Process for producing duplex mode recrystallized high strength aluminum-lithium alloy products with high fracture toughness and method of making the same

Claim 2

A duplex recrystallized grain structured aluminum-lithium product having improved levels of strength and fracture touhness characterized by a fine grain structure at the surface of the product and a coarse grain structure at the center of the product comprised of a lithium-containing aluminum base alloy consisting essentially of 0.5 to 4.0 wt. % Li, 0 to 5.0 wt. % Cu, 0 to 5.0 wt. % Mg, 0.10 to 1.0 wt. % of a grain structure control element selected from the class consisting of Zr, Cr, Hf, Ti, V, Sc, and Mn, 0.5 wt. % max. Fe, and 5 wt. % max. Si, with the balance consisting essentially of aluminum and incidental elements and impurities.

Claim 3

The alloy product of claim 1 wherein said aluminumlithium alloy consists essentially of from 1.5 to 2.5 wt. % Li, 1.6 to 2.8 wt. % Cu, 0.7 to 2.5 wt. % Mg, and 0.03 to 0.19 wt. % Zr, with the balance consisting essentially of aluminum and impurities.

Claim 4

The alloy product of claim 1 wherein said aluminum-lithium alloy consists essentially of from 1.7 to 2.3 wt. % Li, 1.8 to 2.5 wt. % Cu, 1.1 to 1.9 wt. % Mg, and 0.10 to 0.15 wt. % Zr, with the balance consisting essentially of aluminum and impurities.

Claim 5

The alloy product of claim 1 wherein said alloy product has been thermomechanically processed by heating to a presoak temperature of from about 900° to 1050° F. and held at this temperature for about 20 to 40 hours to homogenize the alloy followed by two hot working steps carried out in a temperature range of about 850° to 900° F. with an intermediate heating back to said presoak temperature and an anneal followed by cold working after said hot working steps.

Claim 6

The alloy product of claim 4 wherein the alloy, atter cold working, has been solution heat treated, quenched, and aged, without an intervening anneal after said cold working, to provide recrystallized sheet product having improved levels of strength and fracture toughness.

Claim 7

A recrystallized aluminum-lithium product having a duplex grain structure comprised of a fine grain structure and a coarse grain structure and having improved levels of strength and fracture toughness comprised of a lithium-containing aluminum base alloy consisting essentially of 1.5 to 2.5 wt. % Li, 1.6 to 2.8 wt. % Cu, 0.7 to 2.5 wt. % Mg, 0.05 to 1.0 wt. % of a grain structure control element selected from the class consisting of Zr, Cr, Hf, Ti, V, Sc, and Mn, 0.5 wt. % max. Fe, and 5 wt. % max. Si, with the balance consisting essentially of aluminum and incidental elements and impurities which has been thermomechanically processed by: heating the alloy to a high presoak temperature to homogenize the alloy; cooling the alloy to a first hot working temperature: reheating the alloy, after hot working, back to a high annealing temperature; cooling the alloy to a second hot working temperature to produce a first product; reheating the alloy, after a second hot working, to a lower annealing temperature: and then cold working the alloy.

Claim 8

A recrystallized aluminum-lithium product having a duplex grain structure comprised of a fine grain structure and a coarse grain structure and having improved levels of strength and fracture toughness comprised of a lithium-containing aluminum base alloy consisting essentially of 1.5 to 2.5 wt. % Li, 1.6 to 2.8 wt. % Cu, 0.7 to 2.5 wt. % Mg, 0.05 to 1.0 wt. % of a grain structure control element selected from the class consisting of Zr, Cr, Hf, Ti, V, Sc, and Mn, 0.5 wt. % max. Fe, and 5 wt. % max. Si, with the balance consisting essentially of aluminum and incidental elements and impurities which has been thermomechanically processed by: heating the alloy to a high presoak temperature to homogenize the alloy; cooling the alloy to a first hot working temperature: reheating the alloy, after hot working, back to a high annealing temperature; cooling the alloy to a second hot working temperature to produce a first product; reheating the alloy, after a second hot working, to a lower annealing temperature: and then cold working the alloy.

Claim 9

The alloy product of claim 6 wherein the alloy, after cold working, has been solution heat treated, quenched, and aged, without an intervening anneal after said cold working, to provide a recrystallized sheet product having improved levels of strength and fracture toughness.

Claim 10

The alloy product of claim 7 wherein said duplex mode recrystallized alloy product is further characterized by a fine grain structure adjacent the surface of the alloy product and a coarse grain structure adjacent the center of the alloy product.

Claim 11

The alloy product of claim 8 wherein said grain structure control element comprises zirconium.

Claim 12

The alloy product of claim 9 wherein the amount of said zirconium grain structure control element comprises from 0.10 to 0.15 wt. %.

Claim 13

The alloy product of claim 9 wherein said aluminum-lithium alloy consists essentially of from 1.5 to 2.5 wt. % Li, 1.6 to 2.8 wt. % Cu, 0.7 to 2.5 wt. % Mg, and 0.10 to 0.15 wt. % Zr, with the balance consisting essentially of aluminum and impurities.

Claim 14

The alloy product of claim 9 wherein said aluminum-lithium alloy consists essentially of from 1.7 to 2.3 wt. % Li, 1.8 to 2.5 wt. % Cu, 1.1 to 1.9 wt. % Mg and 0.10 to 0.15 wt. % Zr, with the balance consisting essentially of aluminum and impurities.

Claim 15

The aluminum-lithium alloy of claim 9 wherein said alloy. comprises an alloy product which is initially heated to a presoak temperature of from about 482° to 566° C. (900° to 1050° F.) and held at this temperature for about 20 to 40 hours to homogenize the alloy.

Claim 16

The aluminum-lithium alloy of claim 13 wherein said alloy comprises an alloy product which is air cooled after said homogenization to a first hot working temperature of about 850° to 900° F. and then hot worked at this temperature.

Claim 17

The aluminum-lithium alloy of claim 14 wherein said alloy product has been hot worked by hot rolling to a thickness of from about 1 to 5 inches.

Claim 18

The aluminum-lithium alloy of claim 15 wherein said alloy comprises an alloy product which is reheated, after said hot working, back to a high annealing temperature of from about 900° to 1050° F.; held at this temperature for about 2 hours; then air cooled to a second hot working temperature of from about 850° to 900° F.; and then hot worked at this temperature.

Claim 19

The aluminum-lithium alloy of claim 16 wherein said alloy product has been hot worked a second time by hot rolling said alloy product to a thickness of from about 1.5 to 3 times the desired final gauge of the alloy product.

Claim 20

The aluminum-lithium alloy of claim 17 wherein said alloy comprises an alloy product which is reheated after said second hot working to an annealing temperature of about 750° to 860° F. and held at this temperature for about 10 to 14 hours to anneal said alloy product.

Claim 21

The aluminum-lithium alloy of claim 17 wherein said alloy comprises an alloy product which is reheated after said second hot working to an annealing temperature of about 780° to 820° F. and held at this temperature for about 10 to 14 hours to anneal said alloy product.

Claim 22

The aluminum-lithium alloy of claim 18 wherein said alloy comprises an alloy product which has been air cooled after annealing and then cold worked.

Claim 23

The aluminum-lithium alloy of claim 20 wherein said cold worked alloy, product comprises an alloy product cold rolled to final desired gauge.

Claim 24

The aluainum-lithium alloy of claim 20 wherein said alloy comprises an alloy product which, after said cold working, has been solution heat treated, quenched, and aged.

Claim 25

A process for producing a duplex mode recrystallized aluminum-lithium alloy product having improved levels of strength and fracture toughness characterized by a fine grain structure at the surface of the product and a coarse grain structure at the center of the product comprising the steps of: (a) providing a aluminum-lithium alloy consisting essentially of 0.5 to 4.0 wt. % Li, 0 to 5.0 wt. % Cu, 0 to 5.0 wt. % Mg, 0.5 to 1.0 wt. % of a grain structure control element selected from the class consisting of Zr, Cr, Hf, Ti, V, Sc, and Mn, 0.5 wt. % max. Fe, and 5 wt. % max. Si, with the balance consisting essentially of aluminum and incidental elements and impurities: (b) heating the alloy to a high presoak temperature to homogenize the alloy; (c) cooling the alloy to a first hot working temperature; (d) hot working the alloy; (e) reheating the alloy, after hot working, back to a high annealing temperature; (f) cooling the alloy to a second hot working temperature; (g) hot working said alloy a second time to produce a first intermediate product; (h) reheating the alloy, after said second hot working step, to a lower annealing temperature; and (i) then cold working the alloy.

Claim 26

A process for producing a duplex mode recrystallized aluminum-lithium alloy product having improved levels of strength and fracture toughness characterized by a fine grain structure at the surface of the product and a coarse grain structure at the center of the product comprising the steps of: (a) providing a aluminum-lithium alloy consisting essentially of 0.5 to 4.0 wt. % Li, 0 to 5.0 wt. % Cu, 0 to 5.0 wt. % Mg, 0.5 to 1.0 wt. % of a grain structure control element selected from the class consisting of Zr, Cr, Hf, Ti, V, Sc, and Mn, 0.5 wt. % max. Fe, and 5 wt. % max. Si, with the balance consisting essentially of aluminum and incidental elements and impurities: (b) heating the alloy to a high presoak temperature to homogenize the alloy; (c) cooling the alloy to a first hot working temperature; (d) hot working the alloy; (e) reheating the alloy, after hot working, back to a high annealing temperature; (f) cooling the alloy to a second hot working temperature; (g) hot working said alloy a second time to produce a first intermediate product; (h) reheating the alloy, after said second hot working step, to a lower annealing temperature; and (i) then cold working the alloy.

Claim 27

The process of claim 23 including the further steps of solution heating treating, cold water quenching, and aging said alloy after said cold working step without any intervening annealing step to provide a duplex mode recrystallized sheet product having improved levels of strength and fracture toughness.

Claim 28

The process of claim 23 wherein said step of heating said alloy to a high presoak temperature to homogenize the alloy further comprises heating said alloy to a presoak temperature of from about 482° to 566° C. (900° to 1050° F.) and holding said alloy at this temperature for about 20 to 40 hours to homogenize the alloy.

Claim 29

The process of claim 25 wherein said steps of cooling the alloy to a first hot working temperature and then hot working the alloy further comprise air cooling said alloy after said homogenization to a first hot working temperature of about 880° to 900° F. and then hot working said alloy at this temperature.

Claim 30

The process of claim 26 wherein said hot working step further comprises hot rolling said alloy to a thickness of from about 1 to 5 inches.

Claim 31

The process of claim 26 wherein said step of reheating said alloy, after hot working, back to a high annealing temperature further comprises heating said alloy back to a high annealing temperature of from about 900° to 1050° F. and holding said alloy at this temperature for about 2 hours.

Claim 32

The process of claim 28 wherein said steps of cooling said alloy to a second hot working temperature and then hot working said alloy a second time to produce a first intermediate product further comprise air cooling said alloy to a second hot working temperature of from about 870° to 890° F. and then hot working said alloy at this temperature.

Claim 33

The process of claim 29 wherein said step of hot working said alloy a second time further comprises hot rolling said alloy to a thickness of from about 1.5 to 3 times the desired final gauge of the alloy product.

Claim 34

The process of claim 29 wherein said step of reheating the alloy, after said second hot working step, to a lower annealing temperature further comprises reheating said alloy product, after said second hot working step, to an annealing temperature of about 750° to 860° F. and holding said alloy product at this temperature for about 10 to 14 hours to anneal said alloy product.

Claim 35

The process of claim 31 wherein said step of cold working said alloy product further comprises air cooling said alloy product after said annealing step and then cold rolling said alloy product to final desired gauge.

Claim 36

The process of claim 32 including the further steps of solution heat treating said alloy product after said cold working step and without an intervening anneal step, quenching said solution heat treated alloy product, and then aging sai quenched alloy product.

Claim 37

The process of claim 33 wherein said solution heat treatment step further comprises heating said cold worked alloy product to a temperature of from 960° to 1020° F. for a period of from about 20 to 40 minutes.

Claim 38

The process of claim 34 wherein said quenching step further comprises quenching said alloy product at a rate of at least 100° F. per second from said solution heat treatment temperature to a temperature of about 200° F. or lower using a water quench.

Claim 39

The process of claim 35 wherein said aging step further comprises aging said alloy product in the range of 66° to 150° to 400° F. for a sufficient period of time to increase the yield strength to from about 50 to 85 ksi.

Claim 40

The process of claim 36 wherein said alloy product is aged for a period of from about 30 minutes up to about 24 hours.

Claim 41

A process for producing a duplex mode recrystallized aluminum-lithium alloy product having improved levels of strength and fracture toughness characterized by a fine grain structure at the surface of the product and a coarse grain structure at the center of the product comprising the steps of: (a) providing a aluminum-lithium alloy consisting essentially of from 1.5 to 2.5 wt. % Li, 1.6 to 2.8 wt. % Cu, 0.7 to 2.5 wt. % Mg, and 0.03 to 0.19 wt. % Zr, with the balance consisting essentially of aluminum and impurities. (b) heating the alloy to a high presoak temperature to homogenize the alloy; (c) cooling the alloy to a first hot working temperature; (d) hot working the alloy; (e) reheating the alloy, after hot working, back to a high annealing temperature; (f) cooling the alloy to a second hot working temperature; (g) hot working said alloy a second time to produce a first intermediate product; (h) reheating the alloy, after said second hot working step, to a lower annealing temperature; and (i) then cold working the alloy.

Claim 42

A process for producing a duplex mode recrystallized aluminum-lithium alloy product having improved levels of strength and fracture toughness characterized by a fine grain structure at the surface of the product and a coarse grain structure at the center of the product comprising the steps of: (a) providing a aluminum-lithium alloy consisting essentially of from 1.5 to 2.5 wt. % Li, 1.6 to 2.8 wt. % Cu, 0.7 to 2.5 wt. % Mg, and 0.03 to 0.19 wt. % Zr, with the balance consisting essentially of aluminum and impurities. (b) heating the alloy to a high presoak temperature to homogenize the alloy; (c) cooling the alloy to a first hot working temperature; (d) hot working the alloy; (e) reheating the alloy, after hot working, back to a high annealing temperature; (f) cooling the alloy to a second hot working temperature; (g) hot working said alloy a second time to produce a first intermediate product; (h) reheating the alloy, after said second hot working step, to a lower annealing temperature; and (i) then cold working the alloy.

Claim 43

The alloy product of claim 38 wherein said aluminumlithium alloy consists essentially of from 1.7 to 2.3 wt. % Li, 1.8 to 2.5 wt. % Cu, 1.1 to 1.9 wt. % Mg, and 0.10 to 0.15 wt. % Zr, with the balance consisting essentially of aluminum and impurities.

Claim 44

The method in accordance with claim 38 wherein said product is naturally aged.

Claim 45

A process for producing a duplex mode recrystallized aluminum-lithium alloy product having improved levels of strength and fracture toughness characterized by a fine grain structure at the surface of the product and a coarse grain structure at the center of the product comprising the steps of: (a) providing a aluminum-lithium alloy consisting essentially of 0.5 to 4.0 wt. % Li, 0 to 5.0 wt. % Cu, 0 to 5.0 wt. % Mg, 0.10 to 1.0 wt. % of a grain structure control element selected from the class consisting of Zr, Cr, Hf, Ti, V, Sc, and Mn, 0.5 wt. % max. Fe, and 5 wt. % max. Si, with the balance consisting essentially of aluminum and incidental elements and impurities; (b) heating the alloy to a presoak temperature of from about 900° to 1050° F. and holding said alloy at this temperature for about 20 to 40 hours to homogenize the alloy; (c) air cooling said alloy after said homogenization to a first hot working temperature of about 471° to 880° to 900° F.; (d) hot rolling said alloy to a thickness of from about 1 to 5 inches: (e) reheating said alloy, after hot working, back to a high annealing temperature of from about 900° to 1050° F. and holding said alloy at this temperature for about 2 hours; (f) air cooling said alloy to a second hot working temperature of from about 870° to 890° F.; (g) hot rolling said alloy to a thickness of from about 1.5 to 3 times the desired final gauge of the alloy product; (h) reheating said alloy product, after said second hot working step, to an annealing temperature of about 780° to 820° F. and holding said alloy product at this temperature for about 10 to 14 hours to anneal said alloy product; (i) air cooling said alloy product after said annealing step; (j) cold rolling said alloy product to final desired gauge; (k) solution heat treating said alloy product after said cold working step, and without an intervening anneal step, by heating said old worked alloy product to a temperature of from 96% to 1020° F. for a period of from about 20 to 40 minutes: and (l) quenching said alloy product at a rate of at least 100° F. per second from said solution heat treatment temperature to a temperature of about 200° F. or lower using a water quench.

Claim 46

A process for producing a duplex mode recrystallized aluminum-lithium alloy product having improved levels of strength and fracture toughness characterized by a fine grain structure at the surface of the product and a coarse grain structure at the center of the product comprising the steps of: (a) providing a aluminum-lithium alloy consisting essentially of 0.5 to 4.0 wt. % Li, 0 to 5.0 wt. % Cu, 0 to 5.0 wt. % Mg, 0.10 to 1.0 wt. % of a grain structure control element selected from the class consisting of Zr, Cr, Hf, Ti, V, Sc, and Mn, 0.5 wt. % max. Fe, and 5 wt. % max. Si, with the balance consisting essentially of aluminum and incidental elements and impurities; (b) heating the alloy to a presoak temperature of from about 900° to 1050° F. and holding said alloy at this temperature for about 20 to 40 hours to homogenize the alloy; (c) air cooling said alloy after said homogenization to a first hot working temperature of about 471° to 880° to 900° F.; (d) hot rolling said alloy to a thickness of from about 1 to 5 inches: (e) reheating said alloy, after hot working, back to a high annealing temperature of from about 900° to 1050° F. and holding said alloy at this temperature for about 2 hours; (f) air cooling said alloy to a second hot working temperature of from about 870° to 890° F.; (g) hot rolling said alloy to a thickness of from about 1.5 to 3 times the desired final gauge of the alloy product; (h) reheating said alloy product, after said second hot working step, to an annealing temperature of about 780° to 820° F. and holding said alloy product at this temperature for about 10 to 14 hours to anneal said alloy product; (i) air cooling said alloy product after said annealing step; (j) cold rolling said alloy product to final desired gauge; (k) solution heat treating said alloy product after said cold working step, and without an intervening anneal step, by heating said old worked alloy product to a temperature of from 96% to 1020° F. for a period of from about 20 to 40 minutes: and (l) quenching said alloy product at a rate of at least 100° F. per second from said solution heat treatment temperature to a temperature of about 200° F. or lower using a water quench.

Claim 47

The method in accordance with claim 41 including aging said alloy product in the range of 150° to 400° F. for a period of from about 30 minutes up to about 24 hours to increase the yield strength to from about 50 to 85 ksi.

Claim 48

The method in accordance with claim 41 including naturally aging and stretching said alloy product to produce a T3 temper.