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UACJ Technical ReportsVol.2 201541
UACJ Technical Reports, Vol.2 2015pp. 41-57
TOPICS
15
50719822003
2013UACJ
1 5
2.1
1906Wilm1907Al-Cu-
18
*
18th Japan Institute of Light Metals Medal
Inheriting the Spirit Cultivated in the Development of Extra Super Duralumin: My Study about Microstructural Control in a Superplastic ESD
Aluminum Alloy
Hideo Yoshida
* 652015345-355. The main part of this paper has been published in Journal of Japan Institute of Light Metals, 652015, 345-355.** UACJ Research & Development Division, UACJ Corporation
42UACJ Technical ReportsVol.2 2015
Mg1909Al-4%Cu-0.5%Mg-0.5%MnDuralumin191019141916Fig. 1UACJ
1919
Cu 4%Mg 0.5%Mn 1.0%192111922419266191644 kg/mm2430 MPa28 kg/mm2
270 MPa 22% 17SAl-4%Cu-0.5%Mg-0.5%Mn192217S250007
2.2
Super-Duralumin19278192817S14SAl-4.4%Cu-0.4%Mg-0.9%Si-0.8%Mn
T649 kg/mm2480 MPa42 kg/mm2410 MPa13%17S1931Mg24SAl-4.5%Cu-1.5%Mg-0.6%Mn24S-T349 kg/mm2480 MPa35 kg/mm2 340 MPa18%17S24S24ST3
Fig. 1 Part of frame of Zeppelin Airship shot down near London, brought into Japan by Japanese Navy and stored in UACJ Corporation 1).
UACJ Technical ReportsVol.2 201543
Alclad 24S-T3
1934 SDAl-4.2%Cu-0.75%Mg-0.7%Mn-0.7%Si SA1Al-1.2%Mn-0.8%CuSDC193524S193324S193524SSDSDC24SSA1SA3Al-1.5%/Mn-0.55%Mg193614S24S14ST624S-T324S910193519405
10
2.3
24S11
Fig. 224S1935810Fig. 3No. 175 kg/mm2
740 MPa
Fig. 2Dr. Isamu Igarashi 1892-1986.
Fig. 3 First report on the research of Extra Super Duralumin (cover and abstract) 2).
44UACJ Technical ReportsVol.2 2015
54 58 kg/mm2 530 570 MPa20 12
193669135036Fig. 460 kg/mm2 590 MPaAl-4%Cu-1.5%Mg-0.5%MnDAl-8%Zn-1.5%Mg-0.5%MnSanderSNational Physical LaboratoryZinc DuraluminEAl-20%Zn-2.5%Cu-0.5%Mg-0.5%Mn Al-8%Zn-1.5%Mg-2%Cu-0.5%Mn-0.25%CrESD
Extra Super Duralumin
58 60 kg/mm2 570 590 MPa48 52 kg/mm2 470 510 MPa10 1630 kg12533 km/h432km/h100km/h19421943 7075 Al-5.7%Zn-2.5%Mg-1.6%Cu-0.25%Cr
2.4
13
ESD
Fig. 4 Patent of Extra Super Duralumin, No. 135036 2)
UACJ Technical ReportsVol.2 201545
14
Fig. 515
3.1Al-Zn-Mg
GHQ
Al-Zn-MgAl-Mg-SiAl-Zn-MgHD
Al-5.4%Zn-2.0%Mg-0.55%Mn-0.25%Cr
Fig. 6Al-Zn-Mg1617PFZ8Fig. 771507475Fig. 5 Sayings of Dr. Igarashi collected by Dr. Nagata 15).
1.
2.
3.
4.
5.
(1) At first, it is necessary to master company s history, persons, technology and so on entirely. It takes 4-5 years to master them. Learning lectures in a school only is insufficient.
(2) Industries develop by the daily progress of theory and experiment. It is troublesome to regard the immature theory as absolute.
(3) Fact is important! Don t talk various quibbles. Progres-sion and development are generated only when a new fact inconsistent with expected results is found.
(4) When questions arise, it is necessary to consider repeatedly why they occur and investigate them thor-oughly.
(5) Theme is important. But it is problem who decides the theme.
Fig. 6Dr. Yoshio Baba1935-2012
46UACJ Technical ReportsVol.2 2015
PFZ18
606160637003Aluminum Association
19Al-Mg-Si217
3.2Al-Zn-Mg-Cu
1980B7671980 19832019811821722
B7677075Fig. 8
Fig. 8 B767s fuselage constructed with frames, skins and taper-rolled stringers (left). Manufacturing process of a taper-rolled stringer for airplanes (right) 17) .
Fig. 7Precipitation around Zr (7150) or Cr (7475) compounds in these alloys air-cooled (1 K/s) from solution heat treatment and aged at 163 -44 h 18).
0.2 m
0.2 m
(a) 7150 (Zr)
(b) 7475 (Cr)
UACJ Technical ReportsVol.2 201547
177075197950 m17B767B7779172324KYB2625
1983 1986261986 1989Al-Li
27Fig. 97475Al-Li10-3s-128
4.17475
4.1.1
1970292
707510 m Rockwell InternationalWert3031Fig. 10400 -8 h0.75 1 m22090%482Wert3270757475360 480
Fig. 9Door panel model formed superplastically using a 7475 alloy sheet with fine grains compared with a conventional structure. SPF structure consists of 3 SPF parts and 80 rivets, while conventional one consists of 45 pressed parts and 400 rivets. Cost saving of 30% and weight saving of 15% were achieved by SPF 26) . This panel was superplastically formed by Mitsubishi Heavy Industries.
Conventionaldesign
New design: Integrated door model with SPF beam and stiffener
Conventional structure(45 Parts, 400 Rivets)
SPF structure(3 Parts, 80 Rivets)
Cost saving 30%Weight reduction 15%
48UACJ Technical ReportsVol.2 2015
90480 -5 minFig. 11Table 132Wert400 -8 16 h420 -16 h4004 h
42011 m
4.1.2
400 -8 h480 -2 h4Fig. 12Fig. 1332480 -2 h0.5 2 m0.1 0.2 mE-phaseAl18M3Cr2480Fig. 14Fig. 15
Grain size in L-LT plane/m
Solution heat treatment
Precipitation treatment
Holding time/hWater quenching Furnace cooling
Temperature / 1 2 4 8 16 1 2 4 8 16
480-5 min WQ
360 11 9.5 9.5 19 19 16380 8 8 8 16 16 13400 8 8 6.5 6.5 13 11 11 11420 9.5 9.5 8 6.5 11 11 11 11440 9.5 9.5 9.5 11 11 11 11 11460 11 11 11 11 480 15 15 11 11
No SHT 290 8 11 380 15 11 Process: Solution heat treatment (480-5 min WQ)Precipitation treatment (360-480/1-16 h WQ, FC) Cold rolling (90%)Solution
heat treatment (480-5 min) WQ
Table 1 Effect of precipitation treatment on the grain size in L-LT plane of recrystallized sheet 32).
Fig. 11 Grain refinement process for investigating the effect of conditions of precipitation treatment and cooling rate on recrystallized grain sizeWQWater Quenching, FC: Furnace Cooling (25 /h) 32).
WQ FC
Precipitation CR SHT500
400
300
200
100RT
Tem
pera
ture
/
Fig. 10 Grain refinement process developed by Rockwell International for superplastic 7075 alloy sheets
Reprinted with permission of TMS 30), 31).
Solution treatment
Overaging
Rolling
Recrystallization
Tem
pera
ture
/
Time
482-3 h
400-8 h
482-30 min
22090%
(510 pass)
482
400
200
20
UACJ Technical ReportsVol.2 201549
Fig. 16
32480Fig. 14
Fig. 12 Effect of precipitation treatment on the microstructures of the cross section before and after cold rolling ( all pictures are in the same magnification).
Before cold rolling After cold rolling
400
-8 h
WQ
400
-8 h
FC
480
-2 h
WQ
480
-2 h
FC
50 m50 m
Fig. 13 Effect of precipitation treatment on the TEM structures before and after cold rolling.
Before cold rolling After cold rolling40
0-8
h W
Q40
0-8
h F
C48
0-2
h W
Q48
0-2
h F
C2 m2 m
2 m2 m
2 m2 m
2 m2 m
4 m4 m
2 m2 m
4 m4 m
4 m4 m
Fig. 14 Effect of the resolved solute atom content on TEM structures of cold rolled sheet, tangled dislocation structures in WQ and dislocation cell structures and subgrains by dynamic recovery in FC are observed.
400-8 h WQ 400-8 h FC
0.5 m0.5 m0.5 m0.5 m
Fig. 15 Ring-like tangled dislocation structures around E-phase containing chromium.
0.2 m0.2 m
E-phase E-phase
E-phase
50UACJ Technical ReportsVol.2 2015
400 -8 hFig. 17320340
3235033400Fig. 184801010
480Fig. 1934
400 -8 h
Fig. 17 TEM structures heat-treated at several conditions in a salt bath using the sheet treated by precipitation at 400 -8 h WQ followed by 90% cold rolling.
320-300 s 340-90 s
320-1200 s 400-30 s
2 m2 m
4 m4 m
2 m2 m
2 m2 m
Fig. 16 Effect of precipitation treatment on the change of electrical conductivity before and after cold rolling of 50% 32).
Precipitation
Furnace cooling
Water quenching
Solid Solution
Before cold rollingAfter cold rolling(Reduction 50%)
360400440480
Aging time/h
Elec
tric
al c
ondu
ctiv
ity/I
ACS
%50
40
30
201 2 4 8 16
UACJ Technical ReportsVol.2 201551
480Fig. 20
400 -8 hFig. 2132355N5N
4.1.3
36480 -2 h480 -5 min
Fig. 19 C-curve of precipitation in 7075 alloy (Schematic) 33).
350
Time
Tem
pera
ture
Al3FeAl18Mg3Cr2 (E-phase)
MgZn2, (AIZnMgCu)Al2CuAl2CuMg
500
350
Fig. 20 TEM structures at micro bands and microstructures at shear bands during recovery and recrystallization of the sheet (480 -2 h WQ, 90% CR) heated at 340 360 in a salt bath 32).
340-5 min
L-LT plane 360-90 s L-ST plane
340-20 min 360-5 min
4 m4 m
Fig. 18 TEM structures heat-treated at 480 in a salt bath using the sheet treated by precipitation at 400 -8 h WQ followed by 90% cold rolling.
480-1 s 480-10 s
2 m2 m2 m2 m
52UACJ Technical ReportsVol.2 2015
8.6 m37Fig. 2232 h38420480 -32 h
500
Fig. 23747510-4 s-110-3 s-138
4.2 7475
7475
Fig. 21 Schematic model of the grain refinement process in a 7475 alloy sheet 32).
E-phase
E-phaseMicroband
Soluteatoms(Mg, Zn, Cu)
Largeparticles
E-phase
Intermediateheat treatment
As coldrolled
Low temp.
During heating
Cr, FeCr, Fe
Cr, Fe
Cr, Fe
finegrain
High temp.
Mg3 (Al, Cu, Zu) 5-phase
Zn
MgMg
MgCu
Cu
Cu
Cr, Fe
Cr, FeZn
Zn
Fig. 22 Effect of preheating temperatures for 32 h in a salt bath on cavitations during superplastic deformation at 500 and 2.5x10-4 s-1 without holding at 500 before tensile test in a 7475 alloy SPF sheet 38).
Are
al fr
actio
n of
cav
ity/%
True strain
14
12
10
8
6
4
2
00 0.5 1.0
Original sheet400420440460480500520
Pre-heating time : 32 h (in salt bath)Pre-heating temperature
T=500(Temperature of tension test)=2.510-4 s-1 Holding time : 0 s
400
520440500460
1.5480
420
Original
Fig. 23 Effect of heating rate (salt bath or air furnace) and holding time in pre-heating at 480 and tensile test speed at 500 on the elongation at 500 38).
1000
800
600
400
200
0
Pre-heating time/h/at 480 32
Elom
gatio
n/%
5.610-4 s-1
5.610-3 s-1 (Air Furnace)
5.610-3 s-1 (Salt Bath)
UACJ Technical ReportsVol.2 201553
10-4 s-113910-3 s-1
20 800.6 mmFig. 2440655002.710-3 s-1
Fig. 25Fig. 265040480100 m10 m
50500Fig. 27402.710-3 s-1800 900
Fig. 26 Relation between optimum range of pre-strain temperature and recrystallization peaks in DSC curve 40).
600
Tem
pera
ture
/
Reduction of cold rolling/%
Recrystallization(Peak in DSC curve)
Optimum range ofpre-strain forming
500
400
300
200 20 50 80
Fig. 25 Effect of cold rolling reduction and pre-strain temperature on elongation at 500 40).
300 340 380 420
Temperature of pre-strain forming/
1000
800
600
400
200
0
480-2 h WQ CR (20, 50, 80%)
20%
50%
CR=80%
Pre-strain
SPF
5.610-3s-165% T5002.710-3s-1
Elon
gatio
n/%
Fig. 24 Process and its conditions of thermomechanical treatment for two-step deformation, that is, pre-strain at low temperature and tensile test at high temperature 40).
400
480500
400
300
200
100
RT
IA1 IA2 Pre-strain
FC WQ WQ FC
CR CR
20%50%80%
t3.0t1.2t0.75
t6
RecrystallizationTMT for SPF sheet Tension test
Tem
pera
ture
/
54UACJ Technical ReportsVol.2 2015
10-3 s-1
4.3
7075Fig. 28MILO410 4502 h400 2 h20%300 -2 h400 -2 h480 -5 min400 -2 h
41400 -2 h300 -2 hOO
198042198143
198344198645
Fig. 28 Effect of precipitation treatment conditions and cold rolling reduction on the grain size of 7475 alloy sheet heated at 480 in a salt bath
Process: hot rolling cold rolling (50%) recrystallization (480 -5 min WQ, salt bath) precipitation treatment (none, 300 -2 h WQ and FC , 400 -2 h WQ and FC) cold rolling (0-90%) recrystallization (480 -5 min WQ, salt bath) measurement of grain size.
Grai
n si
ze/
m
0
2040
60
80
100120
140
160
0 20 40 60 80 100
Reduction of cold rolling /%
300C-2 h WQ300C-2 h FC400C-2 h WQ400C-2 h FC480-5 min WQ
Fig. 27 Effect of intermediate heat treatment (IA2 in Fig. 26) on high temperature elongation at 500 40).
Intermediate heat treatment
Elon
gatio
n/%
IACR50% Pre-strain SPFPre-strain=360Tp
=340Tp=T
T
Tp
=290Tp
=290Tp
1000
800
600
400
200
0400WQ
5.610-3 s-165%
SPF =5002.710-3 s-1
400FC
480WQ
480FC
UACJ Technical ReportsVol.2 201555
87475705019 21Al-Li
Wert3031
WertBimodal 30317000
1000464748355N
Al-Li7000700060003000Al-Fe
56UACJ Technical ReportsVol.2 2015
100080007000
UACJUACJFurukawa-Sky-ReviewUACJ
Technical Reports
774 TP3 TP3 Timely Professional5Production Process and Price CostPatent or TP310 20
1 53201260-78. 2 542013264-326. 3
1986. 4
1995 5
1989 6 1001991171. 7 M.B.W. Graham and B.H. Pruitt R&D for Industry, A
Century of Technical Innovation at Alcoa, Cambridge, 1990, 170.
8 20No. 1911950, 2.
9 3819958.
UACJ Technical ReportsVol.2 201557
10 199559.
11 642014,111-116.12 1970
64. 13 29198893-9814 1120043815 602010192-20116 Y. Baba: Tran. JIM.71966224.,
9196824-31.17 502000398-408.18 341984689-
701.19 18197768-79 .20
No. 5061981No. 6031982No. 7021983
21 No. 131985
22 46199689.
23 No. 8071994No. 9041995
24 491999161-165.25
652015, 95-100.26
No. 8021984No. 9011985No. 60011986
27 Al-LiNo. 1051987No. 2051988No. 3071989
28 391989817-823.29 36199537-46.30 J.A. Wert, N.E. Paton, C.H. Hamilton and M.W. Mahoney:
Metallurgical Transactions A, 12A1981, 1267-1276.31 J.A. Wert: Superplastic Forming of Structural Alloys,
edited by N.E. Paton and C.H. Hamilton, TMS-AIME, 1982, 69-83.
32 411991331-337.33 391989, 587-606.34 C.C. Bampton, J.A. Wert and M.W. Mahoney: Metallurgical
Transactions A, 13A1982, 193-198.35 642014285-291.36 1387695
58198312837 411991338-343.38 411991446-452.39 291988
58-68.40 411991453-458.41 1985.42 211980
123-139.43 311981195-205.44 221983115-
120.45 271986333-338.46 391989, 184-189.47 642014179.
48 642014279-284.
Hideo YoshidaUACJ