Patent ID: 8323428

Claim:
A process for forming a dispersion strengthened aluminum alloy to a shaped part comprising the steps of: (a) providing a dispersion-strengthened aluminum alloy billet having a density of at least 90% of theoretical density, the billet being formed to said density by compaction, extrusion, or pressing; and (b) impact forging said billet with a steam hammer, an impact press, or a high energy rate forming press at a temperature of at least about 275° C. to about 450° C. to produce shockwaves, wherein said impact forging step (b) consists of one or two impact forging iterations to forge the billet to conform to the shape of a forging die and thereby shape said stock into said shaped part, wherein said dispersion-strengthened aluminum alloy billet has a composition described by the formula Al bal Fe a Si b X c , wherein X is at least one element selected from the group consisting of Mn, V, Cr, Mo, W, Nb, and Ta, “a” ranges from 2.0 to 7.5 weight-%, “b” ranges from 0.5 to 3.0 weight-%, “c” ranges from 0.05 to 3.5 weight-%, and the balance is aluminum plus incidental impurities, with the proviso that the ratio [Fe+X]:Si is within the range of from about 2:1 to about 5:1.