High-strength mechanical and structural components, and methods of making high-strength components

Abstract

The invention includes components comprising an alloy containing a base metal and less than or equal to 30% alloying elements. The material has a grain size of less than or equal to about 30 microns and an absence of voids and inclusions of a size greater than 1 micron. The components have a yield strength at least 50% greater than the identical alloy composition in the 0 temper condition. Where the material is heat treatable, the yield strength is at least 10% greater than the identical composition in the T6 temper condition. The invention includes a method of producing components by casting and initial treatment to form a billet. The billet is subjected to equal channel angular extrusion and subsequent annealing at a temperature of less than or equal to 0.85 times the minimum temperature for inducing growth of submicron grains to over 1 micron.

Description

TECHNICAL FIELD [0001] The invention pertains to high-strength engine components, vehicle structural components, methods of producing engine components and methods of forming vehicle structural components. BACKGROUND OF THE INVENTION [0002] Development of lightweight materials which can contribute to weight reduction of land, air and space vehicles has become increasingly important. Vehicle weight reduction can result in increased fuel efficiency and reduced emissions. Lighter weight materials also offer improved maneuverability and can additionally reduce manufacturing costs. [0003] Many of the available lightweight materials lack sufficient strength for many structural and engine components. Current materials which are considered to be “lightweight” materials for use in engine or body components of vehicles include, for example, magnesium, aluminum, titanium and beryllium metals and alloys. Optionally, medium-weight materials such as steels are used due to their relatively high-st...

AI Technical Summary

Benefits of technology

[0004] In one aspect the invention encompasses a high-strength engine component comprising an alloy which contains a base metal alloyed with less than or equal to 30% by weight of alloying elements, where the material has an average grain size of less than or equal to about 30 microns. The material has an absence of voids and inclusions of a size greater than 1 micron. The material also has a yield strength (YS) at least 50% greater than the yield strength of the identical alloy composition in an annealed 0 temper condition.

[0005] In one aspect the invention includes high-strength engine components comprising a material consisting of an alloy having a base metal alloyed with less than or equal to 30% by weight of alloying elements. The material has an average grain size of less than or equal to about 30 microns, an absence of voids and inclusions of a size greater than 1 micron and contains soluble second phase precipitates having an average size of less than 30 microns. The material has a yield strength at least 10% greater than the yield strength of the identical alloy composition in the T6 temper condition.

[0006] In one aspect the invention includes a vehicle structural component comprising a material consisting of an alloy comprising at least two elements selected from Al, Ti, Mg, Be, Ni, Fe, Cu, Co, W, Ta, Zn, Ag, Sn, Pb, In, Au, Si, Sb, Mo, V, Sc, Cr, Y, B, Mn, C, Li, P, S, Nb, Zr, Pd, and Cd. The alloy contains a base metal alloyed with less than or equal to 30% of additional alloying elements by weight. The material has an average grain size of less than or equal to about 30 microns, an absence of voids and inclusions having a size greater than 1 micron, and has a yield strength at least 50% greater than the yield strength of the identical alloy composition in the annealed 0 temper condition.

[0007] In one aspect the invention includes a vehicle structu

Problems solved by technology

Many of the available lightweight materials lack sufficient strength for many structural and engine components.

Additionally, many of the available lightweight materials and lower volume medium weight materials lack sufficient strength to meet engine and / or vehicle performance standards and safety goals.

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