Oxide coating for enhancing metal formability

Abstract

This invention discloses a metal product that is suitable for a forming process. By anodizing an oxide layer onto at least one surface of the metal product, the total amount of lubricant that is applied onto the metal product prior to being formed is reduced or eliminated. This invention also discloses a method of generating such an oxide layer onto the metal product.

1 . A method for reducing or eliminating the amount of lubricants used during a forming process comprising: 
 providing a metal product;    anodically generating an oxide layer on at least one surface of said metal product; and    forming said metal product into a shape using said forming process.    
   
   
       2 . A method for reducing or eliminating the amount of lubricants used during a forming process according to  claim 1  wherein providing a metal product, said metal product being an aluminum or an aluminum alloy.  
   
   
       3 . A method for reducing or eliminating the amount of lubricants used during a forming process according to  claim 2  wherein providing an aluminum alloy selected from the group consisting essentially of the Aluminum Association's 1XXX, 2XXX, 3XXX, 4XXX, 5XXX, 6XXX, 7XXX, or 8XXX series of aluminum alloys.  
   
   
       4 . A method for reducing or eliminating the amount of lubricants used during a forming process according to  claim 1  wherein said surface is partially or fully immersed in an electrolyte solution.  
   
   
       5 . A method for reducing or eliminating the amount of lubricants used during a forming process according to  claim 4  wherein anodizing said surface of said metal product in an electrolyte solution selected from the group consisting essentially of sulfuric acid, oxalic acid, phosphoric acid, neutral borate, and chromic acid.  
   
   
       6 . A method for reducing or eliminating the amount of lubricants used during a forming process according to  claim 1  wherein anodizing to generate an oxide layer having a thickness up to about 100 μm.  
   
   
       7 . A method of preparing a metal product for forming according to  claim 1  wherein generating an oxide layer containing tin on said surface of said metal product.  
   
   
       8 . A method for reducing or eliminating the amount of lubricants used during a forming process according to  claim 1  wherein forming said metal product using a forming process.  
   
   
       9 . A method for reducing or eliminating the amount of lubricants used during a forming process according to  claim 8  wherein forming said metal product using a forming process selected from the group consisting essentially of hot forming, cold forming, sheet forming, plate forming, forging, or extruding.  
   
   
       10 . A method for reducing or eliminating the amount of lubricants used during a forming process according to  claim 1  wherein providing a metal product, said metal product being a sheet, plate or a pre-form for an extrusion or forging process.  
   
   
       11 . A method for reducing or eliminating the amount of lubricants used during a forming process according to  claim 1  further comprising applying a lubricant onto said oxide layer prior to forming.  
   
   
       12 . A metal product suitable for forming comprising: 
 an oxide layer on at least one surface of said metal product, said oxide layer being anodically generated on said surface of said metal product prior to forming said metal product into a desired shape using a forming process.    
   
   
       13 . A metal product suitable for forming according to  claim 12  wherein said metal product is aluminum or an aluminum alloy.  
   
   
       14 . A metal product suitable for forming according to  claim 13  wherein said aluminum alloy is selected from the group consisting essentially of the Aluminum Association's 1XXX, 2XXX, 3XXX, 4XXX, 5XXX, 6XXX, 7XXX, or 8XXX series of aluminum alloys.  
   
   
       15 . A metal product suitable for forming according to  claim 12  wherein said anodizing process involves dipping or immersing said surface of said metal product in an electrolyte.  
   
   
       16 . A metal product suitable for forming according to  claim 15  wherein said electrolyte is selected from the group consisting essentially of sulfuric acid, oxalic acid, phosphoric acid, neutral borate, and chromic acid.  
   
   
       17 . A metal product suitable for forming according to  claim 12  wherein said oxide layer has a thickness up to about 100 μm.  
   
   
       18 . A metal product suitable for forming according to  claim 12  wherein said oxide layer contains tin.  
   
   
       19 . A metal product suitable for forming according to  claim 12  wherein said metal product is formed into a desired shaping using a forming process.  
   
   
       20 . A metal product suitable for forming according to  claim 19  wherein said forming process is from the group consisting essentially of hot forming, cold forming, sheet forming, plate forming, forging, or extruding.  
   
   
       21 . A metal product suitable for forming according to  claim 12  wherein said metal product is a sheet, plate or a pre-form for an extrusion or forging process.  
   
   
       22 . A metal product suitable for forming according to  claim 12  further comprising a lubricant applied onto said oxide layer prior to forming.  
   
   
       23 . A method of preparing a metal product for forming comprising: 
 providing a metal product having at least one surface; and    anodically generating an oxide layer on said surface of said metal product.