function of plate gage (ga) is higher than 75.0-1.4*ga, preferably higher than 76.2-1.4*ga, and more preferably higher than 77.0-1.4*ga.
  • the tensile yield strength (TYS) along long transverse (LT) direction is higher than 71.2-1.4*ga, preferably higher than 72.2-1.4*ga, and more preferably higher than 72.7-1.4*ga.
  • the fracture toughness (K1c) along the orientation of Long Transverse - Rolling (T-L) is higher than 28-1.0*ga, preferably higher than 29-1.0*ga, and more preferably higher than 29.5-1.0*ga.
  • the fracture toughness (K1c) along the orientation of Rolling - Long Transverse (L-T) is higher than 28.8-0.6*ga, preferably higher than 30.8-0.6*ga, and more preferably higher than 31.8-0.6*ga.
  • the units for gage (ga), strength, and fracture toughness are inch, ksi, and ksi*in 1/2 respectively.
  • Table 1 gives the chemical compositions and final plate thickness. There are three groups: (1) “Invention”, (2) “Non-Invention (Substantially Ag-free)” and (3) “Non-Invention (Ag)".
  • the third group is obviously not the invention alloy due to the high cost Ag element and/or along with other conditions that do not meet invention alloy chemical composition limits.
  • samples are not invention alloys due to the combination of Cu/Li ratio, Cu, Li, and Zn limits.
  • the Cu/Li ratios for sample 12, 13 14, and 16 are lower than 4.0.
  • the Cu contents in sample 13 and 15 are lower than 3.6 wt. %.
  • the Li content in Sample 13 is higher than 1.05 wt. %.
  • the Zn content in Sample 16 is higher than 0.2 wt. %.
  • the ingots were homogenized at temperatures from 496 to 538°C (925 to 1000°F).
  • the hot rolling temperatures were from 371 to 466°C (700 to 870°F).
  • the ingots were hot rolled at multiple passes into 1" to 6" thickness.
  • the rolled plates were solution heat treated at a temperature range from 493 to 532°C (920 to 990°F).
  • the plates were cold water quenched to room temperature. All example plates were stretched by 2 to 7% in terms of plastic strain.
  • the stretched plates were further aged to T8 temper for strength, fracture, fatigue resistance, and corrosion resistance performance evaluation.
  • the aging temperature was from 160°C (320°F) to 171°C (340°F) for 8 to 70 hours.
  • the strength and fracture toughness as a function of aging process is one critical characteristic for alloy performance.
  • the selected substantially Ag-free addition 3" invention and non-invention alloy plates were evaluated under 166°C (330°F) aging temperature at different aging times.
  • Table 2 gives the tensile and fracture toughness testing results.
  • Tensile in LT direction at quarter thickness (T/4) was conducted under ASTM B557 specification.
  • the plane strain fracture toughness (K1c) in T-L orientations at middle thickness (T/2) was measured under ASTM E399 using CT specimens.
  • invention alloys have much faster / better strength response as aging time increases than non-invention alloys.
  • Such significant difference is mainly due to the distinctive chemical composition difference between invention alloys and non-invention alloys.
  • the desired aging practice with balanced strength and fracture toughness was selected for production aging treatment.
  • the production aged plates were comprehensively evaluated for tensile, fracture, corrosion and fatigue resistance.
  • Table 3 and 4 give the tensile properties along L, LT, and L45 (45° off the rolling direction) directions at quarter thickness (T/4) and middle thickness (T/2) for all production aged plates.
  • Table 5 gives the fracture toughness at the orientations of L-T, T-L and S-L at quarter thickness (T/4) and middle thickness (T/2) for all production aged plates.
  • Table 3 to 5 shows that the low cost invention alloy with unique chemical composition has surprisingly better material properties in terms of the combination of strength and fracture toughness.
  • FIG. 2 gives the comparison of LT TYS strength and K1c T-L fracture toughness between substantially Ag-free invention alloys and Non-invention alloys (No Ag) of 3 inch plates.
  • the invention alloys have a better combination of strength and fracture toughness.
  • the minimum LT TYS can be 67 ksi and minimum K1c T-L can be 25 ksi*in 1/2 for 3" plate.
  • the minimum LT TYS can be 68 ksi and minimum K1c T-L can be 26 ksi*in 1/2 for 3" plate.
  • the minimum LT TYS can be 68.5 ksi and minimum K1c T-L can be 26.5 ksi*in 1/2 for 3" plate.
  • the similar distinctiveness can be demonstrated in FIG. 3 for 3" L TYS and K1c L-T properties.
  • the minimum L TYS can be 70.8 ksi and minimum K1c L-T can be 27 ksi*in 1/2 for 3" plate.
  • the minimum L TYS can be 72.0 ksi and minimum K1c L-T can be 29 ksi*in 1/2 for 3" plate.
  • the minimum L TYS can be 72.8 ksi and minimum K1c L-T can be 30 ksi*in 1/2 for 3" plate.
  • FIG. 4 and 5 gives the comparison of LT TYS vs. K1c T-L and L TYS vs. K1c L-T between low cost substantially Ag-free invention alloys and high cost Ag containing non-invention alloys of 3 inch plates. It surprisingly shows that there is no significant difference between Ag containing non invention alloys and substantially Ag-free invention alloys in terms of the combination of strength and fracture toughness.
  • FIG. 6 to 9 gives the strength and fracture toughness as a function of plate thickness for invention alloy plates.
  • the tensile yield strength (TYS) along long transverse (LT) direction is higher than 71.2-1.4*ga, preferably higher than 72.2-1.4*ga, and more preferably higher than 72.7-1.4*ga.
  • the tensile yield strength (TYS) along rolling (L) direction as function of plate gage (ga) is higher than 75.0-1.4*ga, preferably higher than 76.2-1.4*ga, and more preferably higher than 77.0-1.4*ga.
  • the fracture toughness (K1c) along the orientation of Long Transverse - Rolling (T-L) is higher than 28-1.0*ga, preferably higher than 29-1.0*ga, and more preferably higher than 29.5-1.0*ga.
  • the fracture toughness (K1c) along the orientation of Rolling - Long Transverse (L-T) is higher than 28.8-0.6*ga, preferably higher than 30.8-0.6*ga, and more preferably higher than 31.8-0.6*ga.
  • the units for gage (ga), strength, and fracture toughness are inch, ksi, and ksi*in 1/2 respectively.
  • Corrosion resistance is a key design consideration for airframe manufacturers.
  • the MASTMASSIS test is generally considered to be a good representative accelerated corrosion test method for Al-Li based alloys.
  • the MASTMASSIS test was based on ASTM G85-11 Annex-2 under dry-bottom conditions.
  • the sample size was 4.5" L x 4.5" LT at middle of sheet thickness.
  • the temperature of the exposure chamber through the duration of the test was 49 ⁇ 2°C.
  • the testing through thickness location is T/2 (center of thickness).
  • the testing plane is L-LT plane.
  • the testing duration times were 24, 48, 96, 168, 336, 504, and 672hrs.
  • FIG. 10 gives the typical surface appearances after 672 hours MASTMASSIS testing exposure times.
  • the left photo is from invention alloy Sample #6 with 3 inch plate thickness and right photo is from invention alloy Sample #11 with 6 inch plate thickness.
  • the tested surfaces are very clean and shiny. No exfoliation is evident for all the exposure times. The excellent corrosion resistance of pitting/EA can be concluded for all exposure times for all invention alloy plates.
  • Stress corrosion cracking (SCC) resistance is also critical for aerospace application.
  • the standard stress corrosion cracking resistance testing was performed in accordance with the requirements of ASTM G47 which is alternate immersion in a 3.5% NaCl solution under constant deflection. Three specimens were tested per sample. The stress levels are 45 ksi and 50 ksi.
  • Table 6 gives the SCC testing results for Sample 6, 7, 8, 10 with final production ageing treatment. All specimens survived 30 days testing without failures under 45 ksi or 50 ksi stress levels in ST direction. Table 6: The SCC testing results for Sample 6, 7, 8, 10 with final production ageing treatment Sample ID Lot Gage, in Stress Repeat 1 Repeat 2 Repeat 3 6 187292B8 3.0 45 >30days >30days >30days >30days 7 652929A1 3.0 45 >30days >30days >30days >30days 7 652929A1 3.0 45 >30days >30days >30days >30days 8 187267B0 3.2 50 >30days >30days >30days >30days 10 130369B2 6.0 45 >30days >30days >30days >30days >30days >30days >30days >30days >30days.
  • the fatigue property was tested in accordance with the requirements of ASTM E466.
  • Four LT smooth specimens were tested from each plate at plate thickness center along long transverse (LT) direction.
  • Specimen was tested at 240MPa (35 ksi).
  • Table 7 gives the fatigue testing results of invention alloy plates.
  • the majority of fatigue test specimens had no failures after 300,000 cycles and all plates met the common industrially accepted criterion, i.e. 120,000 cycles of logarithm average of four specimens.
  • Table 7 The smooth fatigue testing results of invention alloy plates Sample ID Lot # Gage, in Specimen-1 Specimen-2 Specimen-3 Specimen-4 Log Average 1 130432B8 1 >300,000 >300,000 >300,000 >300,000 >300,000 >300,000 2 130408B8 2 >300,000 >300,000 >300,000 >300,000 3 130275B1 3 >300,000 >300,000 >300,000 >300,000 >300,000 4 130285B0 3 >300,000 >300,000 >300,000 >300,000 >300,000 >300,000 5 18741380 3 >300,000 >300,000 >300,000 >300,000 >300,000 >300,000 6 187292B8 3 >300,000 >300,000 >300,000 >300,000 >300,000 >300,000 7 652929A1 3 289,683 196,242 244,917 >300,000 >254,222 8 187267B0 3.2 >300,000
  • the material performance is strongly related to material grain structure, which is greatly affected by alloy chemical composition along with thermal mechanical processing procedure. Specifically for Al-Li plate products, an unrecrystallized grain structure is desirable for better strength, fracture toughness and corrosion resistance performance.
  • FIG. 11 to 15 gives the grain structures of different thickness invention alloy plates. All the invention alloy plates have unrecrystallized grain structures at both quarter thickness (T/4) and middle thickness (T/2).

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Claims (13)

  1. Alliage d'aluminium et de lithium à haute résistance, de faible densité et à faible coût comprenant :
    de 3,6 % à 4,1 % en poids de Cu, de 0,8 % à 1,05 % en poids de Li,
    de 0,6 % à 1,0 % en poids de Mg, de 0,2 % à 0,6 % en poids de Mn,
    moins de 0,05 % en poids de Ag, moins de 0,2 % en poids de Zn,
    de 0,03 % à 0,16 % en poids d'au moins un élément de contrôle de la structure des grains choisi dans le groupe constitué de Zr, de Sc, de Cr, de V, de Hf et
    d'autres éléments des terres rares,
    jusqu'à 0,10 % en poids de Ti,
    jusqu'à 0,12 % en poids de Si,
    jusqu'à 0,15 % en poids de Fe,
    jusqu'à 0,15 % en poids chacun d'éléments aléatoires, le total des éléments aléatoires ne dépassant pas 0,35 % en poids, dans lequel les éléments aléatoires ne sont pas inclus de manière intentionnelle et dans lequel les éléments aléatoires comprennent tous les éléments à l'exception de Al, de Cu, de Li, de Mg, de Zr, de Zn, de Mn, de Ag, de Fe, de Si, et de Ti,
    le reste étant de l'aluminium, et
    dans lequel la quantité de Cu en pourcentage massique est au moins égale ou
    supérieure à quatre fois la quantité de Li en pourcentage massique.
  2. Alliage d'aluminium et de lithium selon la revendication 1, comprenant de 3,7 à 4,0 % en poids de Cu.
  3. Alliage d'aluminium et de lithium selon la revendication 1 ou 2, comprenant de 0,9 à 1,0 % en poids de Li.
  4. Alliage d'aluminium et de lithium selon l'une quelconque des revendications 1 à 3, comprenant de 0,7 à 0,9 % en poids de Mg.
  5. Alliage d'aluminium et de lithium selon l'une quelconque des revendications 1 à 4, dans lequel pas de Ag est intentionnellement ajouté à l'alliage d'aluminium.
  6. Alliage d'aluminium et de lithium selon l'une quelconque des revendications 1 à 5, dans lequel pas de Zn est intentionnellement ajouté à l'alliage d'aluminium.
  7. Alliage d'aluminium et de lithium selon l'une quelconque des revendications 1 à 5, comprenant moins de 0,10 % en poids de Zn ;
    comprenant éventuellement moins de 0,05 % en poids de Zn.
  8. Alliage d'aluminium et de lithium selon l'une quelconque des revendications 1 à 7, comprenant un maximum de 0,05 % en poids de Si ;
    et/ou
    comprenant un maximum de 0,08 % en poids de Fe.
  9. Alliage d'aluminium et de lithium selon l'une quelconque des revendications 1 à 8, comprenant :
    de 3,7 % à 4,0 % en poids de Cu, de 0,9 % à 1,0 % en poids de Li,
    de 0,7 % à 0,9 % en poids de Mg, de 0,2 % à 0,6 % en poids de Mn,
    moins de 0,05 % en poids de Ag, moins de 0,2 % en poids de Zn,
    de 0,03 % à 0,16 % en poids d'au moins un élément de contrôle de la structure des grains choisi dans le groupe constitué de Zr, de Sc, de Cr, de V, de Hf et
    d'autres éléments des terres rares,
    jusqu'à 0,10 % en poids de Ti,
    jusqu'à 0,12 % en poids de Si,
    jusqu'à 0,15 % en poids de Fe,
    jusqu'à 0,15 % en poids chacun d'éléments aléatoires, le total de ces éléments aléatoires ne dépassant pas 0,35 % en poids, dans lequel les éléments aléatoires ne sont pas inclus de manière intentionnelle et dans lequel les éléments aléatoires comprennent tous les éléments à l'exception de Al, de Cu, de Li, de Mg, de Zr, de Zn, de Mn, de Ag, de Fe, de Si, et de Ti,
    le reste étant de l'aluminium, et
    dans lequel la quantité de Cu en pourcentage massique est au moins égale ou
    supérieure à quatre fois la quantité de Li en pourcentage massique
  10. Alliage d'aluminium et de lithium selon l'une quelconque des revendications 1 à 9, dans lequel ledit alliage d'aluminium et de lithium se trouve sous la forme d'un produit laminé, extrudé ou forgé, et a une épaisseur allant de 1,27 à 20,32 cm (de 0,5 à 8,0 pouces).
  11. Alliage d'aluminium et de lithium selon la revendication 10, dans lequel ledit alliage d'aluminium et de lithium a une épaisseur allant de 1,27 à 15,24 cm (de 0,5 à 6,0 pouces).
  12. Procédé de fabrication d'un alliage d'aluminium et de lithium à haute résistance, de faible densité et à faible coût, le procédé comprenant :
    a. le moulage de stock d'un lingot de l'alliage d'aluminium comprenant le produit d'alliage d'aluminium et de lithium selon l'une quelconque des revendications 1 à 11 afin de produire un stock de fonte ;
    b. l'homogénéisation du stock de fonte afin de produire un stock de fonte homogénéisé ;
    c. le travail à chaud du stock de fond homogénéisé par l'un ou plusieurs procédés choisis dans le groupe constitué par le laminage, l'extrusion et le forgeage permettant de former un stock travaillé ;
    d. le traitement thermique de mise en solution (SHT) du stock travaillé afin de produire un stock de SHT ;
    e. la trempe à l'eau froide dudit stock de SHT afin de produire un stock de SHT trempé à l'eau froide ;
    f. l'étirage du stock de SHT trempé à l'eau froide afin de produire un stock étire ; et
    g. le vieillissement artificiel du stock étiré.
  13. Procédé selon la revendication 12, dans lequel ladite étape d'homogénéisation inclut l'homogénéisation à des températures allant de 482 à 543 °C (de 900 à 1010 °F) ; dans lequel ladite étape de travail à chaud comprend un laminage à chaud à une température allant de 357 à 482 °C (de 675 à 900 °F) ; dans lequel ladite étape de traitement thermique de mise en solution comprend le traitement thermique de mise en solution dans une plage de températures allant de 482 à 538 °C (de 900 à 1000 °F) ; dans lequel ladite étape d'étirage comprend un étirage allant de 2 à 15 % ; dans lequel ladite étape de vieillissement artificiel comprend le vieillissement à une température allant de 121 à 205 °C (de 250 à 400 °F) et le temps de vieillissement peut être compris dans la plage allant de 2 à 60 heures,
    dans lequel, éventuellement, ladite étape de vieillissement artificiel comprend le vieillissement à une température allant de 149 à 182 °C (de 300 à 360 °F) et le temps de vieillissement peut être compris dans la plage allant de 10 à 48 heures.
EP19155140.7A 2018-02-01 2019-02-01 Alliage de plaque d'aluminium-lithium à faible densité, à faible coût, essentiellement exempt d'ag et de zn, pour application aérospatiale Active EP3521467B1 (fr)

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US15/886,189 US20190233921A1 (en) 2018-02-01 2018-02-01 Low Cost, Low Density, Substantially Ag-Free and Zn-Free Aluminum-Lithium Plate Alloy for Aerospace Application

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