High strength aluminum stamping

Abstract

The invention provides a component formed of an aluminum alloy for use in a vehicle, for example an automotive vehicle component requiring high strength, light-weight, and a complex three-dimensional shape, and a method of manufacturing the component. The method begins by providing a blank formed of an aluminum alloy which is already solution heat treated and tempered, and thus has a temper designation of about T4. The method further includes heating the blank to a temperature of 150° C. to 350° C., preferably 190° C. to 225° C. The method next includes quickly transferring the blank to a hot or warm forming apparatus, and stamping the blank to form the complex three-dimensional shape. Immediately after the forming step, the component has a temper designation of about T6, but preferably not greater than T6, and thus is ready for use in the vehicle without any post heat treatment or machining.

1 . A component for use in a vehicle, comprising:
 an aluminum alloy selected from the group consisting of: a 2000, 6000, 7000, 8000, and 9000 series aluminum alloy; and   the aluminum alloy of the component having a temper designation of about T6; and the aluminum alloy achieving the temper designation of T6 by heating a solution heat treated and tempered blank formed of the aluminum alloy to a temperature of 150° C. to 350° C. before forming the blank.   
     
     
         2 . The component of  claim 1 , wherein the 2000, 6000, 7000, 8000, and 9000 series aluminum alloy of the component has a tensile strength equal to or greater than the minimum tensile strength required by a T6 temper designation. 
     
     
         3 . The component of  claim 1 , wherein the aluminum alloy forms the shape of a bumper for the vehicle. 
     
     
         4 . The component of  claim 1 , wherein the aluminum alloy forms the shape of a reinforcement for the vehicle. 
     
     
         5 . The component of  claim 1 , wherein the aluminum alloy is a 6000 series aluminum alloy. 
     
     
         6 . The component of  claim 1 , wherein the aluminum alloy is a 7000 series aluminum alloy 
     
     
         7 . The component of  claim 1 , wherein the aluminum alloy is a 8000 series aluminum alloy. 
     
     
         8 . The component of  claim 1 , wherein the aluminum alloy is selected from the group consisting of: a 6000, 7000, and 8000 series aluminum alloy; the aluminum alloy of the blank has a temper designation of T4 before the heating step; the heating step includes heating the solution heat treated and tempered blank to a temperature ranging from 190° C. to 225° C.; and the aluminum alloy of the component has the temper designation of T6 immediately after the forming step. 
     
     
         9 . The component of  claim 1 , wherein the heating step includes heating the solution heat treated and tempered blank at a temperature of 150° C. to 350° C. for 2 to 6 minutes, and the forming step includes stamping the solution heat treated and tempered blank while the blank is still at a temperature of at least 150° C. 
     
     
         10 . The component of  claim 1 , wherein the step of heating the solution heat treated and tempered blank includes holding the heated blank at the temperature ranging from 150° C. to 350° C. for 2 to 6 minutes in a furnace, and further including:
 transferring the heated blank from the furnace to a forming apparatus, the transferring step having a duration of not greater than 15 seconds, and 
 wherein the step of forming the blank includes stamping the solution heat treated blank into a component having a three-dimensional shape after the heating step and in the forming apparatus and while the blank is still heated and at a temperature of at least 150° C. 
 
     
     
         11 . The component of  claim 10 , wherein the heating step includes holding the blank at a temperature ranging from 190° C. to 225° C. for 2 to 6 minutes. 
     
     
         12 . The component of  claim 10 , wherein the stamping step occurs within 15 seconds after the heating step. 
     
     
         13 . The component of  claim 1 , wherein the aluminum alloy of the component has a temper designation of T6 immediately after the forming step. 
     
     
         14 . A bumper for a vehicle, comprising:
 an aluminum alloy selected from the group consisting of: a 2000, 6000, 7000, 8000, and 9000 series aluminum alloy; and   the aluminum alloy having a temper designation of T6.   
     
     
         15 . The bumper of  claim 14 , wherein the 2000, 6000, 7000, 8000, and 9000 series aluminum alloy of the component has a tensile strength equal to or greater than the minimum tensile strength required by a T6 temper designation. 
     
     
         16 . The bumper of  claim 14 , wherein the aluminum alloy is selected from the group consisting of: a 6000, 7000, and 8000 series aluminum alloy; the aluminum alloy achieves the temper designation of T6 by heating a solution heat treated and tempered blank formed of the aluminum alloy before forming the blank; the aluminum alloy of the blank has a temper designation of T4 before the heating step; the heating step includes heating the solution heat treated and tempered blank to a temperature ranging from 190° C. to 225° C.; and the aluminum alloy of the component has the temper designation of T6 immediately after the forming step. 
     
     
         17 . The bumper of  claim 14 , wherein the aluminum alloy achieves the temper designation of T6 by heating a solution heat treated and tempered blank formed of the aluminum alloy before forming the blank; the heating step includes heating the solution heat treated and tempered blank at a temperature of 150° C. to 350° C. for 2 to 6 minutes, and the forming step includes stamping the solution heat treated and tempered blank while the blank is still at a temperature of at least 150° C. 
     
     
         18 . The bumper of  claim 14 , wherein the aluminum alloy achieves the temper designation of T6 by heating a solution heat treated and tempered blank formed of the aluminum alloy before forming the blank;
 the step of heating the solution heat treated and tempered blank includes holding the heated blank at the temperature ranging from 150° C. to 350° C. for 2 to 6 minutes in a furnace, and further including:   transferring the heated blank from the furnace to a forming apparatus, the transferring step having a duration of not greater than 15 seconds, and   wherein the step of forming the blank includes stamping the solution heat treated blank into a component having a three-dimensional shape after the heating step and in the forming apparatus and while the blank is still heated and at a temperature of at least 150° C.   
     
     
         19 . The bumper of  claim 18 , wherein the heating step includes holding the blank at a temperature ranging from 190° C. to 225° C. for 2 to 6 minutes. 
     
     
         20 . The bumper of  claim 18 , wherein the stamping step occurs within 15 seconds after the heating step, and the aluminum alloy of the component has a temper designation of T6 immediately after the forming step.