Field of the Invention
[0001] The present invention is directed to a method of improving the fracture toughness
in the short longitudinal direction in aluminum-lithium alloys and a product there
from and, in particular, to a method which controls the levels of copper, manganese,
lithium, and zirconium in the alloys to obtain the improved fracture toughness.
Background Art
[0002] It is well known that adding lithium as an alloying element to aluminum alloys results
in beneficial mechanical properties.
[0003] Aluminum-lithium alloys exhibit improvements in stiffness and strength while reducing
density. Consequently, these types or alloys have utility as structural materials
in airplane and aerospace applications. Examples of known aluminum-lithium alloys
include AA2097 and AA2197. The chemical compositions of these alloys are shown in
Table 1 below.
[0004] Problems exist with aluminum-lithium alloys, particularly in thick plate of about
3 inches (76.2 mm) or greater, in terms of fracture toughness in the short longitudinal
(S-L) direction.
[0005] Toughness values in this direction tend to be significantly lower than toughness
values in other directions such as the longitudinal (L-T) direction or the long transverse
(T-L) direction.
[0006] In view of the drawbacks in aluminum-lithium alloys with respect to fracture toughness,
a need has developed to provide a method of improving the short longitudinal (S-L)
direction fracture toughness for these types of alloys. In response to this need,
the present invention provides both a method and a product therefrom which significantly
increases the fracture toughness of aluminum-lithium alloys in the short longitudinal
(S-L) direction, thereby improving their suitability for more commercial applications.
Summary of the Invention
[0007] A first object of the invention is to improve the fracture toughness in the short
longitudinal (S-L) direction of aluminum-lithium alloys.
[0008] Another object of the invention is to provide a method of making an aluminum-lithium
alloy having improved short longitudinal direction fracture toughness.
[0009] A still further object of the present invention is to utilize an aluminum-lithium
alloy having controlled amounts of copper, lithium, manganese, zinc and zirconium
to achieve fracture toughness improvements.
[0010] Yet another object of the present invention is to provide an aluminum-lithium alloy
product having both improved fracture toughness in the short longitudinal (S-L) direction
and acceptable strength in the short transverse direction.
[0011] Other objects and advantages of the present invention will become apparent as a description
thereof proceeds.
[0012] In satisfaction of the foregoing objects and advantages, the present invention provides
a method for improving the fracture toughness in the short longitudinal (S-L) direction
in an aluminum-lithium alloy article comprising the steps of providing an aluminum
alloy consisting essentially of, in weight percent all subsequent alloying levels
are weight percent unless otherwise indicated): 2.5 to 4.0% copper, 0.8% to less than
1.3% lithium, 0.05 to 0.8% manganese, 0.04 to 0.18% zirconium, with the balance aluminum
and inevitable impurities. The aluminum alloy can also include grain refining elements
such as at least one of boron, titanium, vanadium, manganese, hafnium, scandium and
chromium. Preferably, the aluminum alloy has only impurity levels of zinc so that
it is essentially zinc-free, e.g., less than 0.05 weight percent zinc, more preferably
less than or equal to 0.02%.
[0013] Preferably, the copper content is controlled between 2.7 and 3.0 weight percent.
The lithium content is preferably controlled between about 1.2 to 1.28 weight percent
to provide a low density product with good fracture toughness in the short longitudinal
direction. Manganese is preferably between 0.30 and 0.32 weight percent, with zirconium
being about 0.10 weight percent. It should be appreciated that the amounts of alloying
elements, other than the amounts of lithium and copper, can be within the ranges described
in the preceding paragraph.
[0014] In a modification of the composition described in the preceding paragraph, the lithium
content ranges from about 0.8% to less than 1.2 and the copper content is between
about 2.8 and 4%. This composition should provide even higher combined properties
of fracture toughness and strength, with slightly higher density. In this composition
range, additional theta' precipitate particles (Al2Cu) would precipitate in addition
to T1 precipitate particles (Al2CuLi) at the grain boundaries. This would increase
the combined properties of strength and fracture toughness in the short longitudinal
direction.
[0015] Magnesium can be added if desired, in an amount up to 0.35% weight percent, preferably,
up to 0.25 weight percent. Small amounts of magnesium may be beneficial in terms of
strength and lowering of density. However, excessive amounts may create susceptibility
to stress corrosion cracking and do not provide further benefits in terms of strength
and density reduction.
[0016] The aluminum alloy is cast into an ingot and homogenized for a select period of time.
The homogenized ingot is then hot worked into a shape such as a plate and solution
heat treated for a select period of time. The solution heat treated shape is then
quenched, preferably in water, cold worked, preferably by stretching, and aged for
a select period of time. With this processing, the cold worked (stretched) and aged
shape exhibits equivalent strengths but higher fracture toughness in the short longitudinal
(S-L) direction than similar aluminum alloys having lithium contents greater than
1.38.
[0017] The homogenization and solution heat treating temperatures can range between about
9000 and 1030°F (482 to 554°C), preferably between about 930°F (499°C) and 1000°F
(538°C). More preferably, homogenization temperatures will range between about 940°F
(505°C) to 975°F (524°C), and solution heat treating temperatures will range between
about 975°F (524°C ) to 1000°F (538°C) . The preferred temperature often depends on
the particular alloy composition as will be understood by one skilled in the art.
Homogenization times can be about 8 to 48 hours, preferably about 24 to about 36 hours.
Solution heat treating times can range from about 1 to 10 hours, preferably about
1 hour to 6 hours, more preferably about 2 hours, once the metal reaches a desired
temperature. The plate may be artificially aged without any cold work. However, it
is preferred to provide between about 4 and 8 cold work, preferably by stretching.
The plate is preferably artificially aged between about 300 and 3500F (149 to 177°C)
for between about 4 and about 48 hours, preferably between about 12 and about 36 hours,
with the aging time being a function of the aging temperature.
[0018] Using the inventive processing, an aluminum-lithium alloy article is made having
vastly improved fracture toughness in the short longitudinal (S-L) direction. The
fracture toughness value in the short longitudinal (S-L) direction is at least about
689 of the fracture toughness in the long transverse (T-L) direction. While exhibiting
improved fracture toughness in the short longitudinal (S-L) direction, the inventive
aluminum-lithium alloy articles have tensile yield strengths exceeding about 54 KSI.
Brief Description of the Drawings
[0019] Reference is now made to the drawings of the invention wnerein:
Figure 1 compares the invention to the prior art in terms of tensile yield strength
in the short transverse direction and fracture toughness in the short longitudinal
(S-L) direction;
Figure 2 compares prior art alloy products and the invention alloy products with respect
to lithium content and fracture toughness in the short longitudinal (S-L) direction;
and
Figure 3 compares the prior art alloy products and the invention alloy products with
respect to copper content and fracture toughness in the short longitudinal (S-L) direction.
Description of the Preferred Embodiment
[0020] The present invention solves a significant problem in the field of aluminum-lithium
materials for structural applications such as those found in the aerospace and airplane
industry. That is, by controlling the compositional amounts of copper, lithium, manganese
and zirconium in these types of alloys, acceptable fracture toughness in the short
longitudinal (S-L) direction with acceptable strength in the short transverse (ST)
direction is obtained. This unexpected improvement in fracture toughness in the S-L
direction permits the use of these types of alloys in a wide variety of structural
applications requiring low weight, high strength and stiffness, and good fracture
toughness.
[0021] According to the present invention, the alloy elements of copper, lithium, manganese
and zirconium are controlled in the following ranges to achieve the improvements in
fracture toughness: about 2.5 to 4.0 weight percent copper, about 0.8 to less than
about 1.2 or 1.3 weight percent lithium, about 0.05 to 0.8 weight percent manganese,
about 0.04 to 0.16 weight percent zirconium, with the balance aluminum and inevitable
impurities. One or more grain refining elements can also be added to the aluminum-lithium
composition described above. The grain refining elements can be selected from the
group consisting of titanium in an amount up to 0.2 weight percent, boron in an amount
of up to 0.2 weight percent, vanadium in an amount of up to 0.2 weight percent, manganese
in an amount of up to 0.8 weight percent, hafnium in an amount up to 0.2 weight percent,
scandium in an amount up to 0.5 weight percent, and chromium in an amount up to 0.3
weight percent. Preferably the aluminum is free of zinc. In other words, zinc is present
only as an impurity and at levels less than 0.05 weight percent. It is believed that
zinc in levels greater than such impurity level adversely affects the mechanical properties
of these types of aluminum-lithium alloys.
[0022] The copper content should be kept higher than 2.5 weight percent to achieve high
strength but less than 4.0 weight percent to avoid undissolved particles during solution
heat treatment.
[0023] Higher levels of copper are preferred due to the lower levels of lithium in the alloy.
[0024] The lithium content should be kept higher than 0.8 weight percent to achieve good
strength and low density but less than 1.3 weight percent to avoid a loss of fracture
toughness in the short longitudinal (S-L) direction. The manganese content should
be kept below 0.8 weight percent to avoid large non-dissolvable particles which would
be detrimental to fracture toughness. The manganese should be higher than 0.05 weight
percent to control grain size and homogenous slip behavior during plastic deformation
processing.
[0025] More preferably, the lithium content should be controlled between 1.2 and to less
than 1.3 weight percent. Still more preferably, in one embodiment, the lithium content
is controlled to less than 1.2 weight percent. The manganese is more preferably between
0.3 and 0.32 weight percent with the copper level ranging between about 2.7 and 3.0
weight percent.
[0026] Magnesium can be added if desired, in an amount preferably up to 0.35% weight percent,
preferably, up to 0.25 weight percent. Small amount of magnesium may be beneficial
in terms of strength and lowering of density. However, excessive amounts may create
susceptibility to stress corrosion cracking and do not provide further benefits in
terms of strength and density reduction.
[0027] In conjunction with specifying the alloy composition in the aluminum-lithium alloy
composition above, the alloy is processed by the steps of casting, homogenizing, hot
working (for instance, by rolling, forging, extruding and combinations thereof), solution
heat treating, quenching, cold working (for instance by stretching) and aging to form
an aluminum-lithium article having the improvements in fracture toughness in the S-L
direction.
[0028] As part of this processing, the aluminum-lithium alloy described above is cast into
an ingot, billet or other shape to provide suitable stock for the subsequent processing
operations. Once the shape is cast, it can be stress-relieved as is known in the art
prior to homogenization. The cast shape is then homogenized at temperatures in the
range of 9300F to 1,0300F, 4990C to 55440C, for a sufficient period of time to dissolve
the soluble elements and homogenize the internal structure of the metal. A preferred
homogenization residence time is in the range of 1 to 36 hours, while longer times
do not normally adversely affect the article. The homogenization can be conducted
at one temperature or in multiple steps utilizing several temperatures.
[0029] After homogenization, the cast shape is then hot worked to produce stock such as
sheet, plate, extrusions, or other stock material depending on the desired end use
of the aluminum-lithium alloy article. For example, an ingot having a rectangularly
shaped cross section could be hot worked into a plate form. Since this hot working
step is conventional in the art, a further description thereof is not deemed necessary
for understanding of the invention.
[0030] Following the hot working step, the hot worked shape is then solution heat treated
and quenched. Preferably, the hot worked shape is solution heat treated between 930°
to 1030°F (499° to 554°C) at a time from less than an hour to up to several hours.
This solution heat treated shape is preferably rapidly quenched, e.g. quenched in
ambient temperature water, to prevent or minimize uncontrolled precipitation of strengthening
phases in the alloy.
[0031] The rapid quenching can also include a subsequent air cooling step, if desired.
[0032] The quenched shape is then preferably stretched up to 8% and artificially aged in
the temperature range of 150° to 400°F (66° to 204°C) for sufficient time to further
increase the yield strength, e.g., up to 100 hours, depending on the temperature,
for instance, 24 hours at 300°F (149°C) . The stretched and aged shape is then ready
for use in any application, particularly an aerospace or airplane application. Alternatively,
prior to aging, the shape may be formed into an article and then aged.
[0033] In order to demonstrate the unexpected improvements associated with the present invention,
a comparison was made between properties of articles made from aluminum-lithium alloys
of the prior art and articles made from aluminum-lithium alloys according to the invention.
In this comparison, four prior art chemistries were selected along with four chemistries
according to the invention. An aluminum alloy melt was made from each of the eight
chemistries and processed by casting, homogenizing, solution heat treating, quenching,
stretching and aging to produce an aluminum-lithium alloy article or product. The
aluminum-lithium alloy articles were then subjected to tensile and fracture toughness
testing to compare the mechanical properties of the prior art chemistries to those
corresponding to the instant invention.
[0034] The following details the processing used and test methods to compare the mechanical
properties of the prior art and inventive aluminum-lithium alloy articles. In the
comparison, the prior art articles are designated as Examples 1-4, and the articles
of the invention are designated as Examples 5-8.
[0035] It should be understood that the processing variables and chemistries disclosed in
Examples 5-8 are more preferred embodiments of the invention.
Table 1
|
Si |
Fe |
Cu |
Mn |
Mg |
Zn |
Zr |
Ti |
Li |
AA2097 |
0.12 |
0.15 |
2.5-3.1 |
0.10-0.6 |
0.35 |
0.35 |
0.08-0.16 |
0.15 |
1.2-1.8 |
AA2197 |
0.10 |
0.10 |
2.5-3.1 |
0.10-0.5 |
0.25 |
0.05 |
0.08-0.15 |
0.12 |
1.3-1.7 |
Table 1 Notes
1. Chemical compositions are expressed in a weight percent maximum unless shown
as a range.
2. In addition to the listed elements, each alloy may contain other elements, with
the maximum amount of each other element not exceeding 0.05 wt. % and thetotal of
other elements not exceeding 0.15 wt. %. |
Example 1
[0036] An aluminum alloy consisting of, in weight percent, 2.84 Cu-1.36 Li-.32 Mn.-.1 Zr,
the balance aluminum and impurities, was cast into an ingot with a cross section of
16" (406.4 mm) and 45" (1143 mm) wide. The ingot was homogenized at 950°F (510°C)
for 36 hours, then hot worked to 4" (101.6 mm) thick plate. The plate was then solution
heat treated in a heat treating furnace at a temperature of 990°F (532°C) for 2 hours
and then quenched in water. The plate was then stretched by 6% in the longitudinal
direction at room temperature. For artificial aging, the stretched samples were aged
in an oven at 320°F (160°C)for 24 hours. Tensile properties were determined at the
T/4 plane in accordance with ASTM B-557. Tensile tests in the longitudinal direction
and the long transverse direction used round tensile specimens with .5" (12.7 mm)
diameter and 1" (25.4 mm) gauge length. Tensile tests in the short transverse direction
were conducted with round tensile specimens with .160" (4.1 mm) diameter and .5" (12.7
mm) gauge length. Fracture toughness was determined at the T/4 plane by ASTM standard
practice E266 using W=1.5" (38.1 mm) Compact Tension specimens for the short longitudinal
direction and W=2" (50.8 mm) Compact Tension specimens for the L-T and T-L directions.
The results of these tests are listed in Table 2.
Example 2
[0037] An aluminum alloy consisting of, in weight percent, 2.71 Cu-1.37 Li-.32 Mn.-.1 Zr,
the balance aluminum and impurities, was cast into an ingot with a cross section of
16" (406.4 mm) and 45" (1143 mm) wide. The ingot was homogenized at 950°F (5100C)
for 36 hours, then hot worked to 4" (101.6 mm) thick plate. The plate was then solution
heat treated in a heat treating furnace at a temperature of 990°F (532°C) for 2 hours
and then quenched in water. The plate was then stretched by 6% in the longitudinal
direction at room temperature. For artificial aging, the stretched samples were aged
in an oven at 320°F (160°C)for 24 hours. Tensile properties were determined at the
T/4 plane in accordance with ASTM B-557. Tensile tests in the longitudinal direction
and long transverse direction used round tensile specimens with .5" (12.7 mm) diameter
and 1" (25.4 mm) gauge length. Tensile tests in the short transverse direction were
conducted with round tensile specimens with .160" (4.1 mm) diameter and .5" (12.7
mm) gauge length. Fracture toughness was determined at the T/4 plane by ASTM standard
practice E266 using W=1.5" (38.1 mm) Compact Tension specimens for the short longitudinal
(S-L) direction and W=2" (50.8 mm) Compact Tension specimens for the L-T and T-L directions.
The results of these tests are listed in Table 3.
Example 3
[0038] An aluminum alloy consisting of, in weight percent, 2.77 Cu-1.33 Li-.32 Mn.-. 11
Zr, the balance aluminum and impurities, was cast into an ingot with a cross section
of 16" (406.4 mm) and 45" (1143 mm) wide. The ingot was homogenized at 950°F (510°C)
for 36 hours, then hot worked to 4" (101.6 mm) thick plate. The plate was then solution
heat treated in a heat treating furnace at a temperature of 990°F (532°C) for 2 hours
and then quenched in water. The plate was then stretched by 6% in the longitudinal
direction at room temperature. For artificial aging, the stretched samples were aged
in an oven at 320°F (160°C)for 24 hours. Tensile properties were determined at the
T/4 plane in accordance with ASTM 5-557. Tensile tests in the longitudinal direction
and the long transverse direction used round tensile specimens with .5" (12.7 mm)
diameter and 1" (25.4 mm) gauge length. Tensile tests in short transverse direction
were conducted with round tensile specimens with .160" (4.1 mm) diameter and .5" (12.7
mm) gauge length. Fracture toughness was determined at the T/4 plane by ASTM standard
practice E266 using W=1.5" (38.1 mm) Compact Tension specimens for the short longitudinal
direction and W=2" (50.8 mm) Compact Tension specimens for the L-T and T-L directions.
The results of these tests are listed in Table 4.
Example 4
[0039] An aluminum alloy consisting of, in weight percent, 2.89 Cu-1.36 Li-.32 Mn.-0.1 Zr,
the balance aluminum and impurities, was cast into an ingot with a cross section of
16" (406.4 mm) and 45" (1143 mm) wide. The ingot was homogenized at 950°F (5100C)
for 36 hours, then hot worked to 4" (101.6 mm) thick plate. The plate was then solution
heat treated in a heat treating furnace at a temperature of 990°F (532°C) for 2 hours
and then quenched in water. The plate was then stretched by 6% in the longitudinal
direction at room temperature. For artificial aging, the stretched samples were aged
in an oven at 320°F (160°C)for 24 hours. Tensile properties were determined at the
T/4 plane in accordance with ASTM B-557. Tensile tests in the longitudinal direction
and the long transverse direction used round tensile specimens with .5" (12.7 mm)
diameter and 1" (25.4 mm) gauge length. Tensile tests in the short transverse direction
were conducted with round tensile specimens with .160" (4.1 mm) diameter and .5" (12.7
mm) gauge length. Fracture toughness was determined at the T/4 plane by ASTM standard
practice E266 using W=1.5" (38.1 mm) Compact Tension specimens for the short longitudinal
(S-L) direction and W=2" (50.8 mm) Compact Tension specimens for the L-T and T-L directions.
The results of these tests are listed in Table 5.
Example 5
[0040] An aluminum alloy consisting of, in weight percent, 2.78 Cu-1.21 Li-.31 Mn.-0.1 Zr,
the balance aluminum and impurities, was cast into an ingot with a cross section of
16" (406.4 mm) and 45" (1143 mm) wide. The ingot was homogenized at 950°F (510°C)
for 36 hours, then hot worked to 4" (101.6 mm) thick plate. The plate was then solution
heat treated in a heat treating furnace at a temperature of 990°F (532°C) for 2 hours
and then quenched in water. The plate was then stretched by 8% in the longitudinal
direction at room temperature. For artificial aging, the stretched samples were aged
in an oven at 320°F (160°C)for 24 hours. Tensile properties were determined at the
T/4 plane in accordance with ASTM B-557. Tensile tests in the longitudinal direction
and the long transverse direction used round tensile specimens with .5" (12.7 mm)
diameter and 1" (25.4 mm) gauge length. Tensile tests in the short transverse direction
were conducted with round tensile specimens with .160" (4.1 mm) diameter and .5" (12.7
mm) gauge length. Fracture toughness was determined at the T/4 plane by ASTM standard
practice E26 using W=1.5" (38.1 mm) Compact Tension specimens for the short longitudinal
(S-L) direction and W=2" (50.8 mm) Compact Tension specimens for the L-T and T-L directions.
The results of these tests are listed in Table 6.
Example 6
[0041] An aluminum alloy consisting of, in weight percent, 2.86 Cu-1.28 Li-.3 Mn.-0.1 Zr,
the balance aluminum and impurities, was cast into an ingot with a cross section of
16" (406.4 mm) and 45" (1143 mm) wide. The ingot was homogenized at 950°F (510°C)
for 36 hours, then hot worked to 4" (101.6 mm) thick plate. The plate was then solution
heat treated in a heat treating furnace at a temperature of 990°F (532°C) for 2 hours
and then quenched in water. The plate was then stretched by 6% in the longitudinal
direction at room temperature. For artificial aging, the stretched samples were aged
in an oven at 320°F (160°C) for 24 hours. Tensile properties were determined at the
T/4 plane in accordance with ASTM B-557. Tensile tests in the longitudinal direction
and the long transverse direction used round tensile specimens with .5" (12.7 mm)
diameter and 1" (25.4 mm) gauge length. Tensile tests in the short transverse direction
were conducted with round tensile specimens with .160" (4.1 mm) diameter and .5" (12.7
mm) gauge length. Fracture toughness was determined at the T/4 plane by ASTM standard
practice E266 using W=1.5" (38.1 mm) Compact Tension specimens for the short longitudinal
(S-L) direction and W=2" (50.8 mm) Compact Tension specimens for the L-T and the T-L
directions. The results of these tests are listed in Table 7.
Example 7
[0042] An aluminum alloy consisting of, in weight percent, 2.73 Cu-1.28 Li-.3 Mn.-0.1 Zr,
the balance aluminum and impurities, was cast into an ingot with a cross section of
16" (406.4 mm) and 45" (1143 mm) wide. The ingot was homogenized at 950%F (510°C)
for 36 hours, then hot worked to 4" (101.6 mm) thick plate. The plate was then solution
heat treated in a heat treating furnace at a temperature of 990°F (532°C) for 2 hours
and then quenched in water. The plate was then stretched by 6% in the longitudinal
direction at room temperature. For artificial aging, the stretched samples were aged
in an oven at 320°F (160°C)for 24 hours. Tensile properties were determined at the
T/4 plane in accordance with ASTM B-557. Tensile tests in the longitudinal direction
and the long transverse direction used round tensile specimens with .5" (12.7 mm)
diameter and 1" (25.4 mm) gauge length. Tensile tests in the short transverse direction
were conducted with round tensile specimens with .160" (4.1 mm) diameter and .5" (12.7
mm) gauge length. Fracture toughness was determined at the T/4 plane by ASTM standard
practice E266 using W=1.5" (38.1 mm) Compact Tension specimens for the short longitudinal
(s-L) direction and W=2" (50.8 mm) Compact Tension specimens for the L-T and the T-L
directions. The results of these tests are listed in Table 8.
Example 8
[0043] An aluminum alloy consisting of, in weight percent, 2.83 Cu-1.26 Li-.32 Mn.-0.11
Zr, the balance aluminum and impurities, was cast into an ingot with a cross section
of 16" (406.4 mm) and 45" (1143 mm) wide. The ingot was homogenized at 950°F (510°C)
for 36 hours, then hot worked to 4" (101.6 mm) thick plate. The plate was then solution
heat treated in a heat treating furnace at a temperature of 990°F (532°C) for 2 hours
and then quenched in water. The plate was then stretched by 6% in the longitudinal
direction at room temperature. For artificial aging, the stretched samples were aged
in an oven at 320°F (160°C)for 24 hours. Tensile properties were determined at the
T/4 plane in accordance with ASTM B-557. Tensile tests in the longitudinal direction
and the long transverse direction used round tensile specimens with .5" (12.7 mm)
diameter and 1" (25.4 mm) gauge length. Tensile tests in the short transverse direction
were conducted with round tensile specimens with .160" (4.1 mm) diameter and .5" (12.7
mm) gauge length. Fracture toughness was determined at the T/4 plane by ASTM standard
practice E266 using W=1.5" (38.1 mm) Compact Tension specimens for the short longitudinal
(S-L) direction and W=2" (50.8 mm) Compact Tension specimens for the L-T and the T-L
directions. The results of these tests are listed in Table 9.
[0044] The advantage of the present invention is shown in Figure 1 which correlates the
fracture toughness values in Tables 2-9 in the S-L direction with tensile yield strengths
in the S-T direction. As is evident from Figure 1, no compromise is made in the tensile
yield strengths between the prior art examples and the examples of the invention.
More specifically, the prior art tensile yield strength values range from just above
54 KSI to almost 60 KSI. In comparison, the tensile yield strengths of the examples
according to the invention range from just below 55 KSI to just above 57 KSI. Figure
1 demonstrates that the articles made of the present invention provide significantly
improved fracture toughness in the S-L direction while maintaining acceptable strength
levels in the S-T direction.
[0045] Figure 2 illustrates the unexpected improvements in fracture toughness in the S-L
direction over the prior art. The values depicted in Figure 2 demonstrate that the
fracture toughness in the S-L direction for Examples 5-8 is vastly superior to that
shown for Examples 1-4. This improvement, which relates to lithium content, is quite
unexpected in view of the prior art.
[0046] Figure 3 emphasizes the fact that the improvements in fracture toughness are related
to the lithium content of the alloys. Figure 3 demonstrates that the fracture toughness
does not vary widely with respect to copper content. For Examples 5-8, the fracture
toughness appears to remain relatively the same with increasing or decreasing amounts
of copper. Similarly, the fracture toughness of Examples 1-4 does not vary widely
with increasing or decreasing copper content.
[0047] Referring again to Figure 2, it is believed that the lithium content can be as low
as 0.8 weight percent while still giving improvements in fracture toughness and maintaining
the acceptable strength in the short transverse direction. It is further believed
that the same results are obtainable when practicing the inventive processing in accordance
with the broad processing variable ranges disclosed above.
[0048] Accordingly, an invention has been disclosed in terms of preferred embodiments thereof
which fulfill each and every one of the objects of the present invention as set forth
above and provides a new and improved method for improving the short longitudinal
direction fracture toughness of aluminum-lithium alloys.
[0049] Various changes, modifications and alterations from the teachings of the present
invention may be contemplated by those skilled in the art without departing from the
intended spirit and scope thereof. Accordingly, it is intended that the present invention
only be limited by the terms of the appended claims.
1. A method of improving the fracture toughness in a short longitudinal direction of
an aluminum-lithium alloy article comprising the steps of:
a) providing an aluminum alloy consisting essentially of, in weight percent:
2.5 to 4.0% copper,
0.8 to less than 1.3% lithium,
0.05 to 0.8% manganese,
up to 0.25% magnesium,
0.04 to 0.18% zirconium,
optionally one or more grain refining elements selected from the group consisting
of up to 0.2 % titanium, up to 0.2 % boron, up to 0.2 % vanadium, up to 0.8 % manganese,
up to 0.2 % hafnium, up to 0.5 % scandium, and up to 0.3 % chromium,
the balance aluminum and inevitable impurities;
b) casting the aluminum alloy into an ingot;
c) homogenizing the ingot at between 930° and 1000°F (499 to 538 °C);
d) hot working the homogenized ingot into a hot worked shape;
e) solution heat treating the hot worked shape at between 975° and 1000°F (524 to
538°C);
f) quenching the solution heat treated shape; and
g) cold working and aging the quenched shape.
2. The method of claim 1 wherein the shape is stretched between 4 and 8% and then aged
between 150 and 400 °F (66 to 204 °C), and preferably between about 300 and 350°F
(149 to 177°C).
3. The method of claims 1 or 2 wherein the lithium content is less than 1.2% by weight.
4. The method of claim 1, wherein the lithium content ranges between about 1.2 and 1.28%.
5. The method of claims 1 or 2 wherein the copper content is between 2.7 and 3.0 %.
6. The method of claim 1 wherein the lithium content is less than 1.2% by weight and
the copper content is more than 2.8% by weight.
7. The method of claim 3 wherein zirconium is between 0.04 and 0.16 %.
8. The method of claims 1 to 7 wherein the aluminum alloy is essentially zinc free.
9. The method of claim 1 wherein manganese is higher than 0.05 %.
10. The method of claims 1 to 9, wherein said aluminum-lithium article is a thick plate.
11. The method of claim 1 wherein the fracture toughness of the plate in the short longitudinal
(S-L) direction is at least about 68.5% of the fracture toughness of the plate in
the long transverse (T-L) direction.
12. The product made by the method of claims 1 to 11.
12. The made by the method of claim 1 having a fracture toughness of at least 21.0 ksi√in
(23 MPa√m) the short longitudinal direction.
13. The product made by the method of claim 1 having a fracture toughness of at least
21.0 ksi√in (23 MPa√m) in the short longitudinal direction and a tensile yield strength
of at least 54.0 ksi (372.3 MPa) in the short transverse direction.
14. The product of claim 13 wherein the fracture toughness is at least 22.7 ksi√in (24.94
MPa√m) and the tensile yield strength is at least 54.7 ksi (377 MPa).