U.S. patent application number 11/299683 was filed with the patent office on 2006-07-13 for low internal stress al-zn-cu-mg plates.
Invention is credited to Julien Boselli, Fabrice Heymes, Philippe Lassince, Philippe Lequeu, Sjoerd Van Der Veen.
Application Number | 20060151075 11/299683 |
Document ID | / |
Family ID | 35094196 |
Filed Date | 2006-07-13 |
United States Patent
Application |
20060151075 |
Kind Code |
A1 |
Van Der Veen; Sjoerd ; et
al. |
July 13, 2006 |
Low internal stress Al-Zn-Cu-Mg plates
Abstract
The present invention relates to a method for producing
Al--Zn--Cu--Mg type alloy plates comprising between 4 and 12% zinc,
less than 4% magnesium and less than 4% copper, other
elements.ltoreq.0.5% each, and the remainder aluminum. The method
comprising hot rolling, solution heat-treatment, quenching,
controlled stretching with permanent elongation greater than 0.5%
and aging, wherein the elapsed time D between the end of quenching
and the start of controlled stretching is less than 2 hours. The
invention further relates to plates and products produced or
capable of being produced using such methods.
Inventors: |
Van Der Veen; Sjoerd;
(Clermont-Ferrand, FR) ; Heymes; Fabrice;
(Veyre-Monton, FR) ; Boselli; Julien; (Solihull,
GB) ; Lequeu; Philippe; (Veyre-Monton, FR) ;
Lassince; Philippe; (Issoire, FR) |
Correspondence
Address: |
ATTN: SARAH KIRKPATRICK, I.P. RIGHTS;ALSIUS CORPORATION
15770 LAGUNA CANYON ROAD, SUITE 150
IRVINE
CA
92618
US
|
Family ID: |
35094196 |
Appl. No.: |
11/299683 |
Filed: |
December 13, 2005 |
Current U.S.
Class: |
148/694 ;
148/417; 420/532 |
Current CPC
Class: |
C22C 21/10 20130101;
C22F 1/053 20130101 |
Class at
Publication: |
148/694 ;
148/417; 420/532 |
International
Class: |
C22F 1/04 20060101
C22F001/04; C22C 21/10 20060101 C22C021/10 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 13, 2004 |
FR |
04/13204 |
Claims
1. A method for producing an Al--Zn--Cu--Mg alloy plate comprising
between 4 and 12% zinc, less than 4% magnesium and less than 4%
copper, other elements.ltoreq.0.5% each, and the remainder
aluminum, said method comprising hot rolling, solution
heat-treatment, quenching, controlled stretching with permanent
elongation greater than 0.5% and aging, wherein the elapsed time D
between the end of quenching and the start of controlled stretching
is less than 2 hours.
2. Method according to claim 1, wherein the elapsed time D is less
than or equal to 1 hour and preferentially less than 30
minutes.
3. Method according to claim 1, wherein said alloy is selected from
the group consisting of the alloys AA7010, 7050, 7056, 7449, 7075,
7475, 7150, and 7175.
4. Method according to claim 1, wherein the thickness of said plate
is greater than 40 mm.
5. Method according to claim 1, wherein the thickness of said plate
is between 40 and 80 mm.
6. Method according to claim 1, wherein the thickness of said plate
is between 40 and 150 mm.
7. Method according to claim 1, wherein said plate has a total
elastic energy less than or equal to W
[kJ/m.sup.3]=0.54+0.013(R.sub.p0.2(L) [MPa]-400).
8. Al--Zn--Cu--Mg alloy thick plate comprising between 4 and 12%
zinc, less than 4% magnesium and less than 4% copper, other
elements.ltoreq.0.5% each, and the remainder aluminum, which is hot
rolled, solution treated, quenched, stretched with a permanent
elongation greater than 0.5%, aged, wherein the total elastic
energy of said plate is less than or equal to W
[kJ/m.sup.3]=0.54+0.013(R.sub.p0.2(L) [MPa]-400).
9. Plate according to claim 8, having a thickness between 60 and
100 mm and a total elastic energy less than 2 kJ/m.sup.3.
10. Plate according to claim 9, wherein said total elastic energy
is less than 1.5 kJ/m.sup.3.
11. Plate according to claim 8, having a thickness greater than 100
mm and a total elastic energy less than 1.5 kJ/m.sup.3.
12. Thick plate obtainable by the method according to claim 7.
13. Inspection lot or heat treatment batch of Al--Zn--Cu--Mg alloy
plates comprising between 4 and 12% zinc, less than 4% magnesium
and less than 4% copper, other elements.ltoreq.0.5% each, the
remainder aluminum, in a solution-treated, quenched, stretched and
aged temper, wherein the total elastic energy W in kJ/m of the
plates displays a standard deviation less than or equal to
0.20+0.0030(R.sub.p0.2(L) [MPa]-400) around an average value of
said total elastic energy.
14. Inspection lot or heat treatment batch of thick plates
according to claim 13, wherein said average total elastic energy
value is less than W [kJ/m.sup.3]=0.54+0.013(R.sub.p0.2(L)
[MPa]-400).
15. Inspection lot or heat treatment batch of thick plates
according to claim 13, characterised in that said average total
elastic energy value is less than 3 kJ/m.sup.3.
16. Inspection lot or heat treatment batch according to claim 13
wherein said average total elastic energy value is less than 2
kJ/m.sup.3.
17. Inspection lot or heat treatment batch according to claim 13
wherein a nominal thickness of the plates is between 40 and 100
mm.
18. Inspection lot or heat treatment batch according to claim 13
wherein the plates comprise an alloy selected from the group
consisting of AA7010, 7050, 7056, 7449, 7075, 7475, 7150, and
7175.
19. Inspection lot or heat treatment batch according to claim 13
comprising at least 3 plates.
20. Inspection lot or heat treatment batch according to claim 13
wherein said plates are obtained by a method comprising hot
rolling, solution heat-treatment, quenching, controlled stretching
with permanent elongation greater than 0.5% within a time after
quenching of less than 2 hours.
21. A method for the production of machine components comprising
obtaining a plate according to claim 8 and using said plate for the
production of machine components.
22. A method for reducing the dispersion of the stress level
between different nominally identical plates comprising subjecting
said plates to hot rolling, solution heat-treatment, quenching, and
after quenching, controlling the time period for a predetermined
time before subjecting said plates to controlled stretching with
permanent elongation greater than 0.5%.
23. A method of claim 22 wherein said predetermined time is less
than 2 hours.
24. A method of claim 22, wherein said plates are in the same
production or heat treatment batch.
25. A method of claim 22 wherein said plates comprise an
Al--Zn--Cu--Mg alloy plate comprising between 4 and 12% zinc, less
than 4% magnesium and less than 4% copper, other
elements.ltoreq.0.5% each, and the remainder aluminum
26. A plate prepared by a method of claim 1.
27. An inspection lot or heat treatment batch of claim 13, wherein
said standard deviation is calculated based on at least 3
samples.
28. An inspection lot or heat treatment batch of claim 13, wherein
said standard deviation is calculated based on at least 5
samples.
29. Method according to claim 4, wherein said plate has a total
elastic energy less than or equal to W
[kJ/m.sup.3]=0.54+0.013(R.sub.p0.2(L) [MPa]-400).
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to French Application No.
04/13204 filed Dec. 13, 2004, the content of which is incorporated
herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to a method to relieve the
level of residual stress throughout 7xxx series aluminum alloy
plates subjected to stretching with permanent elongation.
[0004] 2. Description of Related Art
[0005] It is generally known that in 7xxx series aluminum alloys,
natural aging starts immediately after quenching. The underlying
microstructural mechanism is associated with the formation of
Guinier-Preston zones by nucleation, and the formation of
metastable phases which precipitate from a supersaturated aluminum
matrix. The nucleation and growth of these precipitates results in
a rapid increase in the yield stress, as these precipitates impede
the movement of dislocations in the crystalline network. The degree
of hardening by these mechanisms at a given point in a thick plate
will typically depend on the chemical composition, the quenching
rate, the metal grain and sub-grain structure, as well as its
crystallographic texture.
[0006] 7xxx series alloy plates (that is, Al--Zn--Mg type alloys
with or without copper) generally must be quenched rapidly after a
solution heat-treatment thereof to be able to display, after
artificial aging, high mechanical properties throughout their
thickness. The presence of high thermal gradients close to the
plate surface at the time of quenching causes non-homogeneous
plastic strain. As a result, when the plate has completely cooled,
it contains residual stress (internal stress). More specifically,
compression stress is located in the vicinity of the surface, and
stretching stress in the center. The extent of this stress depends
on the alloy and the structure of the material, along with the
solution heat-treatment and quenching method; the order of
magnitude is 200 MPa. A detailed description of the residual stress
in 7xxx type alloys can be found, for example, in the following
articles: J. C. Chevrier, F. Moreaux, G. Beck, J. Bouvaist,
"Contribution a l'etude des contraintes thermiques de trempe.
Application aux alliages d'aluminum." Memoires Scientifiques--Revue
de Metallurgie vol 72, No. 1, p. 83-94 (1975); P. Jeanmart, J.
Bouvaist, "Finite element calculation and measurement of thermal
stresses in quenched plate of high-strength 7075 aluminum alloy",
Materials Science and Technology Vol. 1, No. 10, p. 765-769 (1985);
D. Godard, Doctoral thesis, Institut National Polytechnique de
Lorraine, Nancy 1999, particularly pages 285-290 and 209-250, all
of which are incorporated herein by reference in their
entirety.
[0007] Many of the most common methods to relieve residual stress
in 7xxx series alloy plates make use of plastic strain, either by
stretching in the L direction or by compression in the ST
direction. The advantage of these methods is that they generally do
not affect the hardening potential of the material significantly
during a subsequent artificial aging step. Stretching is considered
to be more effective than compression, as it generally results in
more homogeneous plastic strain.
[0008] U.S. Pat. Nos. 6,159,315 and 6,406,567 (Corus Aluminum
Walzprodukte GmbH) disclose a method of stress relieving solution
heat-treated and quenched plates, comprising a first cold stretch
step in the L direction, followed by a cold-compression step in the
ST direction.
[0009] Patent application WO 2004/053180 (Pechiney Rhenalu)
discloses a method of relieving the residual stress in a plate by
means of edge compression. However, although it makes it possible
to obtain plates with low residual energies, this compression
method is difficult to implement.
[0010] Plastic strain typically makes it possible to relieve
residual stress by a factor of approximately 10. This is
illustrated in FIG. 2. However, in practice, the residual stress in
thick semi-finished products considered as identical may vary
significantly. This may be associated with the variation in their
chemical composition, but also, and above all in many cases, with
the variation in the production process parameters, such as
casting, rolling, quenching, stretching and artificial aging; the
influence of these process parameters on the level of residual
stress in the finished product is still not clearly understood.
Some changes to the process indeed result in a relief in the level
of residual stress (such as the choice of slower quenching or a
higher artificial aging temperature), but they also change the
compromise between some properties which are important for
structural applications, such as, typically, the mechanical
strength, damage tolerance and corrosion resistance. The following
articles discuss such issues and are incorporated herein by
reference in their entireties: R. Habachou, M. Boivin, "Numerical
predictions of quenching and relieving by stretching of aluminum
alloys cylindrical bars", Journal de Mecanique Theorique et
Appliquee, Vol 4, pp. 701-723, 1985; J. C. Boyer and M. Boivin,
"Numerical calculations of residual stress relaxation in quenched
plates", Materials Science and Technology Vol. 1 1985 pp. 786-792;
R. Vignaud, P. Jeanmart, J. Bouvaist, B. Dubost (1990),
"Detensionnement par deformation plastique", Physique et mecanique
de la mise en forme des metaux, Ecole d'ete d'Oleron, directed by
F. Moussy and P. Franciosi, published by Presses du CNRS, 1990, pp.
632-642.
[0011] The critical influence of residual stress on distortion
during machining has been described extensively in the literature.
In the aeronautical industry, complex components are frequently
machined from thick aluminum alloy plates; this frequently results
in more than 80% scrap. Excessive distortion during machining must
often be compensated for by complex and costly measures, such as:
(a) mechanical straightening, (b) shot peening, (c) optimisation of
the location of the target component in the thickness of the plate,
i.e. with respect to the residual stress depth profile, or (d)
modification of the shape of the component with a view to
minimising its strain (it being understood that the permanent set
of the machine part is low if its shape is similar to a symmetric
shape with respect to the longitudinal axis of the plate in which
said component is machined). As a result, aircraft manufacturers
typically prefer plates wherein the residual stress is not only
lower, but also controlled, i.e. displaying a small variation for a
given type of products (alloy, thickness, temper).
[0012] EP 0 731 185 and U.S. Pat. No. 6,077,363 disclose a method
for relieving residual stress in 2024 alloy plates. Optimizing the
manganese content and the hot rolling outlet temperature makes it
possible to obtain a recrystallization rate of over 50% throughout
the thickness. Such a plate displays improved mechanical property
homogeneity as a function of the thickness, and a reduced level of
residual stress after stretching.
[0013] For 7xxx plates, it is generally preferred to retain a
largely non-recrystallized microstructure, particularly for
applications which require high toughness, such as structural
components for aircraft. This is disclosed in the article by F.
Heymes, B. Commet, B. Dubost, P. Lassince, P. Lequeu, and G. M.
Raynaud, "Development of new Al alloys for distortion free machined
aluminum aircraft components", published in 1st International
Non-Ferrous Processing and Technology Conference, St. Louis, Mo.,
1997, 249-255, and incorporated herein by reference.
[0014] The residual stress in plates can be determined by means of
the successive machining method disclosed in the article by Heymes,
Commet et al., referred to above. A method based on this article is
described in detail below, and this article is incorporated herein
by reference.
SUMMARY OF THE INVENTION
[0015] A purpose of the present invention was to propose a method
to obtain 7xxx series aluminum alloy plates which display, in a
stretched temper, a naturally aged temper or in any artificially
aged temper, a lower level of residual stress, without degrading
the mechanical strength and damage tolerance. More specifically, it
was desired to obtain plates which do not distort during machining,
which is observed when the total elastic energy stored in the
plate, W, is less than about 2 kJ/m.sup.3 and preferentially less
than about 1 kJ/m.sup.3.
[0016] The invention relates to a method for producing
Al--Zn--Cu--Mg alloy plates comprising from 4 to 12% zinc, less
than 4% magnesium and less than 4% copper, other
elements.ltoreq.0.5% each, and the remainder aluminum. The method
comprises hot rolling, solution heat-treatment, quenching,
controlled stretching with permanent elongation greater than 0.5%
and aging, wherein the elapsed time D between the end of quenching
and the start of controlled stretching is less than about 2 hours,
and preferentially less than about 1 hour.
[0017] The present invention also relates to an Al--Zn--Cu--Mg
alloy thick plate comprising from 4 to 12% zinc, less than 4%
magnesium and less than 4% copper, other elements.ltoreq.0.5% each,
and the remainder aluminum, which is hot rolled, solution treated,
quenched, stretched with a permanent elongation greater than 0.5%,
aged, wherein its total elastic energy is less than or equal to W
[kJ/m.sup.3]=0.54+0.013(R.sub.p0.2(L) [MPa]-400).
[0018] The invention also relates to an inspection lot or a heat
treatment batch of Al--Zn--Cu--Mg alloy plates comprising from 4 to
12% zinc, less than 4% magnesium and less than 4% copper, other
elements.ltoreq.0.5% each, the remainder aluminum, in a
solution-treated, quenched, stretched and aged temper, wherein the
total elastic energy W (expressed in kJ/m.sup.3) of the plates
displays a standard deviation less than or equal to
0.20+0.0030(R.sub.p0.2(L) [MPa]-400) around an average value.
[0019] Additional objects, features and advantages of the invention
will be set forth in the description which follows, and in part,
will be obvious from the description, or may be learned by practice
of the invention. The objects, features and advantages of the
invention may be realized and obtained by means of the
instrumentalities and combination particularly pointed out in the
appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a schematic representation of the definition of
the three main directions in a plate.
[0021] FIG. 2 is a schematic representation of a stretching curve.
Curve 2 represents the stress condition in the plate core. Curve 1
represents the surface stress condition. This figure shows the
controlled stretching stress relieving principle: before the
controlled stretching, the difference in the stress between the
surface and the core is defined by x and -x. Controlled stretching
reduces this difference (defined by y and -y) typically by a factor
of 10.
[0022] FIG. 3 represents the definition of the parameters h, l and
w of a plate. At the bottom, the strain gauge (with its connection
wire) can be seen schematically.
[0023] FIG. 4 is a schematic representation of the sequences of the
measurement and calculations to determine a residual stress profile
in the plate thickness using the successive layer removal
method.
[0024] FIG. 5 is a schematic representation of the critical part of
the method according to the invention. D refers to the time
interval between the end of quenching and the start of controlled
stretching.
[0025] FIG. 6 shows the natural aging kinetics of 7010 and 7050
alloy plates for two different quenching rates. The X-axis shows
the yield stress in the L direction, the Y-axis the natural aging
time.
[0026] FIG. 7 shows the effect of increasing the variation in yield
stress values on residual stress profiles after quenching.
[0027] FIG. 8 shows the total elastic energy as a function of the
thickness for batches of 7xxx alloy plates according to the
invention (where D.ltoreq.1 hour) (unfilled dots) and according to
the prior art (where D.gtoreq.8 hours) (black squares).
DETAILED DESCRIPTION OF A PREFERRED EMOBIDMENT
a) Terminology
[0028] Unless specified otherwise, all the indications relating to
the chemical composition are expressed as a percentage by weight.
References to alloys herein observe the rules of The Aluminum
Association, known to those skilled in the art. The expression
"Al--Zn--Cu--Mg alloy" refers to an aluminum-based alloy containing
zinc, copper and magnesium alloy elements; such an alloy may also
contain other alloy elements along with other elements, the
presence of which may be intentional or not, e.g. impurities.
[0029] The tempers are defined in the European standard EN 515. The
chemical composition of standardized aluminum alloys is defined,
for example, in the standard EN 573-3. Unless specified otherwise,
the static mechanical properties, i.e. the ultimate tensile
strength UTS or R.sub.m, the tensile yield stress TYS or
R.sub.p0.2, and the elongation at rupture A, are determined by
means of a tensile test according to the standard EN 10002-1, the
position and direction of test piece sampling being defined in the
standard EN 485-1. The toughness K.sub.IC was measured according to
the standard ASTM E 399.
[0030] Unless specified otherwise, the definitions of the European
standard EN 12258-1 are applied.
[0031] Within the scope of the present invention, the term "thick
plate" refers to a plate of a thickness greater than or equal to 6
mm.
[0032] The term "inspection lot" is defined in the standard EN
12258-1; it refers to a shipment or part of a shipment, submitted
for inspection, and which comprises products of the same grade or
alloy, of the same form, temper, size, shape, thickness or
cross-section, and processed in the same manner.
[0033] The term "heat treatment batch" refers to a quantity of
products of the same grade or same alloy, of the same form,
thickness or cross-section, and which were produced in the same
way, wherein the heat treatment or solution heat-treatment followed
by quenching were performed in one furnace load. More than one
solution-treatment batch can be included in one precipitation
furnace load.
[0034] The "aging" comprises natural aging at ambient temperature
and any artificial aging.
[0035] The term "machining" comprises any material removal method
such as turning, free machining, milling, drilling, boring,
tapping, electroerosion, straightening, polishing, and chemical
machining.
[0036] The term "structural element" refers to an element used in
mechanical construction for which the static and/or dynamic
mechanical properties are particularly important for the
performance and integrity of the structure, and for which a
calculation of the structure is generally specified or performed.
It typically consists of a mechanical component, the failure of
which is liable to endanger the safety of said construction, its
users or other parties. For an aircraft, these structural elements
particularly comprise the elements making up the fuselage (such as
the fuselage skin, stringers, bulkheads, circumferential frames),
wings (such as the wing skin, stringers or stiffeners, ribs and
spars) and the tails particularly consisting of horizontal or
vertical stabilisers and floor beams, seat tracks and doors.
[0037] The term "monolithic structural element" refers to a
structural element which has been obtained most frequently by
machining, from a single piece of rolled, extruded, forged or cast
semi-finished product, with no assembly, such as riveting, welding,
bonding, with another piece.
[0038] The L (Length), LT (Long Transverse) and ST (Short
Transverse) directions in a rolled product refer to the direction
of rolling corresponding to the L direction. These three directions
are defined in FIG. 1.
[0039] The term "about" or "approximately" refers to any value
within 10% of a stated given value, particularly preferably within
5% of the stated value.
b) Determination of Residual Stress
[0040] Within the scope of the present invention, the residual
stress was determined using the method based on the successive
removal of layers described in the article "Development of New
Alloy for Distortion Free Machined Aluminum Aircraft Components",
F. Heymes, B. Commet, B. Dubost, P. Lassince, P. Lequeu, G M.
Raynaud, in 1st International Non-Ferrous Processing &
Technology Conference, 10-12 Mar. 1997--Adams's Mark Hotel, St
Louis, Mo. The content of this article is incorporated herein by
reference in its entirety.
[0041] This method mostly applies to stretched plates, wherein the
stress state can be considered as biaxial with its two main
components located in the L and LT directions, and therefore no
component in the ST direction. This method is based on the
determination of the residual stress in the L and LT direction as
measured in full thickness rectangular bars, which are cut from the
plate along these directions. These bars are machined down the ST
direction step by step and at each step, the stress and/or
deflection is measured, as well as the thickness of the bar. A most
preferred way is to measure the strain by using a strain gauge
bound to the surface opposite the machined surface at half-length
of the bar. Then the two residual stress profiles in the L and LT
directions can be calculated. The bar must be sufficiently long to
avoid edge effects. The recommended dimensions as a function of the
plate thickness are given in table 1. TABLE-US-00001 TABLE 1
Dimensions [mm] used for the successive layer removal method Plate
thickness (h) Width (w) Length (1) 20 < h .ltoreq. 100 24 .+-. 1
5h .+-. 1 h > 100 30 .+-. 1 5h .+-. 1
[0042] The one-way strain gauges with thermal expansion
compensation are bonded to the lower surface of the bar (see FIG.
3), according to the manufacturer's instructions. They are then
coated with an insulating lacquer. The value read on each of these
gauges are then set to zero.
[0043] A measurement is performed after each machining pass.
Between 18 and 25 passes are typically taken to obtain a sufficient
number of points to calculate the stress profile. The machining
depth must not be less than 1 mm, so as to obtain a good cutting
quality; for very thick plates, it may be up to 10 mm. Chemical
machining may also be used to remove a very thin layer of metal.
The machining interval should be the same for both samples (i.e. in
the L direction and in the LT direction).
[0044] After each machining pass, the bar is detached from the vice
and the temperature is allowed to stabilise before the strain is
measured. At each step i, the thickness h(i) and the strain
.epsilon.(i) are recorded. The diagram in FIG. 4 shows how these
data are collected.
[0045] These data allow the calculation of the initial stress
profile in each bar in the form of a curve u(i), corresponding to
the average stress in the layer removed during the machining step
i, given by the following formulas: For .times. .times. i = 1
.times. .times. to .times. .times. N - 1 .times. : ##EQU1## u
.function. ( i ) = - E .times. ( .times. ( i + 1 ) - .function. ( i
) ) .times. h .function. ( i + 1 ) 2 [ h .function. ( i ) - h
.function. ( i + 1 ) ] .function. [ 3 .times. h .function. ( i ) -
h .function. ( i + 1 ) ] - S .function. ( i ) ##EQU1.2## where
.times. : ##EQU1.3## S .function. ( i ) = E .times. k = 1 .times. i
- 1 .times. ( .function. ( k + 1 ) - .function. ( k ) ) .function.
[ 1 - 3 .times. h .function. ( k ) .times. ( h .function. ( i ) + h
.function. ( i + 1 ) ) ( 3 .times. h .function. ( k ) - h
.function. ( k + 1 ) ) .times. h .function. ( k + 1 ) ]
##EQU1.4##
[0046] where E is the Young's modulus of the thick plate. This
gives two profiles: u(i).sub.L and u(i).sub.LT corresponding to
rectangular section bars in the L and LT directions. The stress
profiles in the plate are obtained using the following equations:
For .times. .times. i = 1 .times. .times. to .times. .times. N - 1
##EQU2## .sigma. .function. ( i ) L = u .function. ( i ) L + vu
.function. ( i ) LT 1 - v 2 ##EQU2.2## .sigma. .function. ( i ) LT
= u .function. ( i ) LT + vu .function. ( i ) L 1 - v 2
##EQU2.3##
[0047] where v is the Poisson coefficient of the plate. It is then
possible to calculate the energy stored in the plate (W.sub.L,
W.sub.LT and W) using the equations: W L = 500 Eh .times. i = 1 N -
1 .times. .sigma. .function. ( i ) L .function. [ .sigma.
.function. ( i ) L - v .times. .times. .sigma. .function. ( i ) LT
] .times. dh .function. ( i ) ##EQU3## W LT = 500 Eh .times. i = 1
N - 1 .times. .sigma. .function. ( i ) LT .function. [ .sigma.
.function. ( i ) LT - v .times. .times. .sigma. .function. ( i ) L
] .times. dh .function. ( i ) ##EQU3.2## W = W L + W LT
##EQU3.3##
[0048] where W.sub.L represents the stored elastic energy resulting
from the residual stress profile in the L direction, and W.sub.LT
represents the stored energy resulting from the residual stress
profile in the LT direction. W is the total elastic energy stored
in the plate (expressed in kJ or kJ/m.sup.3). The method used to
measure the stress and to obtain the stored elastic energies is
described above specifically, giving, for example, the bar
dimensions used in practice. It should be noted that these
dimensions are not compulsory and do not restrict the method. The
length of the bar does not affect the result. The length of two
times h plus three times the gauge length is sufficient for
measurements using strain gauges. The dimensions given are based on
practical experience and have been adapted to the machining and
measurement means used. Those skilled in the art will easily be
capable of selecting other dimensions without altering the
results.
[0049] Similarly, other techniques may be used to measure the
stress gradient in the plate thickness. After obtaining the stress
profiles .sigma..sub.L and .sigma..sub.LT in the thickness, the
same formulas of the above incremental sums are used to calculate
the stored energies W.sub.L and W.sub.LT. Therefore, it is possible
to obtain the stored energies using any technique enabling stress
measurements in the thickness.
c) Detailed Description of the Invention
[0050] The present invention applies to 7xxx series aluminum alloy
plates, particularly plates, wherein the chemical composition meets
the following criteria:
[0051] 4<Zn<12; Mg<4; Cu<4;
[0052] other elements.ltoreq.0.5 each
[0053] the remainder aluminum,
[0054] and which are treated by means of solution heat-treatment,
quenching and controlled stretching.
[0055] According to the invention, a problem can be solved by
modifying the production process so that the natural aging between
the end of quenching and the start of controlled stretching is
minimized such that the total elastic energy (W) in the
artificially aged state remains below a specific limit value. This
limit value represents a preferred maximum value to retain the
machining strain at an acceptable level; for most applications,
this limit value is about 2 kJ/m.sup.3 for a plate between 60 mm
and 100 mm thick, and preferentially about 1.5 kJ/m.sup.3. For
particularly complex components, it should be about 1
kJ/m.sup.3.
[0056] FIG. 5 shows a diagram of the heat treatment process applied
to a plate after rolling. The solution heat-treatment can be
performed, for example, in a single plateau, in several plateaus or
in a ramp with or without a clearly defined plateau. The same
applies for artificial aging. An important phase within the scope
of the present invention is the elapsed time D between the end of
quenching and the start of controlled stretching. The inventors
found that a long elapsed time D results in greater heterogeneity
of the mechanical properties between the zones near the surface and
the zones near the mid-thickness of the material. This
heterogeneity may essentially be attributed to the differences in
the cooling rate in the plate thickness. FIG. 6 shows the
progression of the yield stress in the L direction, determined
close to the surface and at mid-thickness, as a function of the
natural aging time for very high-strength AA7010 and AA7050 alloy
plates and for different nominal quenching rates. These quenching
rates were obtained on stretching test pieces but they are
representative of the differences in quenching rates observed
between the surface and core of a thick plate. It can be seen that
the difference between the levels of mechanical strength is
accentuated over time.
[0057] The inventors observed that the variation in residual stress
through the thickness of 7xxx alloy plates depends on (i) the
variation in the cooling and plastic strain rates during quenching,
(ii) heterogeneities in the microstructure, granular structure and
texture generated during rolling, and (iii) local variations in the
chemical composition resulting from the casting process (including
solidification and homogenization). Between the end of quenching
and the start of stretching, natural aging is observed throughout
the plate thickness, but the rate of this natural aging depends on
the thickness: the yield stress increases more rapidly in the
vicinity of a surface than at mid-thickness. This is probably due
to the precipitation kinetics: firstly, the potentially hardening
element content of the supersaturated solid solution is greater
near the surface than at mid-thickness (as the semi-continuous
casting process results in macro-segregation such that the
concentration of eutectic elements, such as Cu, Mn and Zn, is
higher close to the surface and the cooling rate during casting is
also higher), and, secondly, close to the surface, a greater
density of heterogeneous sites (gaps, dislocations, etc.) can be
found, facilitating precipitation and resulting from the higher
cooling rate and the higher plasticity during quenching.
[0058] The inventors found, by means of a calculation based on a
finite element model, that an increase in the heterogeneity of the
mechanical properties (i.e. of the yield stress or the strain
hardening coefficients) results in an increase in the residual
stress after stretching. FIG. 7 shows the effect of the increase in
the variation in the yield stress values on the residual stress
profiles after quenching.
[0059] However, this attempt to find a metallurgical explanation
for the method according to the invention does not imply any
limitation of the present invention to the underlying phenomena.
Moreover, the inventors observed that the effect is in fact greater
than the values obtained using the mathematical model.
[0060] Finally, a change to the production process resulting in an
improvement in the homogeneity of the yield stress (R.sub.p02) in
the thickness of the plate after quenching would relieve the
residual stress after controlled stretching or after any stress
relieving by means of plastic strain.
[0061] A method according to the present invention may not give the
same level of improved results for other structural hardening
alloys, such as 2xxx and 6xxx series alloys. For highly
concentrated alloys, i.e. with contents consists of Zn>12%,
Mg>4% and Cu>4%, the stored energy is very high and the
improvement obtained with a method according to the invention may
be as significant. In addition, these alloys may not respond well
to solution heat-treatment.
[0062] A method according to the present invention makes it
possible to produce plates having a total elastic energy which is
preferably less than or equal to W
[kJ/m.sup.3]=0.54+0.013(R.sub.p0.2(L) [MPa]-400).
[0063] In this equation, R.sub.p0.2(L) refers to the yield stress
of the finished plate measured according to the standards EN
10002-1 and EN 485-1. The influence of the thickness on the level
of residual stress and the total elastic energy is expressed here
in terms of the yield stress, measured as recommended by the
standard EN 485-1. The method according to the invention may be
applied advantageously to the manufacture of a plurality of plates
wherein the thickness is between approximately 10 mm and
approximately 250 mm, and more advantageously to plates wherein the
thickness is greater than 25 mm, but these values are not
restrictive.
[0064] A method according to the present invention also makes it
possible to reduce the dispersion between the values of W for a
plurality of plates belonging to the same inspection lot or heat
treatment batch, such that all the plates have a standard deviation
of the total elastic energy W of the different plates around an
average value that is preferably less than or equal to
0.20+0.0086(R.sub.p0.2(L) [MPa]-400)
[0065] and preferentially and advantageously less than or equal to
0.20+0.0030(R.sub.p0.2(L) [MPa]-400).
[0066] In this equation, R.sub.p0.2(L) refers to the average
R.sub.p0.2(L) measurement performed according to the standard for
each of the finished plates in the batch, according to the
standards EN10002-1 and EN485-1.
[0067] The standard deviation between the measurements of the total
elastic energy W of the different plates in a batch may depend on
the number of plates contained in the batch. In particular, a
standard deviation obtained on two measurements is not significant
and may be very high or very low. From 3 plates, the standard
deviation of the measurements may be considered, but
preferentially, the quality control or heat treatment batches used
within the scope of the present invention contain at least 5
plates.
[0068] The use of a method according to the present invention
enables the manufacturer to guarantee that a particular inspection
lot or heat treatment batch comprises plates wherein the average
total elastic energy is preferably less than about 3 kJ/m.sup.3.
Preferentially, this average value is less than about 2 kJ/m.sup.3,
and a value less than about 1 kJ/m.sup.3 is preferred, which
requires excellent control of the critical processes and very
rigorous management of production schedule at the solution
heat-treatment, quenching and stretching stages. In fact, the
implementation of a method according to the instant invention may
require an adaptation of the metal flows within the plant, because
if the producer wishes to produce plates within an elapsed time D
of less than a few hours, it may potentially be necessary to
synchronize the quenching furnace with the stretching bench. In
practice, this involves limiting the intermediate stock to a
minimum between these two machines; this particularly applies to
the particularly preferred embodiments where D<1 hour or D<30
minutes. EP 1 231 290 A1 describes in example 1 thereof, a 38 mm
thick 7449 alloy plate for which controlled stretching was
performed 1 hour after quenching; however, this document does not
provide any information on the benefit of this short time. A method
according to the present invention made it possible to produce
inspection lots or heat treatment batches for which the elapsed
time D between the end of quenching and the start of controlled
stretching is systematically less than 2 hours, which made it
possible to minimize the average and standard deviation of the
total elastic energy W of the plates in these batches. However, the
industrial production of such an inspection lot requires a
reorganization of the product flows around the machines required
for the implementation of the method according to the
invention.
[0069] In another embodiment of the present invention, natural
aging is performed at a low temperature, i.e. at a temperature
below about 10.degree. C. and preferentially at a temperature below
about 5.degree. C., which makes it possible to obtain similar
results in terms of total elastic energy W for times D between 2
hrs and 3 hrs.
[0070] Other preferred embodiments of the invention include those
specified in the dependent claims. The invention is particularly
advantageous for AA7010, 7050, 7056, 7449, 7075, 7475, 7150, 7175
alloy thick plates.
[0071] One advantage of a method according to the invention is the
overall relief in the level of stress in plates. This induces an
overall reduction in the machining strain.
[0072] A further advantage of the method according to the invention
is that the monitoring of the time elapsed between the end of
quenching and the start of stretching also makes it possible to
reduce the dispersion of the stress level observed between
different nominally identical plates, even within the same
production batch or heat treatment batch. This enables improved
standardization of the machining processes for a given product
series and reduces the number of incidents during the production of
machine components in the machining workshop.
[0073] In the examples below, advantageous embodiments of the
invention are given for illustration purposes. These examples are
not restrictive.
EXAMPLES
Example 1
[0074] Three AA7010 alloy rolling ingots were cast by means of
semi-continuous casting. After homogenisation, they were hot rolled
to a thickness of 100 mm. At the hot rolling mill outlet, they
underwent quenching followed by controlled stretching and finally
an artificial aging treatment. The temper of the three products A1,
A2 and A3 obtained in this way was T7651. For these three products,
all the production parameters were nominally identical and well
controlled. The only difference was the elapsed time D between the
end of quenching and the start of stress relieving by means of
stretching.
[0075] Using a similar method, three rolling ingots made of AA7050
alloy were processed by means of homogenisation, hot rolling to a
thickness of 100 mm, quenching, controlled stretching and
artificial aging. The temper of the three products B1, B2 and B3
obtained in this way was T7451. For these three products, all the
production parameters were nominally identical and well controlled,
and the only difference was the elapsed time D between the end of
quenching and the start of stress relieving by means of
stretching.
[0076] Table 2 shows the stored elastic energy in the different
plates obtained, determined in the final temper. When the elapsed
time D between the end of quenching and the start of stress
relieving by means of stretching is reduced, a reduction in the
overall stress level as measured by W.sub.L, W.sub.LT and W is
observed. TABLE-US-00002 TABLE 2 Stored elastic energy (final
temper) as a function of the natural aging time for three 7010 and
7050 alloy plates. Natural aging time W W.sub.L W.sub.LT Plate
Alloy/temper D [h] [kJ/m.sup.3] [kJ/m.sup.3] [kJ/m.sup.3] A1 7010
T7651 1.17 1.02 0.8 0.22 A2 7010 T7651 9 1.76 1.37 0.4 A3 7010
T7651 48.92 2.37 1.74 0.63 B1 7050 T7451 1.25 1.22 0.84 0.38 B2
7050 T7451 8.83 2.28 1.57 0.71 B3 7050 T7451 49.08 3.15 2.02
1.12
[0077] The static mechanical properties were measured in the L, LT
and ST directions at 1/4, 1/2 and 3/4 thickness, in final temper.
The results are compiled in tables 3, 4 and 5. It is observed that
the natural aging time D does not have a significant influence on
the static mechanical characteristics. TABLE-US-00003 TABLE 3
Static mechanical properties (L direction) in final temper as a
function of the natural aging time D for 7010 and 7050 alloy plates
Natural Alloy/ aging R.sub.m(L) R.sub.po.2(L) A.sub.(L) Plate
temper time D [h] Location [MPa] [MPa] [%] A1 7010 T7651 1.17 1/4
thickness 524 479 14.0 1/2 thickness 519 468 12.7 3/4 thickness 533
471 11.0 A2 7010 T7651 9 1/4 thickness 529 480 14.4 1/2 thickness
523 477 11.5 3/4 thickness 539 480 9.6 A3 7010 T7651 48.92 1/4
thickness 521 472 12.6 1/2 thickness 516 466 9.2 3/4 thickness 528
472 8.2 B1 7050 T7451 1.25 1/4 thickness 536 482 13.0 1/2 thickness
519 465 10.4 3/4 thickness 531 470 9.6 B2 7050 T7451 8.83 1/4
thickness 534 479 14.2 1/2 thickness 519 461 10.8 3/4 thickness 533
469 8.7 B3 7050 T7451 49.08 1/4 thickness 534 478 14.2 1/2
thickness 519 459 10.5 3/4 thickness 531 463 9.4
[0078] TABLE-US-00004 TABLE 4 Static mechanical properties (LT
direction) in final temper as a function of the natural aging time
D for 7010 and 7050 alloy plates Natural Alloy/ aging R.sub.m(LT)
R.sub.po.2(LT) A.sub.(LT) Plate temper time D [h] Location [MPa]
[MPa] [%] A1 7010 T7651 1.17 1/4 thickness 529 470 10.4 1/2
thickness 527 464 9.4 3/4 thickness 513 446 9.2 A2 7010 T7651 9 1/4
thickness 536 475 11.0 1/2 thickness 534 478 8.4 3/4 thickness 521
463 8.1 A3 7010 T7651 48.92 1/4 thickness 527 461 10.1 1/2
thickness 526 463 7.8 3/4 thickness 511 452 8.0 B1 7050 T7541 1.25
1/4 thickness 541 461 10.6 1/2 thickness 526 456 6.6 3/4 thickness
516 443 6.7 B2 7050 T7541 8.83 1/4 thickness 541 464 9.6 1/2
thickness 528 464 6.9 3/4 thickness 519 447 7.2 B3 7050 T7451 49.08
1/4 thickness 538 467 10.8 1/2 thickness 527 451 7.8 3/4 thickness
513 440 6.4
[0079] TABLE-US-00005 TABLE 5 Static mechanical properties (ST
direction) in final temper as a function of the natural aging time
D for 7010 and 7050 alloy plates Natural Alloy/ aging R.sub.m(ST)
R.sub.po.2(ST) A.sub.(ST) Plate temper time D [h] Location [MPa]
[MPa] [%] A1 7010 T7651 1.17 1/4 thickness 517 449 6.5 1/2
thickness 508 432 7.7 3/4 thickness 518 455 6.3 A2 7010 T7651 9 1/4
thickness 521 455 5.7 1/2 thickness 520 438 5.3 3/4 thickness 515
442 7.6 A3 7010 T7651 48.92 1/4 thickness 514 451 5.7 1/2 thickness
514 449 5.0 3/4 thickness 509 440 7.4 B1 7050 T7451 1.25 1/4
thickness 507 445 3.4 1/2 thickness 519 470 4.6 3/4 thickness 507
428 5.6 B2 7050 T7451 8.83 1/4 thickness 513 446 4.2 1/2 thickness
513 438 3.9 3/4 thickness 511 413 5.9 B3 7050 T7451 49.08 1/4
thickness 514 423 4.6 1/2 thickness 505 420 4.8 3/4 thickness 513
442 3.7
[0080] The toughness K.sub.IC was also measured in the L-T and T-L
directions at 1/4 thickness. The results, compiled in table 6,
demonstrate that natural aging does not have a significant
influence on toughness. TABLE-US-00006 TABLE 6 Toughness (in final
temper) as a function of the natural aging time D for 7010 and 7050
alloy plates Natural Alloy/ aging K.sub.IC(L-T) K.sub.IC(T-L) Plate
temper time D [h] Location (MPa m) (MPa m) A1 7010 1.17 1/4
thickness 33.6 28.0 T7651 A2 7010 9 1/4 thickness 32.7 26.0 T7651
A3 7010 48.92 1/4 thickness 32.9 27.7 T7651 B1 7050 1.25 1/4
thickness 32.2 26.1 T7451 B3 7050 49.08 1/4 thickness 32.3 27.7
T7451
Example 2
[0081] Three rolling ingots made of AA7475 alloy were processed by
means of homogenisation, hot rolling to a thickness of 46 mm,
quenching and controlled stretching. The temper of the three
products C1, C2 and C3 obtained in this way was W51. For these
three products, all the production parameters were nominally
identical and well controlled and the only difference was the
elapsed time D between the end of quenching and the start of stress
relieving by means of stretching.
[0082] Table 7 shows the stored elastic energy in the different
plates obtained, determined in the final temperature (i.e. after
controlled stretching). When the elapsed time D between the end of
quenching and the start of stress relieving by means of stretching
is reduced, a reduction in the overall stress level W.sub.L,
W.sub.LT and W is observed. TABLE-US-00007 TABLE 7 Stored elastic
energy as a function of the natural aging time D for 7475 alloy W51
plates Alloy/ Natural aging time W W.sub.L W.sub.LT Plate temper D
[h] [kJ/m.sup.3] [kJ/m.sup.3] [kJ/m.sup.3] C1 7475 W51 1.75 2.24
1.6 0.64 C2 7475 W51 22.5 4.51 3.61 0.9 C3 7475 W51 48 5.18 3.97
1.21
Example 3
[0083] Two rolling ingots made of AA7449 alloy were processed by
means of homogenisation, hot rolling to a thickness between 16.5
and 21.5 mm, quenching and controlled stretching, followed by
artificial aging. The temper of the two products D1 and D2 obtained
in this way was T651. For these two products, all the production
parameters were nominally identical and well controlled and the
only difference was the elapsed time D between the end of quenching
and the start of stress relieving by means of stretching.
[0084] Table 8 shows the stored elastic energy in the different
plates obtained, determined in the final temperature (i.e. after
controlled stretching). When the elapsed time D between the end of
quenching and the start of stress relieving by means of stretching
is reduced, a reduction in the overall stress level W.sub.L,
W.sub.LT and W is observed. The slight difference between the
thicknesses of both products does not, as such, result in a
significant difference between their stress levels. TABLE-US-00008
TABLE 8 Stored elastic energy as a function of the natural aging
time D for 7449 alloy T651 plates Natural aging Alloy/ Thickness
time D W W.sub.L W.sub.LT Plate temper [mm] [h] [kJ/m.sup.3]
[kJ/m.sup.3] [kJ/m.sup.3] D1 7449 16.5 10.5 6.3 5.56 0.74 T651 D2
7449 21.5 3 4.17 3.66 0.51 T651
[0085] This result confirms that, even for a high zinc content
Al--Zn--Mg alloy such as 7449, it is possible to reduce the total
elastic energy very significantly by reducing the natural aging
time D.
Example 4
[0086] Using industrial processes wherein the only differences lay
in the waiting time, quality control plate lots according to the
invention were prepared. The stored energy was measured. A
mathematic model was then developed which is used to calculate this
stored energy as a function of the critical parameters of the
production process. The values of the stored energy measured for
plates according to the invention were used to validate this
mathematical model. The same mathematical model was then applied to
batches of Al--Zn--Mg alloy plates obtained using methods according
to the prior art. FIG. 8 shows the values of the stored energy in
the plates according to the invention (where D.ltoreq.1 hour)
(unfilled dots) ("Optimized") and according to the prior art (where
D.gtoreq.8 hours) (black squares).
[0087] It is observed that, for a thickness between approximately
60 mm and approximately 100 mm, the stored energy is maximal. The
method according to the invention results in, for a given
thickness, firstly, a relief in the overall level of residual
stress (i.e. the stored energy W.sub.total) of approximately 50%,
and, secondly, a significant reduction in the statistical
dispersion of this value. The effect of the invention on the
overall level of residual stress is particularly remarkable for
thicknesses between 40 and 150 mm and it is even more marked for
thicknesses between 50 and 100 or even 80 mm.
[0088] Additional advantages, features and modifications will
readily occur to those skilled in the art. Therefore, the invention
in its broader aspects is not limited to the specific details, and
representative devices, shown and described herein. Accordingly,
various modifications may be made without departing from the spirit
or scope of the general inventive concept as defined by the
appended claims and their equivalents.
[0089] All documents referred to herein are specifically
incorporated herein by reference in their entireties.
[0090] As used herein and in the following claims, articles such as
"the", "a" and "an" can connote the singular or plural.
* * * * *