BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
[0001] The present disclosure relates to a manufacturing method of an aircraft member, in
particular, a manufacturing method of a secondary structure member of an aircraft.
2. DESCRIPTION OF RELATED ART
[0002] Due to a recent demand for improvement of fuel efficiency, there is a growing need
in civil aircrafts to reduce the weight of an airframe. While an aluminum alloy is
used for main structure members (fuselage outer plates or the like) of conventional
civil aircrafts, increase of strength of an aluminum alloy member has reached its
limit, which requires a raw material having much higher specific strength.
[0003] In such a situation, composite materials have been applied to the airframe main structure
in recent years. However, this requires high manufacturing cost, long manufacturing
lead time, high assembly cost, or the like.
[0005] A magnesium alloy is an active metal and thus requires anti-corrosion treatment.
In
Japanese Patent Laid-Open No. 2008-536013, a non-chromate conversion coating is formed on the surface of the magnesium alloy
to improve corrosion resistance. On the other hand,
Japanese Patent Laid-Open No. 2010-209452 discloses a magnesium alloy member having high corrosion resistance that does not
require anti-corrosion treatment by defining the number and the size of fine precipitates
containing both Mg and Al that are present in a surface layer region.
[0007] In addition to corrosion resistance, a material applied to an aircraft member is
required to balance strength (tensile strength) and ductility (elongation). Magnesium
alloys have lower strength than aluminum alloys. Thus, it is required to improve the
strength, but the strength of magnesium alloy is in a trade-off relationship with
ductility, and it is difficult to balance the strength and the ductility.
[0008] Further, to apply a magnesium alloy to an aircraft member, it is required to improve
incombustibility to increase an ignition temperature.
[0010] Use of a somewhat large billet is desirable for manufacturing of a large-sized aircraft
member. However, the larger diameter of the billet is more likely to cause an uneven
quality as a whole billet. Such unevenness in quality may become a factor that affects
strength and ductility of the magnesium alloy member.
[0011] The crystal grain diameter and the microstructure of a magnesium alloy are varied
depending on processing conditions, and then the strength and the ductility of magnesium
alloy are varied.
BRIEF SUMMARY OF THE INVENTION
[0012] Fig. 5 illustrates a metallographic structure photograph of an Mg-Al-Ca-Si based
alloy as an example. As illustrated in Fig. 5, α-Mg (Al, Ca being dissolved into a
solid solution), an Mg-Si-Ca compound, an (Mg, Al)
2Ca compound (C36), and the like are included in the metallographic structure. Fig.
6 illustrates a metallographic structure photograph of an Mg-Si-Ca compound. Fig.
7 illustrates a metallographic structure photograph of an (Mg, Al)
2Ca compound.
[0013] According to studies by the present inventors, it has been found that, when an intermetallic
compound such as an Mg-Si-Ca compound and an (Mg, Al)
2 Ca compound is coarsened, the ductility tends to decrease. When the billet is larger,
an (Mg, Al)
2 Ca compound is more likely to be coarsened.
[0014] In a small billet, addition of Si to a magnesium alloy may improve the ductility.
However, according to studies by the present inventors, it has been found that ductility
decreases in a somewhat large billet.
[0015] The present disclosure has been made in view of the above problems and intends to
provide a manufacturing method that enables stable acquisition of a magnesium alloy
member having both good strength and ductility regardless of a billet size.
[0016] To solve the above problems, the manufacturing method of an aircraft member of the
present disclosure employs the following measures.
[0017] The present disclosure provides a manufacturing method of an aircraft member to perform
extrusion processing by using an Mg-Al-Ca based alloy containing (Mg, Al)
2Ca compound, and the manufacturing method of an aircraft member includes: selecting
a billet of an Mg-Al-Ca based alloy containing Al: greater than or equal to 6 atom%
and less than or equal to 8 atom% and Ca: greater than or equal to 3 atom% and less
than or equal to 4 atom% with respect to the whole amount; and extruding the billet
under a condition where a temperature of the billet is maintained to be lower than
a melting temperature of the (Mg, Al)
2Ca.
[0018] According to the manufacturing method of the present disclosure, a billet whose Al
content and Ca content are within the above range is used, and extrusion processing
conditions are optimized, so that an aircraft member having both good strength and
ductility can be obtained more stably than in the conventional methods. Further, according
to the manufacturing method of the present disclosure, an aircraft member that meets
required incombustibility can be obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019]
Fig. 1 is a diagram illustrating a relationship of extrusion conditions, tensile strength
(FTY), and ductility (elongation/EL).
Fig. 2 is a diagram illustrating a range of preferable extrusion processing conditions.
Fig. 3 is a diagram illustrating a relationship of contents of Al and Ca, extrusion
conditions, tensile strength (FTY), and ductility (elongation/EL).
Fig. 4 is a diagram illustrating a result of a corrosion test.
Fig. 5 is a metallographic structure photograph of an Mg-Al-Ca-Si based alloy as one
example.
Fig. 6 is a metallographic structure photograph of an Mg-Si-Ca compound.
Fig. 7 is a metallographic structure photograph of an (Mg, Al)2Ca compound.
DETAILED DESCRIPTION OF THE INVENTION
[0020] A manufacturing method according to the present disclosure is suitable for manufacturing
a secondary structure member for an aircraft. The secondary structure member is a
member installed in a primary structure member such as a stringer. The secondary structure
member is a clip, a bracket, a metal fitting used for fastening pipes, a seat frame,
or the like. The secondary structure member is not loaded as heavily as the primary
structure member.
[0021] One embodiment of a manufacturing method of an aircraft member according to the present
disclosure will be described below with reference to the drawings.
[0022] In the present embodiment, an aircraft member is extruded by using an Mg-Al-Ca based
alloy billet including an (Mg, Al)
2Ca compound (hereinafter, (Mg, Al)
2Ca). The extrusion processing is performed under a condition where the billet temperature
is maintained to be lower than a melting temperature of the (Mg, Al)
2Ca compound. In the extruded aircraft member (extruded material), (Mg, Al)
2Ca is dispersed in a metallographic structure.
[0023] The above Mg-Al-Ca based alloy (billet) is a casting manufactured by melt casting.
The cooling rate during billet casting is lower than or equal to 1000 K/sec, preferably,
lower than or equal to 100 K/sec.
[0024] The diameter of the billet is greater than or equal to 29 mm and less than or equal
to 180 mm. The diameter of the billet may be greater than or equal to 69 mm.
[0025] For the billet, an Mg-Al-Ca based alloy containing Al of greater than or equal to
6 atom% and less than or equal to 8 atom% and Ca of greater than or equal to 3 atom%
and less than or equal to 4 atom% with respect to the whole amount is selected.
[0026] The Mg-Al-Ca based alloy (billet) may contain Mn of greater than 0 atom% and less
than or equal to 0.3 atom%, preferably, greater than or equal to 0.01 and less than
or equal to 0.05.
[0027] The remaining part of the Mg-Al-Ca based alloy (billet) is made of Mg. This not only
means that the whole remaining part is made of Mg but also indicates that the remaining
part may include impurities or other elements to the extent that does not affect the
alloy characteristics.
[0028] The Mg-Al-Ca based alloy (billet) does not contain Si. This not only means that the
Si content is 0 atom% but also indicates that Si may be unavoidably contained (for
example, less than or equal to 0.1 atom%).
[0029] The above Mg-Al-Ca based alloy (billet) contains an (Mg, Al)
2Ca compound. In the Mg-Al-Ca based alloy, (Mg, Al)
2Ca may be contained by preferably greater than or equal to 10 volume% and less than
or equal to 35 volume%, more preferably, greater than or equal to 10 volume% and less
than or equal to 30 volume%.
[0030] The melting temperature of (Mg, Al)
2Ca is 490 degrees Celsius. The melting temperature is derived from a phase diagram.
[0031] The billet temperature during extrusion processing may be maintained to be lower
than the melting temperature by setting an extrusion temperature and an extrusion
exit rate. The "extrusion exit rate" is a rate at which a material is extruded from
an extrusion mold (die) during extrusion molding.
[0032] A extrusion ratio may be higher than or equal to 10 and lower than or equal to 80.
[0033] The cross section of the extruded material may be an L-shape, a T-shape, or a Z-shape,
for example.
[0034] The billet of the Mg-Al-Ca based alloy may be heat-treated at a temperature higher
than or equal to 400 degrees Celsius and lower than or equal to 500 degrees Celsius
for a period longer than or equal to one hour and shorter than or equal to six hours
before extrusion processing. The processing temperature is preferably higher than
or equal to 450 degrees Celsius and lower than or equal to 500 degrees Celsius. More
desirably, the processing time is made shorter, which is about one hour.
[Extrusion Temperature and Extrusion Exit Rate]
[0035] Billets were extruded under predetermined conditions, and the tensile strength (FTY)
and the ductility (elongation/EL) of the obtained extruded material were measured.
[0036] An Mg-Al-Ca based alloy (Φ69 mm) containing Al: 8 atom%, Ca: 4 atom%, and Mn: 0.015
atom% was used for the billet. The extrusion ratio was 15.
[0037] Fig. 1 and Table 1 illustrate measurement results. In Fig. 1, the horizontal axis
(x-axis) represents an extrusion temperature (degrees Celsius), the vertical axis
(y-axis) represents an extrusion exit rate Ve (m/min), and a solid line is a straight
line (y = -0.036x + 17.1) that connects a circle (O) plot (x: 375 degrees Celsius,
y: 3.6 m/min) to a circle plot (x: 450 degrees Celsius, y: 0.9 m/min). In the graph
of the x-y coordinate system of Fig. 1, a colored portion on the right side of the
above-described straight line in the sheet is a region of conditions where the material
temperature during extrusion (billet temperature) exceeds 490 degrees Celsius.
Table 1
| Extrusion material No. |
Extrusion condition |
Tensile strength (MPa) |
Ductility (%) |
| Extrusion temperature (°C) |
Extrusion exit rate (m/min) |
| 1 |
350 |
2.7 |
290 |
5.6 |
| 2 |
375 |
3.6 |
281 |
6.0 |
| 3 |
|
2.7 |
283 |
6.2 |
| 4 |
0.9 |
310 |
3.5 |
| 5 |
400 |
1.5 |
294 |
5.3 |
| 6 |
0.9 |
294 |
4.7 |
| 7 |
420 |
1.5 |
280 |
5.5 |
| 8 |
425 |
2.7 |
264 |
1.6 |
| 9 |
450 |
0.9 |
270 |
7.1 |
[0038] According to Fig. 1 and Table 1, the extruded material (a cross (X) plot /extruded
material No. 8) extruded under a condition where the billet temperature exceeds 490
degrees Celsius (the billet being melted) had tensile strength of 264 MPa and ductility
of 1.6%. On the other hand, all the extruded materials (circle plots /extruded materials
No. 1 to 7, 9) extruded under a condition of a billet temperature at which no melting
occurs (the temperature being maintained to be lower than the billet melting temperature)
had tensile strength greater than or equal to 270 MPa and ductility greater than or
equal to 3%.
[0039] It was suggested from the above results that an extruded material having both good
tensile strength and ductility can be obtained when extrusion processing is performed
under conditions (an extrusion temperature and an extrusion exit rate) where the billet
is not melted.
[0040] Fig. 2 illustrates a range of preferable extrusion processing conditions suggested
from the result of Fig. 1. In Fig. 2, the horizontal axis (x-axis) represents an extrusion
temperature (degrees Celsius), the vertical axis (y-axis) represents an extrusion
exit rate Ve (m/min), a solid line is a straight line (y = -0.036x + 17.1) connecting
a circle plot (x: 375 degrees Celsius, y: 3.6 m/min) to a circle plot (x: 450 degrees
Celsius, y: 0.9 m/min), a long dashed double-short dashed line represents a preferable
range, and a shaded portion between the solid line and the long dashed double-short
dashed line is a region that represents a more preferable range. In the graph of the
x-y coordinate system of Fig. 2, a colored portion on the right side of the above-described
straight line in the sheet is a region of conditions where the material temperature
during extrusion (billet temperature) exceeds 490 degrees Celsius.
[0041] With respect to a straight line connecting a first plot (x: 375 degrees Celsius,
y: 3.6 m/min) to a second plot (x: 450 degrees Celsius, y: 0.9 m/min) in a graph of
the x-y coordinate system where the x-axis represents the extrusion temperature (degrees
Celsius) and the y-axis represents the extrusion exit rate (m/min), it is preferable
to select an extrusion temperature and an extrusion exit rate from values on the straight
line or a range in which x and y are smaller than values on the straight line.
[0042] It is practical that the extrusion temperature is higher than or equal to 350 degrees
Celsius, and the extrusion exit rate is higher than or equal to 0.3 m/min. When the
extrusion temperature is lower than 350 degrees Celsius, the fluidity of the billet
is deteriorated, which makes extrusion difficult. When the extrusion exit rate is
lower than 0.3 m/min, it becomes difficult to perform rate control of the extrusion
apparatus.
[0045] As a reference, Fig. 3 and Table 2 illustrate results obtained by measuring the tensile
strength (FTY) and the ductility (elongation/EL) of extruded materials obtained by
performing extrusion processing by using billets whose Al and Ca contents are larger
than values of the range defined in the present embodiment.
[0046] An Mg-Al-Ca based alloy (Φ69mm) containing Al: 10 atom%, Ca: 5 atom%, and Mn: 0.05
atom% was used for the billet. The extrusion ratio was 15.
Table 2
| Extrusion material No. |
Extrusion condition |
Tensile strength (MPa) |
Ductility (%) |
| Extrusion temperature (°C) |
Extrusion exit rate (m/min) |
| 10 |
400 |
2.7 |
299 |
1.9 |
| 11 |
1.4 |
309 |
2.3 |
[0047] It was confirmed that, in an extruded material obtained by using billets whose Al
and Ca are out of the range of the embodiment described above, there is a case where
the ductility is significantly reduced even when the extrusion processing condition
is within the range disclosed above.
[0048] It was suggested from the above results that it is required to select a billet of
an Mg-Al-Ca based alloy containing Al: greater than or equal to 6 atom% and less than
or equal to 8 atom% and Ca: greater than or equal to 3 atom% and less than or equal
to 4 atom% with respect to the whole amount.
[Ignition Temperature]
[0049] Extruded materials No. 12 to 23 were heated by using a heater, and the temperatures
at the time of ignition were measured. The extrusion ratio during extrusion processing
was 15. The measurement results are illustrated in Table 3.
Table 3
| Extruded material No. |
Billet (ϕ69mm) Composition |
Extrusion condition |
Ignition temperature (°C) |
| Extrusion temperature (°C) |
Extrusion exit rate (m/min) |
Measurement result |
Average |
| 12 |
Mg-8Al-4Ca-0.015Mn |
375 |
3.6 |
1033 |
1038 |
| 13 |
1062 |
| 14 |
1020 |
| 15 |
Mg-8Al-4Ca-0.015Mn |
450 |
0.9 |
1036 |
1039 |
| 16 |
1049 |
| 17 |
1032 |
| 18 |
Mg-6Al-3Ca |
400 |
0.9 |
1080 |
1077 |
| 19 |
1075 |
| 20 |
1077 |
| 21 |
Mg-6Al-3Ca-0.05Mn |
400 |
0.9 |
1017 |
1061 |
| 22 |
1082 |
| 23 |
1085 |
| Reference : Elektron 43 |
845 |
869 |
| 865 |
| 898 |
[0050] All the ignition temperatures of the extruded materials No. 12 to 23 were higher
than or equal to 1000 degrees Celsius. On the other hand, the ignition temperature
of a commercially available magnesium alloy (Elektron 43) was lower than 900 degrees
Celsius. From these results, it is suggested that an extruded material (an aircraft
member) having greater incombustibility than conventional materials can be manufactured
by the method according to the embodiment described above.
[Corrosive Property]
[0051] Billets were extruded under predetermined conditions, and a corrosion test was performed
on the obtained extruded materials (test plates, n = 3) in accordance with a method
compliant with ATSM B117. More specifically, a rectangular-shaped test plate was leaned
internally on a chamber and was continuously sprayed with salt water (5% NaCl) for
96 hours, a weight change of the test plate before and after being sprayed was measured,
and a reduction in thickness (a corrosion rate with time) was calculated.
[0052] As a billet (Φ69 mm), Mg-10Al-5Ca, Mg-10Al-5Ca-0.015Mn, Mg-8Al-4Ca-0.015Mn, Elektron
43 (commercially available magnesium alloy), and 7075-T6 (commercially available aluminum
alloy) were used. The extrusion ratio was 15.
[0053] Fig. 4 illustrates results of the corrosion test. In Fig. 4, the vertical axis represents
a corrosion rate (mm/year), and a bar of each test piece represents an average value.
[0054] The corrosion rate (average) of Mg-10Al-5Ca was 0.75 mm/year. On the other hand,
the corrosion rate (average) of Mg-10Al-5Ca-0.015Mn was 0.125 mm/year. Accordingly,
it was confirmed that the presence of Mn affects the corrosion rate. Similarly, the
corrosion rate (average) of Mg-8Al-4Ca-0.015Mn containing Mn was also low such as
0.175 mm/year.
[0055] The corrosion rate (average) of Elektron 43 was 0.425 mm/year. It was confirmed that
the Mg-Al-Ca based alloy containing Mn has a lower corrosion rate than Elektron 43.
[0056] The corrosion rate (average) of 7075-T6 was 0.15 mm/year. It was confirmed that the
Mg-Al-Ca based alloy containing Mn has the same corrosion rate as 7075-T6.
[Supplementary Notes]
[0057] A refrigerant, a design method of the same, and a freezing machine filled with the
refrigerant described in the above embodiment are understood as follows, for example.
[0058] The present disclosure relates to a manufacturing method of an aircraft member to
perform extrusion processing by using an Mg-Al-Ca based alloy containing (Mg, Al)
2Ca. In the present disclosure, a billet of an Mg-Al-Ca based alloy containing Al:
greater than or equal to 6 atom% and less than or equal to 8 atom% and Ca: greater
than or equal to 3 atom% and less than or equal to 4 atom% with respect to the whole
amount is selected, and the billet is extruded under a condition where the temperature
of the billet is maintained to be lower than a melting temperature of the (Mg, Al)
2Ca. The melting temperature of (Mg, Al)
2Ca is 490 degrees Celsius.
[0059] The Mg-Al-Ca based alloy described above has less specific gravity than an aluminum
alloy used in a conventional aircraft field. Therefore, the weight can be reduced
by 10% or more as compared to an aluminum alloy member by processing such an Mg-Al-Ca
based alloy into an aircraft member.
[0060] According to intensive studies by the present inventors, it has been found that elongation
(ductility) is reduced due to start of melting of (Mg, Al)
2Ca in performing extrusion processing by using an Mg-Al-Ca based alloy containing
(Mg, Al)
2Ca.
[0061] In the disclosure described above, when the extrusion processing is performed under
a condition where (Mg, Al)
2Ca is not melted, a reduction in the ductility due to melting of (Mg, Al)
2Ca can be prevented.
[0062] (Mg, Al)
2Ca that is a C36 type compound is a hard compound. When (Mg, Al)
2Ca is dispersed in a metallographic structure, high strength and relatively large
ductility can be obtained. The degree of dispersion of (Mg, Al)
2Ca may be greater than or equal to 1 piece/µm
2. It is preferable that (Mg, Al)
2Ca be fine (for example, less than or equal to 2 µm).
[0063] Addition of Ca can improve the incombustibility and the mechanical property of the
extruded material (aircraft member). If the Ca content is excessively high, this makes
it difficult to obtain a solidified state of the magnesium alloy, and extrusion processing
becomes difficult. If the Ca content is excessively low, it is not possible to obtain
sufficient incombustibility.
[0064] Addition of Al can improve the mechanical property and the corrosion resistance of
the extruded material. If the Al content is excessively high, it is not possible to
obtain sufficient strength. If the Al content is excessively low, it is not possible
to obtain sufficient ductility.
[0065] Increased contents of Al and Ca contained in an Mg-Al-Ca based alloy may become a
factor of coarsening (Mg, Al)
2Ca in a metallographic structure. If the (Mg, Al)
2Ca is coarsened, the ductility of the extruded material is likely to be reduced. With
the contents of Al and Ca being within the range described above, this may result
in an extruded material having desired ductility.
[0066] In one aspect of the disclosure described above, the condition is set by an extrusion
temperature and an extrusion exit rate, and with respect to a straight line connecting
a first plot (x: 375 degrees Celsius, y: 3.6 m/min) to a second plot (x: 450 degrees
Celsius, y: 0.9 m/min) in a graph of the x-y coordinate system where the x-axis represents
the extrusion temperature (degrees Celsius) and the y-axis represents the extrusion
exit rate (m/min), the extrusion temperature and the extrusion exit rate may be selected
from values on the straight line or a range in which x and y are smaller than values
on the straight line.
[0067] In one aspect of the disclosure described above, the straight line is expressed by
Equation (1): y = -0.036x + 17.1.
[0068] According to intensive studies by the present inventors, when the extrusion temperature
and the extrusion exit rate are selected from the range described above, the temperature
of the billet can be maintained to be lower than the melting temperature of the (Mg,
Al)
2Ca during extrusion processing. Coordinates of the first plot and the second plot
are obtained by actual measurement, which are highly reliable. Therefore, an extruded
material having both good tensile strength and ductility can be more stably manufactured
than in the conventional materials.
[0069] In one aspect of the disclosure described above, it is desirable that the extrusion
temperature in the condition be higher than or equal to 350 degrees Celsius. If the
extrusion temperature is excessively low, the fluidity of the billet is reduced, which
makes the extrusion difficult.
[0070] Given the performance of the extrusion apparatus, in one aspect of the disclosure
described above, it is desirable that the extrusion exit rate in the condition be
higher than or equal to 0.3 m/min.
[0071] In one aspect of the disclosure described above, the extrusion temperature and the
extrusion exit rate may be selected from a range surrounded by three straight lines
of Equation (1), Equation (2): x = 350, and Equation (3): y = 0.3.
[0072] In one aspect of the disclosure described above, the extrusion temperature and the
extrusion exit rate may be selected from a range surrounded by four straight lines
of Equation (1), Equation (2): x =350, Equation (3'): y = 0.9, and Equation (4): y
= 3.6.
[0073] According to intensive studies by the present inventors, it is possible to more reliably
obtain an extruded material having both good tensile strength and ductility by performing
extrusion processing with values of x and y that are smaller than values on the straight
line of (1): y = - 0.036x + 17.1, at an extrusion temperature that is higher than
or equal to 350 degrees Celsius, and at an extrusion exit rate that is higher than
or equal to 0.9 m/min and lower than or equal to 3.6 m/min.
[0074] In one aspect of the disclosure described above, the Mg-Al-Ca based alloy may contain
Mn of greater than 0 atom% and less than or equal to 0.3 atom%.
[0075] Mn has an effect of improving the corrosion resistance even with a small amount.
On the other hand, the ductility of the extruded material is reduced in accordance
with an increase in the addition amount. To balance good corrosion resistance and
ductility, it is desirable to suppress the addition amount of Mn .