US20210189538A1 - Method for manufacturing an aluminum-copper-lithium alloy having improved compressive strength and improved toughness - Google Patents

Method for manufacturing an aluminum-copper-lithium alloy having improved compressive strength and improved toughness Download PDF

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US20210189538A1
US20210189538A1 US17/051,672 US201917051672A US2021189538A1 US 20210189538 A1 US20210189538 A1 US 20210189538A1 US 201917051672 A US201917051672 A US 201917051672A US 2021189538 A1 US2021189538 A1 US 2021189538A1
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Fanny Mas
David Barbier
Samuel Juge
Armelle Danielou
Gaëlle Pouget
Nicolas BAYONA-CARRILLO
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Constellium Issoire SAS
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    • 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21BROLLING OF METAL
    • B21B3/00Rolling materials of special alloys so far as the composition of the alloy requires or permits special rolling methods or sequences ; Rolling of aluminium, copper, zinc or other non-ferrous metals
    • 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
    • C22C21/16Alloys 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
    • C22C21/18Alloys based on aluminium with copper as the next major constituent with zinc
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21BROLLING OF METAL
    • B21B3/00Rolling materials of special alloys so far as the composition of the alloy requires or permits special rolling methods or sequences ; Rolling of aluminium, copper, zinc or other non-ferrous metals
    • B21B2003/001Aluminium or its alloys

Definitions

  • the invention relates to a method for manufacturing products made of aluminum-copper-lithium alloys, in particular, such products intended for aeronautical and aerospace construction.
  • Aluminum alloy products are developed to produce high strength parts intended in particular for the aircraft industry and the aerospace industry.
  • Aluminum alloys containing lithium are of great interest in this regard, as lithium can reduce the density of aluminum by 3% and increase the modulus of elasticity by 6% for each weight percent lithium added.
  • their performance in relation to other properties of use must reach that of commonly used alloys, in particular in terms of compromise between the properties of static mechanical strength (tensile and compressive yield strength, ultimate tensile strength) and damage tolerance properties (toughness, resistance to the fatigue crack propagation), these properties being generally mutually exclusive.
  • static mechanical strength tensile and compressive yield strength, ultimate tensile strength
  • damage tolerance properties toughness, resistance to the fatigue crack propagation
  • These alloys must also have sufficient corrosion resistance, be able to be shaped according to the usual methods and have low residual stresses so that they can be fully machined.
  • U.S. Pat. No. 5,032,359 describes a large family of aluminum-copper-lithium alloys wherein the addition of magnesium and silver, in particular between 0.3 and 0.5 percent by weight, allows to increase the mechanical strength.
  • U.S. Pat. No. 5,455,003 describes a method for manufacturing Al—Cu—Li alloys which have improved mechanical strength and improved toughness at cryogenic temperature, in particular thanks to suitable working hardening and ageing.
  • U.S. Pat. No. 7,229,509 describes an alloy comprising (wt %): (2.5-5.5) Cu, (0.1-2.5) Li, (0.2-1.0) Mg, (0.2-0.8) Ag, (0.2-0.8) Mn, 0.4 max Zr or other grain refiner agents such as Cr, Ti, Hf, Sc, V.
  • Patent application US 2009/142222 A1 describes alloys comprising (in wt %), 3.4 to 4.2% of Cu, 0.9 to 1.4% of Li, 0.3 to 0.7% of Ag, 0.1 to 0.6% of Mg, 0.2 to 0.8% of Zn, 0.1 to 0.6% of Mn and 0.01 to 0.6% of at least one element for controlling the granular structure. This application also describes a method for manufacturing extruded products.
  • Patent application WO2009/036953 relates to an aluminum alloy product for structural elements having a chemical composition comprising, by weight Cu from 3.4 to 5.0, Li from 0.9 to 1.7, Mg from 0.2 to 0.8, Ag from about 0.1 to 0.8, Mn from 0.1 to 0.9, Zn up to 1.5, and one or more elements selected from the group consisting of: (Zr about 0.05 to 0.3, Cr 0.05 to 0.3, Ti about 0.03 to 0.3, Sc about 0.05 to 0.4, Hf about 0.05 to 0.4), Fe ⁇ 0.15, Si ⁇ 0.5, normal and unavoidable impurities.
  • Patent application WO 2012/085359 A2 relates to a method for manufacturing rolled products made of an aluminum-based alloy comprising 4.2 to 4.6 wt % of Cu, 0.8 to 1.30 wt % of Li, 0.3 to 0.8 wt % of Mg, 0.05 to 0.18 wt % of Zr, 0.05 to 0.4 wt % of Ag, 0.0 to 0.5 wt % of Mn, at most 0.20 wt % of Fe+Si, less than 0.20 wt % of Zn, at least one element selected from Cr, Se, Hf and Ti, the amount of said element, if selected, being 0.05 to 0.3 wt % for Cr and for Se, 0.05 to 0.5 wt % for Hf and from 0.01 to 0.15 wt % for Ti, the other elements at most 0.05 wt % each and 0.15 wt % in total, the remainder being aluminum, comprising the steps of preparation, casting, homogenization, rolling with
  • Patent application US2012/0225271 A1 relates to wrought products with a thickness of at least 12.7 mm containing from 3.00 to 3.80 wt % of Cu, from 0.05 to 0.35 wt % of Mg, from 0.975 to 1.385 wt % of Li, wherein ⁇ 0.3 Mg ⁇ 0.15Cu+1.65 ⁇ Li ⁇ 0.3 Mg ⁇ 0.15Cu+1.85, from 0.05 to 0.50 wt % of at least one grain structure control element, wherein the grain structure control element is selected from the group consisting of Zr, Sc, Cr, V, Hf, other rare earth elements, and combinations thereof, up to 1.0 wt % of Zn, up to 1.0 wt % of Mn, up to 0.12 wt % of Si, up to 0.15 wt % of Fe, up to 0.15 wt % of Ti, up to 0.10 wt % of other elements with a total not exceeding 0.35 wt %.
  • Application WO 2013/169901 describes alloys comprising, in percentage by weight, 3.5 to 4.4% of Cu, 0.65 to 1.15% of Li, 0.1 to 1.0% of Ag, 0.45 to 0.75% of Mg, 0.45 to 0.75% of Zn and 0.05 to 0.50% of at least one element for the control of granular structure.
  • the alloys advantageously have a Zn to Mg ratio comprised between 0.60 and 1.67.
  • a first object of the invention is a method for manufacturing a product based on an aluminum alloy wherein, successively,
  • Another object of the invention is a product that can be obtained by the method according to the invention and such that it is a rolled product with a thickness comprised between 8 and 50 mm and having, at mid-thickness,
  • Yet another object is an aircraft structure member, preferably an aircraft upper wing skin element, comprising a product according to the invention.
  • FIG. 1 Compromise between the toughness K app L ⁇ T and the compressive yield strength Rc p0.2 L of the alloys of Example 1.
  • FIG. 2 Graph showing the difference between the value of K app (L ⁇ T) measured according to the alloys of example 1 and the value calculated according to the formula ⁇ 0.5 R cp0.2 (L)+386 as a function of the conventional yield strength R p0.2 measured in the longitudinal direction of the product.
  • FIG. 3 Compromise between the toughness Kapp L ⁇ T and the compressive yield strength Rc p0.2 L of the alloys of Example 2.
  • FIG. 4 Graph showing the difference between the value of K app (LT) measured according to the alloys of example 2 and the value calculated according to the formula ⁇ 0.5 R cp0.2 (L)+375 as a function of the conventional yield strength R p0.2 measured in the longitudinal direction of the product.
  • the tensile static mechanical features in other words the ultimate tensile strength R m , the conventional yield strength at 0.2% elongation R p0.2 , and the elongation at rupture A %, are determined by a tensile test according to standard NF EN ISO 6892-1 (2016), the sampling and direction of the test being defined by standard EN 485 (2016).
  • R p0.2 (L) means R p0.2 measured in the longitudinal direction.
  • the compressive yield strength Rc p0.2 was measured at 0.2% compression according to standard ASTM E9-09 (2016).
  • Rc p0.2 (L) means Rc p0.2 measured in the longitudinal direction.
  • the stress intensity factor (K 1C ) is determined according to standard ASTM E 399 (2012).
  • the standard ASTM E 399 (2012) gives the criteria that allow determining whether K Q is a valid value of K 1C .
  • the values of K Q obtained for different materials are comparable with each other provided that the yield strengths of the materials are of the same order of magnitude.
  • a curve giving the effective stress intensity factor as a function of the effective crack extension, known as the curve R, is determined according to standard ASTM E 561 (ASTM E 561-10-2).
  • the critical stress intensity factor K C in other words the intensity factor which makes the crack unstable, is calculated from the curve R.
  • the stress intensity factor K CO is also calculated by assigning the length of the initial crack at the beginning of the monotonic load, to the critical load. These two values are calculated for a test specimen of the required shape.
  • K app represents the factor K CO corresponding to the test specimen which was used to perform the test of curve R.
  • K eff represents the factor K C corresponding to the test specimen which was used to perform the test of curve R.
  • structure element A mechanical part for which the static and/or dynamic mechanical properties are particularly important for the performance of the structure, and for which a structural calculation is usually required or performed is here called “structure element” or “structural element” of a mechanical construction. These are typically elements the failure of which is likely to endanger the safety of said construction, its users, its customers or others.
  • these structure elements comprise in particular the elements that compose the fuselage (such as the fuselage skin), the stiffeners or stringers of the fuselage, the watertight bulkheads, the circumferential frames of the fuselage, the wings (such as the upper or lower wing skin), the stiffeners (or stringers), the ribs and spars and the empennage in particular composed of horizontal and vertical stabilizers, as well as floor beams, seat tracks and doors.
  • the fuselage such as the fuselage skin
  • stiffeners or stringers of the fuselage the watertight bulkheads
  • the wings such as the upper or lower wing skin
  • stiffeners or stringers
  • the ribs and spars and the empennage in particular composed of horizontal and vertical stabilizers, as well as floor beams, seat tracks and doors.
  • a selected class of aluminum alloys containing in particular specific and critical amounts of lithium, copper, magnesium, and zirconium allows to prepare, under certain processing conditions, products, in particular rolled products, having an improved compromise between toughness, tensile and compressive yield strength.
  • the present inventors have observed that, surprisingly, it is possible to improve, for the products produced from these alloys, the properties of use, in particular those making the products suitable for the production of structure elements in the aeronautical and aerospace fields.
  • the products according to the invention are particularly well adapted to the production of aircraft upper wing skin elements since they have a particularly improved compromise compressive yield strength Rc p0.2 (L) ⁇ toughness Kapp (L ⁇ T).
  • the invention relates in particular to a method wherein an alloy is prepared comprising 3.5 to 4.7 wt % of Cu; 0.6 to 1.2 wt % of Li; 0.2 to 0.8 wt % of Mg; 0.1 to 0.2 wt % of Zr; 0.0 to 0.3 wt % of Ag; 0.0 to 0.8 wt % of Zn; 0.0 to 0.5 wt % of Mn; at most 0.20 wt % of Fe+Si; optionally an element selected from Cr, Sc, Hf and V; the amount of said element, if selected, being 0.05 to 0.3 wt % for Cr and for Sc, 0.05 to 0.5 wt % for Hf and for V; other elements at most 0.05 wt % each and 0.15 wt % in total, a refiner is introduced, the alloy is cast in a crude form, homogenized, hot-worked, solution heat-treated, quenched, cold-worked and tempered
  • the copper content of the products according to the invention is comprised between 3.5 and 4.7 wt %, preferably between 4.0 and 4.6 wt %.
  • the copper content is comprised between 4.1 and 4.5 wt %, preferably between 4.2 and 4.4 wt %.
  • the increase in the copper content contributes to an improvement in the tensile and compressive yield strength.
  • copper in an excessively high quantity, induces a decrease in the toughness in plane stress Kapp.
  • the lithium content of the products according to the invention is comprised between 0.7 to 1.2 wt %.
  • the lithium content is comprised between 0.8 and 1.0 wt %; preferably between 0.85 and 0.95 wt %.
  • the increase in the lithium content has a favorable effect on the density, however the present inventors have observed that for the alloys according to the invention, the selected lithium content allows an improvement in the compromise between mechanical strength, in particular the tensile and compressive yield strength, and toughness. A very high lithium content can lead to a degradation of the toughness.
  • the magnesium content of the products according to the invention is comprised between 0.2% and 0.8 wt %.
  • the magnesium content is at least 0.3% or even 0.4% or 0.5 wt %, which simultaneously improves static mechanical strength and toughness.
  • the magnesium content is less than 0.7 wt % or even 0.65 wt %. Indeed, a high magnesium content can induce a degradation of the toughness.
  • the alloy may contain zinc up to 0.8 wt %.
  • the Zn content is comprised between 0.05 and 0.6 wt %, preferably 0.2 and 0.5 wt % and, more preferably still, between 0.30 and 0.40 wt %.
  • the alloy contains less than 0.05 wt % of Zn, preferably less than 0.02 wt %.
  • the alloy may also contain up to 0.3 wt % of silver.
  • the alloy comprises more than 0.05 wt %, preferably more than 0.1% and more preferably still from 0.2 to 0.3 wt % of Ag.
  • the maximum Ag content is 0.27 wt %.
  • the Ag content is of 0.1 to 0.27 wt % and/or the Zn content is of 0.2 to 0.40 wt %.
  • the alloy may also contain up to 0.5 wt % of manganese.
  • the manganese content is comprised between 0.05 and 0.4 wt %.
  • the manganese content is comprised between 0.2 and 0.37 wt % and preferably between 0.25 and 0.35 wt %.
  • the manganese content is comprised between 0.1 and 0.2 wt % and preferably between 0.10 and 0.20 wt %.
  • the addition of Mn allows to obtain high toughness. However, if the Mn content is too high, the fatigue life can be significantly reduced.
  • the Zr content of the alloy is comprised between 0.1 and 0.2 wt %. In an advantageous embodiment, the Zr content is comprised between 0.10 and 0.15 wt %, preferably between 0.11 and 0.14 wt %.
  • the alloy also contains titanium, the Ti content is comprised between 0.01 and 0.15 wt %, preferably between 0.02 and 0.08 wt %.
  • the refiner introduced into the aluminum alloy bath contains particles of the TiC type.
  • the refiner has the formula AlTi x C y which is also written ATxCy where x and y are the contents of Ti and C in wt % for 1 wt % of Al, and x/y>4.
  • the present inventors have observed that, in the particular case of the present alloy, the presence in the refiner and therefore in the alloy of particles of TiC at the origin of a particular refining of the alloy during casting (AlTiC refining), allows to obtain a product having an optimized compromise of properties.
  • AlTiC refining the presence of particles of TiC in the grain refining rod and in the alloy of an embodiment of the method of the present invention allows an improvement in the compromise between the toughness K app L ⁇ T and the compressive yield strength R c p0.2 L.
  • the sum of the iron content and the silicon content is at most 0.20 wt %.
  • the iron and silicon contents are each at most 0.08 wt %.
  • the iron and silicon contents are at most 0.06% and 0.04 wt %, respectively.
  • a controlled and limited iron and silicon content helps improve the compromise between mechanical strength and damage tolerance.
  • the alloy may also contain at least one element which can contribute to the control of the grain size selected from Cr, Sc, Hf and V, the amount of said element, if selected, being from 0.05 to 0.3 wt % for Cr and for Sc and 0.05 to 0.5 wt % for Hf and for V.
  • the content of the alloy elements can be selected to minimize the density.
  • the additive elements contributing to increase the density such as Cu, Zn, Mn and Ag are minimized and the elements contributing to decrease the density such as Li and Mg are maximized so as to achieve a density less than or equal to 2.73 g/cm 3 and preferably less than or equal to 2.72 g/cm 3 .
  • the content of the other elements is at most 0.05 wt % each and 0.15 wt % in total.
  • the other elements are typically unavoidable impurities.
  • the method for manufacturing products according to the invention comprises the steps of preparation, casting, introducing a refiner, homogenization, hot working, solution heat-treating and quenching, cold working and ageing.
  • the liquid metal bath is then cast in the form of crude form, preferably in the shape of an ingot for rolling.
  • the crude form is then homogenized so as to reach a temperature comprised between 450° C. and 550° and preferably between 480° C. and 530° C. for a period comprised between 5 and 60 hours.
  • the homogenization treatment can be carried out in one or more stages.
  • the crude form is generally cooled to room temperature before being preheated in order to be hot-worked.
  • the hot working can in particular be an extrusion or a hot rolling. Preferably, this is a hot rolling step.
  • the hot rolling is carried out to a thickness preferably comprised between 8 and 50 mm and in a preferred manner between 15 and 40 mm.
  • the product thus obtained is then solution heat-treated to reach a temperature comprised between 490 and 530° C. for 15 min to 8 h, then quenched typically with water at room temperature.
  • the product then undergoes cold working with a cold working of 2 to 16%.
  • the cold working is a controlled tensioning with a permanent set of 2 to 6%, preferably from 2.0% to 4.0%.
  • said product is cold-worked with a cold working rate comprised between 8 to 16%.
  • the cold working is carried out in two steps: the product is first of all cold rolled with a thickness reduction rate comprised between 8 and 12%, preferably 9 and 11%, then subsequently tensioned in a controlled manner with a permanent set comprised between 0.5 and 4%, preferably between 0.5 and 2%.
  • the product is then subjected to an ageing step carried out by heating at a temperature comprised between 130 and 170° C. and preferably between 140 and 160° C. for 5 to 100 hours and preferably 10 to 70 hours.
  • the ageing is carried out at a temperature comprised between 140 and 155° C., preferably between 145 and 150° C., preferably for 18 to 22 hours.
  • the present inventors have observed that, surprisingly, the method according to the invention allows to obtain an advantageous product.
  • the specific and critical contents of the alloy of the present invention associated with a particular manufacturing method allow to achieve excellent properties.
  • the product according to the invention is advantageously a rolled product with a thickness comprised between 8 and 50 mm and having, at mid-thickness,
  • the product according to the invention is a rolled product with a thickness comprised between 8 and 50 mm and having, at mid-thickness,
  • the inventors have in particular observed that, surprisingly, the combination of the introduction into the liquid metal bath of a refiner containing particles of the TiC type so that the Ti content is comprised between 0.01 to 0.15 wt % and a cold working after solution heat-treating with a cold working rate comprised between 8 to 16% is advantageous.
  • this combination allows to obtain a rolled product with a thickness comprised between 8 and 50 mm, at mid-thickness
  • the combination comprising the introduction into the liquid metal bath of a refiner containing particles of TiC type so that the Ti content is comprised between 0.01 to 0.15 wt % and a cold working after solution heat-treating with a cold working rate comprised between 8 to 16% allows to obtain, for a rolled product with a thickness comprised between 8 and 50 mm, at mid-thickness,
  • the alloy products according to the invention allow in particular the manufacture of structure elements, in particular aircraft structure elements.
  • the preferred aircraft structure element is an aircraft upper wing skin element.
  • the plates were homogenized at about 510° C.
  • the homogenized plates were hot rolled at an input temperature of about 450° C. and an output temperature of about 390° C. to obtain for each alloy sheets of thickness 28 mm
  • the sheets were solution heat-treated at about 510° C. for 3 h, quenched with water at 20° C.
  • One sheet of each alloy 1 and 2 was then cold rolled with a thickness reduction rate of 10% (“LAF 10%” condition) followed by tensioning with a permanent elongation of about 1%.
  • LAF 10% thickness reduction rate
  • the toughness in plane stress was also measured at mid-thickness during tests of curve R with CCT test specimens 406 mm wide and 6.35 mm thick. The results are shown in Table 2 and FIG. 1 .
  • FIG. 2 shows the difference between the measured value of Kapp (L ⁇ T) and the value calculated according to the formula “ ⁇ 0.5 R cp0.2 (L)+386” as a function of the conventional yield strength R p0.2 (L) measured in the longitudinal direction L of the product.
  • FIG. 4 shows the difference between the measured value of Kapp (L ⁇ T) and the value calculated according to the formula ⁇ 0.5 Rcp0.2(L)+375 as a function of the conventional yield strength Rp0.2 measured in the longitudinal direction L of the product.

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US17/051,672 2018-05-02 2019-04-24 Method for manufacturing an aluminum-copper-lithium alloy having improved compressive strength and improved toughness Pending US20210189538A1 (en)

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FR1853799A FR3080861B1 (fr) 2018-05-02 2018-05-02 Procede de fabrication d'un alliage aluminium cuivre lithium a resistance en compression et tenacite ameliorees
FR1853799 2018-05-02
PCT/FR2019/050964 WO2019211546A1 (fr) 2018-05-02 2019-04-24 Procede de fabrication d'un alliage aluminium cuivre lithium a resistance en compression et tenacite ameliorees

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