Scalmalloy

30.09.20081Scalmalloy£AuniquehighstrengthandcorrosioninsensitiveAlMgScZrmaterialconceptFrankPalm,EADSInnovationWorksOttobrunn,GermanyICAA11,Aachen,24thofSeptember200830.09.2008211thInternationalConferenceonAluminiumAlloys(ICAA11),Aachen,2008Co-Authors/AcknowledgementsA.J.BoschR.SendenRSPTechnology,Delfzijl,NetherlandsM.KnüwerW.EntelmannAirbusIndustries,Bremen,GermanyF.PalmEADSInnovationWorks,Munich,GermanyALU-Menziken,ALERIS,ALCOA,ALUnna,severalcolleagues&diplomathesis(students),publicfundedprojects(WAFS,WEL-AIR,DATON,ENWERUM,ScaLA)30.09.2008311thInternationalConferenceonAluminiumAlloys(ICAA11),Aachen,2008TechnicalDriverinAircraftEngineeringCorrosionÙDurabilitySources:(ICAA11),Aachen,2008Engineeringmaterialstrength(simplification)|100MPa-------------------------------425MPa-----------------------------------850MPaI|||||||||||||||||||||||||||||___________________________________________________________________|5xxx6xxx2xxx7xxx2xxxLi|___________________________________________________________________|2xxx7xxx2xxxLiCorrosionissues/NotchtoughnessTechnicalDriverinAircraftEngineering30.09.2008511thInternationalConferenceonAluminiumAlloys(ICAA11),Aachen,2008PerceptionofCFRP:•IfyouhaveaweightissueÎCFRPisthesolution•CorrosionÎCFRPisthesolution•“Old”fashionÎCFRPis“hip”•NanotechnologyÎCFRPis“nano”capable….................TechnicalDriverinAircraftEngineeringNewCompetition30.09.2008611thInternationalConferenceonAluminiumAlloys(ICAA11),Aachen,2008HigherStrengthinAlMgSc-Alloys30.09.2008711thInternationalConferenceonAluminiumAlloys(ICAA11),Aachen,2008HigherStrengthinAlMgSc-Alloys30.09.2008811thInternationalConferenceonAluminiumAlloys(ICAA11),Aachen,2008HigherStrengthinAlMgSc-Alloys30.09.2008911thInternationalConferenceonAluminiumAlloys(ICAA11),Aachen,2008Scalmalloy®-PortfolioHypereutecticAlMgScZrMn-Alloys(since2003)Mg-content:1,80–4,30%(higherMg-contentsarepossible)Sc-content:0,70–1,40%Zr-content:0,22–0,55%Mn-content:0,30–0,70%ÎSc/Zr|2:1ÎMg-content”3,30%(inordertomaximizecorrosionresistance)ÎInthedesignation:ScalmalloyX£ÎXrelatestotheSc-content30.09.20081011thInternationalConferenceonAluminiumAlloys(ICAA11),Aachen,2008Scalmalloy®ÙRapidsolidificationWhymelt-sinning?:•Veryhighsolidificationrates•RelativelystableprocessÎmuchhigherusable“powder”output•Handling–storageofpowder(flakes)/riskofsurfacecontamination•Industrialup-scaling30.09.20081111thInternationalConferenceonAluminiumAlloys(ICAA11),Aachen,2008Scalmalloy®ÙRapidsolidificationSourceRSPTechnology30.09.20081211thInternationalConferenceonAluminiumAlloys(ICAA11),Aachen,2008Scalmalloy®ÙRapidsolidificationVideoSourceRSPTechnology30.09.20081311thInternationalConferenceonAluminiumAlloys(ICAA11),Aachen,2008Scalmalloy®FromMeltÎMaterial(Profiles)Scalmalloy0.7(AlMg4,3Sc0,7Zr0,3Mn0,5)Scalmalloy1.25(AlMg3,9Sc1,25Zr0,55Mn0,7)Agingresponse(300°C/8h):Agingresponse(300°C/8h):asmeltspun117HV0.05asmeltspun192HV0.05Aged:157HV0.05aged:212HV0.05Scalmalloy0.7–flakes:Oxidelayer(ESCA)|25nm,consistingofAl2O3andMgO(Spinell)(afterabout4weeksofhandling(transport&storage)30.09.20081411thInternationalConferenceonAluminiumAlloys(ICAA11),Aachen,2008Scalmalloy®ManufacturingChainCIPExtrusionratiotested|8,0-36:1(dependingongeometry)ÎRoundbar(severalextrusiontemperatures300-380°C)ÎAerospaceprofilebarextrudedat360-380°CHIPDegas30.09.20081511thInternationalConferenceonAluminiumAlloys(ICAA11),Aachen,2008TensilestrengthofScalmalloy0.7-1.25-1.4profilematerial(meanvalues),extrusiontemperatures320-350°C0100200300400500600700AlMgSc0.7AlMgSc1.25AlMgSc1.4StandardAlMgScsheetTensile&yieldstrength(MPa)010203040506070Fractureelongation(%)Scalmalloy£=Highstrength&ductilematerialwithexceptionalhighnotchtoughness=lowdensity(ȡ|2,65g/cm³)=verygoodtensilelengthandnotchedfatigue+30-50%Scalmalloy®StrengthEvolution30.09.20081611thInternationalConferenceonAluminiumAlloys(ICAA11),Aachen,2008StrengthevolutioninextrudedAlMgScalloys(0Sc1,0wt%)(=0,1wt%Sc=ca.45MPastrengthincrease)0501001502002503003504004505000,10,20,30,40,50,60,70,80,91AlloycontentofSc(usableforprecipitationhardening)Strengthgain(MPa)=315MPaScalmalloy®YieldStrengthEstimationAlMg4,3Sc0,7Zr0,3Mn0,530.09.20081711thInternationalConferenceonAluminiumAlloys(ICAA11),Aachen,2008StrengthevolutioninextrudedAlMg-typealloys(0Mg5%)(annealedtemper(extrudedintemperaturerange300-350°C))0501001502002503003500,511,522,533,544,55MgcontentUTSandYieldstrength(MPa)135MPa=Scalmalloy®YieldStrengthEstimationAlMg4,3Sc0,7Zr0,3Mn0,530.09.20081811thInternationalConferenceonAluminiumAlloys(ICAA11),Aachen,2008StrengthcapabilitiesofAlMg4,3Sc0,7Zr0,3Mn0,5:UTS§500MPaYS§450MPaA15%EasyUTSapproximationviaHBÎFactor§3,5!StrengthevolutioninextrudedAlMgScalloys(0Sc1,0wt%)(=0,1wt%Sc=ca.45MPastrengthincrease)0501001502002503003504004505000,10,20,30,40,50,60,70,80,91AlloycontentofSc(usableforprecipitationhardening)Strengthgain(MPa)=315MPaStrengthevolutioninextrudedAlMg-typealloys(