Aluminum alloy component

Abstract

To suppress occurrence of stress corrosion cracking in a weld due to tensile residual stress generated in a web or a middle rib in case of bend forming of an aluminum alloy extrusion having the weld on the web or/and the middle rib. In bend forming of the aluminum alloy extrusion, a peak position of tensile residual stress generated in the middle rib exists in a region other than the vicinity of the weld. Since the peak position is away from the weld by a distance, tensile residual stress in the weld is reduced, making it possible to suppress occurrence of stress corrosion cracking.

Claims

1. An aluminum alloy component, comprising an aluminum alloy extrusion including a pair of flanges, a pair of webs connecting the flanges together, and a respective weld on each of the webs, the aluminum alloy component being subjected to bend forming with a bending axis being a direction perpendicular to a longitudinal direction and parallel to the flanges, wherein tensile residual stress exists in the webs and respective welds are formed in an extrusion process that forms the aluminum alloy extrusion, wherein formation positions of the respective welds in the extrusion process are configured such that a peak position of the tensile residual stress exists in a region other than the vicinity of the respective welds.

2. The aluminum alloy component according to claim 1, wherein the bend forming is stretch bend forming.

3. The aluminum alloy component according to claim 1, wherein the pair of webs each connects the pair of flanges together.

4. The aluminum alloy component according to claim 1, wherein the peak position of the tensile residual stress is predicted so that the formation positions of the one or more welds are determined before the extrusion process.

5. An aluminum alloy component, comprising an aluminum alloy extrusion that includes a pair of flanges, a pair of webs connecting the flanges together, and one or more middle ribs located between the webs and connecting the flanges together, and has one or more welds on at least one of the webs or the middle rib, the aluminum alloy component being subjected to bend forming with a bending axis being a direction perpendicular to a longitudinal direction and parallel to the pair of flanges, wherein tensile residual stress exists in the webs and the middle rib, and the one or more welds are formed in an extrusion process that forms the aluminum alloy extrusion, wherein formation positions of the one or more welds in the extrusion process are configured such that a peak position of the tensile residual stress exists in a region other than the vicinity of the one or more welds.

6. The aluminum alloy component according to claim 5, wherein the bend forming is stretch bend forming.

7. The aluminum alloy component according to claim 5, wherein the pair of webs each connects the pair of flanges together.

8. The aluminum alloy component according to claim 5, wherein the one or more middle ribs each connect the pair of flanges together.

9. The aluminum alloy component according to claim 5, wherein the peak position of the tensile residual stress is predicted so that the formation positions of the one or more welds are determined before the extrusion process.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a view for explaining a relationship between a weld on a web and a peak position of tensile residual stress existing in the web in an aluminum alloy component (aluminum alloy extrusion subjected to bend forming) according to the invention.

(2) FIG. 2 is a view for explaining a relationship between a weld on a middle rib and a peak position of tensile residual stress existing in the middle rib in another aluminum alloy component (aluminum alloy extrusion subjected to bend forming) of the invention.

(3) FIGS. 3A to 3C are each another exemplary sectional view of the aluminum alloy component.

(4) FIG. 4 exemplarily illustrates distribution of residual stress generated in the aluminum alloy extrusion that has just been subjected to simple bend forming.

(5) FIG. 5 exemplarily illustrates distribution of residual stress generated in the aluminum alloy extrusion that has just been subjected to stretch bend forming.

DETAILED DESCRIPTION

(6) Hereinafter, the aluminum alloy component according to the invention is specifically described with reference to FIGS. 1 to 3C.

(7) An aluminum alloy extrusion 11 illustrated in FIG. 1 includes a pair of flanges 12 and 13 and a pair of webs 14 and 15 connecting the flanges 12 and 13 together, and has welds 17a to 17d on the flanges 12 and 13 and the webs 14 and 15. The flanges 12 and 13 are parallel to each other, and the webs 14 and 15 are perpendicular to the flanges 12 and 13.

(8) When the aluminum alloy extrusion 11 is subjected to bend forming with a bending axis being a direction perpendicular to a longitudinal direction (extrusion direction) and parallel to the flanges 12 and 13, residual stress is generated along the longitudinal direction (extrusion direction) in each of the webs 14 and 15 of the aluminum alloy extrusion 11 that has just been subjected to bend forming (aluminum alloy component). When simple bending, in which no tension is applied in the longitudinal direction, is performed as the bend forming, as shown in FIG. 4, a peak position p of tensile residual stress is some position in a region between a neutral axis n of bending and an outer bending end, and that position varies depending on the degree of bending. When the bend forming is stretch bend forming, in which tension is applied in the longitudinal direction, as shown in FIG. 5, the peak position p moves to a more inner side of bending than in simple bending, and that position varies depending on the degree of bending and/or tension. Distribution of residual stress generated in the webs 14 and 15 after bend forming can be determined using a known measurement method such as an X-ray diffraction method and a strain gauge method.

(9) In the aluminum alloy extrusion 11 subjected to bend forming (aluminum alloy component of the invention), the peak positions p of tensile residual stress on the webs 14 and 15 exist in regions other than the vicinities of the welds 17c and 17d, respectively. In the invention, as shown in FIG. 1, the vicinities of the welds 17c and 17d each mean a region roughly satisfying D<H/10, where H is height (distance from an outer bending end to an inner bending end) of the aluminum alloy component, and D is a distance from the weld 17c or 17d to the peak position p. This region includes a position (D=0) of the weld 17c or 17d itself. The region other than the vicinity of the weld 17c or 17d means a region roughly satisfying D≥H/10.

(10) In bend forming of the aluminum alloy extrusion 11, fixing the degree of bending and tension makes it possible to experimentally predict a position on the web 14 or 15 to be occupied by the peak position p. In extrusion of the aluminum alloy extrusion 11, formation positions of the welds 17c and 17d are determined by a structure of a porthole dice. Hence, when the degree of bending and tension are fixed, through appropriate dice design, it is possible to form each of the welds 17c and 17d in the region satisfying D≥H/10, locate the peak position p of tensile residual stress generated in the aluminum alloy component (aluminum alloy extrusion 11 subjected to bend forming) in a region other than on the weld 17c or 17d and away from the weld 17c or 17d by the distance D (≥H/10). This reduces tensile residual stress in the weld 17c or 17d of the aluminum alloy component and makes it possible to correspondingly suppress occurrence of stress corrosion cracking.

(11) An aluminum alloy extrusion 21 illustrated in FIG. 2 includes a pair of flanges 22 and 23, a pair of webs 24 and 25, and one middle rib 26 between the webs 24 and 25, and has welds 27a to 27e on the four corners and the middle rib 26. The flanges 22 and 23 are parallel to each other, and the web 24, the web 25, and the middle rib 26 are perpendicular to the flanges 22 and 23.

(12) When the aluminum alloy extrusion 21 is subjected to bend forming with a bending axis being a direction perpendicular to a longitudinal direction (extrusion direction) and parallel to the flanges 22 and 23, residual stress is generated along the longitudinal direction in each of the web 24, the web 25, and the middle rib 26 of the aluminum alloy extrusion 21 that has just been subjected to bend forming (aluminum alloy component). When simple bending is performed as the bend forming, as shown in FIG. 4, the peak position p of tensile residual stress is some position in a region between the neutral axis n of bending and the outer bending end, and that position varies depending on the degree of bending. When the bend forming is stretch bend forming, as shown in FIG. 5, the peak position p moves to a more inner side of bending than in simple bending, and that position varies depending on the degree of bending and/or tension. Residual stress generated in the middle rib 26 after bend forming can be determined using a known measurement method such as an X-ray diffraction method and a strain gauge method.

(13) In the aluminum alloy extrusion 21 subjected to bend forming (aluminum alloy component of the invention), the peak position p of tensile residual stress on the middle rib 26 exists in a region other than the vicinity of the weld 27e. In the invention, as shown in FIG. 2, the vicinity of the weld 27e means a region roughly satisfying D<H/10, where H is height (distance from an outer bending end to an inner bending end) of the aluminum alloy component, and D is a distance from the weld 27e to the peak position p. This region includes a position (D=0) of the weld 27e itself. The region other than the vicinity of the weld 27e means a region roughly satisfying D≥H/10.

(14) In bend forming of the aluminum alloy extrusion 21, fixing the degree of bending and tension makes it possible to experimentally predict a place on the middle rib 26 to be occupied by the peak position p. In extrusion of the aluminum alloy extrusion 21, a formation position of the weld 27e is determined by a structure of a porthole dice. Hence, when the degree of bending and tension are fixed, appropriate dice design makes it possible to form the weld 27e at a position satisfying D≥H/10, locate the peak position p of tensile residual stress generated in the aluminum alloy component (aluminum alloy extrusion 21 subjected to bend forming) in a region other than on the weld 27e and away from the weld 27e by the distance D (≥H/10). This reduces tensile residual stress in the weld 27e of the aluminum alloy component and makes it possible to correspondingly suppress occurrence of stress corrosion cracking.

(15) FIGS. 3A to 3C are each another exemplary sectional shape of an aluminum alloy extrusion as a material of the aluminum alloy component according to the invention.

(16) An aluminum alloy extrusion 31 illustrated in FIG. 3A includes a pair of flanges 32 and 33 and a pair of webs 34 and 35, in which each of the flanges 32 and 33 has projecting flanges (portions projecting outward from the webs 34 and 35) on two horizontal sides.

(17) An aluminum alloy extrusion 41 illustrated in FIG. 3B includes a pair of flanges 42 and 43, a pair of webs 44 and 45, and two middle ribs 46 and 47.

(18) An aluminum alloy extrusion 51 illustrated in FIG. 3C includes a pair of flanges 52 and 53, a pair of webs 54 and 55, and three middle ribs 56 to 58.

(19) When such aluminum alloy extrusions 31, 41, and 51 are each subjected to bend forming with a bending axis being a direction perpendicular to a longitudinal direction and parallel to the flanges, a weld on each web or/and the middle rib is beforehand formed at a position satisfying D≥H/10, making it possible to suppress occurrence of stress corrosion cracking.

(20) A high-strength 7000-series aluminum alloy extrusion, in which stress corrosion cracking tends to occur, can be preferably, but not limitedly, used as the aluminum alloy extrusion as a material of the aluminum alloy component of the invention. A composition defined in JIS or the AA standard can be used as a composition of the 7000-series aluminum alloy. A preferred composition may contain, in percent by mass, Zn: 3 to 8, Mg: 0.4 to 2.5, Cu: 0.05 to 2.0, Ti: 0.005 to 0.2, and at least one of Mn: 0.01 to 0.5, Cr: 0.01 to 0.3, and Zr: 0.01 to 0.3, with the remainder consisting of Al and impurities.

(21) This application claims the benefits of priority to Japanese Patent Application No. 2019-037663, filed Mar. 1, 2019. The entire contents of the above application are herein incorporated by reference.