U.S. patent application number 11/270767 was filed with the patent office on 2007-05-10 for high strength, high toughness, weldable, ballistic quality, castable aluminum alloy, heat treatment for same and articles produced from same.
This patent application is currently assigned to BAC of Virginia, LLC. Invention is credited to Alan Peter Druschitz.
Application Number | 20070102071 11/270767 |
Document ID | / |
Family ID | 38002534 |
Filed Date | 2007-05-10 |
United States Patent
Application |
20070102071 |
Kind Code |
A1 |
Druschitz; Alan Peter |
May 10, 2007 |
High strength, high toughness, weldable, ballistic quality,
castable aluminum alloy, heat treatment for same and articles
produced from same
Abstract
An aluminum alloy cast product is composed of: TABLE-US-00001 Cu
5.00-6.75 weight %, Mg 0.05-0.50 weight %, Mn 0.05-0.65 weight %,
Ti 0.05-0.40 weight %, Ag 0.00-0.40 weight %, Cr 0.00-0.20 weight
%, V 0.00-0.40 weight %, Zr 0.00-0.30 weight %, Fe <0.15 weight
%, Si <0.15 weight %, Ni <0.05 weight %, Zn <0.05 weight
%, impurities <0.05 each weight %, <0.25 total weight %, Al
balance Such an aluminum alloy cast product is heat treated to
eliminate the interdendritic network of second phase particles. The
heat treatment of such an aluminum alloy casting alloy includes
solution heat treatment before hot isostatic pressing.
Inventors: |
Druschitz; Alan Peter;
(Forest, VA) |
Correspondence
Address: |
CARACAPPA AND ASSOCIATES, PC
9712 FOREST ROAD
GOODE
VA
24556
US
|
Assignee: |
BAC of Virginia, LLC
|
Family ID: |
38002534 |
Appl. No.: |
11/270767 |
Filed: |
November 9, 2005 |
Current U.S.
Class: |
148/552 ;
148/439; 420/533 |
Current CPC
Class: |
C22F 1/057 20130101;
C22C 21/12 20130101; C22C 21/16 20130101 |
Class at
Publication: |
148/552 ;
148/439; 420/533 |
International
Class: |
C22C 21/16 20060101
C22C021/16; C22F 1/057 20060101 C22F001/057 |
Claims
1. An aluminum alloy cast product consisting essentially of:
TABLE-US-00020 Cu 5.00-6.75 weight %, Mg 0.05-0.50 weight %, Mn
0.05-0.65 weight %, Ti 0.05-0.40 weight %, Ag 0.00-0.40 weight %,
Cr 0.00-0.20 weight %, V 0.00-0.40 weight %, Zr 0.00-0.30 weight %,
Fe <0.15 weight %, Si <0.15 weight %, Ni <0.05 weight %,
Zn <0.05 weight %, impurities <0.05 each weight %, <0.25
total weight %, Al balance
wherein an aluminum alloy cast product contains an interdendritic
network of second phase particles in the as-cast condition.
2. The cast product of claim 1 wherein the interdendritic network
of second phase particles is eliminated by solution heat treatment
prior to hot isostatic pressing.
3. The cast product of claim 1 wherein the cast product after heat
treatment exhibits relatively high strength, high toughness, high
resistance to penetration from ballistic objects, high resistance
to stress corrosion cracking and low weight.
4. The cast product of claim 1 wherein the cast product is
weldable.
5. A method for producing a cast product of an aluminum alloy,
comprising the steps of: melting the following to form a cast alloy
of: TABLE-US-00021 Cu 5.00-6.75 weight %, Mg 0.05-0.50 weight %, Mn
0.05-0.65 weight %, Ti 0.05-0.40 weight %, Ag 0.00-0.40 weight %,
Cr 0.00-0.20 weight %, V 0.00-0.40 weight %, Zr 0.00-0.30 weight %,
Fe <0.15 weight %, Si <0.15 weight %, Ni <0.05 weight %,
Zn <0.05 weight %, impurities <0.05 each weight %, <0.25
total weight %, and Al balance;
casting a product from the melted cast alloy; heat treating the
cast product to eliminate an interdendritic network of second phase
particles; hot isostatically pressing the heat treated cast product
to eliminate porosity; and heat treating the hot isostatically
pressed cast product to obtain desired mechanical and physical
properties.
6. A product made by the process of claim 5.
7. A cast product of an aluminum alloy consisting essentially of,
in weight percent: TABLE-US-00022 Cu 5.00-6.75 weight %, Mg
0.05-0.50 weight %, Mn 0.05-0.65 weight %, Ti 0.05-0.40 weight %,
Ag 0.00-0.40 weight %, Cr 0.00-0.20 weight %, V 0.00-0.40 weight %,
Zr 0.00-0.30 weight %, Fe <0.15 weight %, Si <0.15 weight %,
Ni <0.05 weight %, Zn <0.05 weight %, impurities <0.05
each weight %, <0.25 total weight %, Al balance
wherein the aluminum alloy casting alloy is grain refined using
aluminum-titanium-boron and/or aluminum-titanium-carbon containing
grain refiner; wherein the aluminum alloy casting alloy is cast in
a sand, ceramic or metal mold to form the cast product; wherein the
aluminum alloy cast product is hot isostatically pressed (HIP'ed)
at 950-975.degree. F. (510-524.degree. C.), 15,000+/-500 psi
(103+/-3.4 MPa) for 2 to 3 hours, solution treated at
950-960.degree. F. (510-516.degree. C.) for 2-4 hours followed by
980-1005.degree. F. (527-541.degree. C.) for 16-120 hours followed
by quenching in water and naturally aged at room temperature or
artificially aged at 310-390.degree. F. (154-199.degree. C.) for 1
to 96 hours; whereby the aluminum alloy product in the naturally
aged condition T4 has a minimum ultimate tensile strength of 57,100
psi (394 MPa), a minimum 0.2% offset yield strength of 38,500 psi
(265 MPa), a minimum elongation of 6.2%, a minimum unnotched impact
strength of 88 joules/cm.sup.2 and passes the ASTM G47 test for
resistance to stress corrosion cracking at an applied stress of
30,000 psi (207 MPa); whereby the aluminum alloy product in the
artificially aged condition T6 has a minimum ultimate tensile
strength of 61,500 psi (424 MPa), a minimum 0.2% offset yield
strength of 47,800 psi (330 MPa) and a minimum elongation of 3.1%;
whereby the aluminum alloy product in the artificially aged
condition T7 has a minimum ultimate tensile strength of 48,600 psi
(335 MPa), a minimum 0.2% offset yield strength of 43,900 psi (303
MPa), a minimum elongation of 1.0%, a minimum unnotched impact
strength of 28 joules/cm.sup.2 and passes the ASTM G47 test for
resistance to stress corrosion cracking at an applied stress of
40,000 psi (276 MPa); whereby the aluminum alloy product in the
artificially aged condition T61 has an average ultimate tensile
strength of 69,660 psi (480 MPa), an average 0.2% offset yield
strength of 59,390 psi (409 MPa), an average elongation of 6.3% an
average unnotched impact strength of 41 joules/cm.sup.2 and has
similar ballistic performance to aluminum alloy wrought alloy 2519
in the T87 condition.
8. An aluminum alloy cast product according to claim 7, wherein,
before the aluminum alloy cast product is hot isostatically
pressed, it is solution treated at 950-960.degree. F.
(510-516.degree. C.) for 2-4 hours followed by 980-1005.degree. F.
(527-541.degree. C.) for 16-120 hours followed by quenching in
water.
9. An aluminum alloy cast product according to claim 7, wherein the
sand cast aluminum alloy product is a seat frame of a military
vehicle.
10. An aluminum alloy cast product according to claim 7, wherein
the sand cast aluminum alloy product is a turret rotor of a
military weapon system.
11. An aluminum alloy cast product according to claim 7, wherein
the sand cast aluminum alloy product is a hatch of a military
weapon system.
12. An aluminum alloy cast product according to claim 7, wherein
the sand cast aluminum alloy product is ballistic armor.
13. An aluminum alloy cast product according to claim 7, wherein
the aluminum alloy product is welding wire.
14. An aluminum alloy cast product consisting essentially of:
TABLE-US-00023 Cu 5.00-6.25 weight %, Mg 0.20-0.50 weight %, Mn
0.20-0.65 weight %, Ti 0.05-0.40 weight %, Ag 0.00-0.40 weight %,
Cr 0.00-0.20 weight %, V 0.05-0.25 weight %, Zr 0.05-0.25 weight %,
Fe <0.15 weight %, Si <0.15 weight %, Ni <0.05 weight %,
Zn <0.05 weight %, impurities <0.05 each weight %, <0.25
total weight %, Al balance
wherein the aluminum alloy casting alloy is grain refined using
aluminum-titanium-boron and/or aluminum-titanium-carbon containing
grain refiner; wherein the aluminum alloy casting alloy is cast in
a sand mold, wherein the aluminum alloy cast product is hot
isostatically pressed (HIP'ed) at 950-975.degree. F.
(510-524.degree. C.), 15,000+/-500 psi (103+/-3.4 MPa) for 2 to 3
hours, solution treated at 980-1005.degree. F. (527-541.degree. C.)
for 16-120 hours followed by quenching in water and naturally aged
at room temperature or artificially aged at 310-390.degree. F.
(154-199.degree. C.) for 12 to 96 hours.
15. An aluminum alloy cast product according to claim 14, wherein
the sand cast aluminum alloy product is a seat frame of a military
vehicle.
16. An aluminum alloy cast product according to claim 14, wherein
the sand cast aluminum alloy product is a turret rotor of a
military weapon system.
17. An aluminum alloy cast product according to claim 14, wherein
the sand cast aluminum alloy product is a hatch of a military
weapon system.
18. An aluminum alloy cast product according to claim 14, wherein
the sand cast aluminum alloy product is ballistic armor.
19. An aluminum alloy cast product according to claim 14, wherein
the aluminum alloy product is welding wire.
20. An aluminum alloy cast product consisting essentially of:
TABLE-US-00024 Cu 5.00-6.25 weight %, Mg 0.20-0.50 weight %, Mn
0.20-0.65 weight %, Ti 0.05-0.40 weight %, Ag 0.00-0.40 weight %,
Cr 0.00-0.20 weight %, V 0.05-0.25 weight %, Zr 0.05-0.25 weight %,
Fe <0.15 weight %, Si <0.15 weight %, Ni <0.05 weight %,
Zn <0.05 weight %, impurities <0.05 each weight %, <0.25
total weight %, Al balance
wherein the aluminum alloy casting alloy is grain refined using
aluminum-titanium-boron and/or aluminum-titanium-carbon containing
grain refiner; wherein the aluminum alloy casting alloy is cast in
a sand mold; wherein the aluminum alloy product is solution treated
at 950-960.degree. F. (510-516.degree. C.) for 2-4 hours followed
by 980-1005.degree. F. (527-541.degree. C.) for 16-120 hours
followed by quenching in water, hot isostatically pressed (HIP'ed)
at 950-975.degree. F. (510-524.degree. C.), 15,000+/-500 psi
(103+/-3.4 MPa) for 2 to 3 hours, solution treated at
980-1005.degree. F. (527-541.degree. C.) for 16-120 hours followed
by quenching in water and naturally aged at room temperature or
artificially aged at 310-390.degree. F. (154-199.degree. C.) for 12
to 96 hours; whereby the aluminum alloy product in the naturally
aged condition T4 has a minimum ultimate tensile strength of 61,000
psi (420 MPa), a minimum 0.2% offset yield strength of 38,500 psi
(265 MPa), a minimum elongation of 10.9%, a minimum unnotched
impact strength of 88 joules/cm.sup.2 and passes the ASTM G47 test
for resistance to stress corrosion cracking at an applied stress of
30,000 psi (207 MPa); whereby the aluminum alloy product in the
artificially aged condition T6 has a minimum ultimate tensile
strength of 66,600 psi (459 MPa), a minimum 0.2% offset yield
strength of 47,800 psi (330 MPa), a minimum elongation of 4.9%, a
minimum unnotched impact strength of 40 joules/cm.sup.2 and nearly
passes the ASTM G47 test for resistance to stress corrosion
cracking at an applied stress of 40,000 psi (276 MPa); whereby the
aluminum alloy product in the artificially aged condition T61 has
an average ultimate tensile strength of 69,660 psi (480 MPa), an
average 0.2% offset yield strength of 59,390 psi (409 MPa), an
average elongation of 6.3%, an average unnotched impact strength of
41 joules/cm.sup.2 and similar ballistic performance to aluminum
alloy wrought alloy 2519 in the T87 condition; whereby the aluminum
alloy product in the artificially aged condition T7 has a minimum
ultimate tensile strength of 59,700 psi (412 MPa), a minimum 0.2%
offset yield strength of 43,900 psi (303 MPa), a minimum elongation
of 3.9%, a minimum unnotched impact strength of 28 joules/cm.sup.2
and passes the ASTM G47 test for resistance to stress corrosion
cracking at an applied stress of 40,000 psi (276 MPa).
21. An aluminum alloy cast product according to claim 20, wherein
the sand cast aluminum alloy product is a seat frame of a military
vehicle.
22. An aluminum alloy cast product according to claim 20, wherein
the sand cast aluminum alloy product is a turret rotor of a
military weapon system.
23. An aluminum alloy cast product according to claim 20, wherein
the sand cast aluminum alloy product is a hatch of a military
weapon system.
24. An aluminum alloy cast product according to claim 20, wherein
the sand cast aluminum alloy product is ballistic armor.
25. An aluminum alloy cast product according to claim 20, wherein
the aluminum alloy product is welding wire.
26. An aluminum alloy casting alloy consisting essentially of:
TABLE-US-00025 Cu 5.00-6.25 weight %, Mg 0.20-0.50 weight %, Mn
0.20-0.65 weight %, Ti 0.05-0.40 weight %, Ag <0.40 weight %, Cr
<0.20 weight %, V <0.05 weight %, Zr <0.10 weight %, Fe
<0.15 weight %, Si <0.15 weight %, Ni <0.05 weight %, Zn
<0.05 weight %, impurities <0.05 eachweight %, <0.25 total
weight %, Al balance
wherein the aluminum alloy casting alloy is grain refined using
aluminum-titanium-boron and/or aluminum-titanium-carbon containing
grain refiner; wherein the aluminum alloy casting alloy is cast in
a sand mold to form a cast product; and wherein the aluminum alloy
cast product is solution treated at 950-960.degree. F.
(510-516.degree. C.) for 2-4 hours followed by 980-1005.degree. F.
(527-541.degree. C.) for 16-120 hours followed by quenching in
water, hot isostatically pressed (HIP'ed) at 950-975.degree. F.
(510-524.degree. C.), 15,000+/-500 psi (103+/-3.4 MPa) for 2 to 3
hours, solution treated at 980-1005.degree. F. (527-541.degree. C.)
for 16-120 hours followed by quenching in water and naturally aged
at room temperature or artificially aged at 310-390.degree. F.
(154-199.degree. C.) for 12 to 96 hours; whereby the aluminum alloy
cast product in the naturally aged condition T4 has a minimum
ultimate tensile strength of 60,800 psi (419 MPa), a minimum 0.2%
offset yield strength of 40,800 psi (287 MPa) and a minimum
elongation of 12.4%; and whereby the aluminum alloy product in the
artificially aged condition T6 has a minimum ultimate tensile
strength of 67,300 psi (464 MPa), a minimum 0.2% offset yield
strength of 52,600 psi (362 MPa) and a minimum elongation of
6.5%;
27. An aluminum alloy cast product according to claim 26, wherein
the sand cast aluminum alloy product is a seat frame of a military
vehicle.
28. An aluminum alloy cast product according to claim 26, wherein
the sand cast aluminum alloy product is a turret rotor of a
military weapon system.
29. An aluminum alloy cast product according to claim 26, wherein
the sand cast aluminum alloy product is a hatch of a military
weapon system.
30. An aluminum alloy cast product according to claim 26, wherein
the sand cast aluminum alloy product is ballistic armor.
31. An aluminum alloy cast product according to claim 26, wherein
the aluminum alloy product is welding wire.
Description
FIELD OF THE INVENTION
[0001] This invention relates to 1) an aluminum alloy for casting
operations, such as sand, investment or permanent mold casting
operations, 2) a heat treatment process for aluminum alloys and 3)
the application of the newly invented aluminum alloy casting alloy
for cast products for racing, aerospace and military (land, sea and
air) applications. TABLE-US-00002 TERMINOLOGY T4: solution heat
treated and then naturally aged to a substantially stable
condition; applies to products that are not cold worked after
solution heat treatment, or in which the effect of cold work in
flattening or straightening may not be recognized in mechanical
property limits T6: solution heat treated and then artificially
aged; applies to products that are not cold worked after solution
heat treatment, or in which the effect of cold work in flattening
or straightening may not be recognized in mechanical property
limits T61: solution heat treated and then artificially aged to
develop maximum strength with adequate ductility T7: solution heat
treated and overaged/stabilized; applies to cast products that are
artificially aged after solution heat treatment to provide
dimensional and strength stability T87: solution heat treated, cold
worked, and then artificially aged; applies to products that are
cold worked to improve strength, or in which the effect of cold
work in flattening or straightening is recognized in mechanical
property limits ST: solution heat treatment; solution heat
treatment is achieved by heating cast or wrought products to a
suitable temperature, holding at that temperature long enough to
allow constituents to enter solid solution and cooling rapidly
enough to hold the constituent in solution HIP: hot isostatic
pressing; simultaneous application of heat and pressure UTS:
ultimate tensile strength YS: yield strength wt %: weight percent
rem: remainder
BACKGROUND OF THE INVENTION
[0002] Only a few aluminum alloy casting alloys have attractive
properties for racing, aerospace and military applications. These
aluminum alloy casting alloys are commonly designated 354, C355,
A356, A357, A201 and A206. However, none of these aluminum alloy
casting alloys have the desirable combination of high strength,
high ductility, high toughness, good resistance to stress corrosion
cracking, good weldability and good castability (i.e. good
resistance to hot tearing and good fluidity). Hot tearing is a
catastrophic event that occurs during the casting process and
renders the cast product unusable. Hot tearing occurs when the
metal contraction due to solidification produces tensile stresses
higher than the strength of the casting. "Spongy" areas, which have
high levels of porosity, due to poor feeding will have low strength
and hot spots caused by the combination of thick and thin sections
will have high tensile contraction stresses that promote hot
tearing.
[0003] Aluminum alloy casting alloys 354, C355, A356 and A357 have
good castability but do not have good mechanical properties.
Aluminum alloy casting alloys A201 and A206 have good mechanical
properties but do not have good castability, good resistance to
stress corrosion cracking or good weldability. Both A201 and A206
alloy have poor fluidity and poor resistance to hot tearing during
casting.
[0004] The chemical compositions and mechanical properties of
aluminum alloy casting alloys are found in ASTM B26/B26M-99,
"Standard Specification for Aluminum-Alloy Sand Castings", Table 1,
and ASTM B686-99, "Standard Specification for Aluminum Alloys
Castings, High-Strength", Table 2 and Table 3. A comparison of the
castability/fluidity, corrosion resistance and weldability of
aluminum alloy casting alloys is shown in Table 4. TABLE-US-00003
TABLE 1 Chemical compositions of aluminum alloy casting alloys
Composition (weight %)* Element A201 A206 354 C355 A356 A357 Cu
4.0-5.0 4.2-5.0 1.6-2.0 1.0-1.5 <0.20 <0.20 Mg 0.15-0.55
0.15-0.35 0.40-0.60 0.40-0.60 0.25-0.45 0.40-0.70 Mn 0.20-0.40
0.20-0.50 0.20 0.20 0.20 0.20 Cr -- -- -- -- -- -- Ti 0.15-0.35
0.15-0.30 0.20 0.20 0.20 0.20 V -- -- -- -- -- -- Zr -- -- -- -- --
-- Fe 0.10 0.10 0.20 0.20 0.20 0.20 Si 0.05 0.05 8.6-9.4 4.5-5.5
6.5-7.5 6.5-7.5 Ni -- 0.05 -- -- -- -- Zn -- 0.10 0.10 0.10 0.10
0.10 Ag 0.40-1.00 -- -- -- -- -- Be -- -- -- -- -- 0.04-0.07
impurities 0.03 each 0.05 each 0.05 each 0.05 each 0.05 each 0.05
each 0.10 total 0.15 total 0.15 total 0.15 total 0.15 total 0.15
total Al balance balance balance balance balance balance *a single
value denotes the maximum amount permitted
[0005] TABLE-US-00004 TABLE 2 Mechanical properties of aluminum
alloy casting alloys Mechanical Properties of Specimens Cut from
Designated Areas of a Casting UTS (min), YS (min), Elongation Alloy
Class No. ksi (MPa) ksi (MPa) (min), % A201 1 60.0 (414) 50.0 (345)
3 2 60.0 (414) 50.0 (345) 5 A206 not available not available not
available not available not available not available 354 1 47.0
(324) 36.0 (248) 3 2 50.0 (345) 42.0 (290) 2 C355 1 41.0 (283) 31.0
(214) 3 2 44.0 (303) 33.0 (228) 3 A356 1 38.0 (262) 28.0 (193) 5 2
40.0 (276) 30.0 (207) 3 3 45.0 (310) 34.0 (234) 3 A357 1 45.0 (310)
35.0 (241) 3 2 50.0 (345) 40.0 (276) 5
[0006] TABLE-US-00005 TABLE 3 Mechanical properties of aluminum
alloy casting alloys Mechanical Properties of Specimens Cut from
Any Area of the Casting UTS (min), YS (min), Elongation Alloy Class
No. ksi (MPa) ksi (MPa) (min), % A201 10 60.0 (414) 50.0 (345) 3 11
56.0 (386) 48.0 (331) 1.5 A206 not available not available not
available not available not available not available 354 10 47.0
(324) 36.0 (248) 3 11 43.0 (297) 33.0 (228) 2 C355 10 41.0 (283)
31.0 (214) 3 11 37.0 (255) 30.0 (207) 1 12 35.0 (241) 28.0 (193) 1
A356 10 38.0 (262) 28.0 (193) 5 11 33.0 (228) 27.0 (186) 3 12 32.0
(221) 22.0 (152) 2 A357 10 38.0 (262) 28.0 (193) 5 11 41.0 (283)
31.0 (214) 3
[0007] TABLE-US-00006 TABLE 4 Comparison of the
castability/fluidity, corrosion resistance and weldability of
aluminum alloy casting alloys* Corrosion Alloy Castability/Fluidity
Resistance Weldability A201 fair fair poor A206 average fair poor
A357 excellent good excellent *www.sfsa.org/tutorials
[0008] The ASTM does not list A206 alloy as an aluminum alloy sand
casting or high-strength aluminum alloy.
[0009] There are numerous aluminum alloy wrought alloys that have
attractive properties for aerospace and military applications but
products from these aluminum alloys must be machined from plate or
billet, which is extremely time consuming and costly, or must be
forged into useful shapes. Some of these aluminum alloy wrought
alloys are 2024, 5083, 6061, 7075, 2219 and 2519.
[0010] The chemical compositions and mechanical properties of
aluminum alloy wrought alloys are found in ASTM B209/B209M-95,
"Standard Specification for Aluminum and Aluminum-Alloy Sheet and
Plate" and are summarized in Table 5 and Table 6. TABLE-US-00007
TABLE 5 Chemical compositions of aluminum alloy wrought alloys
Composition (weight %)* Element 2024 5083 6061 7075 2219 2519** Cu
3.8-4.9 0.10 0.15-0.40 1.2-2.0 5.8-6.8 5.3-6.4 Mg 1.2-1.8 4.0-4.9
0.80-1.2 2.1-2.9 0.02 0.05-0.40 Mn 0.30-0.90 0.40-1.0 0.15 0.30
0.20-0.40 0.10-0.50 Cr 0.10 0.05-0.25 0.04-0.35 0.18-0.28 -- -- Ti
0.15 0.15 0.15 0.20 0.02-0.10 0.05-0.10 V -- -- -- -- 0.05-0.15
0.05-0.15 Zr -- -- -- -- 0.10-0.25 0.10-0.25 Fe 0.50 0.40 0.70 0.50
0.30 0.30 Si 0.50 0.40 0.40-0.80 0.40 0.20 0.25 Ni -- -- -- -- --
-- Zn 0.25 0.25 0.25 5.1-6.1 0.10 0.10 Ag -- -- -- -- -- -- Be --
-- -- -- -- -- impurities 0.05 each 0.05 each 0.05 each 0.05 each
0.05 each 0.05 each 0.10 total 0.15 total 0.15 total 0.15 total
0.15 total 0.15 total Al balance balance balance balance balance
balance *a single value denotes the maximum amount permitted **from
MIL-DTL-46192C(MR)
[0011] TABLE-US-00008 TABLE 6 Mechanical properties of aluminum
alloy wrought alloys Approximate Mechanical Property Limits* UTS
(min), YS (min), Elongation Alloy Temper ksi (MPa) ksi (MPa) (min),
% 2024 T4 62.0 (427) 40.0 (276) 15 T62 63.0 (434) 50.0 (345) 5 T72
60.0 (414) 46.0 (317) 5 5083 as-cast 40.0 (276) 18.0 (124) 16 6061
T4 30.0 (207) 16.0 (110) 16 T62 42.0 (290) 35.0 (241) 10 7075 T6
78.0 (538) 68.0 (469) 7 T7651 71.0 (490) 60.0 (414) 5 2219 T31 46.0
(317) 28.0 (193) 10 T62 54.0 (372) 36.0 (248) 8 2519 T871 68.0
(469) 58.0 (400) 7*** T871 66.0 (455) 59.0 (407) 10**** *the
properties of wrought alloys are a function of thickness **from
MIL-DTL-46192C(MR) ***long transverse direction ****longitudinal
direction
[0012] The ASTM does not list 2519 alloy as an aluminum alloy
wrought alloy. The chemical composition and mechanical property
data for 2519 alloy was taken from MIL-DTL-46192C(MR).
[0013] Aluminum alloy wrought alloy 2519 is currently the premier
aluminum alloy wrought alloy because of its excellent tensile
strength and ballistic qualities. However, aluminum alloy wrought
alloy 2519 requires "stretching" to achieve these properties (see
e.g. U.S. Pat. No. 4,610,733, entitled "High Strength Weldable
Aluminum Base Alloy Product and Method of Making Same" and issued
Sep. 9, 1986 to Sanders, Jr., et al.). Because "stretching" is a
cold working process, the benefit of stretching is lost if the
product is welded or heat treated after "stretching". Further,
products that are cast to shape cannot be "stretched".
[0014] U.S. Pat. No. 2,706,680 (entitled "Aluminum Base Alloy" and
issued Apr. 19, 1955 to Criner) describes aluminum base alloys that
are adapted for service at elevated temperatures, particularly such
as required in certain parts of jet engines. This patent discloses
a magnesium-free aluminum base alloy containing copper as the chief
added component and small amounts of manganese, vanadium and
zirconium which displays a combination of strength and resistance
to fatigue and creep at high temperatures.
[0015] More specifically the aluminum alloy includes from 5 to 13%
copper, 0.15 to 1.7% manganese, 0.05 to 0.20% vanadium, 0.05 to
0.30% zirconium, with an iron impurity not exceeding 0.75% and a
silicon impurity not exceeded 0.40%. The disclosed alloy contains
no more than about 0.02% magnesium, hence it is referred to as
being "magnesium-free". To obtain a finer grain size or enhance
minor characteristics of the alloy it is disclosed to be desirable
to add 0.01 to 0.25% of one or more of the following elements:
cobalt, nickel, molybdenum, tungsten, chromium, titanium, boron,
tantalum and niobium. The thermal treatment disclosed to enhance
the alloy properties consists of heating to a temperature between
960 and 1000.degree. F. for a period of 2 to 24 hours followed by
quenching, preferably in water at 70 to 160.degree. F. The quenched
alloys are then reheated to 350 to 450.degree. F. for a period of 1
to 50 hours. Mechanical properties are disclosed for elevated
temperatures (400 and 600.degree. F.).
[0016] U.S. Pat. No. 2,784,126 (entitled "Aluminum Base Alloy" and
issued Mar. 5, 1957 to Criner) is similar to U.S. Pat. No.
2,706,680 (discussed above) and discloses an aluminum base alloy
that is adapted for service at elevated temperatures. In this
patent, the disclosed chemistry of the alloy consists of from 5 to
13% copper, 0.15 to 1.7% manganese, 0.05 to 0.20% vanadium, 0.05 to
0.30% zirconium and the addition of 0.05 to 0.70% magnesium. In
this patent, the disclosed addition of magnesium is claimed to
improve the strength and resistance to creep and fatigue at high
temperatures. In this patent, samples were cast in the form of
ingots and forged to 1' square bars. The bars were given a solution
heat treatment of 2 hours at 990- 1000.degree. F., quenched in cold
water and precipitation hardened by heating them for 12 hours at
375.degree. F. The disclosed room temperature properties of an
alloy of composition 5.98 wt % Cu, 0.11 wt % Fe, 0.07 wt % Si, 0.21
wt % Mn, 0.10 wt % V and 0.23 wt % Zr are an average ultimate
tensile strength of 61,600 psi, an average 0.2% offset yield
strength of 43,000 psi and an average elongation of 17%. The
disclosed room temperature properties of an alloy of composition
6.09 wt % Cu, 0.15 wt % Fe, 0.11 wt % Si, 0.32 wt % Mn, 0.18 wt %
V, 0.20 wt % Zr and 0.25 wt % Mg are an average ultimate tensile
strength of 71,100 psi, an average 0.2% offset yield strength of
55,700 psi and an average elongation of 13%. In this patent, it is
presumed that forging was required to increase the density of the
disclosed aluminum alloy. This patent does not disclose information
on the properties of castings made from the disclosed alloy.
[0017] One of the reasons that castings typically have inferior
properties compared to wrought products is porosity. However, a low
cost process known as hot isostatic pressing (HIP) is available.
Use of the HIP process with a proper process cycle can produce
significant improvements in mechanical properties of castings with
respect to porosity. The industry standard practice is to (1)
produce a casting, (2) HIP the casting to eliminate detrimental
porosity and then (3) heat treat the casting to develop the
appropriate mechanical properties.
[0018] An aluminum alloy casting alloy and heat treatment process
that produces a cast product with properties equivalent to the
aluminum alloy wrought alloys is desired to reduce material usage,
energy usage and machining time and expense.
BRIEF SUMMARY OF THE INVENTION
[0019] In accordance with principles of the present invention, a
casting is made from an aluminum alloy containing, in weight
percent: TABLE-US-00009 Cu 5.00-6.75; Mg 0.05-0.50; Mn 0.05-0.65;
Ti 0.05-0.40; Ag 0.00-0.40; Cr 0.00-0.20; V 0.00-0.40; Zr
0.00-0.30; Fe <0.15; Si <0.15; Ni <0.05; Zn <0.05;
impurities <0.05 each; <0.25 total; and Al balance.
[0020] The aluminum alloy casting is solution heat treated, then
hot isostatically pressed, then solution heat treated again. This
process produces a cast product having a multitude of second phase
particles, and in particular a cast product in which an
interdendritic network of second phase particles is eliminated.
[0021] More specifically, the aluminum alloy casting is solution
heat treated at 950-960.degree. F. (510-516.degree. C.) for 2-4
hours followed by 980-1005.degree. F. (527-541.degree. C.) for
16-120 hours followed by quenching in water, hot isostatically
pressed (HIP) at 950-975.degree. F. (510-524.degree. C.) and
15,000.+-.500 psi (103.+-.3.4 MPa) for 2 to 3 hours, heat treated
at 950-960.degree. F. (510-516.degree. C.) for 2-4 hours followed
by 980-1005.degree. F. (527-541.degree. C.) for 16-120 hours
followed by quenching in water and aged. The casting may be either
naturally aged at room temperature or artificially aged at
310-390.degree. F. (154-199.degree. C.) for 1 to 96 hours.
[0022] The resulting aluminum alloy product in the naturally aged
condition T4 has a minimum ultimate tensile strength of 57,100 psi
(394 MPa), a minimum 0.2% offset yield strength of 38,500 psi (265
MPa), a minimum elongation of 6.2%, a minimum unnotched impact
strength of 88 joules/cm.sup.2 and passes the ASTM G47 test for
resistance to stress corrosion cracking at an applied stress of
30,000 psi (207 MPa).
[0023] The resulting aluminum alloy product in the artificially
aged condition T6 has a minimum ultimate tensile strength of 66,100
psi (458 MPa), a minimum 0.2% offset yield strength of 47,800 psi
(330 MPa) and a minimum elongation of 3.1%.
[0024] The resulting aluminum alloy product in the artificially
aged condition T7 has a minimum ultimate tensile strength of 48,600
psi (335 MPa), a minimum 0.2% offset yield strength of 43,900 psi
(303 MPa), a minimum elongation of 1.0%, a minimum unnotched impact
strength of 28 joules/cm.sup.2 and passes the ASTM G47 test for
resistance to stress corrosion cracking at an applied stress of
40,000 psi (276 MPa).
[0025] The resulting aluminum alloy product in the artificially
aged condition T61 has an average ultimate tensile strength of
69,660 psi (480 MPa), an average 0.2% offset yield strength of
59,390 psi (409 MPa), an average elongation of 6.3% and an average
unnotched impact strength of 41 joules/cm.sup.2 and has similar
ballistic performance to aluminum alloy wrought alloy 2519 in the
T87 condition.
[0026] The aluminum alloy casting alloy of the present invention is
desirable because it is weldable and retains the desired properties
when heat treated after welding.
BRIEF DESCRIPTION OF THE DRAWING
[0027] In the drawing:
[0028] FIG. 1 is a picture of a seat frame cast with a prior art
aluminum alloy;
[0029] FIG. 2 is a picture of a seat frame cast with an aluminum
alloy according to principles of the present invention;
[0030] FIG. 3 is a picture of a single plate of a known aluminum
alloy wrought alloy and a single plate of the aluminum cast alloy
according to the present invention after ballistic testing; and
[0031] FIG. 4 is a picture of a double plate of a known aluminum
alloy wrought alloy and a double plate of the aluminum cast alloy
according to the present invention after ballistic testing.
DETAILED DESCRIPTION OF THE INVENTION
[0032] Aluminum alloy casting alloys A201 and A206 were purchased
as ingots from a supplier. The aluminum alloy casting alloy in the
illustrated embodiment was produced using A206 ingot with addition
of aluminum-copper, aluminum-manganese, aluminum-chromium,
aluminum-vanadium, aluminum-zirconium master alloys and pure
magnesium. Commercially available aluminum-titanium-boron and
aluminum-titanium-carbon grain refiners were used. The chemical
compositions of a plurality of aluminum alloy casting alloys
produced are shown in Table 7. In Table 7, the columns represent a
weight percentage of the indicated element and each row represents
one mixture of the constituent elements, termed a heat and
designated by a letter A through W. TABLE-US-00010 TABLE 7 Chemical
compositions of aluminum alloy casting alloys Amount in weight
percent Heat ID Cu Cr Mg Mn V Zr Ti Fe Si other Al A 5.60 <0.01
0.26 0.29 0.14 0.23 0.37 0.03 0.08 rem B 6.08 0.18 0.23 0.29 0.13
0.22 0.20 0.03 0.11 rem C 4.50 0.01 0.26 0.40 0.12 0.15 0.19 0.04
0.04 rem D 5.20 0.01 0.24 0.40 0.11 0.14 0.18 0.04 0.04 rem E 5.84
0.11 0.25 0.34 0.13 0.20 0.19 0.04 0.10 rem F 5.88 <0.01 0.24
0.31 0.06 0.10 0.20 0.04 0.04 rem G 5.78 0.28 0.23 0.37 0.20 0.12
0.17 0.04 0.05 rem H 6.15 0.48 0.22 0.33 0.23 0.18 0.18 0.05 0.10
rem I 6.69 <0.01 0.24 0.29 0.11 0.15 0.14 0.05 0.10 rem J 5.61
<0.01 0.23 0.33 0.01 0.02 0.26 0.03 0.04 rem K 5.76 <0.01
0.53 0.33 0.04 0.02 0.23 0.04 0.04 rem L 5.81 <0.01 0.21 0.37
0.24 0.11 0.16 0.04 0.05 rem M 6.10 <0.01 0.24 0.39 0.09 0.12
0.20 0.04 0.05 rem N 6.22 <0.01 0.77 0.25 0.07 0.10 0.04 0.12
0.05 rem O 5.97 <0.01 0.24 0.40 0.08 0.09 0.18 0.05 0.05 High
rem B&C P 5.35 0.01 0.25 0.29 0.10 0.13 0.15 0.05 0.08 0.21 Ag
rem Q 5.94 <0.01 0.16 0.24 0.08 0.10 0.07 0.13 0.11 rem R 6.72
0.10 0.42 0.64 0.11 0.13 0.15 0.08 0.13 rem S 5.61 0.01 0.23 0.30
0.24 <0.01 0.11 0.06 0.05 rem T 5.75 0.01 0.22 0.31 0.03 0.13
0.15 0.05 0.05 rem U 6.12 0.01 0.40 0.41 0.12 0.24 0.14 0.05 0.05
rem V 5.37 <0.01 0.27 0.59 0.15 0.14 0.17 <0.01 0.05 rem W
5.09 <0.01 0.48 0.39 0.14 0.14 0.20 <0.01 0.05 rem
[0033] Castability. The castability of the aluminum alloy casting
alloys of the illustrated embodiment is determined by qualitatively
comparing the fluidity and hot tearing tendency of A201 and A206
alloys to that of the illustrated embodiment. A complex seat frame
casting that has thick and thin sections is poured from each alloy
at various temperatures in chemically bonded sand molds that
contain aluminum chills. Pictures of such seat frame castings are
shown in FIG. 1 and FIG. 2. Aluminum alloy casting alloys A201 and
A206 typically have very limited pouring temperature ranges since
1) the alloy must be poured at a temperature sufficiently high to
completely fill the mold but 2) the alloy must be poured at as low
a temperature as possible to prevent hot tearing.
[0034] For the seat frame casting, good castings could not be
produced in aluminum alloy casting alloy A206. Good castings could
be produced in aluminum alloy casting alloy A201 when poured in the
temperature range 1350-1360.degree. F. Good castings could be
produced in the aluminum alloy casting alloy of this embodiment
(Heats A, B, D & E) when poured in the temperature range
1330-1380.degree. F., a wider temperature range than with aluminum
alloy casting alloy A201. Good seat frame castings could not be
poured from Heat C. Thus, an aluminum alloy casting alloy should
have a minimum copper content of about 5.20 wt % to produce good
fluidity and good resistance to hot tearing. Seat frame castings
were not poured from Heats F-W.
[0035] An example of an aluminum alloy casting alloy A206 casting
with hot tears is shown in FIG. 1 and an example of a good casting
poured in the aluminum alloy casting alloy of the illustrated
embodiment is shown in FIG. 2. The larger pouring range of the
aluminum alloy casting alloy of the illustrated embodiment is due
to improved fluidity (ability to flow and fill a mold) and improved
feeding (ability to supply metal during liquid contraction and the
liquid-to-solid phase transformation). Good castability allows the
production of complex castings at low scrap rates and, therefore,
minimum cost.
[0036] Heat Treatment and Mechanical Properties. The aluminum alloy
casting alloy of the illustrated embodiment is processed using a
pre-HIP solution heat treatment. That is, instead of applying a HIP
process to the cast product, that product is first heat treated.
The mechanical properties of an aluminum alloy cast product are
determined by soundness, chemistry and microstructure. Soundness is
a measure of porosity, which is determined by the feeding
characteristics of the aluminum alloy cast alloy. Soundness can be
improved by hot isostatic pressing (HIP) the cast product. The
chemistry of the aluminum alloy cast alloy ultimately determines
what microstructural phases can be produced. The size, quantity and
distribution of the microstructural phases and porosity determine
the mechanical properties. The size, quantity and distribution of
the microstructural phases are determined by heat treatment.
[0037] The aluminum alloy casting alloys of the illustrated
embodiment produced less porosity than A201 but more porosity than
A206 alloy. For the seat frame casting (FIG. 1, FIG. 2), the
average porosity for A201 alloy was 3.2%, for A206 alloy was 0.5%
and for the aluminum alloy casting alloy of the illustrated
embodiment was 1.5%.
[0038] The aluminum alloy casting alloy of the illustrated
embodiment produced better mechanical properties compared to A201
alloy. Table 8 compares the mechanical properties of samples cut
from seat frame castings produced from aluminum alloy casting alloy
A201 and aluminum alloy casting alloy of heat A of the illustrated
embodiment. TABLE-US-00011 TABLE 8 Average Mechanical Properties of
Specimens Cut from Castings UTS, YS, Elongation, Alloy Heat
Treatment ksi (MPa) ksi (MPa) % A201 ST then 340.degree. F. 46.9
(323) 46.1 (318) 1 (171.degree. C.) for 24 hours Heat A ST then
340.degree. F. 64.3 (443) 60.1 (414) 2 (171.degree. C.) for 24
hours
[0039] Hot isostatic pressing (HIP'ing) is a well known, commercial
process for reducing the porosity in castings. HIP'ing is typically
performed before any other heat treatment. In the illustrated
embodiment, however, solution heat treatment performed before
HIP'ing produces improved mechanical properties, particularly
improved resistance to stress corrosion cracking. However, solution
heat treatment before HIP'ing is not a requirement to produce
satisfactory properties using the aluminum alloy casting alloy of
the illustrated embodiment.
[0040] Sections were cut from castings produced from the aluminum
alloy casting alloy of the illustrated embodiment and heat treated
in various ways to quantitatively determine the effect of HIP'ing
and heat treatment cycle on mechanical properties.
[0041] The heat treatment cycles were: (1) a long pre-HIP solution
heat treatment at 950-960.degree. F. (510-516.degree. C.) for 2-4
hours followed by 990-995.degree. F. (532-535.degree. C.) 96 hours
followed by quenching in water, followed by HIP'ing at
950-975.degree. F. (510-524.degree. C.), 15,000+/-500 psi
(103+/-3.4 MPa) for 2 to 3 hours, followed by a post-HIP solution
heat treatment (see below) and age; (2) a short pre-HIP solution
heat treatment at 950-960.degree. F. (510-516.degree. C.) for 2-4
hours followed by 990-995.degree. F. for 16-20 hours followed by
quenching in water, followed by HIP'ing at 950-975.degree. F.
(510-524.degree. C.), 15,000+/-500 psi (103+/-3.4 MPa) for 2 to 3
hours, followed by a post-HIP solution heat treatment (see below)
and age; and (3) HIP'ing at 950-975.degree. F. (510-524.degree.
C.), 15,000+/-500 psi (103+/-3.4 MPa) for 2 to 3 hours, followed by
a post-HIP solution heat treatment (see below) and age (i.e. no
pre-HIP solution heat treatment).
[0042] The T4 condition was produced by post-HIP solution heat
treatment at 950-960.degree. F. (510-516.degree. C.) for 2-4 hours
followed by 990-995.degree. F. (532-535.degree. C.) for 16-20 hours
followed by quenching in warm water at 120-180.degree. F.
(49-82.degree. C.) and then naturally aging at room temperature for
a minimum of seven days before testing. The T6 condition was
produced by post-HIP solution heat treatment at 950-960.degree. F.
(510-516.degree. C.) for 2-4 hours followed by 990-995.degree. F.
(532-535.degree. C.) for 16-20 hours followed by quenching in warm
water at 120-180.degree. F. (49-82.degree. C.), naturally aging at
room temperature for 8-24 hours and then artificially aging at
325.degree. F. (163.degree. C.) for 24 hours. Material heat treated
to the T6 condition exhibited the best combination of strength and
ductility: HIP'ing increased the tensile ductility by 60 to 101%.
The T61 condition was produced by post-HIP solution heat treatment
at 950-960.degree. F. (510-516.degree. C.) for 2-4 hours followed
by 990-995.degree. F. (532-535.degree. C.) for 16-20 hours followed
by quenching in warm water at 120-180.degree. F. (49-82.degree.
C.), naturally aging at room temperature for 8-24 hours and then
artificially aging at 325.degree. F. (163.degree. C.) for 36 hours.
The T7 condition was produced by post-HIP solution heat treatment
at 950-960.degree. F. (510-516.degree. C.) for 2-4 hours followed
by 990-995.degree. F. (532-535.degree. C.) for 16-20 hours followed
by quenching in warm water at 120-180.degree. F. (49-82.degree.
C.), naturally aging at room temperature for 8-24 hours and then
artificially aging at 390.degree. F. (199.degree. C.) for 24
hours.
[0043] The mechanical properties of samples cut from seat frame
castings produced from the aluminum alloy casting alloy of the
illustrated embodiment and heat treated in various ways are listed
in Table 9. TABLE-US-00012 TABLE 9 Average Mechanical Properties of
Specimens Cut from Castings Impact YS Strength ID Process UTS ksi
(MPa) ksi (MPa) Elongation % joules/cm.sup.2 Heat D Long ST-HIP-T4
-- -- -- 141.6 Short ST-HIP-T4 67.8 (467) 42.5 (293) 24.1 HIP-T4
68.4 (472) 41.4 (285) 24.0 137.7 Heat E Long ST-HIP-T4 68.0 (469)
41.6 (287) 20.0 88.1 Heat D Long ST-HIP-T6 70.6 (487) 49.1 (339)
15.2 88.2 Long ST-T6 69.8 (481) 52.7 (363) 7.6 -- Short ST-HIP-T6
71.7 (494) 50.8 (350) 13.7 -- Short ST-T6 66.7 (460) 52.2 (360) 7.5
-- HIP-T6 72.5 (500) 51.1 (352) 14.1 -- T6 68.1 (470) 51.2 (353)
8.3 -- Heat E Long ST-HIP-T6 70.8 (488) 50.8 (350) 12.2 40.0 Heat D
Long ST-HIP-T61 72.0 (496) 56.6 (390) 13.7 97.2 Short ST-HIP-T61
69.9 (482) 52.5 (362) 12.7 -- HIP-T61 70.5 (486) 51.7 (356) 10.7 --
Heat E Long ST-HIP-T61 71.4 (492) 56.4 (389) 9.2 59.4 Heat D Long
ST-HIP-T7 66.7 (460) 51.1 (352) 8.8 68.8 Short ST-HIP-T7 63.9 (441)
47.6 (328) 9.2 71.6 HIP-T7 -- -- -- 65.4 Heat E Long ST-HIP-T7 65.9
(454) 53.5 (369) 3.9 28.3
[0044] Compared to aluminum alloy casting alloy A206, the aluminum
alloy cast alloy of the illustrated embodiment has improved yield
(design) strength in all heat treatment conditions. Also, the
tensile ductility increased by 167% when subjected to the short
solution heat treatment, followed by HIP'ing, followed by the T6
heat treatment. For comparison, sections from seat frame castings
of each alloy were heat treated using identical processing
conditions (e.g. solution heat treated, HIP'ed or not HIP'ed, then
T6) and the results are listed in Table 10. TABLE-US-00013 TABLE 10
Average Mechanical Properties of Specimens Cut from Castings UTS YS
Elongation Alloy Process ksi (MPa) ksi (MPa) % A206 Short ST-HIP-T6
62.0 (427) 44.4 (306) 18.4 Long ST-T6 63.6 (439) 49.4 (341) 14.7 T6
60.7 (419) 49.2 (339) 6.9 Heat D Short ST-HIP-T6 71.7 (494) 50.8
(350) 13.7 Long ST-T6 68.8 (474) 51.3 (354) 9.1 T6 69.0 (476) 50.5
(348) 9.0
[0045] To more fully determine the effect of chemistry, sections
were cut from Y-block castings produced from different formulations
of the aluminum alloy casting alloy of the illustrated embodiment,
and heat treated using the same conditions. The heat treatment
cycle was a long pre-HIP solution heat treatment at 950-960.degree.
F. (510-516.degree. C.) for 2-4 hours followed by 990-995.degree.
F. (532-535.degree. C.) for 96-120 hours followed by quenching in
water, HIP'ing at 950-975.degree. F. (510-524.degree. C.),
15,000+/-500 psi (103+/-3.4 MPa) for 2 to 3 hours, followed by a
post-HIP solution heat treatment and age.
[0046] The T4 condition was produced by post-HIP solution heat
treatment at 950-960.degree. F. (510-516.degree. C.) for 2-4 hours
followed by 990-995.degree. F. (532-535.degree. C.) for 16-20 hours
followed by quenching in warm water at 120-180.degree. F.
(49-82.degree. C.) and then naturally aging at room temperature for
a minimum of seven days before testing.
[0047] The T6 condition was produced by post-HIP solution heat
treatment at 950-960.degree. F. (510-516.degree. C.) for 2-4 hours
followed by 990-995.degree. F. (532-535.degree. C.) for 16-20 hours
followed by quenching in warm water at 120-180.degree. F.
(49-82.degree. C.), naturally aging at room temperature for 8-24
hours and then artificially aging at 325.degree. F. (163.degree. C)
for 24 hours.
[0048] The T7 condition was produced by post-HIP solution heat
treatment at 950-960.degree. F. (510-516.degree. C.) for 2-4 hours
followed by 990-995.degree. F. (532-535.degree. C.) for 16-20 hours
followed by quenching in warm water at 120-180.degree. F.
(49-82.degree. C.), naturally aging at room temperature for 8-24
hours and then artificially aging at 390.degree. F (199.degree. C)
for 24 hours.
[0049] For an aluminum alloy casting alloy to have good mechanical
properties, copper content should be limited to about 6.25 wt %,
chromium content should be limited to about 0.20 wt % and magnesium
content should be limited to about 0.50 wt %. The addition of
silver was shown to significantly increase yield strength. The
resulting data shows that ductility (e.g. tensile elongation)
decreases as copper content increases, as chromium content
increases and as magnesium content increases. Increasing manganese
content or vanadium content was shown to decrease yield strength
and increase ductility. Increasing zirconium content was shown to
have an inconsistent effect on mechanical properties. The
mechanical properties of samples cut from castings produced from
the aluminum alloy casting alloy of the illustrated embodiment and
heat treated in similar ways are displayed in Table 11.
TABLE-US-00014 TABLE 11 Average Tensile Properties of Specimens Cut
from Castings UTS YS Elongation, Alloy Condition ksi (MPa) ksi
(MPa) % Heat A HIP-Long ST-T4 66.8 (461) 41.9 (289) 18.3 HIP-Long
ST-T6 70.8 (488) 56.1 (387) 7.6 HIP-Short ST-T6 71.0 (490) 56.5
(390) 7.5 Heat B HIP-Short ST-T4 66.6 (459) 42.2 (291) 18.2
HIP-Long ST-T6 67.8 (467) 55.1 (380) 6.7 Long ST-HIP-T6 69.7 (481)
54.5 (376) 7.9 Heat C Long ST-HIP-T4 63.0 (434) 38.0 (262) 23.0
(insufficient Long ST-HIP-T6 66.4 (458) 47.4 (326) 17.4 Cu) Long
ST-HIP-T7 -- -- -- Heat D Long ST-HIP-T4 -- -- -- Long ST-HIP-T6
70.6 (487) 49.1 (339) 15.3 Long ST-HIP-T7 66.7 (460) 51.1 (352) 8.8
Heat E Long ST-HIP-T4 68.0 (469) 41.6 (287) 20.0 Long ST-HIP-T6
70.8 (488) 50.8 (350) 12.2 Long ST-HIP-T7 65.9 (454) 53.5 (369) 3.9
Heat F Long ST-HIP-T4 64.4 (444) 40.5 (279) 21.6 Long ST-HIP-T6
70.7 (487) 51.9 (358) 14.0 Long ST-HIP-T7 64.5 (454) 51.2 (353) 4.5
Heat G Long ST-HIP-T4 52.0 (359) 40.9 (282) 6.0 (excessive Cr) Long
ST-HIP-T6 61.9 (427) 47.1 (325) 4.7 Long ST-HIP-T7 51.2 (353) 46.7
(322) 2.2 Heat H Long ST-HIP-T4 43.6 (301) 40.3 (278) 2.1
(excessive Cr) Long ST-HIP-T6 49.3 (340) 45.1 (311) 1.4 Long
ST-HIP-T7 45.4 (313) 43.9 (303) 0.8 Heat I Long ST-HIP-T4 57.1
(394) 40.7 (281) 6.2 (not optimum Long ST-HIP-T6 66.1 (456) 58.1
(401) 4.0 Cu) Long ST-HIP-T7 55.5 (383) 54.9 (379) 1.0 Heat J Long
ST-HIP-T4 60.8 (419) 40.8 (287) 12.4 Long ST-HIP-T6 67.3 (464) 52.6
(362) 6.5 Long ST-HIP-T7 -- -- -- Heat K Long ST-HIP-T4 64.4 (444)
43.5 (300) 12.6 (excessive Mg) Long ST-HIP-T6 61.5 (424) 53.1 (366)
3.1 Long ST-HIP-T7 48.6 (335) 47.5 (328) 1.0 Heat L Long ST-HIP-T4
61.1 (422) 40.3 (278) 12.7 Long ST-HIP-T6 66.6 (459) 51.1 (352) 7.8
Long ST-HIP-T7 63.2 (436) 49.4 (341) 4.8 Heat M Long ST-HIP-T4 61.4
(424) 41.1 (283) 10.9 Long ST-HIP-T6 -- -- -- Long ST-HIP-T7 62.4
(430) 50.2 (346) 4.1 Heat N Long ST-HIP-T4 43.6 (300) 36.2 (249)
2.7 (excessive Mg) Long ST-HIP-T6 29.4 (202) na 0.2 Long ST-HIP-T7
14.2 (98) na 0.3 Heat O Long ST-HIP-T4 64.3 (443) 40.6 (280) 19.3
(not optimum Long ST-HIP-T6 67.4 (464) 51.9 (358) 6.4 grain
refiner) Long ST-HIP-T7 57.6 (397) 49.0 (338) 1.4 Heat P Long
ST-HIP-T4 65.0 (448) 40.2 (277) 17.1 Long ST-HIP-T6 75.8 (523) 64.9
(448) 8.0 Long ST-HIP-T7 70.2 (484) 57.5 (397) 5.5 Heat Q Long
ST-HIP-T4 61.0 (420) 38.5 (265) 18.1 Long ST-HIP-T6 70.5 (486) 56.6
(390) 8.1 Long ST-HIP-T7 66.3 (457) 54.2 (374) 4.1 Heat R Long
ST-HIP-T4 62.8 (433) 43.3 (299) 7.9 (not optimum Long ST-HIP-T6
69.4 (478) 54.3 (375) 7.2 Cu) Long ST-HIP-T7 61.0 (421) 52.3 (361)
2.7 Heat S Long ST-HIP-T4 61.2 (422) 39.3 (271) 15.2 Long ST-HIP-T6
68.0 (469) 51.3 (354) 11.2 Long ST-HIP-T7 63.4 (437) 48.6 (335) 5.8
Heat T Long ST-HIP-T4 64.2 (443) 40.3 (278) 18.2 Long ST-HIP-T6
66.7 (460) 53.1 (366) 4.6 Long ST-HIP-T7 62.7 (432) 51.6 (356) 3.4
Heat U Long ST-HIP-T4 68.3 (471) 43.8 (302) 15.9 Long ST-HIP-T6
67.6 (466) 53.1 (366) 4.9 Long ST-HIP-T7 62.0 (427) 48.3 (333) 4.0
Heat V Long ST-HIP-T4 62.5 (431) 38.5 (265) 16.0 Long ST-HIP-T6
68.0 (469) 47.8 (330) 9.7 Long ST-HIP-T7 59.7 (412) 43.9 (303) 5.5
Heat W Long ST-HIP-T4 64.3 (443) 42.4 (292) 11.7 Long ST-HIP-T6
69.0 (476) 50.8 (350) 10.4 Long ST-HIP-T7 60.2 (415) 44.9 (310)
6.2
[0050] The aluminum alloy casting alloy of the illustrated
embodiment has good stress corrosion cracking properties that are
enhanced when solution heat treated before HIP'ing. Aluminum alloy
cast alloys and wrought alloys that contain copper typically have
unacceptable stress corrosion cracking properties in the T6
condition but often have acceptable stress corrosion cracking
properties in the T4 or T7 conditions. Samples from two heats (Heat
B, Heat D) were given a variety of heat treatments and then
subjected to the standard stress corrosion cracking test, ASTM
G47-98 (2004). The heat subjected to long solution heat treatment
prior to HIP'ing (Heat D) exhibited significantly improved
resistance to stress corrosion cracking (almost produced
"acceptable" results) in the T6 condition. The stress corrosion
cracking performance, as determined by ASTM G47-98 (2004), for the
two different heat treatment processes and aluminum alloy casting
alloys of the illustrated embodiment are displayed in Table 12.
TABLE-US-00015 TABLE 12 Stress Corrosion Cracking Performance, ASTM
G47 Time to Applied Stress, Failure, Acceptable/ Heat/Condition ksi
(MPa) Days Unacceptable Heat B/HIP-T4 30 (207) >20 acceptable
Heat B/HIP-T6 40 (276) 3 unacceptable Heat B/HIP-T7 40 (276) >20
acceptable Heat D/Long ST-HIP-T4 30 (207) >20 acceptable Heat
D/Long ST-HIP-T6 40 (276) 20 unacceptable* Heat D/Long ST-HIP-T7 40
(276) >20 acceptable *failed on the last day of the test
[0051] The aluminum alloy casting alloy of the illustrated
embodiment is weldable. Aluminum alloy casting alloys are not
normally welded so little or no published data exists for
comparison purposes. However, aluminum alloy wrought alloys are
often welded and the aluminum alloy casting alloy of the
illustrated embodiment compared favorably to published data for
material tested in the heat treated then welded condition. The
welder had no prior experience welding the aluminum alloy casting
alloy of the illustrated embodiment and very little experience with
aluminum alloy 2319 welding wire. The aluminum alloy casting alloy
of the illustrated embodiment can be heat treated after welding to
develop improved properties. Further, solution treatment after
welding but prior to HIP'ing results in significantly improved
yield strength. Solution treatment after welding but prior to
HIP'ing resulted in an 85% increase in yield strength in the T4
condition and a 27% increase in yield strength in the T6 condition.
A comparison of the tensile properties after welding of aluminum
alloy wrought alloy 2219, aluminum alloy wrought alloy 2519 (from
published data) and the aluminum alloy casting alloy of the
illustrated embodiment is displayed in Table 13 and the tensile
properties of the aluminum alloy casting alloy of the illustrated
embodiment after welding followed by heat treatment is displayed in
Table 14. TABLE-US-00016 TABLE 13 Average Tensile Properties after
Welding Alloy YS, ksi (MPa) Elongation, % 2219* 26.0 (179) 3.0
2519* 34.7 (239) 5.5 Heat A 29.5 (203) 1.2 *from U.S. Pat. No.
4,610,733
[0052] TABLE-US-00017 TABLE 14 Average Tensile Properties after
Welding Followed by Heat Treatment Heat/Condition YS, ksi (MPa)
Elongation, % Heat D/Weld-HIP-T4 20.0 (138) 0.9 Heat D/Weld-Long
ST-HIP-T4 37.0 (255) 3.6 Heat D/Weld-HIP-T6 41.7 (288) 2.6 Heat
D/Weld-Long ST-HIP-T6 53.1 (366) 1.7
[0053] The aluminum alloy casting alloy of the illustrated
embodiment in the T61 condition has ballistic properties similar to
aluminum alloy wrought alloy 2519 in the T87 condition. Samples of
the aluminum alloy casting alloy of the illustrated embodiment in
the T61 condition and aluminum alloy wrought alloy 2519 in the T87
condition were machined to the same size and dimensions and shot at
with 0.223 caliber standard rounds at a distance of approximately
50 meters (150 feet). Single plates, 0.5'' thick, of the aluminum
alloy casting alloy of the illustrated embodiment in the T61
condition and the aluminum alloy wrought alloy 2519 in the T87
condition were completely penetrated, as illustrated in FIG. 3.
FIG. 3a is a picture of a single plate of the aluminum alloy
casting alloy of the illustrated embodiment after the ballistic
testing described above, and FIG. 3b is a picture of a single plate
of the aluminum alloy wrought alloy 2519 after the ballistic
testing described above.
[0054] Double plates of the aluminum alloy casting alloy of the
illustrated embodiment in the T61 condition and the aluminum alloy
wrought alloy 2519 in the T87 condition were not penetrated after
the same ballistic testing described above, as illustrated in FIG.
4. FIG. 4a is a picture of a double plate of the aluminum alloy
casting alloy of the illustrated embodiment after the ballistic
testing described above, and FIG. 4b is a picture of a double plate
of the aluminum alloy wrought alloy 2519 after the ballistic
testing described above.
[0055] Articles Made From the Aluminum Alloy Casting Alloy of the
Illustrated Embodiment
[0056] The aluminum alloy casting alloy of the present illustrated
embodiment is ideally suited for articles requiring high strength,
high toughness, resistance to penetration by ballistic objects,
resistance to stress corrosion cracking and light in weight. These
articles are commonly used in racing, aerospace and military (land,
sea and air) vehicles. Specifically, a seat frame for a military
vehicle, (FIG. 1 and FIG. 2), was used as a test casting for
developing the aluminum alloy casting alloy of the illustrated
embodiment. Light-weight armor, a turret rotor, a turret housing
and hatches for a military weapon system, bolts and welding wire
are currently being developed and evaluated. The aluminum alloy
casting alloy of the illustrated embodiment could be a replacement
for aluminum alloy casting alloy A201, which is currently used for
the steering deflector on the AAAV amphibious military vehicle. Of
course, the applications for the aluminum alloy casting alloy of
the illustrated embodiment are not limited to only those articles
discussed above.
[0057] Preferred Embodiments
[0058] The composition for an aluminum alloy casting alloy
according to principles of the present invention, in weight
percent, is as follows: TABLE-US-00018 Cu 5.00-6.75 Mg 0.05-0.50 Mn
0.05-0.65 Ti 0.05-0.40 Ag 0.00-0.40 Cr 0.00-0.20 Ti 0.05-0.40 V
0.00-0.40 Zr 0.00-0.30 Fe <0.15 Si <0.15 Ni <0.05 Zn
<0.05 impurities <0.05 each <0.25 total Al balance
wherein the aluminum alloy casting alloy is grain refined using a
0.04-2.00 weight % addition of aluminum-5 weight % titanium-1
weight % boron and a 0.07-2.00 weight % addition of aluminum-3
weight % titanium-0.15 weight % carbon containing grain
refiner.
[0059] An optimum composition for the aluminum alloy casting alloy,
in weight percent, is as follows: TABLE-US-00019 Cu 5.00-6.25 Mg
0.20-0.50 Mn 0.20-0.40 Ti 0.05-0.40 Ag 0.00-0.40 Cr 0.00-0.20 V
0.05-0.25 Zr 0.05-0.25 Fe <0.10 Si <0.10 Ni <0.05 Zn
<0.05 impurities <0.05 each <0.25 total Al balance
wherein the aluminum alloy casting alloy is grain refined using a
0.04-0.08 weight % addition of aluminum-5 weight % titanium-1
weight % boron and a 0.07-0.10 weight % addition of aluminum-3
weight % titanium-0.15 weight % carbon containing grain
refiner.
[0060] A heat treatment for an aluminum alloy casting alloy
according to principles of the present invention is as follows:
[0061] 1. Solution heat treat at 950-960.degree. F.
(510-516.degree. C.) for 2-4 hours followed by 980-1005.degree. F.
(527-541.degree. C.) for 16-120 hours followed by quenching in
water (this step is optional) [0062] 2. Hot isostatic pressing
(HIP'ing) at 950-975.degree. F. (510-524.degree. C.), 15,000+/-500
psi (103+/-3.4 MPa) for 2 to 3 hours [0063] 3. Solution heat treat
at 950-960.degree. F. (510-516.degree. C.) for 2-4 hours followed
by 980-1005.degree. F. (527-541.degree. C.) for 16-120 hours
followed by quenching in water [0064] 4. Naturally age at room
temperature or artificially age at 310-390.degree. F.
(154-199.degree. C.) for 1 to 96 hours
[0065] The optimum heat treatment for the aluminum alloy casting
alloy is as follows: [0066] 1. Solution heat treat at
950-960.degree. F. (510-516.degree. C.) for 2-4 hours followed by
990-995.degree. F. (532-535.degree. C.) for 68-120 hours followed
by quenching in water [0067] 2. Hot isostatic pressing (HIP'ing) at
950-975.degree. F (510-524.degree. C.), 15,000+/-500 psi (103+/-3.4
MPa) for 2 to 3 hours [0068] 3. Solution heat treat at
990-995.degree. F. (532-535.degree. C.) for 16-24 hours followed by
quenching in water [0069] 4. T4: Naturally age at room temperature;
[0070] T6: Artificially age at 325.degree. F. (163.degree. C.) for
24 hours; [0071] T61: Artificially age at 325-340.degree. F.
(163-171.degree. C.) for 24-36 hours; [0072] T7: Artificially age
at 390.degree. F. (199.degree. C.) for 24 hours.
* * * * *