U.S. patent application number 09/859017 was filed with the patent office on 2002-02-14 for method of quenching alloy sheet to minimize distortion.
Invention is credited to Davenport, Christopher John, Gupta, Alok Kumar, Jeffrey, Paul W., Lagace, Helene P., Urbanek, Jaroslav.
Application Number | 20020017344 09/859017 |
Document ID | / |
Family ID | 25329778 |
Filed Date | 2002-02-14 |
United States Patent
Application |
20020017344 |
Kind Code |
A1 |
Gupta, Alok Kumar ; et
al. |
February 14, 2002 |
Method of quenching alloy sheet to minimize distortion
Abstract
A method of producing a sheet article or other elongated product
of solution heat treated aluminum alloy substantially free of
permanent thermal distortion. The method involves subjecting an
article made of a heat-treatable aluminum alloy to a solution heat
treatment, cooling the article in a gas from the solutionizing
temperature to an upper critical temperature below which
precipitation of second phase particles of the alloy may occur,
further cooling the article in a gas/liquid from the upper
temperature to a lower critical temperature below which
precipitation of the components may no longer occur, and optionally
additionally cooling the article to a temperature below the lower
critical temperature. The cooling of the article in the gas is
carried out at a rate of cooling at which the yield strength of the
article remains high enough to resist permanent deformation caused
by thermal stress generated within the article by the cooling.
Inventors: |
Gupta, Alok Kumar;
(Kingston, CA) ; Lagace, Helene P.; (Kingston,
CA) ; Jeffrey, Paul W.; (Kingston, CA) ;
Urbanek, Jaroslav; (Anna Maria, FL) ; Davenport,
Christopher John; (Rugby, GB) |
Correspondence
Address: |
COOPER & DUNHAM LLP
1185 Ave. of the Americas
New York
NY
10036
US
|
Family ID: |
25329778 |
Appl. No.: |
09/859017 |
Filed: |
May 15, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09859017 |
May 15, 2001 |
|
|
|
09467306 |
Dec 17, 1999 |
|
|
|
Current U.S.
Class: |
148/551 ;
148/698 |
Current CPC
Class: |
C21D 9/573 20130101;
C21D 1/667 20130101; C22F 1/05 20130101; C22F 1/04 20130101; C22F
1/047 20130101 |
Class at
Publication: |
148/551 ;
148/698 |
International
Class: |
C22F 001/04 |
Claims
What we claim is:
1. A method of producing an article of solution heat treated
aluminum alloy substantially free of permanent thermal distortion,
comprising: subjecting an article made of a heat-treatable aluminum
alloy to a solution heat treatment at a solutionizing temperature
to dissolve soluble precipitates present in said alloy, cooling
said article in a gas from said solutionizing temperature to an
upper critical temperature below which precipitation of second
phase particles of said alloy may occur, further cooling said
article in a liquid or gas/liquid mixture from said upper critical
temperature to a lower critical temperature below which
precipitation of said second phase particles may no longer occur,
and optionally additionally cooling said article to a temperature
below said lower critical temperature, wherein said cooling of said
article above the upper critical temperature in said gas is carried
out at a rate of cooling at which the yield strength of the article
remains high enough to resist permanent deformation caused by
thermal stress generated within the article by said cooling, and
said further cooling of said article between the upper and lower
critical temperatures in said liquid takes place at a rate of
cooling fast enough to avoid significant precipitation from said
alloy.
2. The method of claim 1, wherein said cooling of said article
below said lower critical temperature is carried out in a gas.
3. The method of claim 1, wherein said cooling of said article
below said lower critical temperature is carried out at a rate
slower than said further cooling in said liquid or gas/liquid
mixture.
4. The method of claim 1, wherein the cooling of the article in the
gas from said solutionizing temperature to the upper critical
temperature is carried out in a single cooling zone.
5. The method of claim 1, wherein the cooling of the article in the
gas from said solutionizing temperature to the upper critical
temperature is carried out in a plurality of cooling zones.
6. The method of claim 5, wherein the temperature of the gas in
each successive cooling zone is progressively lower.
7. The method of claim 6, wherein the lower temperatures are chosen
to progressively increase the quenching rate in each zone in
proportion to an increase of yield strength of the alloy in each
zone.
8. The method of claim 1, wherein said alloy of said sheet article
is an AA6000 series aluminum alloy.
9. The method of to claim 8, wherein said upper critical
temperature range is about 450.degree. C. and said lower critical
temperature is about 325.degree. C.
10. The method of claim 8, wherein said step of cooling said sheet
article with a gas from said solutionizing temperature to said
upper critical temperature is carried out at a rate of between
10.degree. C./sec and 200.degree. C./sec.
11. The method of claim 8, wherein said step of cooling said sheet
article with a gas from said solutionizing temperature to said
upper critical temperature is conducted at a rate of approximately
20.degree. C./s.
12. The method of claim 8, wherein said step of further cooling
from the upper critical temperature to the lower critical
temperature is conducted at a rate of between 200.degree. C./sec
and 2000.degree. C./sec.
13. The method of claim 8, wherein said step of further cooling
said sheet article with a liquid or a gas/liquid mixture from the
upper critical temperature to the lower critical temperature is
carried out at a rate of between 200.degree. C./sec and 450.degree.
C./sec.
14. The method of claim 1, wherein the article is in the form of a
sheet.
15. The method of claim 1, wherein said further cooling of said
article in a liquid or gas/liquid is carried out in at least two
stages at different cooling rates, said cooling rates increasing
from stage to stage as said cooling progresses.
16. The method of claim 15, wherein said further cooling of said
article exhibits a parabolic or substantially parabolic temperature
profile when sheet article temperature is plotted against distance
down the article.
17. The method of claim 15, wherein said further cooling of said
article is effected by advancing said article past a plurality of
spray nozzles for directing sprays of liquid or liquid/gas onto
said article, said sprays causing said cooling in said at least two
stages at said different rates.
18. The method of claim 17, wherein said article is first advanced
past at least one Coanda nozzle, then past at least one nozzle
directing a spray of liquid at a non-perpendicular angle to an
adjacent surface of said article, and then past at least one nozzle
directing a spray of liquid perpendicular to said surface of said
article.
19. The method of claim 17, which includes adjusting flow rates of
said spray nozzles so that said article encounters sprays of
different intensities as said article is advanced.
20. A method of quenching an article made of aluminum or an
aluminum alloy following solution heat treatment at a solutionizing
temperature while avoiding substantial thermal distortion, wherein
variable cooling rates are employed at different stages of
quenching, characterized in that the article is first cooled in a
gas from the solutionizing temperature to an upper critical
temperature, below which precipitation of second phase particles of
the alloy may occur, at a rate of cooling at which the yield
strength of the article remains high enough to resist permanent
deformation caused by thermal stress generated within the article
by the cooling, followed by further cooling from the upper critical
temperature to a lower critical temperature below which
precipitation of said second phase particles may no longer occur at
a rate of cooling fast enough to avoid significant precipitation
from the alloy.
21. A method according to claim 20, characterized in that the
article is in the form of a sheet.
22. A process of producing a heat treatable aluminum alloy sheet
article in T4 or T4P temper, which comprises direct chill or
continuously casting an alloy to form a casting, homogenizing the
casting above a solvus temperature of the alloy to dissolve soluble
particles present in the casting, hot- and/or cold-rolling the
casting to form a sheet article of final gauge, solutionizing the
sheet article of final gauge at a solutionizing temperature above
the solvus temperature to dissolve soluble particles formed during
the hot- and/or cold-rolling, and quenching the sheet article of
final gauge to form a sheet article in T4 or T4P temper, wherein
the quenching is carried out by cooling the sheet article in a gas
from the solutionizing temperature to an upper critical temperature
below which precipitation of second phase particles of the alloy
may occur, further cooling the article in a liquid or a gas/liquid
mixture from the upper critical temperature to a lower critical
temperature below which precipitation of the second phase particles
may no longer occur, and optionally additionally cooling the
article to a temperature below the lower critical temperature.
23. The process of claim 22, wherein the hot and/or cold rolling of
the casting is carried out with an intermediate annealing step.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a Continuation-in-Part of our prior
application Ser. No. 09/467,306, filed Dec. 17, 1999 (pending).
BACKGROUND OF THE INVENTION
[0002] I. Field of the Invention
[0003] The present invention relates to methods of quenching
heat-treatable aluminum alloy sheet from solutionizing temperatures
to fabricate alloy sheet in either the T4 or T4P tempers, which are
the conditions in which such sheet articles are normally supplied
to automobile manufactures. More particularly, the invention
relates to methods of this kind intended to minimize distortions of
the sheet articles caused by thermal stress generated during
quenching.
[0004] II. Description of the Prior Art
[0005] Manufacturers of aluminum alloy sheet articles are faced
with the challenge of providing thin gauge sheet materials that
have both good formability in the supplied temper and high strength
after a part has been formed and paint-cured. The automobile
industry, in particular, demands such products for use as the raw
material for producing body panels or structural members of reduced
weight in the ongoing quest for improved vehicle economy and fuel
efficiency.
[0006] It has become commonplace to make use of heat-treatable AA
(Aluminum Association) 6000 series, or some AA2000 series, aluminum
alloys for the production of such sheet articles. Heat-treatable
alloys are generally those containing soluble alloying constituents
in amounts that exceed their room temperature solubility limits.
Such alloys may develop enhanced properties upon being subjected to
working and/or heating, followed by a quenching step. These alloys
usually contain hardening elements (e.g. magnesium, silicon and/or
copper) to provide hardening during aging, and other elements, like
Fe, Mn and possibly Cr, to control the formability and grain size.
These alloys are generally direct chill (DC) or continuously cast
and homogenized above the solvus temperature (which is defined as
the temperature above which all the soluble particles, e.g.
Mg.sub.2Si, Al.sub.wCu.sub.xMg.sub.ySi.sub.z (referred to as Q),
and other particles depending on the alloy composition, become
unstable and dissolve in the aluminum matrix), in order to dissolve
the soluble particles present in the as-cast ingot or continuous
strip, and to improve hot ductility for subsequent
thermo-mechanical processing steps. The homogenized ingot is hot-
and cold-rolled to the final gauge with or without an intermediate
annealing step. The final gauge sheet material is then solutionized
above the solvus temperature (usually in the range of 480 to
580.degree. C.) to dissolve the soluble particles that are formed
during the hot- and cold-rolling, and then quenched to obtain the
desired T4 or T4P temper.
[0007] The quenching process is one of the most critical steps in
producing an acceptable sheet material in the supplied temper. The
material is considered highly undesirable if it contains coarse
grain boundary particles since they affect the mechanical
properties of the sheet, such as its bendability, and to some
extent the hardening response during the paint cure. Therefore, it
is essential that the sheet material be rapidly quenched from the
solutionizing temperature to avoid precipitation of the harmful
secondary phase particles on the grain boundaries, and occasionally
within the matrix, and to obtain the best combination of
formability in the supplied temper and hardening response during
the paint cure.
[0008] Unfortunately, rapid quenching from solutionizing
temperature can result in permanent distortion of the sheet
article, particularly for thin gauge products. When such distortion
occurs, the sheet must be flattened mechanically more than usual by
stretching and/or bending to remove the distortions. This decreases
the formability of the material due to the cold working that is
introduced during the stretching operation. It would therefore be
advantageous to avoid such distortion during quenching procedures,
and this goal has already been given consideration in the prior
art. However, steps taken to avoid or minimize distortion can
adversely affect the intended advantages of the quenching
operation, or can introduce costly and inconvenient steps into the
quenching process.
[0009] U.S. Pat. No. 4,784,921 which issued on Nov. 15, 1988 to M.
E. Hyland, et al., discloses a method of producing aluminum sheet
materials suitable for vehicle panels. The method involves a
solution heat treatment followed by rapid quenching at a rate of at
least 10.degree. F./sec (preferably at least 300.degree. F./sec)
from the solutionizing temperature by means of liquid cooling.
After the sheet has reached a temperature of 350.degree. F. or
less, air cooling may be employed to ambient temperature.
[0010] Similarly, U.S. Pat. No. 5,061,327 which issued on Oct. 29,
1991 to D. K. Denzer, teaches of a method preferably involving a
cold water quench directly from the solutionizing temperature. The
preferred method involves sheet alloy quenching in water to
approximately 93.degree. C. at a rate greater than or equal to
56.degree. C./sec, followed by air cooling to ambient
temperature.
[0011] PCT publication WO 98/42885 of Oct. 1, 1998 filed in the
name of Aluminum Company of America discloses a process for the
manufacture of metal alloy sheet without distortion wherein a
controllably variable liquid quenching means is used to control the
time at which an alloy strip remains above a critical temperature
(the so-called Leidenfrost temperature--the temperature above which
a vapor layer is present between the sheet surface and the liquid
cooling film). It is said that the liquid quench cools the metal
through the critical temperature at a rate that can be controllably
varied from each metal alloy composition and can increase or at
least maintain the strength potential of the alloy without physical
distortion. However, this reference links the cooling to variables
that have nothing to do with the material being cooled. The
publication states that the Leidenfrost temperature is functionally
and operatively related to the specific spray orifice used for the
cooling liquid, the flow rate, the physical and chemical properties
of the liquid, and the pressure used to apply the liquid. It is
therefore difficult to achieve the best results for any particular
alloy without carrying out complicated adjustments. Also, while the
material may have a gas layer separating the hot material from the
cooling liquid, this gas layer is created by evaporation of the
cooling liquid, which requires the extraction of heat of
vaporization from the material, thus providing a significantly
higher cooling rate than would be the case if a change of state
from a liquid to a gas was not involved.
[0012] Consequently, the inventors of the present invention have
found that methods involving liquid quenching from solution
temperatures are difficult to control in a way that enables thermal
distortion to be minimized while retaining good formability in the
as-supplied tempers and high strength after the part has been
formed and paint cured.
SUMMARY OF THE INVENTION
[0013] An object of the present invention is to provide a method of
quenching a sheet article of solution heat treated aluminum alloy
in a way that minimizes or avoids distortion of the article, while
also avoiding undue precipitation of second phase particles from
the metal.
[0014] Another object of the invention is to provide such a method
that can be carried out in a practical and relatively inexpensive
manner.
[0015] Another object of the invention is to provide a method of
producing an article made of heat-treatable alloy in T4 or T4P
temper by casting, homogenizing, rolling, and heat treating, while
employing a solutionizing and quenching step that avoids undue
distortion and particle precipitation.
[0016] The invention in one of its aspects provides a method of
producing an article (preferably a sheet) of solution heat treated
metal (preferably aluminum) alloy substantially free of permanent
thermal distortion. The method comprises subjecting an article made
of a heat-treatable aluminum alloy to a solution heat treatment at
a solutionizing temperature to dissolve soluble particles present
in the alloy, cooling the article in a gas from the solutionizing
temperature to an upper critical temperature below which
substantial precipitation of soluble second phase particles may
occur, further cooling the article in a liquid or a liquid/gas
mixture from the upper critical temperature to a lower critical
temperature below which precipitation of the second phase particles
may no longer occur, and optionally additionally cooling the
article to a temperature below the lower critical temperature. The
cooling of the article in the gas above the upper critical
temperature is carried out at a rate of cooling at which the yield
strength of the article remains high enough to resist permanent
deformation caused by thermal stress generated within the article
by the cooling effect, and the further cooling of the article
between the upper and lower critical temperatures in the liquid
takes place at a rate of cooling fast enough to avoid significant
precipitation from the alloy.
[0017] The further cooling of the article in a liquid or a
gas/liquid (i.e. below the upper critical temperature) is
preferably carried out in at least two (and preferably three)
stages at different cooling rates, with the cooling rates
increasing from stage to stage as the cooling progresses. Most
preferably, the further cooling of the article is such that, when
cooled in a continuous process, it creates a parabolic or
substantially parabolic temperature profile when the sheet article
temperature is plotted against distance down the sheet. The further
cooling of the sheet article is preferably effected by advancing
the strip article past a plurality of spray nozzles for directing
sprays of liquid or liquid/gas onto the strip article, the sprays
causing the cooling in the at least two stages at the indicated
different rates. The sheet article is preferably first advanced
past at least one nozzle, which gives a relatively gentle cooling
action, preferably using air or air/water mixtures, then past at
least one nozzle directing a spray of liquid which gives a more
aggressive cooling action, preferably also at a non-perpendicular
angle to an adjacent surface of the sheet article, and then past at
least one nozzle directing a spray of liquid giving the most
aggressive cooling action and preferably also substantially
perpendicular to the surface of the sheet article. Alternatively,
or additionally, the flow rates of the spray nozzles may be
adjusted so that the sheet article encounters sprays of different
intensities or different fluid temperatures as the sheet article is
advanced.
[0018] In another aspect, the invention provides a method of
quenching a sheet article made of a heat-treatable aluminum alloy
following solution heat treatment at a solutionizing temperature
while avoiding substantial thermal distortion, in which variable
cooling rates are employed at different stages of quenching.
Specifically, the article is first cooled in a gas from the
solutionizing temperature to an upper critical temperature, below
which precipitation of second phase particles of the alloy may
occur, at a rate of cooling at which the yield strength of the
article remains high enough to resist permanent deformation caused
by thermal stress generated within the article by the cooling,
followed by further cooling from the upper critical temperature to
a lower critical temperature below which precipitation of said
second phase particles may no longer occur at a rate of cooling
fast enough to avoid significant precipitation from the alloy.
[0019] According to yet another aspect of the invention, there is
provided a process of producing a heat treatable aluminum alloy
sheet article in T4 or T4P temper, which comprises direct chill or
continuously casting an alloy to form a casting, homogenizing the
casting above a solvus temperature of the alloy to dissolve soluble
particles present in the casting, hot- and/or cold-rolling the
casting to form a sheet article of final gauge, solutionizing the
sheet article of final gauge at a solutionizing temperature above
the solvus temperature to dissolve soluble particles formed during
the hot- and/or cold-rolling, and quenching the sheet article of
final gauge to form a sheet article in T4 or T4P temper, wherein
the quenching is carried out by cooling the sheet article in a gas
from the solutionizing temperature to an upper critical temperature
below which precipitation of second phase particles of the alloy
may occur, further cooling the article in a liquid or a gas/liquid
mixture from the upper critical temperature to a lower critical
temperature below which precipitation of the second phase particles
may no longer occur, and optionally additionally cooling the
article to a temperature below the lower critical temperature.
Preferably, the cooling of the article above the upper critical
temperature in the gas is carried out at a rate of cooling at which
the yield strength of the article remains high enough to resist
permanent deformation caused by thermal stress generated within the
article by the cooling, and the further cooling of the article
between the upper and lower critical temperatures in the liquid
takes place at a rate of cooling fast enough to avoid significant
precipitation from the alloy. In this process, the hot and/or cold
rolling of the casting may be carried out with an intermediate
annealing step.
[0020] The invention also relates to a solution-heat-treated alloy
article or sheet produced by the methods and processes described
above.
[0021] The gas cooling step has the practical effect of lowering
the quench-start temperature for the subsequent liquid cooling step
that is carried out at a high rate of cooling and that consequently
generates high thermal stresses. At the lower quench-start
temperature, the alloy has an increased yield strength compared to
that at the solutionizing temperature, and is therefore better able
to resist thermal deformation.
[0022] The initial cooling of the article in the gas (referred to
as slow cooling) may be accomplished by using heated air as the
cooling medium in one or more successive zones of a heat treatment
apparatus through which the article is passed immediately following
the heating zone of a continuous heat treatment furnace. The heated
air in the cooling zone is preferably directed onto one or both of
the surfaces of the sheet article from suitable gas nozzles. The
temperature within the cooling zones may be set at different
(progressively lower) temperatures to successively increase the
quenching rate in approximate proportion to the increase of yield
strength of the metal that occurs with decreasing temperature. In
this way, very low quenching stresses are initially introduced
while the metal yield strength is low.
[0023] The quenching steps of the invention are acceptable
metallurgically because no detrimental precipitation takes place
above the upper critical temperature of the precipitation range.
Therefore, the slow quenching at high temperature does not affect
the eventual metallurgical structure of the alloy sheet product.
Once the upper critical temperature has been reached, rapid
quenching may be carried out to avoid precipitation without causing
thermal distortion. The additional cooling to a temperature below
the lower critical temperature (e.g. ambient or room temperature),
if required at all, is then preferably carried out in a gas, such
as air. However, liquid cooling may alternatively be employed for
this step, or the metal may merely be allowed to stand and cool
naturally.
[0024] The invention is particularly applicable to the treatment of
AA6000 series aluminum alloys. In such cases, the upper critical
temperature is about 450.degree. C. and the lower critical
temperature is about 325.degree. C., and the step of cooling the
sheet article with a gas from the solutionizing temperature to the
upper critical temperature is preferably carried out at a rate of
between 10.degree. C./sec and 200.degree. C./sec., and more
preferably at approximately 20.degree. C./sec. The further cooling
from the upper critical temperature to the lower critical
temperature is preferably conducted at a rate of between
200.degree. C./sec and 2000.degree. C./sec., and preferably between
200.degree. C./sec and 450.degree. C./sec.
[0025] The present invention provides an efficient and productive
method of minimizing thermal distortion during cooling of a sheet
alloy from the solution heat treatment temperature. The method has
the considerable economic advantage that it may be carried out in
conventional quenching equipment (e.g. a continuous heat treatment
line), without undue difficulty and normally without requiring
expensive modifications.
[0026] The present invention is applicable to all heat treatable
alloys that are subjected to solutionizing and quenching during
processing, e.g. aluminum alloys of the AA6000 series, AA2000
series, AA7000 series and Al--Li type alloys. Although the critical
temperature range (upper critical temperature and lower critical
temperature) and the desired cooling rates may be different for
different alloys, the appropriate ranges and cooling rates for each
alloy may be determined by simple experimentation.
[0027] It should be realized that the term "sheet" as used herein
refers to a generally flat (planar) article, often (but not
necessarily) of indefinite length. The thickness of such articles
is not particularly relevant, although automotive sheet articles
(e.g. of AA6111) subjected to solutionizing and quenching normally
have a thickness of 2.3 mm or less, typically 0.8 to 2.0 mm.
However, the term "sheet" is intended to includes a product often
referred to as "plate" (generally taken to mean a rolled product
that is rectangular in cross-section having a thickness not less
than 0.250 inch (6.35 mm) with sheared edges). While the present
invention is primarily concerned with planar articles, such as
metal sheet, the method may also be applied to shaped products,
such as extrusions, in which distortion is a factor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a graph showing how yield strength (YS) of an
alloy (in this case alloy AA6111) declines as the temperature of
the alloy increases and, in particular, how the YS declines rapidly
in the upper temperature range (e.g. above 450.degree. C.);
[0029] FIG. 2 is a graphical illustration of various quenching
methods for AA6111 aluminum alloy according to the prior art and
preferred embodiments of the present invention;
[0030] FIG. 3 is a schematic diagram showing a simplified
cross-section of a part of a heat treatment apparatus suitable for
carrying out one preferred form of the present invention;
[0031] FIGS. 4 and 5 are graphs representing typical temperature
profiles of sheet articles passing through heating and cooling
zones of the heat treatment apparatus. The cooling profile shown is
in accordance with the present invention;
[0032] FIG. 6 is a diagram similar to that of FIG. 3, showing the
part of a heat treatment apparatus used for liquid quenching
according to a further preferred embodiment of the present
invention; and
[0033] FIGS. 7 and 8 are graphs showing modeled temperature profile
predictions for strip articles quenched according to preferred
embodiments of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] The present invention provides a method for minimizing or
eliminating permanent distortion of alloy sheet or other
heat-treatable materials caused by the thermal stresses associated
with quenching practices following solution heat treatments, while
retaining the desirable effects of such solutionizing to the
greatest possible extent.
[0035] Rapid quenching of heat treatable alloys is required in
order to maximize the formability in the as-supplied (to the user)
temper while obtaining high strength, durability and good corrosion
resistance in the final product to meet the strict requirements of
the automotive industry and other users. However, the inventors of
the present invention have realized that such rapid quenching is
necessary only within the range of temperatures in which second
phase precipitation may occur. At temperatures above this range, a
slower rate of cooling may be adopted without significantly
affecting the metallurgical structure of the metal, and a rate of
cooling may be chosen at which the yield strength of the metal
remains high enough to resist thermal stresses generated by the
cooling procedure, thus minimizing or eliminating permanent
deformation of the sheet product. Such deformation is, in fact,
only likely at high temperatures where the yield strength of the
alloy is extremely low compared to the yield strength at ambient
temperature. For most heat-treatable aluminum alloys, once the
temperature has been reduced to the precipitation range, high rates
of cooling may be employed without causing deformation because the
yield strength of the alloy at these temperatures has increased
significantly compared to the yield strength at the solutionizing
temperature.
[0036] Accordingly, the present invention divides the cooling
operation from the solutionizing temperature into two or more
distinct steps. The first step involves a slow rate of cooling
(achieved by gas cooling in a heated gas) from the solutionizing
temperature to the upper critical temperature below which
precipitation may occur, and a second step involves rapid cooling
(achieved by liquid quenching, or mixed liquid and gas quenching)
through the precipitation range between the upper and lower
critical temperatures. The nature of the further cooling (if any)
carried out below the lower critical temperature of the
precipitation range is less critical and may be carried out at any
desired rate using either liquid cooling or gas cooling, although
gas cooling employing air is preferred. At these lower temperatures
the yield strength of the alloy is high enough to resist thermal
deformation without allowing precipitation of detrimental particles
on the grain boundaries.
[0037] The alloy thus obtained is generally aged, following
quenching, to obtain the desired T4 or T4P tempers.
[0038] FIG. 1 is a graph showing how the yield strength (YS) of a
typical AA6000 series alloy (specifically AA6111) falls as the
temperature of the alloy is raised. The vertical axis (ordinate)
shows the yield stress at a particular temperature expressed as a
percentage of the room temperature yield stress (R.TempYS). It will
be seen that the yield stress falls rapidly to zero as temperatures
increase from about 450 to 600.degree. C. Solutionizing often takes
place at temperatures up to about 600.degree. C., so the metal is
very susceptible to deformation at these temperatures. On the other
hand, at a temperature of about 450.degree. C., approximately 50%
of the room temperature yield stress has been developed, so the
material is quite deformation-resistant below this temperature. For
AA6000 series alloys, this is generally the upper critical
temperature of the precipitation range.
[0039] The present invention is described in particular as being a
method of processing aluminum alloy sheets of the Aluminum
Association AA6000 series aluminum alloys and some AA2000, AA7000
and Al--Li alloys. However, it is fully contemplated that the
methods of the present invention provide thermal mechanical
processing procedures which can be beneficial to the working of a
variety of heat-treatable alloys, including other categories of
aluminum alloy, provided the upper end of the temperature range at
which significant precipitation may take place is sufficiently low
that, for the alloy in question, rapid quenching may be initiated
from that temperature without significant distortion of the alloy
sheet product. That is to say, at the upper critical temperature of
the alloy in question, the yield strength of the alloy should be
high enough to resist thermal stresses caused by rapid quenching.
At temperatures above the critical temperature, the cooling rate is
slowed to allow the yield strength of the alloy to increase before
significant thermal stresses are imposed.
[0040] FIG. 2 illustrates temperature-time correlation curves for
AA6111 alloy sheet product. The figure includes regions A, B and C
depicting temperature ranges of importance to the present
invention. Region A is the temperature range between the
solutionizing temperature (T.sub.sol) and the upper critical
temperature (T.sub.upper) below which precipitation may commence.
Region B represents the precipitation range (critical range) in
which secondary phase precipitation may take place if the time and
temperature conditions are appropriate. Region C is the range of
temperatures below T.sub.lower, the temperature below which further
secondary phase precipitation does not take place at any rate of
cooling. It should be noted that these ranges in temperature are
not absolute, and will vary for any given quenching method
depending upon the physical properties of the subject alloy. The
temperature ranges can, however, be determined experimentally for
any given heat treatable alloy.
[0041] Three quenching procedures are illustrated in FIG. 2, namely
Quench 1, Quench 2 and Quench 3. These procedures differ only prior
to time "ts", i.e. the time from the termination of solutionizing
at which the alloy temperature first reaches T.sub.upper. Following
this time, the three procedures follow the same curve.
[0042] Quench 1 depicts a typical temperature gradient for
quenching methods of the prior art, while Quench 2 and Quench 3
depict temperature gradients of the methods embodied by the present
invention.
[0043] In accordance with common practices of the prior art, the
quenching process is generally a single step process which provides
rapid cooling directly from the heat solutionizing temperature
(T.sub.sol) through the critical precipitation temperature range.
As illustrated in FIG. 2, the temperature gradient of Quench 1 is
generally uniform through regions A and B. In contrast, Quench 2
and Quench 3 provide at least one preliminary step of slow cooling
through region A before initiating the rapid cooling step through
region B. The initial cooling of the sheet alloy within region A of
FIG. 1 is conducted by the application of heated air in a manner
such that thermal stress in most or all of the sheet alloy does not
exceed the yield strength of the sheet. This slow cooling using
heated air allows the temperature of the sheet alloy to approach
the critical T.sub.upper temperature at a rate sufficiently slow to
avoid high thermal stresses while allowing the development of
properties of strength and stability sufficient to withstand the
high thermal stresses generated at the onset of rapid
quenching.
[0044] The rate of cooling and the temperature of the heated air
required to produce this rate of cooling can be found empirically.
Alternatively, the rate of cooling may be determined by applying a
mathematical model that uses temperature, pressure, speed, product
gauge and the heat transfer coefficient to calculate the optimum
temperature of the heated air based on the temperature of the metal
following the solutionizing treatment. The temperature of the
cooling gas may be determined using the same mathematical model and
varies with the peak metal temperature targeted. A typical range of
gas temperatures suitable for the AA6111 alloy would be from 300 to
350.degree. C.
[0045] The heated air may be applied in one or more successive
zones of a continuous heat treatment apparatus to gradually cool
the sheet alloy. Upon reaching T.sub.upper, rapid quenching using
water or any other standard high heat capacity liquid (or mixture
of gas and liquid), is initiated in further cooling zones to
provide rapid cooling of the alloy sheet through a temperature
range in which alloy precipitation would readily occur if the rate
of cooling were sufficiently slow. At this stage of quenching, the
yield strength of the sheet alloy has substantially increased from
the yield strength at the solutionizing temperature. As such, the
sheet alloy is capable of withstanding the stress of the quenching
conducted through region B. In particular, the sheet alloy enters
region B with sufficient strength to withstand the stresses from
rapid cooling without suffering the consequence of permanent
thermal distortion. The temperature of the cooling liquid used in
this step may be much the same as the temperature of liquids used
for conventional quenching steps. The temperature is generally
between 18.degree. C. (ambient) and 30.degree. C. (warm).
[0046] Once cooled to a temperature in region C, which is below the
range of precipitation (T.sub.lower), the sheet is strong and no
harmful precipitation occurs. The details of any further cooling
that may be initiated are therefore less critical to the present
invention. The temperature of the cooling medium used for this step
may be controlled by the application of heat or cooling using heat
exchangers. Typically, the temperature varies from 20.degree. C. to
about 100.degree. C.
[0047] The methods of the invention accordingly reduce distortion
by exposing the sheet to a high quench rate only after the alloy is
sufficiently cooled to withstand the associated stresses which
accompany a rapid temperature drop. As a result, permanent
distortion to the sheet alloy is minimized and often
eliminated.
[0048] As noted, the first quenching step of the present invention
occurs within region A of FIG. 2 where the sheet alloy is slowly
cooled with air in one or more stages from the solutionizing
temperature to a temperature just above the predetermined
T.sub.upper temperature. The second quenching step occurs in region
B and is indicative of the preferred rate of cooling through the
critical temperature range. Table 1 further illustrates data on
preferred and working temperatures associated with the present
invention. It should be noted that the upper and lower range
temperatures, as well as the working quenching rates, depend on the
shape and position of the critical time curve (explained below),
while preferred quenching rates are determined from the conditions
which give the best combination of mechanical properties. Ideally,
the closer the working temperatures come to the preferred
temperature, the less thermal distortion expected in the sheet
alloy product.
1TABLE 1 Working and Preferred Quenching Rates for Air and Water
Cooling Phases Cooling Rate Range .degree. C./sec .sup.1st Step
2.sup.nd Step Cooling Range above Cooling to T.sub.upper .degree.
C. below T.sub.upper .degree. C. ALLOY T.sub.upper .degree. C.
Working Preferred Working Preferred AA6111 .gtoreq.450 10-200
.about.20 200-2000 200-450 (air cooling) AA6016 .gtoreq.450 10-200
.about.20 200-2000 340-575 (air cooling)
[0049] As illustrated in FIG. 2, the range of the critical time
curve for AA6111 alloy is found to be within the range of
325.degree. C. to 450.degree. C. The region above the T.sub.upper
temperature (region A) represents the temperature range wherein
slow cooling is preferred. This slow cooling step allows the sheet
alloy to become stronger and thus be able to withstand the thermal
stress of the subsequent aggressive quenching step. The
conventional process as depicted as Quench 1, illustrates the onset
an occasion of rapid cooling from the solutionizing temperature.
The sheet alloy resulting from this treatment will suffer the
effects of permanent distortion as a result of temperature
gradients, induced by the rapid quench, exceeding the yield
strength of the sheet alloy at or near the initial quenching
temperature. Resulting sheet alloy must then be flattened
mechanically by stretching and/or bending to remove the distortion.
Such labor-intensive cold working efforts add to the cost of
processing and decrease the formability of the material.
[0050] As further illustrated in FIG. 2, it is not until the
temperature drops below T.sub.upper at time ts that rapid quenching
must be initiated. Beginning at time ts, the time required to
quench below T.sub.lower directly determines the amount of
precipitation which will occur. The figure shows a critical time
curve S enclosing a shaded region E. At a temperature close to
T.sub.upper, the driving force for precipitation of second phase
particles is very small and nucleation and growth rates are slow
thereby prolonging the start of the precipitation process. On the
other hand, at temperatures around T.sub.lower the driving force is
very large and diffusion rates are too slow thereby impeding the
onset of the precipitation process. Thus, precipitation rapidly
occurs only at the nose N of the critical time curve C where a
large driving force and high diffusion rates are present. The
critical time curve S, as illustrated in FIG. 2, represents the
beginning of this precipitation of second phase particles as a
function of time and temperature. Thus, if the quenching curve
crosses the shaded region E, secondary phase precipitation will
take place to an undesirable extent. The properties of such a
critical time curve, including the number, shape and position of
the curve is largely dependent on alloy composition and the
processing history of the alloy.
[0051] Therefore, an objective of the thermal mechanical processing
of a sheet alloy in region B is to avoid the nose N of the critical
curve C via rapid quenching and thus to eliminate the possibility
of adverse effects caused by second phase precipitation. The time
before the nose of the curve is called the incubation period, which
is less than one second for AA6111. The precipitation process does
not occur provided the time at temperature during quenching or
aging is less than the incubation period or lies to the left of the
critical curve.
[0052] Quench 2 of FIG. 2 employs a constant slow rate of cooling
from the solutionizing temperature to T.sub.upper, the slope of the
curve being gradual enough to avoid the generation of thermal
stresses strong enough to exceed the yield strength of the alloy,
and thus cause permanent deformation.
[0053] An alternative embodiment of the present invention is
depicted in region A of FIG. 2 as Quench 3. In accordance with this
embodiment a plurality of heated air phases are applied in the
initial step of slow cooling to T.sub.upper to progressively
increase the quenching rate in approximate proportion to the
increase of yield strength with decreasing temperature. This can be
accomplished by subjecting the alloy sheet to two or more heated
air phases, operating at progressively lower air temperatures. In
this manner, very low quenching stresses are initially introduced
to the sheet alloy when the yield strength of the alloy is low.
[0054] FIG. 3 is a simplified cross-section of part of a heat
treatment apparatus suitable for carrying out a preferred form of
the present invention. The apparatus 10 is in the form of a tunnel
11 through which the strip article 12 is drawn on a continuous
basis. The apparatus is divided internally into a number of zones.
A first zone 11A forms a last step of the solutionizing procedure.
High temperature gas is introduced into the zone from nozzles 14
located in the top and bottom of the tunnel 11. The strip article
passing through this zone is heated to the solutionizing
temperature.
[0055] A second zone 11B forms a region in which the temperature of
the sheet article is cooled from the solutionizing temperature to
T.sub.upper. Heated gas is injected into the zone through nozzles
15. As the strip article passes through this zone it may be cooled,
for example, according to Quench 2 or Quench 3 of FIG. 2. Different
temperature profiles in this zone can be obtained by varying the
temperature of the gases passing through various nozzles in the
zone.
[0056] The strip article then passes into a third zone 11C in which
the article is quenched from T.sub.upper to T.sub.lower. In the
first part 16 of this zone, so-called "Coanda" nozzles 18 are
provided to deliver a cooling liquid. The nozzles are positioned at
an angle to the surface of the strip article 12 in the direction of
sheet travel and mixes the cooling liquid (water) with air to
reduce the droplet size. The smaller droplet size and angled
positioning of the nozzle serve to improve the cooling efficiency.
In this part of the zone 11C, the temperature of the strip article
is above the Leidenfrost temperature and there is a vapour barrier
between the liquid coolant (water) and the sheet surface. This
arrangement provides more efficient cooling than just spraying
cooling liquid directly onto the strip article. Once the
temperature of the strip article passes through the Leidenfrost
point, the vapour barrier disappears and conventional spray nozzles
may be employed. This further cooling to T.sub.lower is carried out
in a second part 17 of the third zone 11C using conventional
nozzles 20 oriented perpendicular to the surface of the strip
article.
[0057] It should be noted here that, although the present invention
makes use of liquid (or liquid/gas) cooling above the Leidenfrost
temperature in the indicated embodiment, this is employed only
below T.sub.upper and, in contrast, slow cooling by means of a gas
is utilized above T.sub.upper. In this further respect, the present
invention differs from the disclosure of WO 98/42885 (disclosed
earlier) where there is no such slow gas cooling. WO 98/42885
commences with liquid cooling and follows with gas cooling, whereas
the present invention does the opposite. Since the present
invention starts the cooling with a gas, the heat transfer
coefficient is inherently lower at this critical time than would be
the case with liquid cooling as in WO 98/42885 (even taking into
account the gas generation of the Leidenfrost effect because of the
additional cooling effect due to a change of state of the cooling
medium from liquid to gas).
[0058] In a fourth and final zone 11D, cooling below T.sub.lower
takes place by means of a gas introduced through nozzles 21.
[0059] FIGS. 4 and 5 are examples of temperature profiles of metal
sheet articles positioned in heat treatment lines operated
according to the present invention. These are graphs showing the
predicted temperature with elapsed time of a point on the advancing
metal strip article in solutionizing and cooling apparatus of the
type shown in FIG. 3. FIG. 4 shows the predicted profile for light
gauge sheet (1.00 mm), and FIG. 5 shows the profile for heavy gauge
sheet (2.00 mm). The Figures show the rates of change of
temperature of the metal in the various heating and cooling zones
of the heat treatment line. In both cases, it will be seen that,
following the peak solutionizing temperature, there is a slow
cooling period A in a gas (heated air) preceding a rapid liquid
(water) quench B, and then a further cooling period C to low
temperature (post-quench cooling).
[0060] In practice, sheet material subjected to the heat treatments
of FIGS. 4 and 5 is found to be substantially free of thermal
distortion while having good metallurgical properties suitable for
use in the automotive industry.
[0061] According to a further preferred embodiment of the present
invention, the cooling effected below the upper critical
temperature is carried out in at least two (and more preferably
three) stages. Rather than proceeding at an essentially constant
rate throughout this cooling step as in the previous embodiments,
the cooling commences in a first stage at a relatively slow rate
and then proceeds after a short period of time in a subsequent
stage at a much faster rate, or at an increasingly faster rate. A
third even more aggressive cooling stage may be provided. When the
strip is cooled in a continuous heat treatment furnace, the
indicated different stages correspond to different zones or regions
within the heat treatment furnace.
[0062] This further embodiment is based on the realization that, in
the case of a sheet article cooled uniformly across the width of
the sheet article (the preferred arrangement), thermal stresses in
the sheet article are proportional to the second derivative of
temperature at points along the long axis of the sheet article. The
second derivative of temperature is the sheet article temperature
differentiated twice with respect to the distance along the sheet.
It is the gradient of the temperature gradient along the sheet
article length (mathematically expressed as
.delta..sup.2T/.delta.x.sup.2 where T is temperature and x is
distance along the strip). The temperature profile which minimizes
the second derivative of temperature is a parabolic profile with
zero initial gradient. The embodiments described above which employ
pre-cooling with air exploit this by giving an approximation to a
parabola and also cooling gently when the metal is hot. The same
can be done over a much shorter length during the water (or water
and air) part of the quench below the critical temperature, so that
the entire cooling process has a temperature profile
(longitudinally of the strip article) that is, or closely
approximates, a parabola.
[0063] This can be achieved by cooling the strip article by passing
it through heat treatment apparatus of the type shown in part in
FIG. 6. This figure shows an apparatus corresponding generally to
the right hand side of the apparatus of FIG. 3 (the section labeled
"Quench 1 to T lower"), but with modifications as described. The
apparatus of FIG. 6 is the same as the earlier apparatus in that it
has a tunnel 11' through which a strip article 12' is advanced on a
continuous basis in the direction of arrow A over supporting
rollers 30 and 32. In the illustrated part of the apparatus, the
strip article is quenched from T.sub.upper to T.sub.lower, first by
the action of "Coanda" nozzles 18', which cool by the combined
action of water and air, and then by water spray nozzles. The first
pair of spray nozzles 20' (which may be located about 800 mm, for
example, from the Coanda nozzles 18') are orientated at an angle
(e.g. in the range of 25 to 75.degree.) to the strip article 12' in
the direction of advancement of the strip article, as shown in the
drawing, whereas the succeeding pairs of nozzles 20" (which are
preferably spaced about 300 mm from each other) are orientated
perpendicular to the surface of the strip article. The quench is
commenced by the Coanda nozzles 18' (causing a first stage of
cooling in a first zone of this region of the apparatus). The
Coanda nozzles also act as air knives to prevent water from running
back towards the earlier zone (not shown). The angled water spray
nozzles 20' bring about a second stage of the quench (in a second
zone of the apparatus) which causes cooling at a faster rate than
that of the Coanda nozzles 18', but at a slower rate than the
succeeding nozzles 20" by use of a lower spray intensity. This can
be referred to as "gentle water cooling" followed by "aggressive
water cooling" of the perpendicular nozzles 20". Thus, the overall
cooling operation following the solution heat treatment may be
referred to as "air cooling to the upper critical temperature, then
water and air cooling, gentle water cooling and aggressive water
cooling." During the air or air/water cooling part of the cooling
procedure below the upper critical temperature, the cooling heat
transfer coefficient optimally, for 1 mm thick sheet, falls within
the range of 150-300 W/m.sup.2K. During the subsequent stages of
the cooling, the rate of cooling optimally falls within the range
of 300 to 2000 W/m.sup.2K. The method still achieves high overall
quench rates between about 470.degree. C. and 250.degree. C. and
thus satisfies the metallurgical requirements (no substantial
precipitation), while minimizing thermal distortion.
[0064] To achieve a heat transfer coefficient of 150 W/m.sup.2K or
more in the first cooling stage, it is usually necessary to use
both top and bottom air Coanda nozzles 18', as shown. As a guide to
the volume flows required to achieve both the coefficients and
avoid excessive air temperature rise, the total volume (top and
bottom) would preferably be about 3.0 m.sup.3/sec per meter width.
The air velocity would need to be about 40 meters/second which
implies a nozzle width of about 35 mm with 1.5 m.sup.3/sec per
meter of width of air flow on the top and bottom.
[0065] It is also important to size the air extraction system to
maintain a lower air static pressure in the quench chamber than in
the up and down-stream oven section, in order to contain the water
spray effectively.
[0066] If necessary, the perpendicular nozzles 20" may be of
adjustable spray intensity so that the cooling rate may be caused
to increase further as the strip article passes through the zones
of the quenching region.
[0067] FIG. 7 shows modeled results for the further preferred
embodiment which achieves the same average quench rate down to
250.degree. C. (140.degree. C. per second) as the apparatus of FIG.
3, but in which the second derivative of temperature with respect
to sheet article length at the start of the quench is reduced by a
factor of three. There are higher values of the second derivative
further down the strip article, but in these locations the
temperature of the strip article is lower and the yield strength is
higher.
[0068] FIG. 8 shows modeled results for spray intensities set to
give an average quench rate of 200.degree. C. per second down to
250.degree. C. and, again, to restrict the second derivative of
temperature when the strip is hot. This shows the importance of
being able to grade the spray intensities along the length of the
strip article.
[0069] It will be seen that the temperature profiles of FIGS. 7 and
8 more accurately represent a part of a parabola, thus minimizing
distortion effects during the quenching operation.
[0070] In all cases, of course, the temperature curve or profile
achieved in the quenching zone should avoid the precipitation zone
(shaded region of FIG. 2) to avoid the formation of precipitates.
However, as will be seen from FIG. 2, for most alloys there is room
at the top of the region B that allows the quenching rate to be a
little slower at higher temperatures.
[0071] In accordance with the method of the present invention,
detrimental alloy precipitation is avoided prior to rapid
quenching. Accordingly, the present invention provides a sheet
alloy of superior quality having preferred characteristics of
workability, strength and durability. In addition, the present
invention provides a method whereby thermal distortion is minimized
and often eliminated. Therefore, the need for addition working
after the performance of step-wise cooling of the present invention
is obviated. Thus, there is provided a method to minimize
distortion with improved overall efficiency. Accordingly, the sheet
alloy produced by this method may have better strength and
formability than sheet alloys of the prior art.
* * * * *