Abstract: A method of producing an integrated monolithic aluminum structure, the method including the steps of: (a) providing an aluminum alloy plate with a predetermined thickness of at least 25.4 mm, wherein the aluminum alloy plate is a 7xxx-series alloy provided in a W-temper; (b) optionally pre-machining of the aluminum alloy plate to an intermediate machined structure; (c) high-energy hydroforming of the plate or optional intermediate machined structure against a forming surface of a rigid die having a contour in accordance with a desired curvature of the integrated monolithic aluminum structure, the high energy hydroforming causing the plate or the intermediate machined structure to conform to the contour of the forming surface to at least one of a uniaxial curvature and a biaxial curvature; (d) solution heat-treating and cooling of the high-energy hydroformed structure; (e) machining and (f) ageing of the final integrated monolithic aluminum structure.

Abstract: A method of producing an integrated monolithic aluminum structure including providing an 7xxx-series aluminum alloy plate with a predetermined thickness of at least 10 mm, and wherein the plate has been solution heat treated and stretched, heat-treating the plate product in a first of a plurality of artificial ageing steps required to achieve a final temper state, high-energy hydroforming the plate against a forming surface of a rigid die having a contour with a desired curvature of the integrated monolithic aluminum structure, the high energy forming causing the aluminum alloy plate to conform to the forming surface contour to at least one of a uniaxial curvature and a biaxial curvature, heat-treating the integrated monolithic aluminum structure through a remaining ageing step of the ageing steps to achieve a desired final temper, and machining the high-energy formed structure to a near-final or final machined integrated monolithic aluminum structure.

Abstract: A method of producing an integrated monolithic aluminum structure, the method including the steps of: (a) providing an aluminum alloy plate with a predetermined thickness of at least 3 mm, wherein the aluminum alloy plate is a 2xxx-series alloy provided in an F-temper or an O-temper; (b) optionally pre-machining of the aluminum alloy plate to an intermediate machined structure; (c) high-energy hydroforming of the plate or optional intermediate machined structure against a forming surface of a rigid die having a contour in accordance with a desired curvature of the integrated monolithic aluminum structure, the high-energy hydroforming causing the plate or the intermediate machined structure to conform to the contour of the forming surface to at least one of a uniaxial curvature and a biaxial curvature; (d) solution heat-treating and cooling of the high-energy hydroformed structure; (e) machining and (f) ageing of the final integrated monolithic aluminum structure.

Abstract: A method of producing an integrated monolithic aluminum structure, comprising: providing an aluminum alloy plate with a thickness of at least 38.1 mm, wherein the plate is a 2xxx-series alloy in a T3-temper and has a composition comprising, in wt. %: Cu 3.8-4.5, Mn 0.3-0.8, Mg 1.1-1.6, Si up to 0.15, Fe up to 0.20, Cr up to 0.10, Zn up to 0.25, Ti up to 0.15, Ag up to 0.10, balance aluminum; optionally pre-machining the plate to an intermediate machined structure; high-energy hydroforming the plate or intermediate structure against a rigid die forming surface having a desired curvature contour of the integrated monolithic aluminum structure, causing the plate or the intermediate structure to conform to the forming surface contour; machining or mechanical milling the high-energy formed structure to a near-final or final machined integrated monolithic aluminum structure; ageing the final integrated monolithic aluminum structure to a desired temper.

Abstract: A method of manufacturing an AA2xxx-series aluminium alloy plate product having improved fatigue failure resistance and a reduced number of flaws, the method comprising the following steps (a) casting an ingot of an aluminium alloy of the 2xxx-series, the aluminium alloy comprising (in wt. %): Cu 1.9 to 7.0, Mg 0.3 to 1.8, Mn up to 1.2, balance aluminium and impurities, each 0.05 max, total 0.15; (b) homogenizing and/or preheating the cast ingot; (c) hot rolling the ingot into a plate product by rolling the ingot with multiple rolling passes characterized in that, when at an intermediate thickness of the plate between 100 and 200 mm, at least one high reduction hot rolling pass is carried out with a thickness reduction of at least 15%; wherein the plate product has a final thickness of less than 60 mm. The invention is also related to an aluminium alloy product produced by this method.

Abstract: The invention relates to a wrought 7xxx-series aluminium alloy product having a composition comprising, in wt. %, Zn 6.40 to 7.50, Mg 2.15 to 2.75, Cu 1.20 to 2.00, and wherein Cu+Mg<4.50, and wherein Mg<2.5+5/3(Cu?1.2), Fe up to 0.25, Si up to 0.25, and optionally one or more elements selected from the group consisting of: (Zr up to 0.3, Cr up to 0.3, Mn up to 0.45, Ti up to 0.25, Sc up to 0.5, Ag up to 0.5), the balance being aluminium and impurities, and having been aged to achieve a conventional tensile yield strength (in MPa) measured in the L-direction measured at quarter thickness of more than 485?0.

Abstract: Provided herein is a rolled composite aerospace product comprising a 2XXX-series core layer and an Al—Cu alloy clad layer coupled to at least one surface of the 2XXX-series core layer, wherein the Al—Cu alloy is an aluminium alloy comprising about 0.06% to 2.8% Cu, and preferably about 0.10% to 1.8% Cu. The rolled composite aerospace product is ideally suitable for structural aerospace parts. Also described herein is a method of manufacturing a rolled composite aerospace product.

Abstract: Described herein is an aging process of a solution-heat-treated and quenched 2XXX-series aluminum alloy wrought product, comprising the steps of: (1) aging the product in a first aging step at one or more temperatures within a range of 90° C. to 120° C. for a cumulative period of time of at least 10 hours; and (2) subsequently aging the product in a second aging step at one or more temperatures within a range of 150° C. to 205° C. for a cumulative period of time of at least 4 hours. The wrought aluminum alloy can be processed to various product forms, e.g., sheet, thin plate, thick plate, extruded or forged products.

Abstract: The invention relates to a rolled composite aerospace product comprising a 2XXX-series core layer and a 6XXX-series aluminium alloy clad layer coupled to at least one surface of the 2XXX-series core layer, wherein the 6XXX-series aluminium alloy comprises, in wt. %, Si 0.3% to 1.0%, Mg 0.3% to 1.1%, Mn 0.04% to 1.0%, Fe 0.03% to 0.4%, Cu up to 0.10%, Cr up to 0.25%, V up to 0.2%, Zr up to 0.2%, Zn up to 0.5%, Ti up to 0.15%, unavoidable impurities each <0.05%, total <0.15%, balance aluminium. The invention further relates to a method of manufacturing such a rolled composite aerospace product.

Abstract: The invention relates to a wrought 7xxx-series aluminium alloy product having a composition comprising, in wt. %., Zn 6.20 to 7.50, Mg 2.15 to 2.75, Cu 1.20 to 2.00, and wherein Cu+Mg<4.50, and wherein Mg<2.5+5/3(Cu-1.2), Fe up to 0.25, Si up to 0.25, and optionally one or more elements selected from the group consisting of: (Zrup to 0.3,Crup to 0.3,Mnup to 0.45,Tiup to 0.25, Scup to 0.5, Agup to 0.5), the balance being aluminium and impurities.

Abstract: Provided herein is a rolled composite aerospace product comprising a 2XXX-series core layer and an Al—Cu alloy clad layer coupled to at least one surface of the 2XXX-series core layer, wherein the Al—Cu alloy is an aluminium alloy comprising about 0.06% to 2.8% Cu, and preferably about 0.10% to 1.8% Cu. The rolled composite aerospace product is ideally suitable for structural aerospace parts. Also described herein is a method of manufacturing a rolled composite aerospace product.

Abstract: Described herein is a method of manufacturing an aluminium alloy rolled product of a heat-treatable aluminium alloy, comprising: semi-continuous casting a heat-treatable aluminium alloy into a rolling ingot; homogenizing of the rolling ingot to a peak metal temperature (PMT) and whereby said aluminium alloy has a specific energy associated with a DSC signal less than 2 J/g in absolute value; hot rolling of the rolling ingot in multiple hot rolling steps into a hot rolled product having a final rolling gauge of at least 1 mm, whereby the hot rolled product during at least one of the last three rolling steps has a temperature less than 50° C. below PMT; quenching of the hot rolled product at final rolling gauge from hot-mill exit temperature to below 175° C.; optionally stress relieving and ageing of the quenched and optionally stress relieved hot rolled product.

Abstract: The invention relates to a method for the heat treatment of a moving aluminium alloy strip, the aluminium strip has an upper-surface and a lower-surface, the method comprising moving the aluminium strip over at least two rotating heating rolls, wherein the heating rolls comprises an outer-surface, such that a surface of the aluminium strip is in heat-transfer contact with the outer-surface of the heating rolls to induce heat into the aluminium strip to heat the aluminium strip at an annealing temperature, and comprising moving the aluminium alloy strip over a first rotating heating roll followed by moving the aluminium strip over a second rotating heating roll such that alternating the upper-surface and the lower-surface of the aluminium strip are in heat-transfer contact with the outer-surface of the rotating heating rolls.

Abstract: The invention relates to a rolled composite aerospace product comprising a 2XXX-series core layer and a 6XXX-series aluminium alloy clad layer coupled to at least one surface of the 2XXX-series core layer, wherein the 6XXX-series aluminium alloy comprises, in wt. %, Si 0.3% to 1.0%, Mg 0.3% to 1.1%, Mn 0.04% to 1.0%, Fe 0.03% to 0.4%, Cu up to 0.10%, Cr up to 0.25%, V up to 0.2%, Zr up to 0.2%, Zn up to 0.5%, Ti up to 0.15%, unavoidable impurities each <0.05%, total <0.15%, balance aluminium. The invention further relates to a method of manufacturing such a rolled composite aerospace product.

Abstract: The invention relates to a rolled composite aerospace product comprising a 2XXX-series core layer and an Al—Mg alloy clad layer coupled to at least one surface of the 2XXX-series core layer, wherein the Al—Mg alloy is a 5XXX-series aluminium alloy comprising 0.4% to 4.8% Mg, and preferably 0.7% to 4.5% Mg.

Abstract: The invention relates to a rolled composite aerospace product (10) comprising a 2XXX-series core layer (20), preferably an AA2024-series aluminium alloy, and an Al—Mn alloy layer (30) coupled to at least one surface of the 2XXX-series core layer, and wherein the Al—Mn alloy layer (30) is of a 3XXX-series aluminium alloy comprising 0.3% to 2.0% Mn.

Abstract: The invention relates to a wrought 7xxx-series aluminium alloy product having a composition comprising, in wt. %., Zn 6.40 to 7.50, Mg 2.15 to 2.75, Cu 1.20 to 2.00, and wherein Cu+Mg<4.50, and wherein Mg<2.5+5/3(Cu?1.2), Fe up to 0.25, Si up to 0.25, and optionally one or more elements selected from the group consisting of: (Zr up to 0.3, Cr up to 0.3, Mn up to 0.45, Ti up to 0.25, Sc up to 0.5, Ag up to 0.5), the balance being aluminium and impurities, and having been aged to achieve a conventional tensile yield strength (in MPa) measured in the L-direction measured at quarter thickness of more than 485?0.

Abstract: A method of producing an integrated monolithic aluminum structure, comprising: providing an aluminum alloy plate with a thickness of at least 38.1 mm, wherein the plate is a 2xxx-series alloy in a T3-temper and has a composition comprising, in wt. %: Cu 3.8-4.5, Mn 0.3-0.8, Mg 1.1-1.6, Si up to 0.15, Fe up to 0.20, Cr up to 0.10, Zn up to 0.25, Ti up to 0.15, Ag up to 0.10, balance aluminum; optionally pre-machining the plate to an intermediate machined structure; high-energy hydroforming the plate or intermediate structure against a rigid die forming surface having a desired curvature contour of the integrated monolithic aluminum structure, causing the plate or the intermediate structure to conform to the forming surface contour; machining or mechanical milling the high-energy formed structure to a near-final or final machined integrated monolithic aluminum structure; ageing the final integrated monolithic aluminum structure to a desired temper.

Abstract: A method of manufacturing an AA2xxx-series aluminium alloy plate product having improved fatigue failure resistance and a reduced number of flaws, the method comprising the following steps (a) casting an ingot of an aluminium alloy of the 2xxx-series, the aluminium alloy comprising (in wt. %): Cu 1.9 to 7.0, Mg 0.3 to 1.8, Mn up to 1.2, balance aluminium and impurities, each 0.05 max., total 0.15; (b) homogenizing and/or preheating the cast ingot; (c) hot rolling the ingot into a plate product by rolling the ingot with multiple rolling passes characterized in that, when at an intermediate thickness of the plate between 100 and 200 mm, at least one high reduction hot rolling pass is carried out with a thickness reduction of at least 15%; wherein the plate product has a final thickness of less than 60 mm. The invention is also related to an aluminium alloy product produced by this method.

Abstract: A method of producing an integrated monolithic aluminum structure, the method including the steps of: (a) providing an aluminum alloy plate with a predetermined thickness of at least 25.4 mm, wherein the aluminum alloy plate is a 7xxx-series alloy provided in a W-temper; (b) optionally pre-machining of the aluminum alloy plate to an intermediate machined structure; (c) high-energy hydroforming of the plate or optional intermediate machined structure against a forming surface of a rigid die having a contour in accordance with a desired curvature of the integrated monolithic aluminum structure, the high energy hydroforming causing the plate or the intermediate machined structure to conform to the contour of the forming surface to at least one of a uniaxial curvature and a biaxial curvature; (d) solution heat-treating and cooling of the high-energy hydroformed structure; (e) machining and (f) ageing of the final integrated monolithic aluminum structure.