The present disclosure generally relates to aluminum alloy, and specifically relates to aluminum alloy having visible grains and aluminum alloy colored by double anodization.
Aluminum alloy are widely used. However, most metallurgical features of currently available aluminum alloy are not visible to a human eye. For example, grain boundaries of currently available aluminum alloy are microscopic in size and they cannot be seen or analyzed without optical magnification. Also, currently available aluminum alloy barely have any cosmetic appearance by themselves, which limits their use in products.
Embodiments relate to processing an aluminum alloy to render grain boundaries visible to a human eye. The iron concentration in the aluminum alloy is reduced to obtain a concentration of iron below a threshold value. The aluminum alloy is then heated at a first temperature for a period of time to cause recrystallization of aluminum. The aluminum alloy is aged at a second temperature for another period of time to enhance the strength of the aluminum alloy. The second temperature is lower than the first temperature.
In one or more embodiments, the average grain size of the aluminum alloy is grown to at least 100 μm.
In one or more embodiments, the solutionizing temperature is higher than 480° C.
Embodiments also relate to anodizing an aluminum alloy. The grain boundaries of the aluminum alloy is etched. Then the aluminum alloy is etched with a first color. The anodizing causes grain boundaries and grains of the aluminum alloy to be coated with an anodic oxide layer of the first color. The anodic oxide layer of the first color is removed from the grains of the aluminum alloy. The aluminum alloy is anodized with a second color. The anodizing causes the grains of the aluminum alloy to be coated with an anodic oxide layer of the second color.
FIG. (FIG.) 1 is a diagram illustrating a process for producing aluminum alloy having visible grains by heat treatment, in accordance with an embodiment.
The figures depict embodiments of the present disclosure for purposes of illustration only.
Embodiments relate to a type of aluminum alloy with grains visible to naked eyes. The aluminum alloy may have an average grain size of at least 100 μm. The aluminum alloy can be produced by a process such as casting, extrusion, solutionizing, aging, and etching. The solutionizing causes recrystallization of aluminum and causes grains of the aluminum to grow. Compared with the solutionizing, the aging is performed at lower temperature but enhances strength of the aluminum alloy. The etching makes grain boundaries of the aluminum alloy more prominent, rendering the grains of the aluminum alloy visible to a naked human eye.
Embodiments also relate to a type of aluminum alloy colored by double anodization. Grain boundary of the aluminum alloy are etched so that there are grooves at the grain boundaries. The double anodization includes a first anodizing and a second anodizing. The first anodizing creates a first anodizing layer coating the grain boundaries and the grains. The first anodizing layer is then removed from the grains but remains in the grooves. The second anodizing creates a second anodizing layer coating the grains, but not coating the grain boundaries because the grain boundaries are still coated with the first anodizing layer. The first and second anodizing layers have different colors, and therefore, the grain boundaries are distinct from the grains.
FIG. (FIG.) 1 is a diagram illustrating a process 100 for producing aluminum alloy having visible grains by heat treatment, in accordance with an embodiment. The process 110 includes casting 110, extrusion 120, solutionizing 130, aging 140, and etching 150. In some embodiments, the process 100 may include different or additional steps than those described below in conjunction with
The casting 110 solidifies liquid aluminum alloy in a mold. In some embodiments, the casting 110 is direct chill casting that produces cylindrical or rectangular solid ingots of aluminum alloy. A cooling process of the direct chill casting includes two cycles of cooling of the aluminum alloy. The first cycle of cooling is through heat expansion through the mold, and the second cycle of cooling is through application of a coolant (e.g., water) on the ingots. The second cycle of cooling contribute majority of the cooling process.
During the casting 110, iron (Fe) concentration in the aluminum alloy is reduced. Iron is a grain inhibitor, meaning that it can inhibit grain growth. Accordingly, high concentration of iron can cause small grain size.
Compared with the grains in the image 210, the grains in the image 220 has a larger average grain size. The average grain size in the image 210 is approximately 20 μm whereas the average grain size in the image 220 is approximately 60 μm to 80 μm. Thus,
In some embodiments, iron concentration in the aluminum alloy is reduced to below 0.12 wt %. For example, iron concentration in the aluminum alloy after the casting 110 is approximately 0.01 wt % or 0.03 wt %. Iron can be removed from the aluminum alloy through various methods, including reducing amount of recycled aluminum that carries high amount of iron, adding filter to the aluminum alloy during the casting 110 to remove phases containing iron, cleaning furnaces/molds that are made of iron based material to reduce iron contamination, melting aluminum in Graphite or Molybdenum based crucible to reduce iron contamination, adding alloying elements that react with iron during the casting 110, other similar methods to remove iron, or any combination thereof. Other appropriate methods for removing iron from aluminum alloy can be used. For example, iron is removed from the aluminum alloy by precipitation and separation of intermetallic phases (e.g., Fe-rich phases) from the liquid aluminum alloys. The separation can be performed through several techniques, such as filtration, centrifugal and electromagnetic separation, or any combination thereof. As another example, iron can be removed through electroslag refining (ESR). In addition to iron, other types of grain inhibitors, such as zirconium, scandium, titanium, carbide, etc, can also be removed from the aluminum alloy.
Turning back to
The solutionizing 130 is a heat treatment process that causes grain growth. In some embodiments, the solutionizing 130 is conducted at a temperature (i.e., solutionizing temperature) that is at least as high as a recrystallization temperature of the aluminum alloy. Thus, the solutionizing 130 is accompanied with recrystallization. Recrystallization is a process where original grains are replaced by a set of new grains and the new grains grow until the original grains have been entirely consumed. Also, because iron and other types of grain inhibitors are reduced from the aluminum alloy during the casting 110, the new grains of the aluminum alloy can grow into bigger sizes, compared with aluminum alloy having a higher concentration of iron or other types of grain inhibitors. Consequently, average grain size of the aluminum alloy is increased after the solutionizing 130.
In some embodiments, grain growth of aluminum alloy occurs in a different heat treatment process than the solutionizing 130. For example, grain growth of aluminum alloy (e.g., AA5XXX, AA3XXX and AA1XXX alloys) occurs during an annealing treatment that causes recrystallization. The annealing treatment can either be full annealing or partial annealing. As another example, grain growth can occur during pre-heating prior to processes, such as hot stamping or hot forging.
In some embodiments, the average grain size after the solutionizing 130 is greater than 100 μm, so that the new grains are visible to a naked human eye. In one embodiment, the average grain size can fall into millimeter scale, e.g., 1-2 mm. The average grain size is at least partially dependent on solutionizing temperature. Different solutionizing temperatures can result in different grain sizes.
As illustrated by the image 310, PCG and cross-section grain of the aluminum alloy solutionized at 500° C. have different grain sizes. Grain size of the PCG is about 200 μm. But the cross-section grain, as shown in the image 340 is significantly larger than the PCG. The PCG grain sizes of the aluminum alloy solutionized at higher temperatures are larger, shown by the image 330 compared with the image 310. Also, difference between PCG and cross-section grains is lower for the aluminum alloy solutionized at higher temperatures. The grain size in the image 320 is similar to the grain size in the image 350. Difference between the grain sizes in the image 330 and 360 is not apparent. In some embodiment, 545° C. is selected as the solutionizing temperature for the aluminum alloy because it corresponds to larger grains and uniform distribution of grain size. A solutionizing temperature higher than 545° C. can be selected for generating even larger grains. However, because larger grains result in lower strength, in some other embodiments, a solutionizing temperature lower than 545° C. may be selected for consideration of strength. In some embodiments, PCG layers are removed via machining to achieve consistent grain structure.
In one embodiment, the solutionizing temperate is higher than 480° C. For example, for 6000 series aluminum alloy, the solutionizing 130 can be conducted at 530° C. for 1 hour. The increased grain size can result in lower strength of the aluminum alloy. The lower strength can be improved by the aging 140.
Turning back to
In some embodiments, a hardness test is conducted on the aged aluminum alloy to determine whether the aluminum alloy has sufficient strength. Also, grains size of surface coarse grains (i.e., peripheral coarse grains) can be measured for estimating strength of the aluminum alloy. If the tests show that the strength of the aluminum alloy is lower than required or preferred, one or more additional aging processes are conducted on the aluminum alloy to improve strength. In some embodiments, after the aging 140, the aluminum alloy is machined and/or polished for a smooth surface, e.g., a mirror-like finish, in order to facilitate the etching 150.
The etching 150 enhances contrast between grains boundaries and grains by creating grooves at the grain boundaries so that the grain boundaries are distinct from the grains. For example, an etchant is applied on the aged aluminum alloy for a predetermined amount of time (i.e., etching time). Atoms located on the grain boundaries dissolve in the etchant, resulting in the grooves. The grain boundaries appear as black likes and the grains becomes more visible.
Different etchants or different etching times can result in grooves having different depth or different surface finish, causing different appearance of the aged aluminum alloy. In some embodiments, etchant is selected from a group including Caustic Soda (NaOH), Hydrofluoric Acid (HF), and Iron III Chloride (FeCl3), or any combination thereof. Other types of etchants can also be used for the etching 150.
Different appearances can also be created by changing etching time. Turning now to
Alternative to the etching 150, grain boundaries can be highlighted by precipitating anodic phases on the grain boundaries. In some embodiments, the grain boundaries are cathodic and grains are anodic. Precipitation of cathodic phases in the grain boundaries and subsequent exposure to a corrosive environment (e.g., 3.5 wt % NaCl solution) can result in preferential corrosion of the grains and cause the grain boundaries higher than the grains. Time of the exposure to the corrosive environment and corrosivity of the corrosive environment can be adjusted to achieve a desired height difference. Taking Al—Cu—Li system as an example, cathodic phases deposited at the grain boundaries can be non-Li containing phase. Consequently, the grains have more Li. Li is highly reactive and can make the grains more anodic. In some other embodiments, the grain boundaries are anodic and the grains are cathodic, causing the grains higher than the grain boundaries.
The etched aluminum alloy can be further processed. For example, the etched aluminum alloy can be colored by double anodization, which coated an anodic layer of one color on the grains and another anodic layer of a different color on the grain boundaries. More details about double anodization are provided below in conjunction with
The lapping 810 creates a smooth surface of the aluminum alloy sample. The etching 820 can be similar to the etching 160 described in conjunction with
The first anodizing 830 coats the aluminum alloy sample (both the grains and grain boundaries) with a first anodization layer. The first anodization layer has a first color. Accordingly, both the grains and the grain boundaries have the first color. In some embodiments, the first anodization layer is an anodic oxide layer.
The first anodization layer is removed 840, e.g., by lapping. For example, a layer having a depth of 10-50 μm is removed. After the removing 840, the first anodization layer coating the grains is removed. But because of the grooves at the grain boundaries, the grain boundaries are still coated with the first anodization layer.
The second anodizing 850 coats the grains of the aluminum alloy sample with another anodization layer, e.g., another anodic oxide layer. The other anodic oxide layer has a second color. The second color can be different from the first color. Because the grain boundaries are coated with the first anodization layer, the grain boundaries are not coated with the second anodization layer by the second anodizing 850. Accordingly, the grains are coated with the second color while the grain boundaries are coated with the first color. The color difference enhances contrast between the grains and the grain boundaries.
The steps in the process 100 and the process 800 can be combined, re-ordered, or selected in order to create a predetermined cosmetic appearance of an aluminum alloy piece. Also, different portions of an aluminum alloy piece can be processed differently for creating distinctive cosmetic appearances among those portions. For example, a predetermined pattern can be made on the aluminum alloy piece.
The diagram 950 shows the aluminum alloy sample after the second anodizing 850. The grains 910 are coated with the second anodizing layer 970, which can be, e.g., an anodic oxide layer. But because the grooves 930 are coated with the first anodization layer 940 before the second anodizing 850, there is no second anodizing layer 970 on top of the grooves 930. Accordingly, the grains 910 and the grain boundaries 920 are coated with two different anodization layers. In embodiments where the first anodization layer 940 has a different color from the second anodization layer 970, the grain boundaries 920 are distinct from the grains 910.
The language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter. It is therefore intended that the scope of the patent rights be limited not by this detailed description, but rather by any claims that issue on an application based hereon. Accordingly, the disclosure of the embodiments is intended to be illustrative, but not limiting, of the scope of the patent rights, which is set forth in the following claims.
This application claims priority under 35 U.S.C. § 119(e) to U.S. Patent Application No. 62/551,654 filed on Aug. 29, 2017, which is incorporated by reference herein in its entirety.
Number | Date | Country | |
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62551654 | Aug 2017 | US |