Alloy composition for making blister-free aluminum forgings and parts made therefrom

Abstract

An aluminum alloy, which is more resistant to high temperature oxidation-type blistering, comprises: about 0.65-0.9 wt. % silicon, about 4-4.7 wt. % copper, about 0.6-0.9 wt. % manganese, about 0.35-0.55 wt. % magnesium, up to about 0.15 wt. % iron and a balance of aluminum, incidental elements and impurities. By reducing iron content, the invention has reduced scrap rates in some forging part lines to 0%. An improvement in fracture toughness performance was also observed.

What is claimed is:  
     
         1 . An improved aluminum alloy with reduced susceptibility to high temperature oxidation, said alloy consisting essentially of: about 0.65-0.9 wt. % silicon, about 4-4.7 wt. % copper, about 0.6-0.9 wt. % manganese, about 0.35-0.55 wt. % magnesium, up to about 0. 15 wt. % iron and a balance of aluminum, incidental elements and impurities.  
     
     
         2 . The alloy of  claim 1  which further contains one or more of: up to about 0.25 wt. % zinc, up to about 0.15 wt. % titanium, up to about 0.1 wt. % chromium, and up to about 0.001 wt. % beryllium.  
     
     
         3 . The alloy of  claim 1  which contains about 0.7-0.85 wt. % silicon.  
     
     
         4 . The alloy of  claim 1  which contains about 4.1-4.5 wt. % copper.  
     
     
         5 . The alloy of  claim 1  which contains about 0.65-0.85 wt. % manganese.  
     
     
         6 . The alloy of  claim 1  which contains about 0. 14 wt. % iron or less.  
     
     
         7 . The alloy of  claim 1  which is suitable for manufacturing into a forged part.  
     
     
         8 . The alloy of  claim 7  wherein said forged part is a vehicle wheel.  
     
     
         9 . The alloy of  claim 7  wherein said forged part is an aerospace wheel.  
     
     
         10 . The alloy of  claim 7  wherein said forged part is an aerospace brake component.  
     
     
         11 . The forged part of  claim 7  which exhibits improved fracture toughness performance as compared to its 2014 aluminum counterpart.  
     
     
         12 . A forged aircraft wheel having reduced susceptibility to high temperature oxidation, said wheel made of an alloy composition consisting essentially of: about 0.65-0.9 wt. % silicon, about 4-4.7 wt. % copper, about 0.6-0.9 wt. % manganese, about 0.35-0.55 wt. % magnesium, up to about 0.15 wt. % iron and a balance of aluminum, incidental elements and impurities.  
     
     
         13 . The wheel of  claim 12  which further contains one or more of: up to about 0.25 wt. % zinc, up to about 0. 15 wt. % titanium, up to about 0.1 wt. % chromium, and up to about 0.001 wt. % beryllium.  
     
     
         14 . The wheel of  claim 12  which contains about 0.7-0.85 wt. % silicon.  
     
     
         15 . The wheel of  claim 12  which contains about 4.1-4.5 wt. % copper.  
     
     
         16 . The wheel of  claim 12  which contains about 0.65-0.85 wt. % manganese.  
     
     
         17 . The wheel of  claim 12  which contains about 0.14 wt. % iron or less.  
     
     
         18 . The wheel of  claim 12  which is an inboard wheel.  
     
     
         19 . The wheel of  claim 12  which exhibits improved fracture toughness performance as compared to its 2014 aluminum counterpart.  
     
     
         20 . A forged vehicular brake component having reduced susceptibility to high temperature oxidation, said brake component made of an alloy composition consisting essentially of: about 0.65-0.9 wt. % silicon, about 4-4.7 wt. % copper, about 0.6-0.9 wt. % manganese, about 0.35-0.55 wt. % magnesium, up to about 0.15 wt. % iron and a balance of aluminum, incidental elements and impurities.  
     
     
         21 . The brake component of  claim 20  which further contains one or more of: up to about 0.25 wt. % zinc, up to about 0.15 wt. % titanium, up to about 0.1 wt. % chromium, and up to about 0.001 wt. % beryllium.  
     
     
         22 . The brake component of  claim 20  which contains about 0.7-0.85 wt. % silicon.  
     
     
         23 . The brake component of  claim 20  which contains about 4.1-4.5 wt. % copper.  
     
     
         24 . The brake component of  claim 20  which contains about 0.65-0.85 wt. % manganese.  
     
     
         25 . The brake component of  claim 20  which contains about 0.14 wt. % iron or less.  
     
     
         26 . The brake component of  claim 20  which exhibits improved fracture toughness performance as compared to its 2014 aluminum counterpart.  
     
     
         27 . The brake component of  claim 20  which is a piston housing.