Method for fabrication of tubes using rolling and extrusion

Abstract

A method for producing a high strength aluminum alloy tubing containing L1 2 dispersoids from an aluminum alloy powder containing the L1 2 dispersoids. The powder is consolidated into a billet having a density of about 100 percent. The tube is formed by at least one of direct extrusion, Mannesmann process, pilgering, and rolling.

1 . A method for forming a high strength aluminum alloy component containing L1 2  dispersoids, comprising the steps of:
 placing in a container a quantity of an aluminum alloy powder containing an L1 2  dispersoid L1 2  comprising Al 3 X dispersoids wherein X is at least one first element selected from the group comprising:
 about 0.1 to about 4.0 weight percent scandium, about 0.1 to about 20.0 weight percent erbium, about 0.1 to about 15.0 weight percent thulium, about 0.1 to about 25.0 weight percent ytterbium, and about 0.1 to about 25.0 weight percent lutetium; 
 at least one second element selected from the group comprising about 0.1 to about 20.0 weight percent gadolinium, about 0.1 to about 20.0 weight percent yttrium, about 0.05 to about 4.0 weight percent zirconium, about 0.05 to about 10.0 weight percent titanium, about 0.05 to about 10.0 weight percent hafnium, and about 0.05 to about 5.0 weight percent niobium; and 
 the balance substantially aluminum; 
   the alloy powder having a mesh size of less than 350 mesh in a container,   vacuum degassing the powder at a temperature of about 300° F. (149° C.) to about 900° F. (482° C.) for about 0.5 hours to about 8 days;   sealing the degassed powder in the container under vacuum;   heating the sealed container at about 300° F. (149° C.) to about 900° F. (482° C.) for about 15 minutes to eight hours;   vacuum hot pressing the heated container to form a solid billet;   removing the container from the formed billet; and   forming the billet into a tube.   
     
     
         2 . The method of  claim 1 , wherein the billet is rolled into a sheet and the sheet is rolled into a tube. 
     
     
         3 . The method of  claim 1 , wherein the billet is formed into a tube by the Mannesmann process. 
     
     
         4 . The method of  claim 1 , wherein the billet is formed into a tube by the pilgering process. 
     
     
         5 . The method of  claim 1 , wherein the billet is extruded directly into a tube. 
     
     
         6 . The method of  claim 1 , wherein the aluminum alloy powder contains at least one metal selected from the group comprising:
 about 1.0 to about 8.0 weight percent magnesium, (4-25) weight percent silicon, (0.1-3) weight percent manganese, about 0.5 to about 3.0 weight percent lithium, about 0.2 to about 6.0 weight percent copper, about 3.0 to about 12.0 weight percent zinc, and about 1.0 to about 12.0 weight percent nickel.   
     
     
         7 . The method of  claim 1 , wherein the aluminum alloy powder contains at least one ceramic selected from the group comprising: about 5 to about 40 volume percent aluminum oxide, about 5 to about 40 volume percent silicon carbide, about 5 to about 40 volume percent aluminum nitride, about 5 to about 40 volume percent titanium diboride, about 5 to about 40 volume percent titanium boride, about 5 to about 40 volume percent boron carbide and about 5 to about 40 volume percent titanium carbide. 
     
     
         8 . The method of  claim 5 , wherein the tube extrusion is carried out at a temperature of from about 300° F. (149° C.) to about 850° F. (454.4° C.). 
     
     
         9 . The method of  claim 5 , wherein the tube extrusion rate is about 0.1 min −1  to 25 min −1 . 
     
     
         10 . The method of  claim 1 , wherein the billet temperature ranges from about 300° F. (149° C.) to about 850° F. (454.4° C.) and the billet has a soak time ranging from about 1 hour to about 10 hours. 
     
     
         11 . A high strength aluminum alloy tube, comprising:
 a vacuum hot pressed aluminum alloy billet containing an L1 2  dispersoid comprising Al 3 X dispersoids wherein X is at least one first element selected from the group comprising:
 about 0.1 to about 4.0 weight percent scandium, about 0.1 to about 20.0 weight percent erbium, about 0.1 to about 15.0 weight percent thulium, about 0.1 to about 25.0 weight percent ytterbium, and about 0.1 to about 25.0 weight percent lutetium; 
 at least one second element selected from the group comprising about 0.1 to about 20.0 weight percent gadolinium, about 0.1 to about 20.0 weight percent yttrium, about 0.05 to about 4.0 weight percent zirconium, about 0.05 to about 10.0 weight percent titanium, about 0.05 to about 10.0 weight percent hafnium, and about 0.05 to about 5.0 weight percent niobium; and 
   the balance substantially aluminum; and   the billet being formed into a tube.   
     
     
         12 . The alloy tube of  claim 11 , wherein the alloy powder contains at least one metal selected from the group comprising:
 about 1.0 to about 8.0 weight percent magnesium, (4-25) weight percent silicon, (0.1-3) weight percent manganese, about 0.5 to about 3.0 weight percent lithium, about 0.02 to about 6.0 weight percent copper, about 3.0 to about 12.0 weight percent zinc and about 1.0 to about 12.0 weigh percent nickel.   
     
     
         13 . The alloy tube of  claim 11 , wherein the aluminum alloy tube powder contains at least one ceramic selected from the group comprising: about 5 to about 40 volume percent aluminum oxide, about 5 to about 40 volume percent silicon carbide, about 5 to about 40 volume percent aluminum nitride, about 5 to about 40 volume percent titanium diboride, about 5 to about 40 volume percent titanium boride, about 5 to about 40 volume percent boron carbide and about 5 to about 40 volume percent titanium carbide. 
     
     
         14 . The alloy tube of  claim 11 , wherein the tube is formed by rolling a rolled sheet into a tube. 
     
     
         15 . The alloy tube of  claim 11 , wherein the tube is formed by the Mannesmann process. 
     
     
         16 . The alloy tube of  claim 11 , wherein the tube is formed by the pilgering process. 
     
     
         17 . The alloy tube of  claim 11 , wherein the tube is formed by direct extrusion. 
     
     
         18 . The alloy tube of  claim 17 , wherein the extrusion is carried out at a temperature from about 300° F. (149° C.) to about 850° F. (454.4° C.). 
     
     
         19 . The alloy tube of  claim 17 , wherein the extrusion rate is about 0.1 min −1  to about 25 min −1 . 
     
     
         20 . The alloy tube of  claim 11 , wherein the tube forming temperature is about 300° F. (149° C.) to about 850° F. (454.4° C.).