Optimization of aluminum hot working

Abstract

A method of hot forming an aluminum alloy component may include heating the aluminum alloy component in a heating furnace to a solutionizing temperature, cooling the aluminum alloy component to a desired forming temperature, deforming the aluminum alloy component into a desired shape in a forming device while the aluminum alloy component is at the desired forming temperature, maintaining a constant temperature during the deformation of the aluminum alloy component, and quenching the aluminum alloy component to a low temperature below a solvus temperature.

That which is claimed is: 
     
         1 . A method of hot forming an aluminum alloy component, the method comprising:
 heating the aluminum alloy component in a heating furnace to a solutionizing temperature;   cooling the aluminum alloy component to a desired forming temperature;   transferring the aluminum alloy component from the heating furnace to a forming device;   deforming the aluminum alloy component into a desired shape in the forming device while the aluminum alloy component is at the desired forming temperature; and   quenching the aluminum alloy component to a low temperature below a solvus temperature, wherein the low temperature is in a range of approximately 0° C. to approximately 280° C.,   wherein the heating of the aluminum alloy component to the solutionizing temperature occurs over a period of approximately 5 minutes.   
     
     
         2 . The method of  claim 1 , wherein the aluminum alloy component comprises a 7xxx alloy. 
     
     
         3 . The method of  claim 2 , wherein the aluminum alloy component comprises a 7075 alloy. 
     
     
         4 . The method of  claim 1 , wherein the desired forming temperature is in a range of approximately 400° C. to approximately 440° C. 
     
     
         5 . The method of  claim 1 , wherein the solutionizing temperature is in a range of approximately 400° C. to approximately 600° C. 
     
     
         6 . The method of  claim 5 , wherein the solutionizing temperature is approximately 480° C. 
     
     
         7 . The method of  claim 1 , further comprising artificially aging the aluminum alloy component. 
     
     
         8 . The method of  claim 1 , further comprising maintaining a constant temperature during the deformation of the aluminum alloy component, wherein the constant temperature is held to within ±10° C. 
     
     
         9 . The method of  claim 1 , wherein:
 the aluminum alloy component is an ingot;   the forming device is a rolling mill; and   the desired shape is a plate or a sheet.   
     
     
         10 . The method of  claim 1 , wherein the forming device is a forming press. 
     
     
         11 . The method of  claim 1 , further comprising maintaining the aluminum alloy component at the solutionizing temperature for a predetermined time, wherein the predetermined time is up to approximately 30 minutes. 
     
     
         12 . The method of  claim 1 , wherein the quenching comprises die quenching with water flowing internally through a die such that the aluminum alloy component is cooled at a rate between approximately 50° C./second and approximately 500° C./second. 
     
     
         13 . A method of hot forming an aluminum alloy component, the method comprising:
 heating the aluminum alloy component in a heating furnace to a solutionizing temperature;   cooling the aluminum alloy component to a desired forming temperature in a range of approximately 380° C. to approximately 470° C.;   deforming the aluminum alloy component into a desired shape in a forming device while the aluminum alloy component is at the desired forming temperature; and   quenching the aluminum alloy component to a low temperature below a solvus temperature, wherein the low temperature is in a range of approximately 0° C. to approximately 280° C.,   wherein heating the aluminum alloy component in the heating furnace results in an approximate grain size of 10-35 microns for the aluminum alloy component.   
     
     
         14 . The method of  claim 13 , wherein the desired forming temperature is in a range of approximately 400° C. to approximately 440° C. 
     
     
         15 . The method of  claim 13 , wherein the heating of the aluminum alloy component to the solutionizing temperature occurs in a range of approximately 10 seconds to 15 minutes. 
     
     
         16 . The method of  claim 15  wherein the heating of the aluminum alloy component to the solutionizing temperature occurs in approximately 5 minutes. 
     
     
         17 . The method of  claim 13 , further comprising maintaining a constant temperature during the deformation of the aluminum alloy component, wherein the constant temperature is held to within ±10° C. 
     
     
         18 . The method of  claim 13 , wherein:
 the aluminum alloy component is an ingot;   the forming device is a rolling mill; and   the desired shape is a plate or a sheet.   
     
     
         19 . The method of  claim 13 , wherein the forming device is a forming press. 
     
     
         20 . A method of hot forming an aluminum alloy component, the method comprising:
 heating the aluminum alloy component in a heating furnace to a solutionizing temperature, wherein the heating is performed at a rate such that (i) the aluminum alloy component reaches the solutionizing temperature after a period of at least 5 minutes and (ii) the aluminum alloy component comprises an approximate grain size of at least 10 microns;   cooling the aluminum alloy component to a desired forming temperature in a range of approximately 380° C. to approximately 470° C.;   deforming the aluminum alloy component into a desired shape in a forming device while the aluminum alloy component is at the desired forming temperature; and   quenching the aluminum alloy component to a low temperature below a solvus temperature, wherein the low temperature is in a range of approximately 0° C. to approximately 280° C.