WO2018237196A1 - IMPROVED THICK CORRELATED 7XXX ALUMINUM ALLOYS AND METHODS OF PRODUCING THE SAME - Google Patents

IMPROVED THICK CORRELATED 7XXX ALUMINUM ALLOYS AND METHODS OF PRODUCING THE SAME Download PDF

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Publication number
WO2018237196A1
WO2018237196A1 PCT/US2018/038838 US2018038838W WO2018237196A1 WO 2018237196 A1 WO2018237196 A1 WO 2018237196A1 US 2018038838 W US2018038838 W US 2018038838W WO 2018237196 A1 WO2018237196 A1 WO 2018237196A1
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WIPO (PCT)
Prior art keywords
aluminum alloy
7xxx aluminum
alloy product
ksi
sqrt
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PCT/US2018/038838
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English (en)
French (fr)
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WO2018237196A9 (en
Inventor
Julien Boselli
Gary H. Bray
Cagatay Yanar
Lynette M. Karabin
Severine CAMBIER
Francine S. Bovard
Jen C. Lin
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Arconic Inc.
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Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=62904621&utm_source=***_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=WO2018237196(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Arconic Inc. filed Critical Arconic Inc.
Priority to BR112019026036-6A priority Critical patent/BR112019026036B1/pt
Priority to CN201880038484.5A priority patent/CN110832094A/zh
Priority to CA3066252A priority patent/CA3066252C/en
Priority to EP18740432.2A priority patent/EP3642375B1/en
Priority to RU2019143665A priority patent/RU2745433C1/ru
Publication of WO2018237196A1 publication Critical patent/WO2018237196A1/en
Publication of WO2018237196A9 publication Critical patent/WO2018237196A9/en
Priority to US16/708,117 priority patent/US20200115780A1/en

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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/10—Alloys based on aluminium with zinc as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/002—Changing 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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/053—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with zinc as the next major constituent

Definitions

  • the present patent application relates to improved thick wrought 7xxx aluminum alloy products and methods for producing the same.
  • Aluminum alloys are useful in a variety of applications. However, improving one property of an aluminum alloy without degrading another property is elusive. For example, it is difficult to increase the strength of a wrought aluminum alloy without affecting other properties such as fracture toughness or corrosion resistance. 7xxx (Al-Zn-Mg based) are prone to corrosion. See, e.g., Bonn, W. Grubl, "The stress corrosion behaviour of high strength AIZnMg alloys," Paper held at the International Meeting of Associazione Italiana di Metallurgie, "Aluminum Alloys in Aircraft Industries," Turin, October 1976.
  • the present patent application relates to improved thick wrought 7xxx aluminum alloy products, and methods for producing the same.
  • the new thick wrought 7xxx aluminum alloy products (“the new 7xxx aluminum alloy products") may realize an improved combination of environmentally assisted crack resistance and at least one of strength, elongation, and fracture toughness, among other properties.
  • the new 7xxx aluminum alloy products generally include high amounts of manganese. Manganese in combination with appropriate amounts of zinc, magnesium, and copper has been found to facilitate production of thick 7xxx aluminum alloy products having a high resistance to environmentally assisted cracking.
  • the new 7xxx aluminum alloy products thus generally include (and in some instances consist of, or consist essentially of) from 0.15 to 0.50 wt. % Mn in combination with 5.5-7.5 wt. % Zn, 0.95-2.20 wt. % Mg, and 1.50-2.40 wt. % Cu.
  • the new wrought 7xxx aluminum alloy products are generally at least 1.5 inches thick, and may be up to 12 inches thick, and realize resistance to environmentally assisted cracking in the short transverse (ST) direction, which resistance is important for aerospace and other applications, especially those with structural loading in the short transverse (ST) direction.
  • Such thick, wrought 7xxx aluminum alloy product generally also realize good strength, elongation, fracture toughness and crack-deviation resistance properties.
  • the new wrought 7xxx aluminum alloy products generally realize an improved combination of corrosion resistance and at least one of strength, elongation, fracture toughness and crack-deviation resistance.
  • the new 7xxx aluminum alloy products may include normal grain structure control materials, grain refiners, and impurities.
  • the new 7xxx aluminum alloy products may include one or more of Zr, Cr, Sc, and Hf as grain structure control materials (e.g., from 0.05-0.25 wt. % each of one or more of Zr, Cr, Sc, and Hf), limiting the total amounts of these elements such that large primary particles do not form in the alloy.
  • the new 7xxx aluminum alloy products may include up to 0.15 wt. % Ti as a grain refiner, optionally with some of the titanium in the form of TiB 2 and/or TiC.
  • the new 7xxx aluminum alloy products may include up to 0.20 wt. % Fe and up to 0.15 wt. % Si as impurities. Lower amounts of iron and silicon may be used.
  • the balance of the new 7xxx aluminum alloy products is generally aluminum and other unavoidable impurities (other than iron and silicon).
  • the new 7xxx aluminum alloy products generally include from 0.15 to 0.50 wt. % Mn.
  • the new 7xxx aluminum alloy products generally include a sufficient amount of the manganese to facilitate realization of environmentally assisted crack resistance (EAC resistance) in the new 7xxx aluminum alloy products.
  • EAC resistance environmentally assisted crack resistance
  • a new 7xxx aluminum alloy product includes at least 0.18 wt. % Mn to facilitate EAC resistance.
  • a new 7xxx aluminum alloy product includes at least 0.20 wt. % Mn.
  • a new 7xxx aluminum alloy product includes at least 0.22 wt. % Mn.
  • a new 7xxx aluminum alloy product includes at least 0.25 wt. % Mn.
  • a new 7xxx aluminum alloy product includes at least 0.275 wt. % Mn.
  • a new 7xxx aluminum alloy product includes not greater than 0.45 wt. % Mn. In another embodiment, a new 7xxx aluminum alloy product includes not greater than 0.40 wt. % Mn. In yet another embodiment, a new 7xxx aluminum alloy product includes not greater than 0.375 wt. % Mn. In another embodiment, a new 7xxx aluminum alloy product includes not greater than 0.35 wt. % Mn. In another embodiment, a new 7xxx aluminum alloy product includes not greater than 0.325 wt. % Mn. In yet another embodiment, a new 7xxx aluminum alloy product includes not greater than 0.30 wt. % Mn.
  • the new 7xxx aluminum alloy products generally include tailored amounts of zinc, magnesium and copper, in addition to the manganese, to facilitate realization of EAC resistance in combination with good strength and/or fracture toughness properties, among others.
  • the new 7xxx aluminum alloy products generally include from 0.15 to 0.50 wt. % Mn, such as any of the manganese limits / ranges described above, in combination with 5.5-7.5 wt. % Zn, 0.95-2.20 wt. % Mg, and 1.50-2.4 wt. % Cu.
  • the new 7xxx aluminum alloy products generally include from 0.15 to 0.50 wt. % Mn, such as any of the manganese limits / ranges described above, in combination with 5.5-7.2 wt. % Zn, 1.05-2.05 wt. % Mg, and 1.5-2.2 wt. % Cu.
  • the new 7xxx aluminum alloy products generally include from 5.5 to 7.5 wt. % Zn.
  • a new alloy includes not greater than 7.4 wt. % Zn.
  • a new alloy includes not greater than 7.3 wt. % Zn.
  • a new alloy includes not greater than 7.2 wt. % Zn.
  • a new alloy includes not greater than 7.1 wt. % Zn.
  • a new alloy includes not greater than 7.0 wt. % Zn.
  • a new alloy includes not greater than 6.9 wt. % Zn.
  • a new alloy includes not greater than 6.8 wt.
  • a new alloy includes not greater than 6.7 wt. % Zn. In one embodiment, a new alloy includes at least 5.5 wt. % Zn. In another embodiment, a new alloy includes at least 5.75 wt. % Zn. In yet another embodiment, a new alloy includes at least 6.0 wt. % Zn. In another embodiment, a new alloy includes at least 6.25 wt. % Zn. In another embodiment, a new alloy includes at least 6.375 wt. % Zn. In another embodiment, a new alloy includes at least 6.5 wt. % Zn.
  • the new 7xxx aluminum alloy products generally include from 1.5 to 2.4 wt. % Cu.
  • a new alloy includes not greater than 2.3 wt. % Cu.
  • a new alloy includes not greater than 2.2 wt. % Cu.
  • a new alloy includes not greater than 2.1 wt. % Cu.
  • a new alloy includes not greater than 2.0 wt. % Cu.
  • a new alloy includes at least 1.55 wt. % Cu.
  • a new alloy includes at least 1.60 wt. % Cu.
  • a new alloy includes at least 1.65 wt. % Cu.
  • a new alloy includes at least 1.70 wt. % Cu. In yet another embodiment, a new alloy includes at least 1.75 wt. % Cu. In another embodiment, a new alloy includes at least 1.80 wt. % Cu.
  • the new 7xxx aluminum alloy products generally include from 0.95 to 2.2 wt. % Mg.
  • a new alloy includes at least 1.05 wt. % Mg.
  • a new alloy includes at least 1.15 wt. % Mg.
  • a new alloy includes at least 1.25 wt. % Mg.
  • a new alloy includes at least 1.35 wt. % Mg.
  • a new alloy includes at least 1.40 wt. % Mg.
  • a new alloy includes at least 1.45 wt. % Mg.
  • a new alloy includes at least 1.50 wt. % Mg.
  • a new alloy includes at least 1.55 wt. % Mg. In another embodiment, a new alloy includes at least 1.60 wt. % Mg. In yet another embodiment, a new alloy includes at least 1.65 wt. % Mg. In another embodiment, a new alloy includes at least 1.70 wt. % Mg. In one embodiment, a new alloy includes not greater than 2.15 wt. % Mg. In another embodiment, a new alloy includes not greater than 2.10 wt. % Mg. In yet another embodiment, a new alloy includes not greater than 2.05 wt. % Mg. In another embodiment, a new alloy includes not greater than 2.00 wt. % Mg. In another embodiment, a new alloy includes not greater than 1.95 wt. % Mg. In yet another embodiment, a new alloy includes not greater than 1.90 wt. % Mg.
  • a first 7xxx aluminum alloy product includes from 5.5 - 7.5 wt. % Zn, 1.7 - 2.2 wt. % Mg and 1.5 - 2.4 wt. % Cu. In one embodiment, the first 7xxx aluminum alloy product includes not greater than 7.2 wt. % Zn or not greater than 7.0 wt. % Zn (e.g., to facilitate improved EAC resistance). In one embodiment, the first 7xxx aluminum alloy product comprises 6.0 - 7.0 wt. % Zn.
  • a second 7xxx aluminum alloy product includes from 5.5 - 7.5 wt. % Zn, 1.35 - 1.7 wt. % Mg and 1.5 - 2.1 wt. % Cu.
  • the first 7xxx aluminum alloy product may realize, for instance, higher strength than the second aluminum alloy product, but possibly at the expense of reduced fracture toughness and/or reduced elongation.
  • the second 7xxx aluminum alloy product includes not greater than 7.2 wt. % Zn or not greater than 7.0 wt. % Zn (e.g., to facilitate improved EAC resistance).
  • the second 7xxx aluminum alloy product comprises 6.0 - 7.0 wt. % Zn.
  • a third 7xxx aluminum alloy product includes from 5.5 - 7.5 wt. % Zn, 1.7 - 2.2 wt. % Mg and 1.5 - 1.8 wt. % Cu.
  • This third 7xxx aluminum alloy product may be a lower strength zone of the first 7xxx aluminum alloy product region.
  • the third 7xxx aluminum alloy product includes not greater than 7.2 wt. % Zn or not greater than 7.0 wt. % Zn (e.g., to facilitate improved EAC resistance).
  • the third 7xxx aluminum alloy product comprises 6.0 - 7.0 wt. % Zn.
  • a fourth 7xxx aluminum alloy product includes from 5.5 - 7.5 wt. % Zn, 1.7 - 2.2 wt. % Mg and 1.8 - 2.0 wt. % Cu.
  • This forth 7xxx aluminum alloy product may be a middle strength zone of the first 7xxx aluminum alloy product region.
  • the fourth 7xxx aluminum alloy product includes not greater than 7.2 wt. % Zn or not greater than 7.0 wt. % Zn (e.g., to facilitate improved EAC resistance).
  • the fourth 7xxx aluminum alloy product comprises 6.0 - 7.0 wt. % Zn.
  • a fifth 7xxx aluminum alloy product includes from 5.5 - 7.5 wt. % Zn, 1.7 - 2.2 wt. % Mg and 2.0 - 2.4 wt. % Cu.
  • This fifth 7xxx aluminum alloy product may be a higher strength zone of the first 7xxx aluminum alloy product region.
  • a fifth 7xxx aluminum alloy product includes 2.0 - 2.2 wt. % Cu.
  • the fifth 7xxx aluminum alloy product includes not greater than 7.2 wt. % Zn or not greater than 7.0 wt. % Zn (e.g., to facilitate improved EAC resistance).
  • the fifth 7xxx aluminum alloy product comprises 6.0 - 7.0 wt. % Zn.
  • the third 7xxx aluminum alloy product may realize higher toughness and/or elongation as compared to the fourth or fifth aluminum alloy products.
  • the fourth 7xxx aluminum alloy product may realize higher toughness and/or elongation as compared to the fifth aluminum alloy products.
  • a new alloy includes a total amount of copper and magnesium such that (wt. % Cu + wt. % Mg) > 2.9 wt. %. In another embodiment, a new alloy includes a total amount of copper and magnesium such that (wt. % Cu + wt. % Mg) > 3.0 wt. %. In yet another embodiment, a new alloy includes a total amount of copper and magnesium such that (wt. % Cu + wt. % Mg) > 3.1 wt. %. In another embodiment, a new alloy includes a total amount of copper and magnesium such that (wt. % Cu + wt. % Mg) > 3.2 wt. %.
  • a new alloy includes a total amount of copper and magnesium such that (wt. % Cu + wt. % Mg) > 3.3 wt. %. In yet another embodiment, a new alloy includes a total amount of copper and magnesium such that (wt. % Cu + wt. % Mg) > 3.35 wt. %. In another embodiment, a new alloy includes a total amount of copper and magnesium such that (wt. % Cu + wt. % Mg) > 3.4 wt. %. In yet another embodiment, a new alloy includes a total amount of copper and magnesium such that (wt. % Cu + wt. % Mg) > 3.45 wt. %.
  • a new alloy includes a total amount of copper and magnesium such that (wt. % Cu + wt. % Mg) > 3.5 wt. %. In yet another embodiment, a new alloy includes a total amount of copper and magnesium such that (wt. % Cu + wt. % Mg) > 3.55 wt. %. In another embodiment, a new alloy includes a total amount of copper and magnesium such that (wt. % Cu + wt. % Mg) > 3.6 wt. %. In yet another embodiment, a new alloy includes a total amount of copper and magnesium such that (wt. % Cu + wt. % Mg) > 3.65 wt. %. In another embodiment, a new alloy includes a total amount of copper and magnesium such that (wt. % Cu + wt. % Mg) > 3.7 wt. %.
  • a new alloy includes a total amount of copper and magnesium such that (wt. % Cu + wt. % Mg) ⁇ 4.5 wt. %. In another embodiment, a new alloy includes a total amount of copper and magnesium such that (wt. % Cu + wt. % Mg) ⁇ 4.4 wt. %. In yet another embodiment, a new alloy includes a total amount of copper and magnesium such that (wt. % Cu + wt. % Mg) ⁇ 4.3 wt. %. In another embodiment, a new alloy includes a total amount of copper and magnesium such that (wt. % Cu + wt. % Mg) ⁇ 4.2 wt.
  • a new alloy includes a total amount of copper and magnesium such that (wt. % Cu + wt. % Mg) ⁇ 4.1 wt. %. In another embodiment, a new alloy includes a total amount of copper and magnesium such that (wt. % Cu + wt. % Mg) ⁇ 4.0 wt. %.
  • the amounts of zinc, magnesium and copper within the 7xxx aluminum alloy product satisfy the relationship: 2.362 ⁇ Mg+0.429*Cu+0.067*Zn ⁇ 3.062. In another embodiment, the amounts of zinc, magnesium and copper within the 7xxx aluminum alloy product satisfy the relationship: 2.502 ⁇ Mg+0.429*Cu+0.067*Zn ⁇ 2.912. In yet another embodiment, the amounts of zinc, magnesium and copper within the 7xxx aluminum alloy product satisfy the relationship: 2.662 ⁇ Mg+0.429*Cu+0.067*Zn ⁇ 3.062. In another embodiment, the amounts of zinc, magnesium and copper within the 7xxx aluminum alloy product satisfy the relationship: 2.662 ⁇ Mg+0.429*Cu+0.067*Zn ⁇ 2.912. Any of the zinc, magnesium, and copper amounts described in the preceding paragraphs may be used in combination with the above-shown empirical relationships.
  • the amounts of zinc and magnesium within the 7xxx aluminum alloy product are such that the weight ratio of zinc-to-magnesium is not greater than 5.25: 1 (i.e., (wt. % Zn / wt. % Mg) ⁇ 5.25: 1). In one embodiment, a weight ratio of zinc-to- magnesium is not greater than 5.00: 1 (i.e., (wt. % Zn / wt. % Mg) ⁇ 5.00: 1). In another embodiment, a weight ratio of zinc-to-magnesium is not greater than 4.75: 1 (i.e., (wt. % Zn / wt. % Mg) ⁇ 4.75: 1).
  • a weight ratio of zinc-to-magnesium is not greater than 4.60: 1 (i.e., (wt. % Zn / wt. % Mg) ⁇ 4.60: 1). In another embodiment, a weight ratio of zinc-to-magnesium is not greater than 4.50: 1 (i.e., (wt. % Zn / wt. % Mg) ⁇ 4.50: 1). In yet another embodiment, a weight ratio of zinc-to-magnesium is not greater than 4.40: 1 (i.e., (wt. % Zn / wt. % Mg) ⁇ 4.40: 1).
  • a weight ratio of zinc-to- magnesium is not greater than 4.35: 1 (i.e., (wt. % Zn / wt. % Mg) ⁇ 4.35: 1). In yet another embodiment, a weight ratio of zinc-to-magnesium is not greater than 4.30: 1 (i.e., (wt. % Zn / wt. % Mg) ⁇ 4.30: 1). In another embodiment, a weight ratio of zinc-to-magnesium is not greater than 4.25: 1 (i.e., (wt. % Zn / wt. % Mg) ⁇ 4.25: 1).
  • a weight ratio of zinc-to-magnesium is not greater than 4.20: 1 (i.e., (wt. % Zn / wt. % Mg) ⁇ 4.20: 1). In another embodiment, a weight ratio of zinc-to-magnesium is not greater than 4.15: 1 (i.e., (wt. % Zn / wt. % Mg) ⁇ 4.15: 1). In yet another embodiment, a weight ratio of zinc-to-magnesium is not greater than 4.10: 1 (i.e., (wt. % Zn / wt. % Mg) ⁇ 4.10: 1).
  • a weight ratio of zinc-to-magnesium is not greater than 4.00: 1 (i.e., (wt. % Zn / wt. % Mg) ⁇ 4.00: 1). In yet another embodiment, a weight ratio of zinc-to- magnesium is not greater than 3.95: 1 (i.e., (wt. % Zn / wt. % Mg) ⁇ 3.95: 1). In another embodiment, a weight ratio of zinc-to-magnesium is not greater than 3.90: 1 (i.e., (wt. % Zn / wt. % Mg) ⁇ 3.90: 1).
  • the amounts of zinc and magnesium within the 7xxx aluminum alloy product are such that the weight ratio of zinc-to-magnesium is at least 3.0: 1 (i.e., (wt. % Zn / wt. % Mg) > 3.0: 1). In one embodiment, the amounts of zinc and magnesium within the 7xxx aluminum alloy product are such that the weight ratio of zinc-to-magnesium is at least 3.25: 1 (i.e., (wt. % Zn / wt. % Mg) > 3.25: 1).
  • the amounts of zinc and magnesium within the 7xxx aluminum alloy product are such that the weight ratio of zinc-to-magnesium is at least 3.33: 1 (i.e., (wt. % Zn / wt. % Mg) > 3.33 : 1). In yet another embodiment, the amounts of zinc and magnesium within the 7xxx aluminum alloy product are such that the weight ratio of zinc-to-magnesium is at least 3.45: 1 (i.e., (wt. % Zn / wt. % Mg) > 3.45: 1). In another embodiment, the amounts of zinc and magnesium within the 7xxx aluminum alloy product are such that the weight ratio of zinc-to-magnesium is at least 3.55: 1 (i.e., (wt.).
  • the amounts of zinc and magnesium within the 7xxx aluminum alloy product are such that the weight ratio of zinc-to- magnesium is at least 3.60: 1 (i.e., (wt. % Zn / wt. % Mg) > 3.60: 1).
  • the new 7xxx aluminum alloy product may include one or more of Zr, Cr, Sc, and Hf as grain structure control materials (e.g., from 0.05-0.25 wt. % each of one or more of Zr, Cr, Sc, and Hf), limiting the total amounts of these elements such that large primary particles do not form in the alloy.
  • Grain structure control materials may, for instance, facilitate an appropriate grain structure (e.g., an unrecrystallized grain structure).
  • a new 7xxx aluminum alloy product generally includes at least 0.05 wt. % of the grain structure control materials. In one embodiment, a new 7xxx aluminum alloy product includes at least 0.07 wt. % of the grain structure control materials.
  • a new 7xxx aluminum alloy product includes at least 0.09 wt. % of the grain structure control materials.
  • a new 7xxx aluminum alloy product generally includes not greater than 1.0 wt. % of the grain structure control materials.
  • a new 7xxx aluminum alloy product includes not greater than 0.75 wt. % of the grain structure control materials.
  • a new 7xxx aluminum alloy product includes not greater than 0.50 wt. % of the grain structure control materials.
  • the grain structure control materials are selected from the group consisting of Zr, Cr, Sc, and Hf.
  • the grain structure control materials are selected from the group consisting of Zr and Cr.
  • the grain structure control material is Zr.
  • the grain structure control material is Cr.
  • the grain structure control materials comprise both Zr and Cr, and a new 7xxx aluminum alloy product includes at least 0.07 wt. % Zr and at least 0.07 wt. % Cr, wherein the wt. % Zr plus the wt. % Cr is not greater than 0.40 wt. % (i.e., wt. % Zr + wt. % Cr ⁇ 0.40 wt. %).
  • the grain structure control materials comprise both Zr and Cr, and a new 7xxx aluminum alloy product includes at least 0.07 wt. % Zr and at least 0.07 wt. % Cr, wherein the wt. % Zr plus the wt.
  • the grain structure control materials comprise both Zr and Cr, and a new 7xxx aluminum alloy product includes at least 0.07 wt. % Zr and at least 0.07 wt. % Cr, wherein the wt. % Zr plus the wt. % Cr is not greater than 0.30 wt. % (i.e., wt. % Zr + wt. % Cr ⁇ 0.30 wt. %).
  • the grain structure control materials comprise both Zr and Cr, and a new 7xxx aluminum alloy product includes at least 0.07 wt. % Zr and at least 0.07 wt. % Cr, wherein the wt. % Zr plus the wt. % Cr is not greater than 0.25 wt. % (i.e., wt. % Zr + wt. % Cr ⁇ 0.25 wt. %).
  • the grain structure control materials comprise both Zr and Cr, and a new 7xxx aluminum alloy product includes at least 0.07 wt. % Zr and at least 0.07 wt. % Cr, wherein the wt. % Zr plus the wt.
  • % Cr is not greater than 0.20 wt. % (i.e., wt. % Zr + wt. % Cr ⁇ 0.20 wt. %).
  • a new 7xxx aluminum alloy product may include at least 0.09 wt. % of at least one of Zr and Cr.
  • a new 7xxx aluminum alloy product may include at least 0.09 wt. % of both Zr and Cr.
  • the grain structure control material is Zr, and a new 7xxx aluminum alloy product includes from 0.07 to 0.18 wt. % Zr. In another embodiment, the grain structure control material is Zr, and a new 7xxx aluminum alloy product includes from 0.07 to 0.16 wt. % Zr. In yet another embodiment, the grain structure control material is Zr, and a new 7xxx aluminum alloy product includes from 0.08 to 0.15 wt. % Zr. In another embodiment, the grain structure control material is Zr, and a new 7xxx aluminum alloy product includes from 0.09 to 0.14 wt. % Zr.
  • a new 7xxx aluminum alloy product generally contains low amounts of the Cr, Sc, and Hf (e.g., ⁇ 0.04 wt. % each of Cr, Sc, and Hf). In one embodiment, a new 7xxx aluminum alloy product contains not greater than 0.03 wt. % each of Cr, Sc, and Hf. In another embodiment, a new 7xxx aluminum alloy product contains not greater than 0.02 wt. % each of Cr, Sc, and Hf. In another embodiment, a new 7xxx aluminum alloy product contains not greater than 0.01 wt. % each of Cr, Sc, and Hf. In another embodiment, a new 7xxx aluminum alloy product contains not greater than 0.005 wt. % each of Cr, Sc, and Hf.
  • the grain structure control material is Cr, and a new 7xxx aluminum alloy product includes from 0.07 to 0.25 wt. % Cr.
  • the grain structure control material is Cr, and a new 7xxx aluminum alloy product includes from 0.07 to 0.20 wt. % Cr.
  • the grain structure control material is Cr, and a new 7xxx aluminum alloy product includes from 0.08 to 0.15 wt. % Cr.
  • the grain structure control material is Cr, and a new 7xxx aluminum alloy product includes from 0.10 to 0.15 wt. % Cr.
  • a new 7xxx aluminum alloy product contains low amounts of Cr (e.g., ⁇ 0.04 wt.
  • a new 7xxx aluminum alloy product contains not greater than 0.03 wt. % Cr. In another embodiment, a new 7xxx aluminum alloy product contains not greater than 0.02 wt. % Cr. In yet another embodiment, a new 7xxx aluminum alloy product contains not greater than 0.01 wt. % Cr. In another embodiment, a new 7xxx aluminum alloy product contains not greater than 0.005 wt. % Cr.
  • a new 7xxx aluminum alloy includes low amounts of zirconium (e.g., ⁇ 0.04 wt. % Zr). In one embodiment, a new 7xxx aluminum alloy product contains not greater than 0.03 wt. % Zr. In another embodiment, a new 7xxx aluminum alloy product contains not greater than 0.02 wt. % Zr. In yet another embodiment, a new 7xxx aluminum alloy product contains not greater than 0.01 wt. % Zr. In another embodiment, a new 7xxx aluminum alloy product contains not greater than 0.005 wt. % Zr.
  • the new 7xxx aluminum alloy product may include up to 0.15 wt. % Ti. Titanium may be used to facilitate grain refining during casting, such as by using TiB 2 or TiC. Elemental titanium may also or alternatively be used. In one embodiment, the new 7xxx aluminum alloy product includes from 0.005 to 0.025 wt. % Ti.
  • the new 7xxx aluminum alloy product may include up to 0.15 wt. % Si and up to 0.20 wt. % Fe as impurities.
  • the amount of silicon and iron may be limited so as to avoid detrimentally impacting the combination of strength, fracture toughness and crack deviation resistance.
  • the new 7xxx aluminum alloy product may include up to 0.12 wt. % Si and up to 0.15 wt. % Fe as impurities.
  • the new 7xxx aluminum alloy product may include up to 0.10 wt. % Si and up to 0.12 wt. % Fe as impurities.
  • the new 7xxx aluminum alloy product may include up to 0.08 wt.
  • the new 7xxx aluminum alloy product may include up to 0.06 wt. % Si and up to 0.08 wt. % Fe as impurities.
  • the new 7xxx aluminum alloy product may include up to 0.04 wt. % Si and up to 0.06 wt. % Fe as impurities.
  • the new 7xxx aluminum alloy product may include up to 0.03 wt. % Si and up to 0.05 wt. % Fe as impurities.
  • the new 7xxx aluminum alloy product has a thickness of from 1.5 to 12.0 inches. In one embodiment, the new 7xxx aluminum alloy product has a thickness of from 2.0 to 10.0 inches. In another embodiment, the new 7xxx aluminum alloy product has a thickness of from 3.0 to 8.0 inches (7.62 - 20.3 cm). In another embodiment, the new 7xxx aluminum alloy product has a thickness of from 1.5 to 8.0 inches. In another embodiment, the new 7xxx aluminum alloy product has a thickness of from 1.5 to 6.0 inches. In another embodiment, the new 7xxx aluminum alloy product has a thickness of from 1.5 to 4.0 inches. In another embodiment, the new 7xxx aluminum alloy product has a thickness of from 2.0 to 8.0 inches.
  • the new 7xxx aluminum alloy product has a thickness of from 2.0 to 6.0 inches. In another embodiment, the new 7xxx aluminum alloy product has a thickness of from 3.0 to 6.0 inches. In another embodiment, the new 7xxx aluminum alloy product has a thickness of from 4.0 to 10.0 inches. In another embodiment, the new 7xxx aluminum alloy product has a thickness of from 4.0 to 8.0 inches. In another embodiment, the new 7xxx aluminum alloy product has a thickness of from 4.0 to 6.0 inches.
  • a new 7xxx aluminum alloy product is a rolled product (e.g., a plate product).
  • a new 7xxx aluminum alloy product is an extruded product.
  • a new 7xxx aluminum alloy product is a forged product (e.g., a hand forged product, a die forged product).
  • the new 7xxx aluminum alloy products may realize an improved combination of properties.
  • a new 7xxx aluminum alloy product realizes a typical tensile yield strength (L) of at least 63 ksi as per ASTM E8 and B557.
  • a new 7xxx aluminum alloy product realizes a typical tensile yield strength (L) of at least 64 ksi. In yet another embodiment, a new 7xxx aluminum alloy product realizes a typical tensile yield strength (L) of at least 65 ksi. In another embodiment, a 7xxx aluminum alloy product may realize a typical tensile yield strength (L) of at least 66 ksi. In yet another embodiment, a 7xxx aluminum alloy product may realize a typical tensile yield strength (L) of at least 67 ksi. In another embodiment, a 7xxx aluminum alloy product may realize a typical tensile yield strength (L) of at least 68 ksi.
  • a 7xxx aluminum alloy product may realize a typical tensile yield strength (L) of at least 69 ksi. In another embodiment, a 7xxx aluminum alloy product may realize a typical tensile yield strength (L) of at least 70 ksi. In yet another embodiment, a 7xxx aluminum alloy product may realize a typical tensile yield strength (L) of at least 71 ksi. In another embodiment, a 7xxx aluminum alloy product may realize a typical tensile yield strength (L) of at least 72 ksi. In yet another embodiment, a 7xxx aluminum alloy product may realize a typical tensile yield strength (L) of at least 73 ksi.
  • a new 7xxx aluminum alloy product realizes a typical tensile yield strength (ST) of at least 57 ksi as per ASTM E8 and B557.
  • a 7xxx aluminum alloy product may realize a typical tensile yield strength (ST) of at least 58 ksi.
  • a 7xxx aluminum alloy product may realize a typical tensile yield strength (ST) of at least 59 ksi.
  • a 7xxx aluminum alloy product may realize a typical tensile yield strength (ST) of at least 60 ksi.
  • a 7xxx aluminum alloy product may realize a typical tensile yield strength (ST) of at least 61 ksi. In another embodiment, a 7xxx aluminum alloy product may realize a typical tensile yield strength (ST) of at least 62 ksi. In yet another embodiment, a 7xxx aluminum alloy product may realize a typical tensile yield strength (ST) of at least 63 ksi. In another embodiment, a 7xxx aluminum alloy product may realize a typical tensile yield strength (ST) of at least 64 ksi. In yet another embodiment, a 7xxx aluminum alloy product may realize a typical tensile yield strength (ST) of at least 65 ksi. In another embodiment, a 7xxx aluminum alloy product may realize a typical tensile yield strength (ST) of at least 66 ksi.
  • a new 7xxx aluminum alloy product realizes a typical K IC plane-strain fracture toughness (L-T) of at least 25 ksi-sqrt-inch as per ASTM E8 and E399- 12.
  • a new 7xxx aluminum alloy product realizes a typical 3 ⁇ 4c plane-stain fracture toughness (L-T) of at least 27 ksi-sqrt-inch.
  • a new 7xxx aluminum alloy product realizes a typical K IC plane-stain fracture toughness (L-T) of at least 28 ksi-sqrt-inch.
  • a new 7xxx aluminum alloy product realizes a typical 3 ⁇ 4c plane-stain fracture toughness (L-T) of at least 29 ksi-sqrt-inch.
  • a new 7xxx aluminum alloy product realizes a typical Kic plane-stain fracture toughness (L-T) of at least 30 ksi-sqrt-inch.
  • a new 7xxx aluminum alloy product realizes a typical K IC plane-stain fracture toughness (L-T) of at least 31 ksi-sqrt-inch.
  • a new 7xxx aluminum alloy product realizes a typical Kic plane-stain fracture toughness (L-T) of at least 32 ksi-sqrt-inch. In yet another embodiment, a new 7xxx aluminum alloy product realizes a typical K IC plane-stain fracture toughness (L-T) of at least 33 ksi-sqrt-inch. In another embodiment, a new 7xxx aluminum alloy product realizes a typical Kic plane-stain fracture toughness (L-T) of at least 34 ksi-sqrt- inch.
  • a new 7xxx aluminum alloy product realizes a typical Kic plane-stain fracture toughness (L-T) of at least 35 ksi-sqrt-inch. In another embodiment, a new 7xxx aluminum alloy product realizes a typical K IC plane-stain fracture toughness (L-T) of at least 36 ksi-sqrt-inch. In yet another embodiment, a new 7xxx aluminum alloy product realizes a typical 3 ⁇ 4c plane-stain fracture toughness (L-T) of at least 37 ksi-sqrt-inch.
  • a new 7xxx aluminum alloy product realizes a typical K IC plane-stain fracture toughness (L-T) of at least 38 ksi-sqrt-inch.
  • a new 7xxx aluminum alloy product realizes a typical Kic plane-stain fracture toughness (L-T) of at least 39 ksi-sqrt-inch.
  • a new 7xxx aluminum alloy product realizes a typical Ki C plane-stain fracture toughness (L-T) of at least 40 ksi-sqrt-inch.
  • a new 7xxx aluminum alloy product realizes a typical Ki C plane-stain fracture toughness (L-T) of at least 41 ksi-sqrt-inch.
  • a new 7xxx aluminum alloy product realizes a typical Kic plane-stain fracture toughness (L-T) of at least 42 ksi-sqrt- inch.
  • a new 7xxx aluminum alloy product realizes a typical Ki C plane-stain fracture toughness (L-T) of at least 43 ksi-sqrt-inch.
  • a new 7xxx aluminum alloy product realizes a typical Ki C plane-stain fracture toughness (L-T) of at least 44 ksi-sqrt-inch. In yet another embodiment, a new 7xxx aluminum alloy product realizes a typical 3 ⁇ 4c plane-stain fracture toughness (L-T) of at least 45 ksi-sqrt-inch.
  • a new 7xxx aluminum alloy product realizes a typical Kic plane-strain fracture toughness (S-L) of at least 20 ksi-sqrt-inch as per ASTM E8 and E399- 12.
  • a new 7xxx aluminum alloy product realizes a typical Ki C plane- strain fracture toughness (S-L) of at least 22 ksi-sqrt-inch.
  • a new 7xxx aluminum alloy product realizes a typical Kic plane-strain fracture toughness (S-L) of at least 24 ksi-sqrt-inch.
  • a new 7xxx aluminum alloy product realizes a typical K IC plane-strain fracture toughness (S-L) of at least 26 ksi-sqrt-inch. In another embodiment, a new 7xxx aluminum alloy product realizes a typical Kic plane-strain fracture toughness (S-L) of at least 28 ksi-sqrt-inch. In another embodiment, a new 7xxx aluminum alloy product realizes a typical K IC plane-strain fracture toughness (S-L) of at least 30 ksi- sqrt-inch.
  • a new 7xxx aluminum alloy product realizes a typical K IC plane-strain fracture toughness (S-L) of at least 32 ksi-sqrt-inch. In another embodiment, a new 7xxx aluminum alloy product realizes a typical Kic plane-strain fracture toughness (S-L) of at least 34 ksi-sqrt-inch. In another embodiment, a new 7xxx aluminum alloy product realizes a typical K IC plane-strain fracture toughness (S-L) of at least 36 ksi-sqrt-inch.
  • a new 7xxx aluminum alloy product realizes a typical Kic plane-strain fracture toughness (S-L) of at least 38 ksi-sqrt-inch. In another embodiment, a new 7xxx aluminum alloy product realizes a typical K IC plane-strain fracture toughness (S-L) of at least 40 ksi-sqrt-inch.
  • a new 7xxx aluminum alloy product realizes a typical elongation (L) of at least 8% as per ASTM E8 and B557. In another embodiment, a new 7xxx aluminum alloy product realizes a typical elongation (L) of at least 9%. In yet another embodiment, a new 7xxx aluminum alloy product realizes a typical elongation (L) of at least 10%. In another embodiment, a new 7xxx aluminum alloy product realizes a typical elongation (L) of at least 1 1%. In yet another embodiment, a new 7xxx aluminum alloy product realizes a typical elongation (L) of at least 12%.
  • a new 7xxx aluminum alloy product realizes a typical elongation (L) of at least 13%. In yet another embodiment, a new 7xxx aluminum alloy product realizes a typical elongation (L) of at least 14%). In another embodiment, a new 7xxx aluminum alloy product realizes a typical elongation (L) of at least 15%>. In yet another embodiment, a new 7xxx aluminum alloy product realizes a typical elongation (L) of at least 16%>.
  • a new 7xxx aluminum alloy product realizes a typical elongation (ST) of at least 3%> as per ASTM E8 and B557. In another embodiment, a new 7xxx aluminum alloy product realizes a typical elongation (ST) of at least 4%>. In yet another embodiment, a new 7xxx aluminum alloy product realizes a typical elongation (ST) of at least 5%. In another embodiment, a new 7xxx aluminum alloy product realizes a typical elongation (ST) of at least 6%>. In yet another embodiment, a new 7xxx aluminum alloy product realizes a typical elongation (ST) of at least 7%>.
  • a new 7xxx aluminum alloy product realizes a typical elongation (ST) of at least 8%. In yet another embodiment, a new 7xxx aluminum alloy product realizes a typical elongation (ST) of at least 9%. In another embodiment, a new 7xxx aluminum alloy product realizes a typical elongation (ST) of at least 10%.
  • a new 7xxx aluminum alloy product realizes a typical L-S crack deviation resistance (Kmax-dev) of at least 25 ksi-sqrt-in.
  • a new 7xxx aluminum alloy product realizes a typical L-S crack deviation resistance (K max- dev) of at least 27 ksi-sqrt-in.
  • a new 7xxx aluminum alloy product realizes a typical L-S crack deviation resistance (K max-dev ) of at least 29 ksi-sqrt-in.
  • a new 7xxx aluminum alloy product realizes a typical L-S crack deviation resistance (K max- dev) of at least 31 ksi-sqrt-in.
  • a new 7xxx aluminum alloy product realizes a typical L-S crack deviation resistance (K max-dev ) of at least 33 ksi-sqrt-in.
  • a new 7xxx aluminum alloy product realizes a typical L-S crack deviation resistance (K max- de V ) of at least 35 ksi-sqrt-in.
  • a new 7xxx aluminum alloy product realizes a typical L-S crack deviation resistance (Kmax- dev) of at least 37 ksi-sqrt-in.
  • a new 7xxx aluminum alloy product realizes a typical L-S crack deviation resistance (K max .d ev ) of at least 39 ksi-sqrt-in.
  • a new 7xxx aluminum alloy product realizes a typical L-S crack deviation resistance (Kmax-dev) of at least 41 ksi-sqrt-in.
  • a new 7xxx aluminum alloy product realizes a typical L-S crack deviation resistance (K ma x-dev) of at least 43 ksi-sqrt-in.
  • a new 7xxx aluminum alloy product realizes a typical L-S crack deviation resistance (K ma x-dev) of at least 45 ksi-sqrt-in. In another embodiment, a new 7xxx aluminum alloy product realizes a typical L-S crack deviation resistance (K ma x-dev) of at least 47 ksi-sqrt-in. In yet another embodiment, a new 7xxx aluminum alloy product realizes a typical L-S crack deviation resistance (K max -dev) of at least 49 ksi-sqrt-in. In another embodiment, a new 7xxx aluminum alloy product realizes a typical L-S crack deviation resistance (K max -dev) of at least 50 ksi-sqrt-in.
  • a new 7xxx aluminum alloy product realizes a typical EAC resistance at 85% of TYS-ST of at least 80 days. In another embodiment, a new 7xxx aluminum alloy product realizes a typical EAC resistance at 85% of TYS-ST of at least 100 days. In another embodiment, a new 7xxx aluminum alloy product realizes a typical EAC resistance at 85% of TYS-ST of at least 120 days. In another embodiment, a new 7xxx aluminum alloy product realizes a typical EAC resistance at 85% of TYS-ST of at least 140 days. In another embodiment, a new 7xxx aluminum alloy product realizes a typical EAC resistance at 85% of TYS-ST of at least 160 days.
  • a new 7xxx aluminum alloy product realizes a typical EAC resistance at 85% of TYS-ST of at least 180 days. In another embodiment, a new 7xxx aluminum alloy product realizes a typical EAC resistance at 85% of TYS-ST of at least 200 days. In another embodiment, a new 7xxx aluminum alloy product realizes a typical EAC resistance at 85% of TYS-ST of at least 220 days. In another embodiment, a new 7xxx aluminum alloy product realizes a typical EAC resistance at 85% of TYS-ST of at least 240 days. In another embodiment, a new 7xxx aluminum alloy product realizes a typical EAC resistance at 85% of TYS-ST of at least 260 days.
  • a new 7xxx aluminum alloy product realizes a typical EAC resistance at 85% of TYS-ST of at least 280 days. In another embodiment, a new 7xxx aluminum alloy product realizes a typical EAC resistance at 85% of TYS-ST of at least 300 days.
  • a new 7xxx aluminum alloy product realizes a typical EAC resistance at 60% of TYS-ST of at least 90 days. In another embodiment, a new 7xxx aluminum alloy product realizes a typical EAC resistance at 60% of TYS-ST of at least 120 days. In another embodiment, a new 7xxx aluminum alloy product realizes a typical EAC resistance at 60% of TYS-ST of at least 150 days. In another embodiment, a new 7xxx aluminum alloy product realizes a typical EAC resistance at 60% of TYS-ST of at least 180 days. In another embodiment, a new 7xxx aluminum alloy product realizes a typical EAC resistance at 60% of TYS-ST of at least 210 days.
  • a new 7xxx aluminum alloy product realizes a typical EAC resistance at 60% of TYS-ST of at least 240 days. In another embodiment, a new 7xxx aluminum alloy product realizes a typical EAC resistance at 60% of TYS-ST of at least 270 days. In another embodiment, a new 7xxx aluminum alloy product realizes a typical EAC resistance at 60% of TYS-ST of at least 300 days. In another embodiment, a new 7xxx aluminum alloy product realizes a typical EAC resistance at 60% of TYS-ST of at least 330 days. In another embodiment, a new 7xxx aluminum alloy product realizes a typical EAC resistance at 60% of TYS-ST of at least 360 days.
  • a new 7xxx aluminum alloy product realizes a typical EAC resistance at 60% of TYS-ST of at least 390 days. In another embodiment, a new 7xxx aluminum alloy product realizes a typical EAC resistance at 60% of TYS-ST of at least 420 days. In another embodiment, a new 7xxx aluminum alloy product realizes a typical EAC resistance at 60% of TYS-ST of at least 450 days. In another embodiment, a new 7xxx aluminum alloy product realizes a typical EAC resistance at 60% of TYS-ST of at least 480 days. In another embodiment, a new 7xxx aluminum alloy product realizes a typical EAC resistance at 60% of TYS-ST of at least 500 days.
  • the new thick 7xxx aluminum alloy products may be suitable for parts in various aerospace applications.
  • the alloy product is an aerospace structural component.
  • the aircraft structural component may be any of an upper wing panel (skin), an upper wing stringer, an upper wing cover with integral stringers, a spar, a spar cap, a spar web, a rib, rib feet or a rib web, stiffening elements, frames, a landing gear component (e.g., a cylinders, beams), drag braces, bulkheads, flap track assemblies, fuselage and windshield frames, gear ribs, side stays, fittings, a fuselage component (e.g., a fuselage skin), and space components (e.g., for rockets and other vehicles that may exit the earth).
  • a fuselage component e.g., a fuselage skin
  • space components e.g., for rockets and other vehicles that may exit the earth.
  • the alloy product is an armor component (e.g., of a motorized vehicle). In one embodiment, the alloy product is used in the oil and gas industry (e.g., as pipes, structural components). In one embodiment, the alloy product is a thick mold block / mold plate product (e.g., for injection molding). In one embodiment, the alloy product is an automotive product.
  • the new thick 7xxx aluminum alloy products may be made into wrought products by casting an aluminum alloy having any of the aforementioned compositions into an ingot or billet, followed by homogenizing of the ingot or billet.
  • the homogenized ingot or billet may worked by rolling, extruding, or forging to final gauge, generally by hot working, optionally with some cold working.
  • the final gauge product may be solution heat treated, and then quenched, and then stress relieved (e.g., by stretching or compression) and then artificially aged.
  • the new 7xxx aluminum alloys may be made into shape castings or by additive manufacturing into additively manufactured products.
  • the additively manufactured products may be used as-is, or may be subsequently processed, e.g., processed via mechanical, thermal, or thermomechanical treatment.
  • TYS(L) typically longitudinal (L) tensile yield strength
  • TYS(L) is determined in accordance with ASTM B557-10 and by measuring the tensile yield strength (TYS) in the longitudinal direction (L) at the T/4 location from at least three different lots of material, and with at least duplicate specimens being tested for each lot, for a total of at least 6 different measured specimen values, with the typical TYS(L) being the average of the at least 6 different measured specimen values.
  • Typical elongation (L) is measured during longitudinal tensile testing.
  • TYS(ST) typically longitudinal (ST) tensile yield strength
  • ST short transverse direction
  • K IC typically plane strain fracture toughness
  • K IC typically plane strain fracture toughness (S-L)
  • ASTM E399-12 is determined in accordance with ASTM E399-12, by measuring the plane strain fracture toughness in the S-L direction at the T/2 location from at least three different lots of material using a C(T) specimen, where "W” and "B” are per the below table, with at least duplicate specimens being tested for each lot, for a total of at least 6 different measured specimen values, and with the typical plane strain fracture toughness (K IC ) (S-L) being the average of the at least 6 different valid 3 ⁇ 4 measured specimen values.
  • the typical L-S crack deviation resistance properties are to be determined per the procedure described in commonly-owned U.S. Patent Application Publication No. 2017/0088920, paragraph 0058, which procedure is incorporated herein by reference, except: (a) the "W" dimension of the specimen shall be 2.0 inches (5.08 cm), (b) the specimen shall be centered at T/2 (as opposed to the notch tip), and (c) the test specimens may be tested in lab air as opposed to high humidity air.
  • EAC resistance is tested per ASTM G49 and per the conditions defined below. At least three short transverse (ST) samples are taken from mid-thickness of the final product and between W/4 and 3W/4 of the final product. The extracted samples are then machined into tensile specimens per ASTM E8 and matching the dimensions of FIG. 3 (the dimensions of FIG. 3 are in inches). If the final product thickness is at least 2.25 inches, then the length of the tensile specimen is 2.00 inches, as shown in FIG. 3. If the final product thickness is from 1.50 inches to less than 2.25 inches, the length of the specimen must be at least 1.25 inches and should be as close to 2.00 inches as possible.
  • the tensile specimens Prior to testing the tensile specimens are to be cleaned / degreased by washing in acetone. The tensile specimens are then strained in the short-transverse direction at 85% or 60% of their ST tensile yield strength (strength being measured at room temperature).
  • the stressing frame used is a constant strain type per ASTM G49, section 7.2.2 (see, e.g., FIG. 4a of ASTM G49).
  • the strained specimens are then placed into a controlled cabinet having air at 85% relative humidity (without additions to the air, such as chlorides) and a temperature of 70°C. At least three specimens must be tested.
  • the "typical EAC resistance" is the lowest failure date of the at least three specimens.
  • the "typical EAC resistance" is 76 days.
  • a failure is when the specimen breaks into two halves, either along the gauge length or at one of the specimen shoulders adjoining the gauge length. Shoulder failures are statistically equivalent to gauge length failures. Thread failures are not included when determining typical EAC resistance. A thread failure is when a crack occurs in a threaded end of a specimen as opposed to in the gauge length. Thread failures are generally not detectable until the specimen is removed from the stressing frame.
  • the term “or” is an inclusive “or” operator, and is equivalent to the term “and/or,” unless the context clearly dictates otherwise.
  • the term “based on” is not exclusive and allows for being based on additional factors not described, unless the context clearly dictates otherwise.
  • the meaning of “a,” “an,” and “the” include plural references, unless the context clearly dictates otherwise.
  • the meaning of “in” includes “in” and “on”, unless the context clearly dictates otherwise.
  • FIG. 1 is a graph showing EAC resistance properties of Example 1 alloys at 85% of its TYS -ST.
  • FIG. 2 is a graph showing EAC resistance properties of Example 1 alloys at 60% of its TYS -ST.
  • FIG. 3 is an illustration of a tensile specimen for testing EAC resistance properties.
  • FIG. 4 is a graph showing EAC resistance properties of Example 3 alloys at 85% of its TYS -ST.
  • FIG. 5 is a graph showing EAC resistance properties of Example 3 alloys at 60% of its TYS -ST.
  • FIG. 6 is a graph showing EAC resistance properties of Example 4 alloys at 85% of its TYS -ST.
  • FIG. 7 is a graph showing EAC resistance properties of Example 4 alloys at 60% of its TYS-ST.
  • 7085-LS is a lab scale version of a conventional aluminum alloy, registered with the Aluminum Association as aluminum alloy 7085.
  • the registered version of the 7085 alloy requires, among other things, 0.08 - 0.15 wt. % Zr, not greater than 0.04 wt. % Mn and not greater than 0.04 wt. % Cr, as shown by the document "International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys", The Aluminum Association (2009), page 12.
  • Commonly-owned U.S. Patent No. 6,972, 110 also relates to the 7085 alloy.
  • Alloys 1-7 are new alloys having lower amounts of zinc (Zn) and/or also having manganese (Mn).
  • each alloy was aluminum and unavoidable impurities ( ⁇ 0.03 wt. % each, ⁇ 0.10 wt. % total).
  • the ingots were stress-relieved, sawed into multiple sections, scalped, homogenized, and then hot rolled to plate having a final gauge of about 1.75 inches (4.445 cm).
  • the alloy plates were then solution heat treated and then hot water quenched in 190°F water (87.8°C) to simulate cooling conditions at T/2 (mid-thickness) for 5 inch plate relative to cold water (ambient) quenching.
  • the plates were then stretched about 2.25% and then artificially aged. Table 2, below, provides the aging conditions for the various alloys.
  • N/A means specimen data not applicable due to thread failure.
  • the new alloys with manganese and having zinc, magnesium, and copper within the scope of the formula 2.362 ⁇ Mg+0.429*Cu+0.067*Zn ⁇ 3.062 realize an improved combination of properties, including EAC resistance properties, over the conventional 7085 materials.
  • This data also suggests that using a Zn/Mg (wt. % ratio) of not greater than 5.25: 1 in combination with the use of manganese may lead to an improved combination of properties.
  • FIGS. 1-2 illustrate the tensile strength versus EAC results. As shown, alloys falling within the scope of the composition ranges defined herein realize an improved combination of EAC resistance and strength.
  • the plant produced materials include the label PP.
  • the lab scale materials include the label LS.
  • the plant produced materials have a dark border on the data markers.
  • Alloys 2, 3, 6 and 7 achieve an improved combination of mechanical and corrosion properties over the conventional 7085-T7451 alloy.
  • each alloy was aluminum and unavoidable impurities ( ⁇ 0.03 wt. % each, ⁇ 0.10 wt. % total).
  • the ingots were then hot rolled to a final gauge of 1.75 inches, and then solution heat treated, and then hot water quenched to simulate cooling conditions at T/2 (mid- thickness) for approximately 8-inch thick plate.
  • the plates were then stretched about 2.25% and then artificially aged, after which mechanical and corrosion properties were tested. The aging conditions and results are shown in Tables 10-13, below.
  • Example 3 the same testing standards as Example 1 were used for strength, fracture toughness, EAC resistance and L-S crack deviation resistance (K max- dev)- The shown strength and elongation values are averages of duplicate specimens. The fracture toughness values are taken from a single specimen. The crack deviation values are averages of triplicate specimens.
  • alloy 7085 simulating around 8 inch thick plate realizes longer days to failure than alloy 7085 shown in Table 4a and 4b that simulated around 5 inch thick plate.
  • alloy 11 realizes no EAC failures after 300 days, but with significantly higher strength and fracture toughness than that of alloy 7050. Alloy 11 realizes significantly better EAC resistance properties than alloy 7085 and with similar strength and fracture toughness properties. Alloys 8-10 have slightly lower properties, but may realize properties similar to alloy 11 if alloys 8-10 had at least 1.35 wt. % Mg and/or a lower weight ratio of zinc-to-magnesium (e.g., a ratio of not greater than 4.75: 1, (wt. % Zn)/(wt. % Mg)).
  • each alloy was aluminum and unavoidable impurities ( ⁇ 0.03 wt. % each, ⁇ 0.10 wt. % total).
  • the ingots were then hot rolled to various final gauges, and then solution heat treated and quenched in cold water.
  • the plates were then stretched about 2.25-2.50% and then artificially aged.
  • Table 15, below, provides the various conditions for the various alloys.
  • Table 16 provides various artificial aging conditions listed in Table 15.
  • the 7085 plates were aged to a T7451-type or a T7651-type temper (see, ANSI H35.1, AMS-4329A).
  • the 7050 plates were also aged to a T7451-type or a T651-type temper.
  • Example 4 For this Example 4, the same ASTM testing standards as Example 1 were used for strength, fracture toughness and EAC resistance.
  • the typical L-S crack deviation resistance properties (K max-dev ) were determined per the procedure described in commonly-owned U.S. Patent Application Publication No. 2017/0088920, paragraph 0058, as modified above per the Definitions section, above.
  • the shown strength, elongation and fracture toughness values are averages of duplicate specimens.
  • the crack deviation values are averages of triplicate specimens.
  • Tables 17-19 below.
  • test result was technically invalid per ASTM E399- 17, and is thus a KQ value, as a result of Pmax/PQ being greater than 1. 1 .
  • test result is usable for lot release given that B has been maximized at the specified test location.
  • alloys 12-14 show significantly improved EAC resistance over 7085 at equivalent gauge for at least one of the aging conditions.
  • alloys 12-14 exhibit significantly better strength and fracture toughness relative to 7050 in similar gauges and a comparable strength and fracture toughness relative to 7085.
  • EAC resistance increases with increasing gauge for given aging practices.

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BR112019026036B1 (pt) 2024-02-06
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