High strength aluminum stamping
The invention provides a component formed of an aluminum alloy for use in a vehicle, for example an automotive vehicle component requiring high strength, light-weight, and a complex three-dimensional shape, and a method of manufacturing the component. The method begins by providing a blank formed of an aluminum alloy which is already solution heat treated and tempered, and thus has a temper designation of about T4. The method further includes heating the blank to a temperature of 150° C. to 350° C., preferably 190° C. to 225° C. The method next includes quickly transferring the blank to a hot or warm forming apparatus, and stamping the blank to form the complex three-dimensional shape. Immediately after the forming step, the component has a temper designation of about T6, but preferably not greater than T6, and thus is ready for use in the vehicle without any post heat treatment or machining.
1. A method of manufacturing a component for use in a vehicle, comprising:
heating a solution heat treated and tempered blank formed of an aluminum alloy to a temperature of 150° C. to 350° C., holding the blank at the temperature of 150° C. to 350° C. for 2 to 6 minutes, and forming the heated blank while the blank is still heated and at a temperature of at least 150° C.
2. The method of claim 1 , wherein the aluminum alloy is selected from the group consisting of: a 2000, 6000, 7000, 8000, and 9000 series aluminum alloy; and the 2000, 6000, 7000, 8000, and 9000 series aluminum alloy of the component has a tensile strength equal to or greater than the minimum tensile strength of the same aluminum alloy having a temper designation of T6 after the heating step.
3. The method of claim 1 , wherein the aluminum alloy is formed into the shape of a bumper for the vehicle.
4. The method of claim 1 , wherein the aluminum alloy is formed into the shape of a reinforcement for the vehicle.
5. The method of claim 1 , wherein the aluminum alloy is a 6000 series aluminum alloy.
6. The method of claim 1 , wherein the aluminum alloy is a 7000 series aluminum alloy.
7. The method of claim 1 , wherein the aluminum alloy is an 8000 series aluminum alloy.
8. The method of claim 1 , wherein the aluminum alloy is selected from the group consisting of: a 6000, 7000, and 8000 series aluminum alloy; the aluminum alloy of the blank has a temper designation of T4 before the heating step; the heating step includes heating the solution heat treated and tempered blank to a temperature ranging from 190° C. to 225° C.; and the aluminum alloy of the component has the temper designation of T6 immediately after the forming step.
9. The method of claim 1 , wherein the step of heating the solution heat treated and tempered blank is conducted in a furnace, and further including:
transferring the heated blank from the furnace to a forming apparatus, the transferring step having a duration of not greater than 15 seconds, and
wherein the step of forming the blank includes stamping the solution heat treated blank into a component having a three-dimensional shape after the heating step and in the forming apparatus and while the blank is still heated and at a temperature of at least 150° C.
10. The method of claim 9 , wherein the holding step includes holding the blank at a temperature ranging from 190° C. to 225° C. for 2 to 6 minutes.
11. The method of claim 9 , wherein the stamping step occurs within 15 seconds after the heating step.
12. The method of claim 1 , wherein the aluminum alloy of the component has a temper designation of T6 immediately after the forming step.