EP3467138A1 - Method and system for forming aluminum alloy blank - Google Patents
Method and system for forming aluminum alloy blank Download PDFInfo
- Publication number
- EP3467138A1 EP3467138A1 EP17194723.7A EP17194723A EP3467138A1 EP 3467138 A1 EP3467138 A1 EP 3467138A1 EP 17194723 A EP17194723 A EP 17194723A EP 3467138 A1 EP3467138 A1 EP 3467138A1
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- EP
- European Patent Office
- Prior art keywords
- blank
- alloy
- forming
- temperature
- forming tool
- 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.)
- Granted
Links
- 238000000034 method Methods 0.000 title claims abstract description 51
- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 29
- 230000032683 aging Effects 0.000 claims abstract description 41
- 238000001816 cooling Methods 0.000 claims abstract description 31
- 239000000956 alloy Substances 0.000 claims abstract description 28
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 22
- 238000010438 heat treatment Methods 0.000 claims abstract description 15
- 238000010791 quenching Methods 0.000 claims abstract description 14
- 230000000171 quenching effect Effects 0.000 claims abstract description 8
- 238000001953 recrystallisation Methods 0.000 claims abstract description 8
- 239000000463 material Substances 0.000 claims description 6
- 239000000203 mixture Substances 0.000 description 7
- 239000003973 paint Substances 0.000 description 7
- 239000006104 solid solution Substances 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 3
- 238000001556 precipitation Methods 0.000 description 3
- 238000005275 alloying Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000009792 diffusion process Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000005304 joining Methods 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000012141 concentrate Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000004090 dissolution Methods 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
- 238000010899 nucleation Methods 0.000 description 1
- 230000006911 nucleation Effects 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 238000012805 post-processing Methods 0.000 description 1
- 239000002244 precipitate Substances 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
Images
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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/20—Deep-drawing
- B21D22/26—Deep-drawing for making peculiarly, e.g. irregularly, shaped articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/16—Heating or cooling
Definitions
- the present disclosure relates to a heat treatment method of blank sheets of aluminum alloys, and especially to a method suitable for blank sheets of any aluminum alloy grade, composition or temper.
- the hot forming of blank sheets is important, in particular hot forming of blank sheets of high strength aluminum alloys.
- a method of forming a 6xxx or 7xxx series Al alloy blank into a component comprises the steps of heating the blank to a solutionization (SHT) temperature, T SHT , for the alloy of the blank at a heating station and keeping the blank at said SHT temperature until SHT is complete, cooling the blank at a cooling station to an intermediate temperature, T ITM , at which the kinetic movement for the alloy in the blank stops and at a cooling rate that is high enough such that re-crystallization in the alloy of the blank does not occur, forming the blank in a forming tool, quenching the formed blank to room temperature, T E , and artificially ageing the formed and quenched blank in an ageing station.
- SHT solutionization
- a method is provided that, with high accuracy of the formed components and low amount of springbacks, is suitable for any 6xxx or 7xxx series aluminum alloy grade sheet blank.
- the time in which the blank is kept at or above the solution heat treatment (SHT) temperature may be chosen to be sufficient to ensure maximum concentration of hardening elements, such as copper, zinc, magnesium, manganese, silicon etc. in the solid solution.
- the concentration and rate of dissolution of these elements in the solid solution may increase with increasing temperature.
- the SHT composition of the solid solution may be preserved at the intermediate temperature. If the blank were to be cooled in a too slow rate, the alloying elements may diffuse through the solid solution and concentrate at the grain boundaries, in large voids, undissolved particles or other undesired locations. To achieve improved strength properties of the formed part, it may be desirable to avoid such recrystallization and decrease the diffusion process and maintain the alloying elements in the solid solution by providing a rapid cooling.
- the cooling rate to achieve this may be selected depending on the aluminum alloy grade and composition of the blank. Further, a quenching rate may be selected depending on the aluminum alloy grade and composition of the blank.
- the intermediate temperature may be a temperature in an intermediate temperature range being above room temperature and below the SHT temperature.
- the time required for a given amount of precipitation may increase due to low solute diffusion coefficients.
- the rate of precipitate formation is low due to the inability of atoms to diffuse, increased nucleation or precipitation and growth at the temperature range.
- an intermediate temperature for a 7xxx series Al alloy blank may be chosen between 400-420 oC. Further, for a AA6082 Al alloy blank, the intermediate temperature may be chosen as 300-350 oC. At such temperatures, the kinetic movement in the alloy material of the blank may have stopped.
- the cooling to the intermediate temperature may be performed at a cooling station being separate from the forming tool.
- the cooling may thereby be provided fast and with homogeneous temperature in the blank.
- a cooling rate of at least 30 K/s may be chosen.
- a cooling rate of at least 30 K/s, at least 50 K/s, or preferably about 100 K/s may be chosen.
- the intermediate temperature may be selected depending on the Al alloy of the blank, and being above 100 oC.
- the intermediate temperature should be selected as a temperature wherein the kinetic movement of the alloy material of the blank stops.
- the optimal intermediate temperature may differ.
- the intermediate temperature may be above 100 oC.
- the intermediate temperature may be selected being the highest possible temperature at which the kinetic movement in the present alloy material stops.
- the forming tool may be preheated to the intermediate temperature.
- the blank may thereby be formed at the intermediate temperature.
- the temperature of the blank may thereby be controlled during the forming, which may improve the accuracy in the properties of the final formed component.
- the blank may be kept at the intermediate temperature during the forming step in the forming tool.
- the temperature of the tool may be controlled in order to keep the temperature of both the tool and the blank stable at the intermediate temperature during the forming.
- the temperature of the forming tool may be controlled in order to quench the formed blank to room temperature.
- a temperature control function may be provided for the forming tool in order to control the temperature of the forming tool to the intermediate temperature throughout the forming step.
- the forming and the quenching may be performed in separate forming tools.
- a first forming tool may form the blank at the intermediate temperature, and a second forming tool may quench the blank to room temperature.
- the first forming tool may be preheated to the intermediate temperature, thereby keeping the blank at the intermediate temperature during the forming.
- the blank may then be transferred to the second forming tool, quenching the blank to room temperature.
- the second forming tool may be a cold forming tool.
- the first forming tool may not be preheated, thereby cooling the blank during the forming.
- the blank may then in the second forming tool be quenched in a controlled manner to room temperature in the second forming tool.
- a 6xxx or 7xxx series Al alloy blank forming system comprising a heating station configured to heat a blank to its SHT temperature, T SHT , a cooling station configured to cool the blank to an intermediate temperature T ITM , at which the kinetic movement for the alloy in the blank has stopped and at a cooling rate that is high enough such that re-crystallization in the alloy of the blank does not occur, a forming tool configured to form and quench the blank, and an ageing station configured to provide an artificial ageing process to the formed and quenched blank.
- a method 100 comprises a first step of heating 102 a 6xxx or 7xxx series Al alloy blank 2 to the solutionization (SHT) temperature for the specific alloy of the blank 2.
- SHT solutionization
- a blank forming system 1 is provided, wherein the heating 102 is performed in a heating station 10.
- the temperature of the blank 2 is kept at the SHT temperature or above until the solutionization of the alloy of the blank 2 is complete.
- the blank 2 is cooled 104 to an intermediate temperature.
- the cooling 104 is performed at a cooling station 20.
- the intermediate temperature is selected for the alloy of the blank 2 at which temperature the kinetic movement for the alloy stops.
- the cooling 104 is performed at a cooling rate high enough such that re-crystallization in the alloy of the blank 2 does not occur.
- the blank 2 is formed 106 in a forming tool 32 at a press station 30 in the blank forming system 1.
- the press station 30 may be a press suitable for aluminum alloy blank sheet forming, such as a hydraulic press, a servo press (servo hydraulic or servo mechanical).
- the formed blank 2', or formed component 2' is quenched 108 in the forming tool 32 to room temperature.
- the formed blank 2' is artificially aged 110 at an ageing station 40.
- the ageing process is provided to control and limit the recrystallization in the alloy material of the blank 2.
- Fig. 3 illustrates the blank forming method 100 according to an embodiment of the present invention.
- the blank 2 is heated from room temperature T E to the SHT temperature T SHT , and kept at the T SHT for a necessary time t 1 -t 2 as discussed above.
- the blank 2 is rapidly cooled to the intermediate temperature T ITM at the necessary cooling rate as discussed above.
- the blank 2 is then formed during t 2 -t 3 in the forming tool 32.
- the formed blank 2' is quenched to room temperature T E .
- the formed component 2' is processed for artificial ageing by being heated to an ageing temperature T A .
- the component 2' is kept at the ageing temperature T A during a period t 5 -t 6 until the ageing process is complete.
- the time t 3 -t 4 provides a transfer of the formed blank to the ageing station 40.
- the blank 2 is transferred between the different stations 10, 20, 30, 40.
- the transfer may be performed such that minimal heat loss in the blank 2 is achieved.
- Figs. 4 and 5 illustrates a method 200 and system 3 according to an embodiment of the invention.
- the steps of heating 202 and cooling 204 correspond to the steps 102 and 104 as discussed above.
- the blank 2 is formed 206 in a preheated first forming tool 32a at a press station 30 in the blank forming system 3.
- the first forming tool 32a is preheated to the intermediate temperature.
- the blank 2 is thereby not further cooled when arranged in the first forming tool 32a.
- the intermediate temperature may be kept in the first forming tool 32a and the blank 2 throughout the forming process 106.
- the formed blank is moved to a separate cold second forming tool 32b.
- the blank is quenched to room temperature.
- the cold second forming tool 32b may further form and quench the blank to its final shaped component.
- Fig. 5 further illustrates an optional arrangement of ageing which can be used for either of the above presented embodiments.
- a first pre-ageing step is performed at a pre-ageing station 40a, in which the formed component 2' is heated to the ageing temperature T A , kept at T A until the pre-ageing is complete and then cooled to room temperature T E .
- the component 2' is again heated to T A , kept at T A for a time period and thereafter cooled to room temperature T E , to provide a paint baking of the component 2'.
- the component can be heated to a different temperature in the paint baking process than the temperature T A in the pre-ageing process.
- a two-step ageing process is thereby provided comprising pre-ageing and paint baking.
- the pre-ageing process is integrated in the forming/stamping line, and performed in direct connection to the forming of the component 2'.
- the paint baking process may be performed at a later stage, whichever may be suitable for the production line.
- the use of the pre-ageing process prevents natural ageing after stamping in the second forming tool. Otherwise, natural ageing may occur after about 30 minutes for 7xxx series Al alloy materials or about one hour for 6xxx series Al alloy materials.
- the paint baking process cannot take effect on the formed component to achieve peak hardness.
- the pre-ageing process further enables post processing activities such as transport to another location, storage for a required period before assembly or joining operations. Then, the paint baking operation may be performed at the most suitable time to provide optimal peak hardness in a short cycle time and at a low cost. This may e.g. be after joining the formed component 2' to a desired assembly.
- Fig. 6 illustrates the process blank forming method 200 according to an embodiment of the present invention.
- the blank 2 is heated from room temperature T E to the SHT temperature T SHT , and kept at the T SHT for a necessary time t 1 -t 2 as discussed above. Between t 2 and t 3 , the blank 2 is cooled to the intermediate temperature T ITM at the necessary cooling rate as discussed above. The blank 2 is then formed during t 3 -t 4 in the preheated first forming tool 32a. Between t 4 and t 5 the formed blank 2' is quenched to room temperature T E in the second forming tool 32b.
- Fig. 6 further illustrate the process of the embodiment comprising a pre-ageing and a paint baking step as discussed above.
- the formed blank 2' is processed for artificial ageing by being heated to the ageing temperature T A and kept at the ageing temperature T A during a period t 7 -t 8 .
- the blank 2' is in the second ageing station 40b again heated to the ageing temperature T A and kept at T A between t 11 -t 12 until the ageing process is complete.
- the blank 2' formed to a final shaped component is then again cooled to room temperature T E .
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- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Crystallography & Structural Chemistry (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Shaping Metal By Deep-Drawing, Or The Like (AREA)
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Abstract
Description
- The present disclosure relates to a heat treatment method of blank sheets of aluminum alloys, and especially to a method suitable for blank sheets of any aluminum alloy grade, composition or temper.
- In especially the automotive industry, the hot forming of blank sheets is important, in particular hot forming of blank sheets of high strength aluminum alloys. There are numerous methods known for forming aluminum alloy blanks. E.g. the hot forming die quenching methods as presented in
WO2010/032002 andWO2015/136299 . - However, such known methods have several drawbacks. For instance, these methods are not suitable for all aluminum alloy grades. The method in
WO2010/032002 may be suitable for AA6082 material, but not for any AA7xxx material. Further, the aluminum alloy grade material compositions and tempers may vary from different material suppliers. The resulting formed components using the known methods are very sensitive to different compositions and tempers. - Further, the known processes have problems in being suitable for mass production due to lack of stability, repeatability and accuracy of the formed components.
- Consequently, there is a need for production method for forming aluminum alloy blank sheets which alleviate the mentioned drawbacks of known technology.
- It is an object of the present invention to provide an improved solution that alleviates the mentioned drawbacks with present devices. Furthermore, it is an object to provide a method resulting in improved accuracy of the formed parts and which method is suitable for any aluminum alloy grade, composition and temper.
- The invention is defined by the appended independent claims, with embodiments being set forth in the appended dependent claims, in the following description and in the drawings.
- According to a first aspect of the present invention, a method of forming a 6xxx or 7xxx series Al alloy blank into a component is provided. The method comprises the steps of heating the blank to a solutionization (SHT) temperature, TSHT, for the alloy of the blank at a heating station and keeping the blank at said SHT temperature until SHT is complete, cooling the blank at a cooling station to an intermediate temperature, TITM, at which the kinetic movement for the alloy in the blank stops and at a cooling rate that is high enough such that re-crystallization in the alloy of the blank does not occur, forming the blank in a forming tool, quenching the formed blank to room temperature, TE, and artificially ageing the formed and quenched blank in an ageing station.
- By using a method according to the present invention, a method is provided that, with high accuracy of the formed components and low amount of springbacks, is suitable for any 6xxx or 7xxx series aluminum alloy grade sheet blank.
- The time in which the blank is kept at or above the solution heat treatment (SHT) temperature may be chosen to be sufficient to ensure maximum concentration of hardening elements, such as copper, zinc, magnesium, manganese, silicon etc. in the solid solution. The concentration and rate of dissolution of these elements in the solid solution may increase with increasing temperature.
- By cooling the blank at a specific cooling rate the SHT composition of the solid solution may be preserved at the intermediate temperature. If the blank were to be cooled in a too slow rate, the alloying elements may diffuse through the solid solution and concentrate at the grain boundaries, in large voids, undissolved particles or other undesired locations. To achieve improved strength properties of the formed part, it may be desirable to avoid such recrystallization and decrease the diffusion process and maintain the alloying elements in the solid solution by providing a rapid cooling. The cooling rate to achieve this may be selected depending on the aluminum alloy grade and composition of the blank. Further, a quenching rate may be selected depending on the aluminum alloy grade and composition of the blank.
- The intermediate temperature may be a temperature in an intermediate temperature range being above room temperature and below the SHT temperature. In the intermediate temperature range, the time required for a given amount of precipitation may increase due to low solute diffusion coefficients. Though the thermodynamic potential for precipitation for most aluminum alloy grades are mostly high at the intermediate temperature because of the high degree of solute supersaturation, the rate of precipitate formation is low due to the inability of atoms to diffuse, increased nucleation or precipitation and growth at the temperature range.
- As an example, an intermediate temperature for a 7xxx series Al alloy blank may be chosen between 400-420 ºC. Further, for a AA6082 Al alloy blank, the intermediate temperature may be chosen as 300-350 ºC. At such temperatures, the kinetic movement in the alloy material of the blank may have stopped.
- The cooling to the intermediate temperature may be performed at a cooling station being separate from the forming tool. The cooling may thereby be provided fast and with homogeneous temperature in the blank.
- As an example, for a 6xxx series Al alloy (such as AA6082), a cooling rate of at least 30 K/s may be chosen. Further, for a 7xxx series Al alloy, a cooling rate of at least 30 K/s, at least 50 K/s, or preferably about 100 K/s, may be chosen.
- In one embodiment, the intermediate temperature may be selected depending on the Al alloy of the blank, and being above 100 ºC. The intermediate temperature should be selected as a temperature wherein the kinetic movement of the alloy material of the blank stops. Depending on which 6xxx or 7xxx series Al alloy is used in the blank, the optimal intermediate temperature may differ. However, the intermediate temperature may be above 100 ºC. Further, the intermediate temperature may be selected being the highest possible temperature at which the kinetic movement in the present alloy material stops.
- In one embodiment, the forming tool may be preheated to the intermediate temperature. The blank may thereby be formed at the intermediate temperature. The temperature of the blank may thereby be controlled during the forming, which may improve the accuracy in the properties of the final formed component.
- In one embodiment, the blank may be kept at the intermediate temperature during the forming step in the forming tool. The temperature of the tool may be controlled in order to keep the temperature of both the tool and the blank stable at the intermediate temperature during the forming. After the forming, the temperature of the forming tool may be controlled in order to quench the formed blank to room temperature. A temperature control function may be provided for the forming tool in order to control the temperature of the forming tool to the intermediate temperature throughout the forming step.
- In one embodiment, the forming and the quenching may be performed in separate forming tools. A first forming tool may form the blank at the intermediate temperature, and a second forming tool may quench the blank to room temperature. In a further embodiment, the first forming tool may be preheated to the intermediate temperature, thereby keeping the blank at the intermediate temperature during the forming. The blank may then be transferred to the second forming tool, quenching the blank to room temperature. The second forming tool may be a cold forming tool. Alternatively, the first forming tool may not be preheated, thereby cooling the blank during the forming. The blank may then in the second forming tool be quenched in a controlled manner to room temperature in the second forming tool.
- According to a second aspect of the present invention, a 6xxx or 7xxx series Al alloy blank forming system is provided. The system comprises a heating station configured to heat a blank to its SHT temperature, TSHT, a cooling station configured to cool the blank to an intermediate temperature TITM, at which the kinetic movement for the alloy in the blank has stopped and at a cooling rate that is high enough such that re-crystallization in the alloy of the blank does not occur, a forming tool configured to form and quench the blank, and an ageing station configured to provide an artificial ageing process to the formed and quenched blank.
- Further embodiments of the system according to the present invention may be provided similarly as discussed above for the method.
- The invention will in the following be described in more detail with reference to the enclosed drawings, wherein:
-
Fig. 1 shows a flow chart of a method according to an embodiment of the invention; -
Fig. 2 shows a block scheme of a system according to an embodiment of the invention; -
Fig. 3 shows a diagram view of a process of the method according to an embodiment of the invention; -
Fig. 4 shows a flow chart of a method according to an embodiment of the invention; -
Fig. 5 shows a block scheme of a system according to an embodiment of the invention; and -
Fig. 6 shows a diagram view of a process of the method according to an embodiment of the invention. - The present invention will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, like numbers refer to like elements.
- As illustrated in
figure 1 , amethod 100 according to an embodiment of the present invention comprises a first step of heating 102 a 6xxx or 7xxx seriesAl alloy blank 2 to the solutionization (SHT) temperature for the specific alloy of the blank 2. As further seen infig. 2 , a blank formingsystem 1 is provided, wherein theheating 102 is performed in aheating station 10. In theheating station 10, when the blank 2 has reached its SHT temperature or above, the temperature of the blank 2 is kept at the SHT temperature or above until the solutionization of the alloy of the blank 2 is complete. - In a next step, the blank 2 is cooled 104 to an intermediate temperature. In the blank forming
system 1, the cooling 104 is performed at acooling station 20. The intermediate temperature is selected for the alloy of the blank 2 at which temperature the kinetic movement for the alloy stops. The cooling 104 is performed at a cooling rate high enough such that re-crystallization in the alloy of the blank 2 does not occur. - In a next step, the blank 2 is formed 106 in a forming
tool 32 at apress station 30 in the blank formingsystem 1. Thepress station 30 may be a press suitable for aluminum alloy blank sheet forming, such as a hydraulic press, a servo press (servo hydraulic or servo mechanical). - After forming 106 of the blank 2, the formed blank 2', or formed component 2', is quenched 108 in the forming
tool 32 to room temperature. - Finally, the formed blank 2' is artificially aged 110 at an ageing
station 40. The ageing process is provided to control and limit the recrystallization in the alloy material of the blank 2. -
Fig. 3 illustrates the blank formingmethod 100 according to an embodiment of the present invention. The blank 2 is heated from room temperature TE to the SHT temperature TSHT, and kept at the TSHT for a necessary time t1-t2 as discussed above. At t2 the blank 2 is rapidly cooled to the intermediate temperature TITM at the necessary cooling rate as discussed above. The blank 2 is then formed during t2-t3 in the formingtool 32. At t3 the formed blank 2' is quenched to room temperature TE. - At the ageing
station 40, the formed component 2' is processed for artificial ageing by being heated to an ageing temperature TA. The component 2' is kept at the ageing temperature TA during a period t5-t6 until the ageing process is complete. The time t3-t4 provides a transfer of the formed blank to the ageingstation 40. - The blank 2 is transferred between the
different stations -
Figs. 4 and5 illustrates amethod 200 andsystem 3 according to an embodiment of the invention. The steps ofheating 202 and cooling 204 correspond to thesteps tool 32a at apress station 30 in the blank formingsystem 3. The first formingtool 32a is preheated to the intermediate temperature. The blank 2 is thereby not further cooled when arranged in the first formingtool 32a. The intermediate temperature may be kept in the first formingtool 32a and the blank 2 throughout the formingprocess 106. - Next, the formed blank is moved to a separate cold second forming
tool 32b. In the cold second formingtool 32b, the blank is quenched to room temperature. The cold second formingtool 32b may further form and quench the blank to its final shaped component. -
Fig. 5 further illustrates an optional arrangement of ageing which can be used for either of the above presented embodiments. In such ageing embodiment, a first pre-ageing step is performed at apre-ageing station 40a, in which the formed component 2' is heated to the ageing temperature TA, kept at TA until the pre-ageing is complete and then cooled to room temperature TE. After transfer to asecond ageing station 40b, the component 2' is again heated to TA, kept at TA for a time period and thereafter cooled to room temperature TE, to provide a paint baking of the component 2'. Alternatively, the component can be heated to a different temperature in the paint baking process than the temperature TA in the pre-ageing process. A two-step ageing process is thereby provided comprising pre-ageing and paint baking. - Preferably, the pre-ageing process is integrated in the forming/stamping line, and performed in direct connection to the forming of the component 2'. The paint baking process may be performed at a later stage, whichever may be suitable for the production line.
- The use of the pre-ageing process prevents natural ageing after stamping in the second forming tool. Otherwise, natural ageing may occur after about 30 minutes for 7xxx series Al alloy materials or about one hour for 6xxx series Al alloy materials. The paint baking process cannot take effect on the formed component to achieve peak hardness. The pre-ageing process further enables post processing activities such as transport to another location, storage for a required period before assembly or joining operations. Then, the paint baking operation may be performed at the most suitable time to provide optimal peak hardness in a short cycle time and at a low cost. This may e.g. be after joining the formed component 2' to a desired assembly.
-
Fig. 6 illustrates the process blank formingmethod 200 according to an embodiment of the present invention. The blank 2 is heated from room temperature TE to the SHT temperature TSHT, and kept at the TSHT for a necessary time t1-t2 as discussed above. Between t2 and t3, the blank 2 is cooled to the intermediate temperature TITM at the necessary cooling rate as discussed above. The blank 2 is then formed during t3-t4 in the preheated first formingtool 32a. Between t4 and t5 the formed blank 2' is quenched to room temperature TE in the second formingtool 32b. -
Fig. 6 further illustrate the process of the embodiment comprising a pre-ageing and a paint baking step as discussed above. At thepre-ageing station 40a, the formed blank 2' is processed for artificial ageing by being heated to the ageing temperature TA and kept at the ageing temperature TA during a period t7-t8. After being cooled to room temperature, the blank 2' is in thesecond ageing station 40b again heated to the ageing temperature TA and kept at TA between t11-t12 until the ageing process is complete. The blank 2' formed to a final shaped component is then again cooled to room temperature TE. - In the drawings and specification, there have been disclosed preferred embodiments and examples of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation, the scope of the invention being set forth in the following claims.
Claims (10)
- A method (100) of forming a 6xxx or 7xxx series Al alloy blank (2), wherein the method comprises the steps of:heating (102) the blank to a solutionization (SHT) temperature (TSHT) for the alloy of the blank at a heating station (10) and keeping the blank at said SHT temperature until SHT is complete,cooling (104) the blank at a cooling station (20) to an intermediate temperature (TITM) at which the kinetic movement for the alloy in the blank stops and at a cooling rate that is high enough such that re-crystallization in the alloy of the blank does not occur,forming (106) the blank in a forming tool (32),quenching (108) the formed blank (2') to room temperature (TE),artificially ageing (110) the formed and quenched blank in an ageing station (40).
- The method according to claim 1, wherein the intermediate temperature (TITM) is selected depending the alloy of the blank (2) and when the kinetic movement of the material of the alloy stops, wherein the intermediate temperature is above 100 ºC.
- The method according to any of the preceding claims, wherein the forming tool (32) is preheated to the intermediate temperature (TITM).
- The method according to any of the preceding claims, wherein the blank (2) is kept at the intermediate temperature (TITM) during the forming (106) in the forming tool (32).
- The method according to any of the preceding claims, wherein the forming is performed in a first forming tool (32a) and the quenching is performed in a second forming tool (32b).
- A 6xxx or 7xxx series Al alloy blank forming system (1, 3) comprising,
a heating station (10) configured to heat a blank (2) to its SHT temperature (TSHT),
a cooling station (20) configured to cool the blank to an intermediate temperature (TITM) at which the kinetic movement for the alloy in the blank has stopped and at a cooling rate that is high enough such that re-crystallization in the alloy of the blank does not occur,
at least one forming tool (32) configured to form and quench the blank, and
an ageing station (40) configured to provide an artificial ageing process to the formed and quenched blank (2'). - The system according to claim 6, wherein the cooling station (20) is configured to cool the blank (2) to the intermediate temperature (TITM) being selected depending the alloy of the blank (2) and when the kinetic movement of the material of the alloy stops, and wherein the intermediate temperature is above 100 ºC.
- The system according to claim 6 or 7, wherein the forming tool is configured to be preheated to the intermediate temperature prior to forming the blank.
- The system according to any of the claim 5-8, wherein the forming tool is configured to keep the blank (2) at the intermediate temperature (TITM) during the forming (106) in the forming tool (32).
- The system according to any of the claims 5-9, wherein the system comprises a first forming tool (32a) configured to form the blank (2), and a second forming tool (32b) configured to quench the blank.
Priority Applications (11)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PT171947237T PT3467138T (en) | 2017-10-04 | 2017-10-04 | Method and system for forming aluminum alloy blank |
PL17194723T PL3467138T3 (en) | 2017-10-04 | 2017-10-04 | Method for forming aluminum alloy blank |
ES17194723T ES2906633T3 (en) | 2017-10-04 | 2017-10-04 | Method for forming aluminum alloy preforms |
EP17194723.7A EP3467138B1 (en) | 2017-10-04 | 2017-10-04 | Method for forming aluminum alloy blank |
JP2020517798A JP2020536166A (en) | 2017-10-04 | 2018-10-03 | Methods and systems for forming aluminum alloy blanks |
CA3084330A CA3084330A1 (en) | 2017-10-04 | 2018-10-03 | Method and system for forming aluminum alloy blank |
PCT/EP2018/076913 WO2019068767A1 (en) | 2017-10-04 | 2018-10-03 | Method and system for forming aluminum alloy blank |
CN201880061712.0A CN111315910A (en) | 2017-10-04 | 2018-10-03 | Method and system for shaping aluminum alloy blanks |
US16/652,908 US20200299818A1 (en) | 2017-10-04 | 2018-10-03 | Method and system for forming aluminum alloy blank |
MX2020003344A MX2020003344A (en) | 2017-10-04 | 2018-10-03 | Method and system for forming aluminum alloy blank. |
KR1020207011254A KR20200110737A (en) | 2017-10-04 | 2018-10-03 | Method and system for forming aluminum alloy blanks |
Applications Claiming Priority (1)
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EP17194723.7A EP3467138B1 (en) | 2017-10-04 | 2017-10-04 | Method for forming aluminum alloy blank |
Publications (2)
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EP3467138A1 true EP3467138A1 (en) | 2019-04-10 |
EP3467138B1 EP3467138B1 (en) | 2021-11-24 |
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EP17194723.7A Active EP3467138B1 (en) | 2017-10-04 | 2017-10-04 | Method for forming aluminum alloy blank |
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US (1) | US20200299818A1 (en) |
EP (1) | EP3467138B1 (en) |
JP (1) | JP2020536166A (en) |
KR (1) | KR20200110737A (en) |
CN (1) | CN111315910A (en) |
CA (1) | CA3084330A1 (en) |
ES (1) | ES2906633T3 (en) |
MX (1) | MX2020003344A (en) |
PL (1) | PL3467138T3 (en) |
PT (1) | PT3467138T (en) |
WO (1) | WO2019068767A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP3896188A1 (en) | 2020-04-15 | 2021-10-20 | Politechnika Wroclawska | A method of manufacturing of energy-absorbing elements made of age-hardenable aluminum alloy sheets that facilitate further joining |
Families Citing this family (1)
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WO2024091271A1 (en) * | 2022-10-28 | 2024-05-02 | Atieva, Inc. | Hot-stamping aluminum formation process |
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- 2017-10-04 ES ES17194723T patent/ES2906633T3/en active Active
- 2017-10-04 EP EP17194723.7A patent/EP3467138B1/en active Active
- 2017-10-04 PT PT171947237T patent/PT3467138T/en unknown
-
2018
- 2018-10-03 JP JP2020517798A patent/JP2020536166A/en active Pending
- 2018-10-03 MX MX2020003344A patent/MX2020003344A/en unknown
- 2018-10-03 CA CA3084330A patent/CA3084330A1/en active Pending
- 2018-10-03 US US16/652,908 patent/US20200299818A1/en not_active Abandoned
- 2018-10-03 CN CN201880061712.0A patent/CN111315910A/en active Pending
- 2018-10-03 KR KR1020207011254A patent/KR20200110737A/en not_active Application Discontinuation
- 2018-10-03 WO PCT/EP2018/076913 patent/WO2019068767A1/en active Application Filing
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Also Published As
Publication number | Publication date |
---|---|
PT3467138T (en) | 2022-02-21 |
WO2019068767A1 (en) | 2019-04-11 |
EP3467138B1 (en) | 2021-11-24 |
PL3467138T3 (en) | 2022-04-04 |
KR20200110737A (en) | 2020-09-25 |
JP2020536166A (en) | 2020-12-10 |
ES2906633T3 (en) | 2022-04-19 |
CA3084330A1 (en) | 2019-04-11 |
MX2020003344A (en) | 2020-07-28 |
CN111315910A (en) | 2020-06-19 |
US20200299818A1 (en) | 2020-09-24 |
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