Method of producing an aluminum alloy product

Abstract

A 7000 series aluminum alloy characterized by high strength, high fatigue resistance and high fracture toughness consists essentially of 5.9 to 6.9% zinc, 2.0 to 2.7% magnesium, 1.9 to 2.5% copper, 0.08 to 0.15% zirconium, a maximum of 0.15% iron, maximum of 0.12% silicon, a maximum of 0.06% titanium, a maximum of 0.04% chromium, a maximum of 0.05% for each of any other trace elements present in the alloy, the total of the other trace elements in the allow being a maximum of 0.15%, the balance of the alloy being aluminum. The foregoing alloy is hot worked to provide a wrought product, such as an extruded or plate product, in which recrystallization is held to a minimum. The wrought product is subjected to a solution treatment, quench, and elevated temperature aging cycle, normally until the product is at or near its maximum strength.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows: 
     
       1. .[.A method of producing.]. .Iadd.An upper wing skin of a commercial jet aircraft comprising .Iaddend.an improved alloy product .Iadd.having high strength, high fracture toughness and high fatigue resistance made in accordance with the process .Iaddend.comprising the steps of: (a) providing a body composed of an alloy consisting essentially of 5.9 to 6.9% zinc, 2.0 to 2.7% magnesium, 1.9 to 2.5% copper, 0.08 to 0.15% zirconium, a maximum of 0.15% iron, a maximum of 0.12% silicon, a maximum of 0.06% titanium, a maximum of 0.04% chromium, a maximum of 0.05% for each of any other trace elements present in the alloy, the maximum total of said other trace elements being 0.15%, the balance being aluminum, all percentages herein by weight based on the total alloy,   (b) working said body .Iadd.to a thickness of less than about 1.5 inches .Iaddend.to provide a wrought product, said .[.alloy.]. .Iadd.body .Iaddend.being hot worked .[.so as to prevent substantial recrystallization of said alloy.]. .Iadd.by rolling at a temperature that is intentionally maintained sufficiently high so that less than about 50 volume % of said alloy is recrystallized product.Iaddend.,   (c) subjecting said product to solution treatment and quenching, .Iadd.and .Iaddend.   (d) subjecting said product to an artificial aging treatment at an elevated temperature .Iadd.wherein said artificial aging treatment is continued only until said alloy reaches its peak strength.Iaddend..   
     
     
       2. .[.The method of claim 1.]. .Iadd.An upper wing skin of a commercial jet aircraft comprising an improved alloy product having high strength, high fracture toughness and high fatigue resistance made in accordance with the process comprising the steps of: (a) providing a body composed of an alloy consisting essentially of 5.9 to 6.9% zinc, 2.0 to 2.7% magnesium, 1.9 to 2.5% copper, 0.08 to 0.15% zirconium, a maximum of 0.15% iron, a maximum of 0.12% silicon, a maximum of 0.06% titanium, a maximum of 0.04% chromium, a maximum of 0.05% for each of any other trace elements present in the alloy, the maximum total of said other trace elements being 0.15%, the balance being aluminum, all percentages herein by weight based on the total alloy,   (b) working said body to a thickness of less than about 1.5 inches to provide a wrought product, said body being hot worked by rolling at a temperature that is intentionally maintained sufficiently high so that less than about 30 volume % of said alloy is recrystallized product,   (c) subjecting said product to solution treatment and quenching, and   (d) subjecting said product to an artificial aging treatment at an elevated temperature .Iaddend.wherein said artificial aging treatment is continued only until said alloy reaches its peak strength.   
     
     
       3. .[.The method of claim 1.]. .Iadd.An upper wing skin of a commercial jet aircraft comprising an improved alloy product having high strength, high fracture toughness and high fatigue resistance made in accordance with the process comprising the steps of: (a) providing a body composed of an alloy consisting essentially of 5.9 to 6.9% zinc, 2.0 to 2.7% magnesium, 1.9 to 2.5% copper, 0.08 to 0.15% zirconium, a maximum of 0.15% iron, a maximum of 0.12% silicon, a maximum of 0.06% titanium, a maximum of 0.04% chromium, a maximum of 0.05% for each of any other trace elements present in the alloy, the maximum total of said other trace elements being 0.15%, the balance being aluminum, all percentages herein by weight based on the total alloy,   (b) working said body to a thickness of less than about 1.5 inches to provide a wrought product, said body being hot worked by rolling at a temperature that is intentionally maintained sufficiently high so that less than about 50 volume % of said alloy is recrystallized product,   (c) subjecting said product to solution treatment and quenching, and   (d) subjecting said product to an artificial aging treatment at an elevated temperature .Iaddend.wherein said artificial aging treatment comprises:   first aging said product at an intermediate temperature above room temperature and below said elevated temperature, and   thereafter aging said product at said elevated temperature until said alloy reaches it peak strength.   
     
     
       4. .[.The method of claim 3.]. .Iadd.An upper wing skin of a commercial jet aircraft comprising an improved alloy product having high strength, high fracture toughness and high fatigue resistance made in accordance with the process comprising the steps of: (a) providing a body composed of an alloy consisting essentially of 5.9 to 6.9% zinc, 2.0 to 2.7% magnesium, 1.9 to 2.5% copper, 0.08 to 0.15% zirconium, a maximum of 0.15% iron, a maximum of 0.12% silicon, a maximum of 0.06% titanium, a maximum of 0.04% chromium, a maximum of 0.05% for each of any other trace elements present in the alloy, the maximum total of said other trace elements being 0.15%, the balance being aluminum, all percentages herein by weight based on the total alloy,   (b) working said body to a thickness of less than about 1.5 inches to provide a wrought product, said body being hot worked by rolling at a temperature that is intentionally maintained sufficiently high so that less than about 50 volume % of said alloy is recrystallized product,   (c) subjecting said product to solution treatment and quenching, and   (d) subjecting said project to an artificial aging treatment at an elevated temperature wherein said artificial aging treatment comprises:   first aging said product at an intermediate temperature above room temperature and below said elevated temperature, and   thereafter aging said product at said elevated temperature until said alloy reaches its peak strength .Iaddend.wherein the second aging step comprises:   aging said product at said elevated temperature T of from 300° F. to 340° F. for about the period of time (t T ) indicated by the following formula: ##EQU3## wherein Y is a factor read from the graph of FIG. 1 for a desired aging temperature T, wherein t 325  can range from about 3 to 5 hours, and wherein t T  can be varied up to about ±3 hours from the value calculated by the formula.   
     
     
       5. The method of claim 1.]. .Iadd.An upper wing skin of a commercial jet aircraft comprising an improved alloy product having high strength, high fracture toughness and high fatigue resistance made in accordance with the process comprising the steps of: (a) providing a body composed of an alloy consisting essentially of 5.9 to 6.9% zinc, 2.0 to 2.7% magnesium, 1.9 to 2.5% copper, 0.08 to 0.15% zirconium, a maximum of 0.15% iron, a maximum of 0.12% silicon, a maximum of 0.06% titanium, a maximum of 0.04% chromium, a maximum of 0.05% for each of any other trace elements present in the alloy, the maximum total of said other trace elements being 0.15%, the balance being aluminum, all percentages herein by weight based on the total alloy,   (b) working said body to a thickness of less than about 1.5 inches to provide a wrought product, said body being hot worked by rolling at a temperature that is intentionally maintained sufficiently high so that less than about 50 volume % of said alloy is recrystallized product,   (c) subjecting said product to solution treatment and quenching, and   (d) subjecting said product to an artificial aging treatment at an elevated temperature .Iaddend.wherein said artificial aging step comprises:   initially aging said product for a period of from 4 to 48 hours at a temperature of from 225° F. to 275° F., and   thereafter aging said product for a period of from 3 to 12 hours at an elevated temperature of from 310° F. to 325° F. .[.   
     
     
       6.  The method of claims 1, 2, 3, 4 or 5 wherein said alloy is hot worked at a temperature sufficiently high so that less than about 50% of said alloy is recrystallized..]. .[.7. The method of claims 1, 2, 3, 4 or 5 wherein said alloy is hot worked at a temperature sufficiently high so that less than about 30% of said alloy is recrystallized..]. .[.8. The method of claim 1 wherein said artificial aging treatment is continued after said alloy reaches peak strength to enhance the corrosion resistance properties of said alloy..]. .[.9. The product produced by the method of claim 1..]. .[.10. The product produced by the method of claim 2..]. .[.11. The product produced by the method of claim 3..]. .[.12. The product produced by the method of claim 4..]. .[.13. The product produced by the method of claim 5..]. .[.14. The product produced by the method of claim 6..]. .[.15. The product produced by the method of claim 7..]. 
     
     
        .[.16. The product produced by the method of claim 8..]. .Iadd.17.  An upper wing skin of a commercial jet aircraft comprising an improved alloy product having high strength, high fracture toughness and high fatigue resistance made in accordance with the process comprising the steps of: (a) providing a body composed of an alloy consisting essentially of 5.9 to 6.9% zinc, 2.0 to 2.7% magnesium, 1.9 to 2.5% copper, 0.08 to 0.15% zirconium, a maximum of 0.15% iron, a maximum of 0.12% silicon, a maximum of 0.06% titanium, a maximum of 0.04% chromium, a maximum of 0.05% for each of any other trace elements present in the alloy, the maximum total of said other trace elements being 0.15%, the balance being aluminum, all percentages herein by weight based on the total alloy,   (b) working said body to a thickness of less than about 1.5 inches to provide a wrought product, said body being hot worked by rolling at a temperature that is intentionally maintained sufficiently high so that less than about 50 volume % of said alloy is recrystallized product,   (c) subjecting said product to solution treatment and quenching, and   (d) subjecting said product to an artificial aging treatment at an elevated temperature, to thereby produce a product having a minimum compression yield strength of 76 ksi, an average fracture toughness of 70 ksi√in., and a fatigue crack growth rate of 7.3 microinches per cycle at an average cyclic stress intensity ΔK of 11 ksi√in.   
     
     
        at R=0.06. .Iaddend. .Iadd.18.  An upper wing skin of a commercial jet aircraft comprising an improved alloy product having high strength, high fracture toughness and high fatigue resistance made in accordance with the process comprising the steps of: (a) providing a body composed of an alloy consisting essentially of 5.9 to 6.9% zinc, 2.0 to 2.7% magnesium, 1.9 to 2.5% copper, 0.08 to 0.15% zirconium, a maximum of 0.15% iron, a maximum of 0.12% silicon, a maximum of 0.06% titanium, a maximum of 0.04% chromium, a maximum of 0.05% for each of any other trace elements present in the alloy, the maximum total of said other trace elements being 0.15%, the balance being aluminum, all percentages herein by weight based on the total alloy,   (b) working said body to a thickness of less than about 1.5 inches to provide a wrought product, said body being hot worked by rolling at a temperature that is intentionally maintained sufficiently high so that less than about 30 volume % of said alloy is recrystallized product,   (c) subjecting said product to solution treatment and quenching, and   (d) subjecting said product to an artificial aging treatment at an elevated   
     
     
        temperature. .Iaddend. .Iadd.19.  An upper wing skin of a commercial jet aircraft comprising an improved alloy product having high strength, high fracture toughness and high fatigue resistance made in accordance with the process comprising the steps of: (a) providing a body composed of an alloy consisting essentially of 5.9 to 6.9% zinc, 2.0 to 2.7% magnesium, 1.9 to 2.5% copper, 0.08 to 0.15% zirconium, a maximum of 0.15% iron, a maximum of 0.12% silicon, a maximum of 0.06% titanium, a maximum of 0.04% chromium, a maximum of 0.05% for each of any other trace elements present in the alloy, the maximum total of said other trace elements being 0.15%, the balance being aluminum, all percentages herein by weight based on the total alloy,   (b) working said body to a thickness of less than about 1.5 inches to provide a wrought product, said body being hot worked by rolling at a temperature that is intentionally maintained sufficiently high so that less than about 30 volume % of said alloy is recrystallized product,   (c) subjecting said product to solution treatment and quenching, and   (d) subjecting said product to an artificial aging treatment at an elevated temperature wherein said artificial aging treatment comprises:   first aging said product at an intermediate temperature above room temperature and below said elevated temperature, and   thereafter aging said product at said elevated temperature until said alloy   
     
     
        reaches its peak strength. .Iaddend. .Iadd.20.  An upper wing skin of a commercial jet aircraft comprising an improved alloy product having high strength, high fracture toughness and high fatigue resistance made in accordance with the process comprising the steps of: (a) providing a body composed of an alloy consisting essentially of 5.9 to 6.9% zinc, 2.0 to 2.7% magnesium, 1.9 to 2.5% copper, 0.08 to 0.15% zirconium, a maximum of 0.15% iron, a maximum of 0.12% silicon, a maximum of 0.06% titanium, a maximum of 0.04% chromium, a maximum of 0.05% for each of any other trace elements present in the alloy, the maximum total of said other trace elements being 0.15%, the balance being aluminum, all percentages herein by weight based on the total alloy,   (b) working said body to a thickness of less than about 1.5 inches to provide a wrought product, said body being hot worked by rolling at a temperature that is intentionally maintained sufficiently high so that less than about 30 volume % of said alloy is recrystallized product,   (c) subjecting said product to solution treatment and quenching, and   (d) subjecting said product to an artificial aging treatment at an elevated temperature wherein said artificial aging treatment comprises:   first aging said product at an intermediate temperature above room temperature and below said elevated temperature, and   thereafter aging said product at said elevated temperature until said alloy reaches its peak strength wherein the second aging step comprises:   aging said product at said elevated temperature T of from 300° F. to 340° F. for about the period of time (t T ) indicated by the following formula: ##EQU4##.Iaddend. wherein Y is a factor read from the graph of FIG. 1 for a desired aging temperature T, wherein t 325  can range from about 3 to 5 hours, and wherein t T  can be varied up to about ±3 hours from the value   
     
     
        calculated by the formula.  .Iadd.21.  An upper wing skin of a commercial jet aircraft comprising an improved alloy product having high strength, high fracture toughness and high fatigue resistance made in accordance with the process comprising the steps of: (a) providing a body composed of an alloy consisting essentially of 5.9 to 6.9% zinc, 2.0 to 2.7% magnesium, 1.9 to 2.5% copper, 0.08 to 0.15% zirconium, a maximum of 0.15% iron, a maximum of 0.12% silicon, a maximum of 0.06% titanium, a maximum of 0.04% chromium, a maximum of 0.05% for each of any other trace elements present in the alloy, the maximum total of said other trace elements being 0.15%, the balance being aluminum, all percentages herein by weight based on the total alloy,   (b) working said body to a thickness of less than about 1.5 inches to provide a wrought product, said body being hot worked by rolling at a temperature that is intentionally maintained sufficiently high so that less than about 30 volume % of said alloy is recrystallized product,   (c) subjecting said product to solution treatment and quenching, and   (d) subjecting said product to an artificial aging treatment at an elevated temperature wherein said artificial aging step comprises:   initially aging said product for a period of from 4 to 48 hours at a temperature of from 225° F. to 275° F., and   thereafter aging said product for a period of from 3 to 12 hours at an elevated temperature of from 310° F. to 325° F. .Iaddend.