7075 Ultra-thick Aerospace Aluminum Forging Plate

7075 aluminum alloy (AMS 4045, ASTM B247) represents a premium high-strength aerospace material optimized for critical aircraft structural components. The ultra-thick forged plate variant provides exceptional strength-to-weight performance through specialized processing:

Primary Alloying Elements:

Zinc (Zn): 5.1-6.1% (primary strengthening element)

Magnesium (Mg): 2.1-2.9% (precipitation hardening)

Copper (Cu): 1.2-2.0% (strength enhancement)

Chromium (Cr): 0.18-0.28% (corrosion resistance)

Base Material:

Aluminum (Al): ≥87.1% (balance)

Controlled Impurities:

Iron (Fe): ≤0.50% max

Silicon (Si): ≤0.40% max

Manganese (Mn): ≤0.30% max

Titanium (Ti): ≤0.20% max

Ultra-Thick Forging Process:

Premium Ingot Production:

Vacuum-degassed primary aluminum

Triple filtration through ceramic filters

Direct-chill (DC) casting with controlled cooling

Homogenization Treatment:

460-480°C for 24-48 hours (thickness-dependent)

Computer-controlled thermal profiles

Surface Conditioning:

Scalping minimum 12mm per surface

Ultrasonic inspection for internal quality

Multi-directional Forging:

Initial breakdown: 410-430°C

Final forging: 360-380°C

Deformation ratio: 4:1 minimum

Multi-directional working for optimal isotropy

Solution Heat Treatment:

465-480°C for thickness-specific duration

Computer-monitored temperature uniformity

Quenching:

Polymer quenchant with controlled concentration

Agitation rate: 3-5 m/s minimum

Core cooling rate: >50°C/sec minimum

Controlled Stretching:

1.5-3.0% permanent deformation

Artificial Aging:

T651/T7351 tempers: Multi-stage aging cycle

Temperature control: ±2°C maximum deviation

All processing maintains complete traceability with digital monitoring throughout manufacturing.

Through-Thickness Performance:

Property variation <8% between surface and core (up to 250mm thickness)

Directionality ratio (L:LT:ST): 1.00:0.95:0.85 for tensile strength

Core-to-surface hardness variation: ≤10 HB maximum

Critical Processing Parameters:

Grain Structure Control:

Unrecrystallized, fibrous grain morphology

Cr-dispersoid pinning of grain boundaries

Specialized thermal profile for thick sections

Precipitate Engineering:

MgZn₂ (η/η') precipitate size: 5-15nm

Al₂CuMg (S-phase) distribution

Al₇Cu₂Fe intermetallic control

Quench Rate Optimization:

Polymer concentration: 12-18%

Agitation system: Multi-directional high-velocity flow

Minimum center cooling rate: 55°C/sec

Microstructural Characteristics:

Grain Size: ASTM 8-10 (15-30μm)

Grain Aspect Ratio: 3:1 to 5:1 (L:ST)

Recrystallized Volume Fraction: <15% maximum

Precipitate Density: >10¹⁷/cm³

Inclusion Rating: ≤0.3 per ASTM E45

*Whichever is greater

Ultra-Thick Specific Parameters:

Density: 2.81 g/cm³ (±0.02)

Weight Formula: Thickness(mm) × Width(m) × Length(m) × 2.81 = Weight(kg)

Machining Allowance: Recommend 15mm per side for critical dimensions

Ultrasonic Testing: 100% volumetric inspection per AMS-STD-2154 Class A

Heat Treatment Parameters:

Solution Heat Treatment:

Temperature: 465-480°C

Time: 1 hour per 25mm thickness (minimum)

Quench Delay: <12 seconds maximum

Artificial Aging:

T651: 120°C for 24 hours

T7351: 115°C for 6-8 hours + 175°C for 8-16 hours

Temperature Tolerance: ±2°C

Manufacturing Best Practices:

Cutting Fluids: Water-soluble coolant with pH 8.5-9.5

Chip Management: High-pressure coolant for evacuation

Fixturing: Distributed clamping to minimize distortion

Cutting Strategy: Climb milling for optimal surface finish

Residual Stress Management: Rough machine, stress relieve, finish machine

Surface Treatment Options:

Anodizing:

Type II (Sulfuric): 10-25μm

Type III (Hard): 25-75μm

Chromic: 2-8μm for maximum fatigue performance

Conversion Coatings:

Chromate per MIL-DTL-5541 Class 1A

Trivalent chromium pretreatment

Paint Systems:

High-solids epoxy primer

Polyurethane topcoat

Mechanical Surface Enhancement:

Shot peening (0.008-0.012A intensity)

Laser shock peening

Special Considerations for Ultra-Thick Sections:

Residual Stress Distribution: Through-thickness mapping required

Thermal Inertia: Slow response to temperature changes

Deep Hardenability: Consistent properties through section

Mandatory Inspection Regime:

Chemical Composition:

Optical emission spectroscopy

Verification of all major elements and impurities

Mechanical Testing:

Full tensile test (L, LT, ST directions)

K₁c fracture toughness testing

Hardness survey (25mm grid minimum)

Non-Destructive Testing:

Ultrasonic inspection per AMS-STD-2154 Class A

Penetrant inspection of critical surfaces

Microstructural Analysis:

Grain size and morphology

Inclusion rating per ASTM E45

Certification Documentation:

Material Test Report (MTR) per EN 10204 3.1/3.2

Chemical analysis certification

Mechanical properties certification

Heat treatment chart records

NDT reports with acceptance criteria

Primary Aerospace Applications:

Bulkhead structures

Wing spars and carry-through structures

Landing gear components

Fuselage frames and longerons

Thick section structural members

Upper wing skins

High-load fittings

Performance Advantages for Ultra-Thick Sections:

Uniform properties throughout thickness

Superior damage tolerance

Enhanced stress corrosion resistance in T7 tempers

Improved through-thickness strength

Superior machinability in thick sections

Consistent quality through rigorous processing controls

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