This invention focuses on improving the formability of age-hardenable aluminum alloys. The innovation utilizes a tailored heat treatment approach to locally enhance the strength of alloy sheets, which significantly reduces thickness variation during the forming process.
Figure (1) Thickness Distribution Map of Formed Alloy Sheet (Without Tailored Heat Treatment).
Aerospace manufacturing standards require components formed from metallic sheets to have minimal changes in thickness, whether thinning or thickening, within a stringent narrow range. Achieving this with complex geometries and large shape changes poses significant challenges, often leading to material defects and inconsistent product quality.
- Tailored Heat Treatment: The method involves region-based localized heat treatment to increase the strength of hardenable alloy sheets.
- Transition of Alloy Hardness: The process can adjust the hardness from T4 to T6 or from solutionized to T4, depending on the requirements.
- Simulation: Utilizes simulation techniques to identify regions prone to thinning and thickening, allowing targeted treatment.
- Simulation-Based Design: The initial prototype involves using simulation tools to identify critical areas in the alloy sheets.
- Heat Treatment Equipment: Employs specialized equipment to apply localized heat treatment, such as gas flames, laser sources, resistive heating coils, electromagnetic induction heating, or microwave heating.
The technology has reached TRL 4, indicating successful demonstration and validation in a laboratory environment. A simulation-based prototype has been developed to identify regions prone to thinning or thickening in alloy sheets. Specialized localized heat treatment methods—such as laser, resistive heating, or induction—have been experimentally applied to these regions, confirming the effectiveness of the approach in improving sheet formability and reducing thickness variation under controlled conditions. These results establish a solid foundation for further validation in relevant operational settings.
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The technology offers significant societal benefits by enhancing the safety and performance of components used in critical applications such as aerospace and automotive sectors. By reducing thickness variation and improving the structural integrity of metallic sheets, the method contributes to the reliability and longevity of end products, ultimately leading to safer transportation systems. Additionally, the targeted heat treatment approach minimizes material waste and energy consumption, resulting in lower environmental impact and promoting sustainable manufacturing practices.
- Aerospace: Manufacturing of aircraft components that require strict adherence to thickness standards.
- Automotive: Production of lightweight and high-strength vehicle parts.
- Industrial Machinery: Fabrication of parts with complex geometries that require precise material properties.
3469/MUM/2014
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