Predicting the Impact of Quenching on Mechanical Properties of Complex-Shaped Aluminum Alloy Parts

The mechanical properties of age-hardenable aluminum alloy extrusions are critically dependent on the rate at which the part is cooled (quenched) after the forming operation. The present study continues the development of an intelligent spray quenching system, which selects the optimal nozzle configuration based on part geometry and composition such that the magnitude and uniformity of hardness (or yield strength) is maximized while residual stresses are minimized. The quenching of a complex-shaped part with multiple, overlapping sprays was successfully modeled using spray heat transfer correlations as boundary conditions within a finite element program. The hardness distribution of the heat-treated part was accurately predicted using the quench factor technique; that is, the metallurgical transformations that occur within the part were linked to the cooling history predicted by the finite element program. This study represents the first successful attempt at systematically predicting the mechanical properties of a quenched metallic part from knowledge of only the spray boundary conditions.