CA2968224A1 - Aluminum alloy for high-pressure vaccum die casting operations - Google Patents
Aluminum alloy for high-pressure vaccum die casting operations Download PDFInfo
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Abstract
The present disclosure concerns aluminum alloys which can be used in high pressure vacuum die casting operations, aluminum products comprising same and process using same. The aluminum alloy comprises, in weight percent:
between about 5.0 and less than 8.0 of Si;
between about 0.3 and about 0.6 of Mn;
between about 0.1 to about 0.6 Mg;
between about 0.003 to about 0.03 Sr;
between about 0.03 to about 0.15 Zr;
up to about 0.20 Fe;
up to about 0.10 Ti;
up to about 0.15 Mo; and the balance being aluminum and unavoidable impurities.
between about 5.0 and less than 8.0 of Si;
between about 0.3 and about 0.6 of Mn;
between about 0.1 to about 0.6 Mg;
between about 0.003 to about 0.03 Sr;
between about 0.03 to about 0.15 Zr;
up to about 0.20 Fe;
up to about 0.10 Ti;
up to about 0.15 Mo; and the balance being aluminum and unavoidable impurities.
Description
ALUMINUM ALLOY FOR HIGH-PRESSURE VACUUM DIE CASTING OPERATIONS
TECHNOLOGICAL FIELD
The present disclosure concerns aluminum alloy amenable for high pressure vacuum die casting operations.
BACKGROUND
High pressure vacuum die casting allows the manufacturing of aluminum products which can be larger, thinner and have a more complex shape. High pressure vacuum die casting is thus increasingly used, especially in the automotive industry. Once cast, aluminum products often require a heat treatment to improve their tensile properties (ultimate tensile strength, yield strength, elongation), which is costly and can cause distortion in the final product (especially if the shape of the product is complex).
It would thus be desirable to be provided with an aluminum alloy that can be used for high pressure vacuum die casting operations which would not require a heat treatment to exhibit acceptable tensile properties. It would further be desirable that the aluminum alloy improve one or more tensile properties, such as the quality index, in the resulting product.
BRIEF SUMMARY
The present disclosure concerns to the use of Zr, optionally in combination with Mo, in aluminum alloys to improve the quality index of an aluminum product comprising same and made by high pressure vacuum die casting operations.
In a first aspect, the present disclosure provides an aluminum alloy suitable for high-pressure vacuum die casting operations. The aluminum alloy comprises, in weight percent:
between about 5.0 and less than 8.0 of Si;
between about 0.3 and about 0.6 of Mn;
between about 0.1 to about 0.6 Mg;
between about 0.003 to about 0.03 Sr;
between about 0.03 to about 0.15 Zr;
up to about 0.20 Fe;
up to about 0.10 Ti;
up to about 0.15 Mo; and the balance being aluminum and unavoidable impurities.
In an embodiment, the aluminum alloy comprises between about 6.0 to about 7.5 Si. In another embodiment, the aluminum alloy comprises between about 0.45 to about 0.60 Mn.
In still
TECHNOLOGICAL FIELD
The present disclosure concerns aluminum alloy amenable for high pressure vacuum die casting operations.
BACKGROUND
High pressure vacuum die casting allows the manufacturing of aluminum products which can be larger, thinner and have a more complex shape. High pressure vacuum die casting is thus increasingly used, especially in the automotive industry. Once cast, aluminum products often require a heat treatment to improve their tensile properties (ultimate tensile strength, yield strength, elongation), which is costly and can cause distortion in the final product (especially if the shape of the product is complex).
It would thus be desirable to be provided with an aluminum alloy that can be used for high pressure vacuum die casting operations which would not require a heat treatment to exhibit acceptable tensile properties. It would further be desirable that the aluminum alloy improve one or more tensile properties, such as the quality index, in the resulting product.
BRIEF SUMMARY
The present disclosure concerns to the use of Zr, optionally in combination with Mo, in aluminum alloys to improve the quality index of an aluminum product comprising same and made by high pressure vacuum die casting operations.
In a first aspect, the present disclosure provides an aluminum alloy suitable for high-pressure vacuum die casting operations. The aluminum alloy comprises, in weight percent:
between about 5.0 and less than 8.0 of Si;
between about 0.3 and about 0.6 of Mn;
between about 0.1 to about 0.6 Mg;
between about 0.003 to about 0.03 Sr;
between about 0.03 to about 0.15 Zr;
up to about 0.20 Fe;
up to about 0.10 Ti;
up to about 0.15 Mo; and the balance being aluminum and unavoidable impurities.
In an embodiment, the aluminum alloy comprises between about 6.0 to about 7.5 Si. In another embodiment, the aluminum alloy comprises between about 0.45 to about 0.60 Mn.
In still
2 another embodiment, the aluminum alloy comprises between about 0.15 and about 0.3 Mg. In yet another embodiment, the aluminum alloy comprises between about 0.005 to about 0.02 Sr.
In still another embodiment, the aluminum alloy comprises between about 0.05 and about 0.15 Zr. In yet another embodiment, the aluminum alloy comprises between about 0.08 to about 0.20 Fe. In yet a further embodiment, the aluminum alloy comprises between about 0.03 and about 0.10 Ti. In still another embodiment, the aluminum alloy comprises between about 0.05 and about 0.15 Mo.
In a second aspect, the present application provides a foundry ingot comprising the aluminum alloy described herein for making an aluminum product with a high pressure vacuum die casting operation.
In a third aspect, the present application provides an aluminum cast product comprising the aluminum alloy described herein or made from the foundry ingot described herein.
In a fourth aspect, the present application provides a process for improving the quality index of an aluminum product comprising a modified aluminum alloy when compared to a corresponding aluminum product comprising a first aluminum alloy. The process comprises combining Zr with the first aluminum alloy to provide the modified aluminum alloy, wherein the first aluminum alloy comprises, in weight percent:
between about 5.0 and less than 8.0 of Si;
between about 0.3 and about 0.6 of Mn;
between about 0.1 to about 0.6 Mg;
between about 0.003 to about 0.03 Sr;
up to about 0.20 Fe;
up to about 0.10 Ti;
up to about 0.15 Mo; and the balance being aluminum and unavoidable impurities;
The weight percent of Zr in the modified aluminum alloy is higher than about 0.03 and equal to and lower than about 0.15. In an embodiment, the improved tensile property is yield strength. In an embodiment, the modified aluminum alloy comprises between about 6.0 and about 7.5 Si. In still another embodiment, the modified aluminum alloy comprises between about 0.45 and about 0.60 of Mn. In yet another embodiment, the modified aluminum alloy comprises between about 0.15 and about 0.3 Mg. In a further embodiment, the modified aluminum alloy comprises between about 0.005 to about 0.02 Sr. In still another embodiment, the modified aluminum alloy comprises between about 0.05 and about 0.15 Zr. In yet a further embodiment, the modified aluminum alloy comprises between about 0.08 to about 0.20 Fe. In still another embodiment, =
In still another embodiment, the aluminum alloy comprises between about 0.05 and about 0.15 Zr. In yet another embodiment, the aluminum alloy comprises between about 0.08 to about 0.20 Fe. In yet a further embodiment, the aluminum alloy comprises between about 0.03 and about 0.10 Ti. In still another embodiment, the aluminum alloy comprises between about 0.05 and about 0.15 Mo.
In a second aspect, the present application provides a foundry ingot comprising the aluminum alloy described herein for making an aluminum product with a high pressure vacuum die casting operation.
In a third aspect, the present application provides an aluminum cast product comprising the aluminum alloy described herein or made from the foundry ingot described herein.
In a fourth aspect, the present application provides a process for improving the quality index of an aluminum product comprising a modified aluminum alloy when compared to a corresponding aluminum product comprising a first aluminum alloy. The process comprises combining Zr with the first aluminum alloy to provide the modified aluminum alloy, wherein the first aluminum alloy comprises, in weight percent:
between about 5.0 and less than 8.0 of Si;
between about 0.3 and about 0.6 of Mn;
between about 0.1 to about 0.6 Mg;
between about 0.003 to about 0.03 Sr;
up to about 0.20 Fe;
up to about 0.10 Ti;
up to about 0.15 Mo; and the balance being aluminum and unavoidable impurities;
The weight percent of Zr in the modified aluminum alloy is higher than about 0.03 and equal to and lower than about 0.15. In an embodiment, the improved tensile property is yield strength. In an embodiment, the modified aluminum alloy comprises between about 6.0 and about 7.5 Si. In still another embodiment, the modified aluminum alloy comprises between about 0.45 and about 0.60 of Mn. In yet another embodiment, the modified aluminum alloy comprises between about 0.15 and about 0.3 Mg. In a further embodiment, the modified aluminum alloy comprises between about 0.005 to about 0.02 Sr. In still another embodiment, the modified aluminum alloy comprises between about 0.05 and about 0.15 Zr. In yet a further embodiment, the modified aluminum alloy comprises between about 0.08 to about 0.20 Fe. In still another embodiment, =
3 the modified aluminum alloy comprises between about 0.03 and about 0.10 Ti. In yet another embodiment, the modified aluminum alloy comprises between about 0.05 and about 0.15 Mo. In an embodiment, the aluminum product is a cast product and the process further comprises submitting the modified aluminum alloy to high pressure vacuum die casting to make the cast aluminum product. The present disclosure provides an aluminum product obtainable or obtained by the process described herein.
In a sixth aspect, the present disclosure provides a process for making an aluminum product having an improved quality index. The process comprising working the aluminum alloy described herein or the foundry ingot described herein in the aluminum product. In an embodiment, the aluminum product is a cast product and the process further comprises submitting the aluminum alloy to high pressure vacuum die casting to make the cast product.
The disclosure also provides an aluminum product obtainable or obtained by the process described herein.
In the context of the present disclosure, the term "about" means that the recited numerical value is part of a range that varies within standard experimental error.
BRIEF DESCRIPTION OF THE DRAWINGS
Having thus generally described the nature of the invention, reference will now be made to the accompanying drawing, showing by way of illustration, a preferred embodiment thereof, and in which:
Fig. 1 provides the various characteristics of the tested alloys. Results are shown as the strength (in MPa; = = mean ultimate tensile strength; = = mean yield strength, X = mean quality index) or the elongation ( Yo , A = mean elongation) of the tested alloys (1st row of the X axis), depending on their post-cast treatment (2nd row of the X axis, F = temper or as cast, T5 = T5 treatment). Each data point represents the mean value of 8 different samples.
DETAILED DESCRIPTION
The present disclosure concerns to the use of Zr, optionally in combination with Mo, in aluminum alloys to increase the strength, without substantially decreasing the elongation (e.g., improving the quality index), of an aluminum product comprising same and made by high pressure vacuum die casting (HPVDC) operations. The aluminum alloys of the present disclosure are thus amenable to HPVDC operations. As it is known in the art, die casting operations involve melting and heating solid metals, such as aluminum alloys, to a desired temperature and adding the molten alloy to a mold with proper shape. High pressure vacuum die casting operations also involve applying a vacuum to the mold to remove the air and eliminate oxidation/gas entrapment during filing and forcing the entry of the melted/heated aluminum alloy with a piston. As such, aluminum alloys being submitted to high pressure vacuum die casting operations must be amenable to conditions encountered during these
In a sixth aspect, the present disclosure provides a process for making an aluminum product having an improved quality index. The process comprising working the aluminum alloy described herein or the foundry ingot described herein in the aluminum product. In an embodiment, the aluminum product is a cast product and the process further comprises submitting the aluminum alloy to high pressure vacuum die casting to make the cast product.
The disclosure also provides an aluminum product obtainable or obtained by the process described herein.
In the context of the present disclosure, the term "about" means that the recited numerical value is part of a range that varies within standard experimental error.
BRIEF DESCRIPTION OF THE DRAWINGS
Having thus generally described the nature of the invention, reference will now be made to the accompanying drawing, showing by way of illustration, a preferred embodiment thereof, and in which:
Fig. 1 provides the various characteristics of the tested alloys. Results are shown as the strength (in MPa; = = mean ultimate tensile strength; = = mean yield strength, X = mean quality index) or the elongation ( Yo , A = mean elongation) of the tested alloys (1st row of the X axis), depending on their post-cast treatment (2nd row of the X axis, F = temper or as cast, T5 = T5 treatment). Each data point represents the mean value of 8 different samples.
DETAILED DESCRIPTION
The present disclosure concerns to the use of Zr, optionally in combination with Mo, in aluminum alloys to increase the strength, without substantially decreasing the elongation (e.g., improving the quality index), of an aluminum product comprising same and made by high pressure vacuum die casting (HPVDC) operations. The aluminum alloys of the present disclosure are thus amenable to HPVDC operations. As it is known in the art, die casting operations involve melting and heating solid metals, such as aluminum alloys, to a desired temperature and adding the molten alloy to a mold with proper shape. High pressure vacuum die casting operations also involve applying a vacuum to the mold to remove the air and eliminate oxidation/gas entrapment during filing and forcing the entry of the melted/heated aluminum alloy with a piston. As such, aluminum alloys being submitted to high pressure vacuum die casting operations must be amenable to conditions encountered during these
4 operations. For example, aluminum alloys that are submitted to high pressure vacuum die casting must avoid or limit high holding temperatures in the furnace to avoid excessive die wear, must be fluid enough to allow HPVDC operations and must avoid or limit die soldering.
One of the advantages of the aluminum alloys of the present disclosure is that, once they have been cast, the resulting aluminum products already exhibit adequate tensile properties (e.g., ultimate tensile strength, yield strength and/or elongation) and do not require a heat treatment following by a quenching treatment to improve them. As used in the context of the present disclosure, a "heat treatment" refers to a post-cast step in which the aluminum product is submitted to a temperature high enough for the Mg to return into solid solution inside the Al matrix (e.g., the solvus temperature of Mg in the Al matrix). To maintain the Mg atoms in the solid solution, a quenching step must also be performed after the heating step. For example, typical heat treatments include a heating step to a temperature at least 450 C
for at least 1 h.
Still in the context of the present disclosure, a "quenching treatment" refers to a post-cast step in which the aluminum product, which has been submitted to a heat treatment step, is cooled rapidly, usually by contacting it with air or immersing it in a liquid (e.g., such as, for example, at a rate of 4 C/sec).
The cast aluminum product of the present disclosure can be submitted to an optional aging treatment in which the aluminum alloy cast product is submitted to a temperature high enough to provide enough energy to the Mg atoms to precipitate out of the Al matrix, but below the solvus temperature of Mg in the Al matrix. Typical aging treatment do not require a subsequent quenching step. In one embodiment, the aging treatment is a T5 aging step and can, for example, include heating the cast aluminum product to a temperature of at least 150 C (but less than 450 C) for at least 1 h.
The aluminum alloys of the present disclosure comprise silicon (Si). In an embodiment, the aluminum alloys comprise, in weight percent, between about 5.0 to less than about 8.0 Si (in weight percent). It is important that the aluminum alloy of the present disclosure do not comprise less than 5.0 Si, as such low concentrations of Si would be detrimental to the flowability of the molten aluminum alloy during HPVDC operations. It is also important that the aluminum alloy of the present disclosure do not comprise 8.0 or more Si, since high concentrations of Si would be detrimental to the elongation property of a HPVDC-cast aluminum product containing same. In an embodiment, the aluminum alloys comprise at least, in weight percent, about
One of the advantages of the aluminum alloys of the present disclosure is that, once they have been cast, the resulting aluminum products already exhibit adequate tensile properties (e.g., ultimate tensile strength, yield strength and/or elongation) and do not require a heat treatment following by a quenching treatment to improve them. As used in the context of the present disclosure, a "heat treatment" refers to a post-cast step in which the aluminum product is submitted to a temperature high enough for the Mg to return into solid solution inside the Al matrix (e.g., the solvus temperature of Mg in the Al matrix). To maintain the Mg atoms in the solid solution, a quenching step must also be performed after the heating step. For example, typical heat treatments include a heating step to a temperature at least 450 C
for at least 1 h.
Still in the context of the present disclosure, a "quenching treatment" refers to a post-cast step in which the aluminum product, which has been submitted to a heat treatment step, is cooled rapidly, usually by contacting it with air or immersing it in a liquid (e.g., such as, for example, at a rate of 4 C/sec).
The cast aluminum product of the present disclosure can be submitted to an optional aging treatment in which the aluminum alloy cast product is submitted to a temperature high enough to provide enough energy to the Mg atoms to precipitate out of the Al matrix, but below the solvus temperature of Mg in the Al matrix. Typical aging treatment do not require a subsequent quenching step. In one embodiment, the aging treatment is a T5 aging step and can, for example, include heating the cast aluminum product to a temperature of at least 150 C (but less than 450 C) for at least 1 h.
The aluminum alloys of the present disclosure comprise silicon (Si). In an embodiment, the aluminum alloys comprise, in weight percent, between about 5.0 to less than about 8.0 Si (in weight percent). It is important that the aluminum alloy of the present disclosure do not comprise less than 5.0 Si, as such low concentrations of Si would be detrimental to the flowability of the molten aluminum alloy during HPVDC operations. It is also important that the aluminum alloy of the present disclosure do not comprise 8.0 or more Si, since high concentrations of Si would be detrimental to the elongation property of a HPVDC-cast aluminum product containing same. In an embodiment, the aluminum alloys comprise at least, in weight percent, about
5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7,
6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4,
7.5, 7.6, 7.7, 7.8 or 7.9 Si. In still another embodiment, the aluminum alloys comprise less than about 8.0, such as, for example at most 7.9, 7.8, 7.7, 7.6, 7.5, 7.4, 7.3, 7.2, 7.1, 7.0, 6.9, 6.8, 6.7, 6.6, 6.5, 6.4, 6.3, 6.2, 6.1, 6.0, 5.9, 5.8, 5.7, 5.6, 5.5, 5.4, 5.3, 5.2 or 5.1 Si. In still another embodiment, the aluminum alloy of the present disclosure comprises between about 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8 or 7.9 and less than about 8.0, 7.9, 7.8, 7.7, 7.6, 7.5, 7.4, 7.3, 7.2, 7.1, 7.0, 6.9, 6.8, 6.7, 6.6, 6.5, 6.4, 6.3, 6.2, 6.1, 6.0, 5.9, 5.8, 5.7, 5.6, 5.5, 5.4, 5.3, 5.2 or 5.1 Si. In another embodiment, the aluminum alloys comprise, in weight percent, between about 6.0 and about 7.5 Si. In embodiment, the aluminum alloys comprise at least, in weight percent, about 5 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3 or 7.4 Si. In still another embodiment, the aluminum alloys comprise at most about 7.5, 7.4, 7.3, 7.2, 7.1, 7.0, 6.9, 6.8, 6.7, 6.6, 6.5, 6.4, 6.3, 6.2 or 6.1 Si. In still another embodiment, the aluminum alloy of the present disclosure comprises between about 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3 or 7.4 and about 7.5, 7.4, 7.3, 7.2, 7.1, 7.0, 6.9, 6.8, 6.7, 6.6, 6.5, 6.4, 6.3, 6.2 or 6.1 Si. In yet another embodiment, the aluminum alloy of the present disclosure comprises between about 6.0 and about 7.2 Si.
The aluminum alloys of the present disclosure comprise manganese (Mn). The presence of Mn is limits the adhesion of the aluminum alloy to the mold used during HPVDC
operations and, in some embodiments, also increases strength in the corresponding aluminum product. In an embodiment, the aluminum alloys comprise between about 0.3 to about 0.6 Mn (in weight percent). It is important that the Mn content of the aluminum alloys of the present disclosure be at least 0.3 (weight percent) in order to avoid or limit die soldering. In a further embodiment, the aluminum alloys comprise at least about 0.3, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.4, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49, 0.5, 0.51, 0.52, 0.53, 0.54, 0.55, 0.56, 0.57, 0.58 or 0.59 Mn. In still another embodiment, the aluminum alloys comprise at most about 0.6, 0.59, 0.58, 0.57, 0.56, 0.55, 0.54, 0.53, 0.52, 0.51, 0.5, 0.49, 0.48, 0.47, 0.46, 0.45, 0.44, 0.43, 0.42, 0.41, 0.4, 0.39, 0.38, 0.37, 0.36, 0.35, 0.34, 0.33, 0.32 or 0.31 Mn. In yet another embodiment, the aluminum alloys comprise between about 0.3, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.4, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49, 0.5, 0.51, 0.52, 0.53, 0.54, 0.55, 0.56, 0.57, 0.58 or 0.59 and about 0.6, 0.59, 0.58, 0.57, 0.56, 0.55, 0.54, 0.53, 0.52, 0.51, 0.5, 0.49, 0.48, 0.47, 0.46, 0.45, 0.44, 0.43, 0.42, 0.41, 0.4, 0.39, 0.38, 0.37, 0.36, 0.35, 0.34, 0.33, 0.32 or 0.31 Mn. In an embodiment, the aluminum alloys comprise between about 0.45 to about 0.6 Mn. In a further embodiment, the aluminum alloys comprise at least about 0.45, 0.46, 0.47, 0.48, 0.49, 0.5, 0.51, 0.52, 0.53, 0.54, 0.55, 0.56, 0.57, 0.48 or 0.59 Mn.
In still another embodiment, the aluminum alloys comprise at most about 0.6, 0.59, 0.58, 0.57, 0.56, 0.55, 0.54, 0.53, 0.52, 0.51, 0.5, 0.49, 0.48, 0.47 or 0.46 Mn. In yet another embodiment, the aluminum alloys comprise between about 0.45, 0.46, 0.47, 0.48, 0.49, 0.5, 0.51, 0.52, 0.53, 0.54, 0.55, 0.56, 0.57, 0.48 or 0.59 and about 0.6, 0.59, 0.58, 0.57, 0.56, 0.55, 0.54, 0.53, 0.52, 0.51, 0.5, 0.49, 0.48, 0.47 or 0.46 Mn.
The aluminum alloys of the present disclosure comprise magnesium (Mg). The presence of Mg provides strength to the resulting cast product and as such it should be provided as at least 0.1 in the aluminum alloys of the present disclosure. However, the presence of Mg is also associated with a primary phase (Pi phase) with Fe which can be detrimental to strength. As such, the concentration of Mg must be limited to about 0.6 in the aluminum alloys of the present disclosure. In an embodiment, the aluminum alloys comprise between about 0.1 to about 0.6 Mg (in weight percent). In a further embodiment, the aluminum alloys comprise at least about 0.1, 0.11, 0.12, 0.13, 0.14, 0.15, 0.16, 0.17, 0.18, 0.19, 0.2, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26, 0.27, 0.28, 0.29, 0.3, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.4, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49, 0.5, 0.51, 0.52, 0.53, 0.54, 0.55, 0.56, 0.57, 0.58 or 0.59 Mg. In still another embodiment, the aluminum alloys comprise at most about 0.6, 0.59, 0.58, 0.57, 0.56, 0.55, 0.54, 0.53, 0.52, 0.51, 0.5, 0.49, 0.48, 0.47, 0.46, 0.45, 0.44, 0.43, 0.42, 0.41, 0.4, 0.39, 0.38, 0.37, 0.36, 0.35, 0.34, 0.33, 0.32, 0.31, 0.3, 0.29, 0.28, 0.27, 0.26, 0.25, 0.24, 0.23, 0.22, 0.21, 0.2, 0.19, 0.18, 0.17, 0.16, 0.15, 0.14, 0.13, 0.12 or 0.11 Mg. In yet another embodiment, the aluminum alloys comprise between about 0.1, 0.11, 0.12, 0.13, 0.14, 0.15, 0.16, 0.17, 0.18, 0.19, 0.2, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26, 0.27, 0.28, 0.29, 0.3, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.4, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49, 0.5, 0.51, 0.52, 0.53, 0.54, 0.55, 0.56, 0.57, 0.58 or 0.59 and about 0.6, 0.59, 0.58, 0.57, 0.56, 0.55, 0.54, 0.53, 0.52, 0.51, 0.5, 0.49, 0.48, 0.47, 0.46, 0.45, 0.44, 0.43, 0.42, 0.41, 0.4, 0.39, 0.38, 0.37, 0.36, 0.35, 0.34, 0.33, 0.32, 0.31, 0.3, 0.29, 0.28, 0.27, 0.26, 0.25, 0.24, 0.23, 0.22, 0.21, 0.2, 0.19, 0.18, 0.17, 0.16, 0.15, 0.14, 0.13, 0.12 or 0.11 Mg. In an embodiment, the aluminum alloys comprise between about 0.15 to about 0.3 Mg. In a further embodiment, the aluminum alloys comprise at least about 0.15, 0.16, 0.17, 0.18, 0.19, 0.2, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26, 0.27, 0.28 or 0.29 Mg. In still another embodiment, the aluminum alloys comprise at most about 0.3, 0.29, 0.28, 0.27, 0.26, 0.25, 0.24, 0.23, 0.22, 0.21, 0.2, 0.19, 0.18, 0.17 or 0.16 Mg. In yet another embodiment, the aluminum alloys comprise between about 0.15, 0.16, 0.17, 0.18, 0.19, 0.2, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26, 0.27, 0.28 or 0.29 and about 0.3, 0.29, 0.28, 0.27, 0.26, 0.25, 0.24, 0.23, 0.22, 0.21, 0.2, 0.19, 0.18, 0.17 or 0.16 Mg.
The aluminum alloy of the present disclosure comprise strontium (Sr). Sr acts as a Si-phase modifier in the aluminum alloys of the present disclosure. In an embodiment, the aluminum alloys of the present disclosure comprise between about 0.003 to about 0.03 Sr (in weight percent). In a further embodiment, the aluminum alloys comprise at least about 0.003, 0.004, 0.005, 0.006, 0.007, 0.008, 0.009, 0.01, 0.011, 0.012, 0.013, 0.014, 0.015, 0.016, 0.017, 0.018, 0.019, 0.02, 0.021, 0.022, 0.023, 0.024, 0.025, 0.026, 0.027, 0.028 or 0.029 Sr. In still another embodiment, the aluminum alloys comprise at most about 0.03, 0.029, 0.028, 0.027, 0.026, 0.025, 0.024, 0.023, 0.022, 0.021, 0.02, 0.019, 0.018, 0.017, 0.016, 0.015, 0.014, 0.013, 0.012, 0.011, 0.01, 0.009, 0.008, 0.007, 0.006, 0.005 or 0.004 Sr. In yet another embodiment, the aluminum alloys comprise between about 0.003, 0.004, 0.005, 0.006, 0.007, 0.008, 0.009, 00.1, 0.011, 0.012, 0.013, 0.014, 0.015, 0.016, 0.017, 0.018, 0.019, 0.02, 0.021, 0.022, 0.023, 0.024, 0.025, 0.026, 0.027, 0.028 or 0.029 and about 0.03, 0.029, 0.028, 0.027, 0.026, 0.025, 0.024, 0.023, 0.022, 0.021, 0.02, 0.019, 0.018, 0.017, 0.016, 0.015, 0.014, 0.013, 0.012, 0.011, 0.01, 0.009, 0.008, 0.007, 0.006, 0.005 or 0.004 Sr. In an embodiment, the aluminum alloys comprise between about 0.005 to about 0.02 Sr. In a further embodiment, the aluminum alloys comprise at least about 0.005, 0.006, 0.007, 0.008, 0.009, 0.01, 0.011, 0.012, 0.013, 0.014, 0.015, 0.016, 0.017, 0.018 or 0.019 Sr. In still another embodiment, the aluminum alloys comprise at most about 0.02, 0.019, 0.018, 0.017, 0.016, 0.015, 0.014, 0.013, 0.012, 0.011, 0.01, 0.009, 0.008, 0.007 or 0.006 Sr. In yet another embodiment, the aluminum alloys comprise between about 0.005, 0.006, 0.007, 0.008, 0.009, 0.01, 0.011, 0.012, 0.013, 0.014, 0.015, 0.016, 0.017, 0.018 or 0.019 and about 0.02, 0.019, 0.018, 0.017, 0.016, 0.015, 0.014, 0.013, 0.012, 0.011, 0.01, 0.009, 0.008, 0.007 or 0.006 Sr.
The aluminum alloys of the present disclosure comprise zirconium (Zr). As indicated herein, the presence of Zr in the aluminum alloys improve the strength (e.g., ultimate tensile strength and/or yield strength) of the corresponding cast aluminum product comprising same without substantially sacrificing its elongation properties. The deliberate addition of Zr thus improves the quality index of a HPVDC cast aluminum product comprising same. The aluminum alloys of the present disclosure comprise at most about 0.15 Zr to avoid or limit the formation of primaries and, ultimately die wear for higher holding temperature in the furnace needed for Zr level above 0.15. In an embodiment, the aluminum alloys comprise between about 0.03 and about 0.15 Zr (in weight percent). In a further embodiment, the aluminum alloys comprise at least about 0.03, 0.04, 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13 or 0.14 Zr. In still another embodiment, the aluminum alloys comprise at most about 0.15, 0.14, 0.13, 0.12, 0.11, 0.1, 0.09, 0.08, 0.07, 0.06, 0.05 or 0.04 Zr. In yet another embodiment, the aluminum alloys comprise between about 0.03, 0.04, 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13 or 0.14 and about 0.15, 0.14, 0.13, 0.12, 0.11, 0.1, 0.09, 0.08, 0.07, 0.06, 0.05 or 0.04 Zr. In an embodiment, the aluminum alloys comprise between about 0.05 to about 0.15 Zr. In a further embodiment, the aluminum alloys comprise at least about 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13 or 0.14 Zr. In still another embodiment, the aluminum alloys comprise at most about 0.15, 0.14, 0.13, 0.12, 0.11, 0.1, 0.09, 0.08, 0.07 or 0.06 Zr. In yet another embodiment, the aluminum alloys comprise between about 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13 or 0.14 and about 0.15, 0.14, 0.13, 0.12, 0.11, 0.1, 0.09, 0.08, 0.07 or 0.06 Zr.
The aluminum alloys of the present disclosure comprise iron (Fe). In the aluminum alloys of the present disclosure, Fe can be present at a weight percent of up to 0.20. In an embodiment, the aluminum alloys of the present disclosure comprise at least 0.08 Fe in order to avoid or limit die soldering. In embodiments, the weight percent of Fe in the aluminum alloys of the present disclosure is between about 0.08 to about 0.20. For example, the aluminum alloys of the present disclosure comprises between about 0.08, 0.09, 0.1, 0.11, 0.12, 0.13, 0.14, 0.15, 0.16, 0.17, 0.18 or 0.19 and about 0.20, 0.19, 0.18, 0.17, 0.16, 0.15, 0.14, 0.13, 0.12, 0.11, 0.1 or Fe.
The aluminum alloys of the present disclosure comprise manganese (Mn). The presence of Mn is limits the adhesion of the aluminum alloy to the mold used during HPVDC
operations and, in some embodiments, also increases strength in the corresponding aluminum product. In an embodiment, the aluminum alloys comprise between about 0.3 to about 0.6 Mn (in weight percent). It is important that the Mn content of the aluminum alloys of the present disclosure be at least 0.3 (weight percent) in order to avoid or limit die soldering. In a further embodiment, the aluminum alloys comprise at least about 0.3, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.4, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49, 0.5, 0.51, 0.52, 0.53, 0.54, 0.55, 0.56, 0.57, 0.58 or 0.59 Mn. In still another embodiment, the aluminum alloys comprise at most about 0.6, 0.59, 0.58, 0.57, 0.56, 0.55, 0.54, 0.53, 0.52, 0.51, 0.5, 0.49, 0.48, 0.47, 0.46, 0.45, 0.44, 0.43, 0.42, 0.41, 0.4, 0.39, 0.38, 0.37, 0.36, 0.35, 0.34, 0.33, 0.32 or 0.31 Mn. In yet another embodiment, the aluminum alloys comprise between about 0.3, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.4, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49, 0.5, 0.51, 0.52, 0.53, 0.54, 0.55, 0.56, 0.57, 0.58 or 0.59 and about 0.6, 0.59, 0.58, 0.57, 0.56, 0.55, 0.54, 0.53, 0.52, 0.51, 0.5, 0.49, 0.48, 0.47, 0.46, 0.45, 0.44, 0.43, 0.42, 0.41, 0.4, 0.39, 0.38, 0.37, 0.36, 0.35, 0.34, 0.33, 0.32 or 0.31 Mn. In an embodiment, the aluminum alloys comprise between about 0.45 to about 0.6 Mn. In a further embodiment, the aluminum alloys comprise at least about 0.45, 0.46, 0.47, 0.48, 0.49, 0.5, 0.51, 0.52, 0.53, 0.54, 0.55, 0.56, 0.57, 0.48 or 0.59 Mn.
In still another embodiment, the aluminum alloys comprise at most about 0.6, 0.59, 0.58, 0.57, 0.56, 0.55, 0.54, 0.53, 0.52, 0.51, 0.5, 0.49, 0.48, 0.47 or 0.46 Mn. In yet another embodiment, the aluminum alloys comprise between about 0.45, 0.46, 0.47, 0.48, 0.49, 0.5, 0.51, 0.52, 0.53, 0.54, 0.55, 0.56, 0.57, 0.48 or 0.59 and about 0.6, 0.59, 0.58, 0.57, 0.56, 0.55, 0.54, 0.53, 0.52, 0.51, 0.5, 0.49, 0.48, 0.47 or 0.46 Mn.
The aluminum alloys of the present disclosure comprise magnesium (Mg). The presence of Mg provides strength to the resulting cast product and as such it should be provided as at least 0.1 in the aluminum alloys of the present disclosure. However, the presence of Mg is also associated with a primary phase (Pi phase) with Fe which can be detrimental to strength. As such, the concentration of Mg must be limited to about 0.6 in the aluminum alloys of the present disclosure. In an embodiment, the aluminum alloys comprise between about 0.1 to about 0.6 Mg (in weight percent). In a further embodiment, the aluminum alloys comprise at least about 0.1, 0.11, 0.12, 0.13, 0.14, 0.15, 0.16, 0.17, 0.18, 0.19, 0.2, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26, 0.27, 0.28, 0.29, 0.3, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.4, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49, 0.5, 0.51, 0.52, 0.53, 0.54, 0.55, 0.56, 0.57, 0.58 or 0.59 Mg. In still another embodiment, the aluminum alloys comprise at most about 0.6, 0.59, 0.58, 0.57, 0.56, 0.55, 0.54, 0.53, 0.52, 0.51, 0.5, 0.49, 0.48, 0.47, 0.46, 0.45, 0.44, 0.43, 0.42, 0.41, 0.4, 0.39, 0.38, 0.37, 0.36, 0.35, 0.34, 0.33, 0.32, 0.31, 0.3, 0.29, 0.28, 0.27, 0.26, 0.25, 0.24, 0.23, 0.22, 0.21, 0.2, 0.19, 0.18, 0.17, 0.16, 0.15, 0.14, 0.13, 0.12 or 0.11 Mg. In yet another embodiment, the aluminum alloys comprise between about 0.1, 0.11, 0.12, 0.13, 0.14, 0.15, 0.16, 0.17, 0.18, 0.19, 0.2, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26, 0.27, 0.28, 0.29, 0.3, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.4, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49, 0.5, 0.51, 0.52, 0.53, 0.54, 0.55, 0.56, 0.57, 0.58 or 0.59 and about 0.6, 0.59, 0.58, 0.57, 0.56, 0.55, 0.54, 0.53, 0.52, 0.51, 0.5, 0.49, 0.48, 0.47, 0.46, 0.45, 0.44, 0.43, 0.42, 0.41, 0.4, 0.39, 0.38, 0.37, 0.36, 0.35, 0.34, 0.33, 0.32, 0.31, 0.3, 0.29, 0.28, 0.27, 0.26, 0.25, 0.24, 0.23, 0.22, 0.21, 0.2, 0.19, 0.18, 0.17, 0.16, 0.15, 0.14, 0.13, 0.12 or 0.11 Mg. In an embodiment, the aluminum alloys comprise between about 0.15 to about 0.3 Mg. In a further embodiment, the aluminum alloys comprise at least about 0.15, 0.16, 0.17, 0.18, 0.19, 0.2, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26, 0.27, 0.28 or 0.29 Mg. In still another embodiment, the aluminum alloys comprise at most about 0.3, 0.29, 0.28, 0.27, 0.26, 0.25, 0.24, 0.23, 0.22, 0.21, 0.2, 0.19, 0.18, 0.17 or 0.16 Mg. In yet another embodiment, the aluminum alloys comprise between about 0.15, 0.16, 0.17, 0.18, 0.19, 0.2, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26, 0.27, 0.28 or 0.29 and about 0.3, 0.29, 0.28, 0.27, 0.26, 0.25, 0.24, 0.23, 0.22, 0.21, 0.2, 0.19, 0.18, 0.17 or 0.16 Mg.
The aluminum alloy of the present disclosure comprise strontium (Sr). Sr acts as a Si-phase modifier in the aluminum alloys of the present disclosure. In an embodiment, the aluminum alloys of the present disclosure comprise between about 0.003 to about 0.03 Sr (in weight percent). In a further embodiment, the aluminum alloys comprise at least about 0.003, 0.004, 0.005, 0.006, 0.007, 0.008, 0.009, 0.01, 0.011, 0.012, 0.013, 0.014, 0.015, 0.016, 0.017, 0.018, 0.019, 0.02, 0.021, 0.022, 0.023, 0.024, 0.025, 0.026, 0.027, 0.028 or 0.029 Sr. In still another embodiment, the aluminum alloys comprise at most about 0.03, 0.029, 0.028, 0.027, 0.026, 0.025, 0.024, 0.023, 0.022, 0.021, 0.02, 0.019, 0.018, 0.017, 0.016, 0.015, 0.014, 0.013, 0.012, 0.011, 0.01, 0.009, 0.008, 0.007, 0.006, 0.005 or 0.004 Sr. In yet another embodiment, the aluminum alloys comprise between about 0.003, 0.004, 0.005, 0.006, 0.007, 0.008, 0.009, 00.1, 0.011, 0.012, 0.013, 0.014, 0.015, 0.016, 0.017, 0.018, 0.019, 0.02, 0.021, 0.022, 0.023, 0.024, 0.025, 0.026, 0.027, 0.028 or 0.029 and about 0.03, 0.029, 0.028, 0.027, 0.026, 0.025, 0.024, 0.023, 0.022, 0.021, 0.02, 0.019, 0.018, 0.017, 0.016, 0.015, 0.014, 0.013, 0.012, 0.011, 0.01, 0.009, 0.008, 0.007, 0.006, 0.005 or 0.004 Sr. In an embodiment, the aluminum alloys comprise between about 0.005 to about 0.02 Sr. In a further embodiment, the aluminum alloys comprise at least about 0.005, 0.006, 0.007, 0.008, 0.009, 0.01, 0.011, 0.012, 0.013, 0.014, 0.015, 0.016, 0.017, 0.018 or 0.019 Sr. In still another embodiment, the aluminum alloys comprise at most about 0.02, 0.019, 0.018, 0.017, 0.016, 0.015, 0.014, 0.013, 0.012, 0.011, 0.01, 0.009, 0.008, 0.007 or 0.006 Sr. In yet another embodiment, the aluminum alloys comprise between about 0.005, 0.006, 0.007, 0.008, 0.009, 0.01, 0.011, 0.012, 0.013, 0.014, 0.015, 0.016, 0.017, 0.018 or 0.019 and about 0.02, 0.019, 0.018, 0.017, 0.016, 0.015, 0.014, 0.013, 0.012, 0.011, 0.01, 0.009, 0.008, 0.007 or 0.006 Sr.
The aluminum alloys of the present disclosure comprise zirconium (Zr). As indicated herein, the presence of Zr in the aluminum alloys improve the strength (e.g., ultimate tensile strength and/or yield strength) of the corresponding cast aluminum product comprising same without substantially sacrificing its elongation properties. The deliberate addition of Zr thus improves the quality index of a HPVDC cast aluminum product comprising same. The aluminum alloys of the present disclosure comprise at most about 0.15 Zr to avoid or limit the formation of primaries and, ultimately die wear for higher holding temperature in the furnace needed for Zr level above 0.15. In an embodiment, the aluminum alloys comprise between about 0.03 and about 0.15 Zr (in weight percent). In a further embodiment, the aluminum alloys comprise at least about 0.03, 0.04, 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13 or 0.14 Zr. In still another embodiment, the aluminum alloys comprise at most about 0.15, 0.14, 0.13, 0.12, 0.11, 0.1, 0.09, 0.08, 0.07, 0.06, 0.05 or 0.04 Zr. In yet another embodiment, the aluminum alloys comprise between about 0.03, 0.04, 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13 or 0.14 and about 0.15, 0.14, 0.13, 0.12, 0.11, 0.1, 0.09, 0.08, 0.07, 0.06, 0.05 or 0.04 Zr. In an embodiment, the aluminum alloys comprise between about 0.05 to about 0.15 Zr. In a further embodiment, the aluminum alloys comprise at least about 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13 or 0.14 Zr. In still another embodiment, the aluminum alloys comprise at most about 0.15, 0.14, 0.13, 0.12, 0.11, 0.1, 0.09, 0.08, 0.07 or 0.06 Zr. In yet another embodiment, the aluminum alloys comprise between about 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13 or 0.14 and about 0.15, 0.14, 0.13, 0.12, 0.11, 0.1, 0.09, 0.08, 0.07 or 0.06 Zr.
The aluminum alloys of the present disclosure comprise iron (Fe). In the aluminum alloys of the present disclosure, Fe can be present at a weight percent of up to 0.20. In an embodiment, the aluminum alloys of the present disclosure comprise at least 0.08 Fe in order to avoid or limit die soldering. In embodiments, the weight percent of Fe in the aluminum alloys of the present disclosure is between about 0.08 to about 0.20. For example, the aluminum alloys of the present disclosure comprises between about 0.08, 0.09, 0.1, 0.11, 0.12, 0.13, 0.14, 0.15, 0.16, 0.17, 0.18 or 0.19 and about 0.20, 0.19, 0.18, 0.17, 0.16, 0.15, 0.14, 0.13, 0.12, 0.11, 0.1 or Fe.
8 In embodiments, the weight percent of Fe in the aluminum alloys of the present disclosure is between about 0.16 to about 0.20.
Titanium (Ti) can be included in the aluminum alloys of the present disclosure as a grain refiner.
For example, the weight percent of Ti of the aluminum alloys of the present disclosure can be up to 0.10, for example between about 0.03 and about 0.10. In an embodiment, the weight percent of Ti in the aluminum alloy can be equal to or higher than about 0.03, 0.04, 0.05, 0.06, 0.07, 0.08 or 0.09. In another embodiment, the weight percent of Ti in the aluminum alloy is equal to or less than about 0.10, 0.09, 0.08, 0.07, 0.06, 0.05 or 0.04. In yet another embodiment, the weight percent of Ti in the aluminum alloy is between about 0.03, 0.04, 0.05, 0.06, 0.07, 0.08 or 0.09 and about 0.10, 0.09, 0.08, 0.07, 0.06, 0.05 or 0.04.
The aluminum alloys of the present disclosure can optionally comprise molybdenum (Mo). As shown herein, Mo can contribute in improve the strength of a corresponding cast aluminum product, especially when such product is intended to or has been submitted to an aging step (such as, for example, a T5 aging step). When present, the weight percent of Mo can be up to 0.15 in the aluminum alloys of the present disclosure. The aluminum alloys of the present disclosure comprise at most 0.15 Mo to avoid or limit the formation of primaries and, ultimately, die wear for higher holding temperatures needed in the furnace for Mo>0.15. In an embodiment, the aluminum alloys of the present disclosure comprise between about 0.05 to about 0.15 Mo.
For example, the aluminum alloys of the present disclosure can comprise at least about 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13 or 0.14 Mo. In yet another example, the aluminum alloys of the present disclosure comprises at most about 0.15, 0.14, 0.13, 0.12, 0.11, 0.1, 0.09, 0.08, 0.07 or 0.06 Mo. In still another embodiment, the aluminum alloys of the present disclosure comprises between about 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13 or 0.14 and about 0.15, 0.14, 0.13, 0.12, 0.11, 0.1, 0.09, 0.08, 0.07 or 0.06 Mo.
In some embodiments of the aluminum alloys of the present disclosure, in order to avoid or limit the formation of a primary phase, the combined weight percent of both Fe and Mn is lower than 0.8. Otherwise stated, in some embodiments of the present disclosure, in the aluminum alloys, the relationship between Fe (in weight percent) and Mn (in weight percent) is the following:
Fe + Mn < 0.8.
In other embodiments of the aluminum alloys of the present disclosure, in order to control the sludge factor (e.g., the formation of sludge at holding temperatures) , the relationship between Fe (in weight percent), Mn (in weight percent) and Cr (if present, in weight percent) is the following:
1xFe + 2xMn + 3xCr < 1.4.
Titanium (Ti) can be included in the aluminum alloys of the present disclosure as a grain refiner.
For example, the weight percent of Ti of the aluminum alloys of the present disclosure can be up to 0.10, for example between about 0.03 and about 0.10. In an embodiment, the weight percent of Ti in the aluminum alloy can be equal to or higher than about 0.03, 0.04, 0.05, 0.06, 0.07, 0.08 or 0.09. In another embodiment, the weight percent of Ti in the aluminum alloy is equal to or less than about 0.10, 0.09, 0.08, 0.07, 0.06, 0.05 or 0.04. In yet another embodiment, the weight percent of Ti in the aluminum alloy is between about 0.03, 0.04, 0.05, 0.06, 0.07, 0.08 or 0.09 and about 0.10, 0.09, 0.08, 0.07, 0.06, 0.05 or 0.04.
The aluminum alloys of the present disclosure can optionally comprise molybdenum (Mo). As shown herein, Mo can contribute in improve the strength of a corresponding cast aluminum product, especially when such product is intended to or has been submitted to an aging step (such as, for example, a T5 aging step). When present, the weight percent of Mo can be up to 0.15 in the aluminum alloys of the present disclosure. The aluminum alloys of the present disclosure comprise at most 0.15 Mo to avoid or limit the formation of primaries and, ultimately, die wear for higher holding temperatures needed in the furnace for Mo>0.15. In an embodiment, the aluminum alloys of the present disclosure comprise between about 0.05 to about 0.15 Mo.
For example, the aluminum alloys of the present disclosure can comprise at least about 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13 or 0.14 Mo. In yet another example, the aluminum alloys of the present disclosure comprises at most about 0.15, 0.14, 0.13, 0.12, 0.11, 0.1, 0.09, 0.08, 0.07 or 0.06 Mo. In still another embodiment, the aluminum alloys of the present disclosure comprises between about 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13 or 0.14 and about 0.15, 0.14, 0.13, 0.12, 0.11, 0.1, 0.09, 0.08, 0.07 or 0.06 Mo.
In some embodiments of the aluminum alloys of the present disclosure, in order to avoid or limit the formation of a primary phase, the combined weight percent of both Fe and Mn is lower than 0.8. Otherwise stated, in some embodiments of the present disclosure, in the aluminum alloys, the relationship between Fe (in weight percent) and Mn (in weight percent) is the following:
Fe + Mn < 0.8.
In other embodiments of the aluminum alloys of the present disclosure, in order to control the sludge factor (e.g., the formation of sludge at holding temperatures) , the relationship between Fe (in weight percent), Mn (in weight percent) and Cr (if present, in weight percent) is the following:
1xFe + 2xMn + 3xCr < 1.4.
9 In yet another embodiment, some of the aluminum alloys of the present disclosure meet both of these criteria (in order to avoid or limit the formation of primaries and control the sludge factor) :
Fe + Mn <0.8 1xFe + 2xMn + 3xCr < 1.4.
The balance of the aluminum alloy of the present disclosure is aluminum (Al) and unavoidable impurities. In an embodiment, each impurity is present, in weight percent, at a maximum of about 0.05 and the total unavoidable impurities is present, in weight percent, at less than about 0.15.
The aluminum alloys of the present disclosure can be provided as foundry ingots. The ingots made from cast alloys (such as foundry ingots or ingot Ts) can be cast.
The aluminum alloys of the present disclosure can be submitted to HPVDC
operations to provide cast aluminum products. In an embodiment of the present disclosure, the cast aluminum products made from the aluminum alloys of the present disclosure by HPVDC
exhibit a higher ultimate tensile strength, a higher yield strengthõ a higher quality index and/or a higher elongation than a corresponding aluminum product, made by HPVDC, but with a different aluminum alloy.
The present disclosure also provides a process for improving the quality index of an aluminum product when compared to a control aluminum product. In the context of the present disclosure, an improvement of the quality index is indicative of a gain in strength which is substantially better than the decrease (if any) in elongation of the aluminum product (when compared to a control aluminum product). In the process, the aluminum product is made from or comprises the aluminum alloy of the present disclosure (comprising Zr as a deliberate addition) whereas the control aluminum product is made from or comprises a first aluminum alloy (lacking Zr as a deliberate addition). The process comprises adding Zr (at the weight percent described above) to a first aluminum alloy (comprising Si, Mn, Mg, Sr and optionally Fe, Ti and/or Mo, each at the weight percent described above) to provide the modified aluminum alloy (comprising Si, Mn, Mg, Sr, Zr and optionally Fe, Ti and/or Mo, each at the weight percent described above). In the context of the present disclosure, the term "aluminum product" can refer to a final cast products or to an intermediary ingot which can further be worked into a differently shaped aluminum product. As such, the process can further comprises casting the aluminum alloy in the aluminum product. In the embodiments in which the aluminum product is a cast product, the latter can be an automotive part, such as a chassis. In such embodiment, the cast product can have a width/height between about 1.5 mm to about 5 mm. The present disclosure also provides an aluminum product obtainable or obtained by the process described herewith.
The present disclosure also provides a process for making an aluminum product having an improved quality index, of an aluminum product when compared to a control aluminum product lacking a deliberate addition of Zr. The process comprises working the aluminum alloy or the modified aluminum alloy described herewith or the ingot described herewith in the aluminum 5 -- product. The working step can include casting the aluminum alloy directly into a cast product or intermediary ingots. As such, in the context of the present disclosure, the term "aluminum product" can refer to a final cast products or to an intermediary ingot which can further be worked into a differently shaped aluminum product. In embodiments in which aluminum product is a cast product, the process can also include a post-cast heat treatment, such as, for example,
Fe + Mn <0.8 1xFe + 2xMn + 3xCr < 1.4.
The balance of the aluminum alloy of the present disclosure is aluminum (Al) and unavoidable impurities. In an embodiment, each impurity is present, in weight percent, at a maximum of about 0.05 and the total unavoidable impurities is present, in weight percent, at less than about 0.15.
The aluminum alloys of the present disclosure can be provided as foundry ingots. The ingots made from cast alloys (such as foundry ingots or ingot Ts) can be cast.
The aluminum alloys of the present disclosure can be submitted to HPVDC
operations to provide cast aluminum products. In an embodiment of the present disclosure, the cast aluminum products made from the aluminum alloys of the present disclosure by HPVDC
exhibit a higher ultimate tensile strength, a higher yield strengthõ a higher quality index and/or a higher elongation than a corresponding aluminum product, made by HPVDC, but with a different aluminum alloy.
The present disclosure also provides a process for improving the quality index of an aluminum product when compared to a control aluminum product. In the context of the present disclosure, an improvement of the quality index is indicative of a gain in strength which is substantially better than the decrease (if any) in elongation of the aluminum product (when compared to a control aluminum product). In the process, the aluminum product is made from or comprises the aluminum alloy of the present disclosure (comprising Zr as a deliberate addition) whereas the control aluminum product is made from or comprises a first aluminum alloy (lacking Zr as a deliberate addition). The process comprises adding Zr (at the weight percent described above) to a first aluminum alloy (comprising Si, Mn, Mg, Sr and optionally Fe, Ti and/or Mo, each at the weight percent described above) to provide the modified aluminum alloy (comprising Si, Mn, Mg, Sr, Zr and optionally Fe, Ti and/or Mo, each at the weight percent described above). In the context of the present disclosure, the term "aluminum product" can refer to a final cast products or to an intermediary ingot which can further be worked into a differently shaped aluminum product. As such, the process can further comprises casting the aluminum alloy in the aluminum product. In the embodiments in which the aluminum product is a cast product, the latter can be an automotive part, such as a chassis. In such embodiment, the cast product can have a width/height between about 1.5 mm to about 5 mm. The present disclosure also provides an aluminum product obtainable or obtained by the process described herewith.
The present disclosure also provides a process for making an aluminum product having an improved quality index, of an aluminum product when compared to a control aluminum product lacking a deliberate addition of Zr. The process comprises working the aluminum alloy or the modified aluminum alloy described herewith or the ingot described herewith in the aluminum 5 -- product. The working step can include casting the aluminum alloy directly into a cast product or intermediary ingots. As such, in the context of the present disclosure, the term "aluminum product" can refer to a final cast products or to an intermediary ingot which can further be worked into a differently shaped aluminum product. In embodiments in which aluminum product is a cast product, the process can also include a post-cast heat treatment, such as, for example,
10 -- a T5 or T6 treatment (e.g., solution heat treatment and artificial aging steps). In the embodiments in which the aluminum product is a cast product, the latter can be an automotive part, such as a chassis. The present disclosure also provides an aluminum product obtainable or obtained by the process described herewith. In such embodiment, the cast product can have a width/height between about 1.5 mm to about 5 mm.
-- The present invention will be more readily understood by referring to the following examples which are given to illustrate the invention rather than to limit its scope.
EXAMPLE
Various alloys have been made and their elemental composition is provided in Table 1. The alloys have been submitted to high-pressure vacuum die casting and either been characterized -- "as cast" (F condition) or submitted to a T5 treatment (temper at 210 C for 2.5 h) prior to characterization.
Table 1. Elemental composition (in weight percentage) of the various alloys characterized Alloy Si Fe Mn Mg Ti Sr Zr Mo A 7.4 0.17 0.49 0.20 0.08 0.018 0.00 0.00 7.3 0.17 0.48 0.19 0.07 0.015 0.11 0.00 7.2 0.17 0.47 0.19 0.08 0.016 0.10 0.11 7.0 0.17 0.46 0.20 0.08 0.015 0.21 0.20 To evaluate the characteristics of the tested alloys on the ultimate tensile strength (UTS) and -- yield strength (YS), the tensile tests were carried out using the INSTRONO
universal testing machine with ASTM E8.
As seen on Figure 1, the addition of Zr increased the yield strength, especially after T5 temper treatment (compare alloy A to B, C or D). The combination of Zr and Mo allowed the maintenance of elongation both in as-cast product as well as those submitted to a T5 temper
-- The present invention will be more readily understood by referring to the following examples which are given to illustrate the invention rather than to limit its scope.
EXAMPLE
Various alloys have been made and their elemental composition is provided in Table 1. The alloys have been submitted to high-pressure vacuum die casting and either been characterized -- "as cast" (F condition) or submitted to a T5 treatment (temper at 210 C for 2.5 h) prior to characterization.
Table 1. Elemental composition (in weight percentage) of the various alloys characterized Alloy Si Fe Mn Mg Ti Sr Zr Mo A 7.4 0.17 0.49 0.20 0.08 0.018 0.00 0.00 7.3 0.17 0.48 0.19 0.07 0.015 0.11 0.00 7.2 0.17 0.47 0.19 0.08 0.016 0.10 0.11 7.0 0.17 0.46 0.20 0.08 0.015 0.21 0.20 To evaluate the characteristics of the tested alloys on the ultimate tensile strength (UTS) and -- yield strength (YS), the tensile tests were carried out using the INSTRONO
universal testing machine with ASTM E8.
As seen on Figure 1, the addition of Zr increased the yield strength, especially after T5 temper treatment (compare alloy A to B, C or D). The combination of Zr and Mo allowed the maintenance of elongation both in as-cast product as well as those submitted to a T5 temper
11 (compares alloy A and B to alloy C). The addition of Zr and Mo also increased the ultimate tensile strength and quality index, especially after T5 temper. The presence of Zr and Mo increases strength and improves the quality index which shows that the strength increase is not loss in the elongation.
While the invention has been described in connection with specific embodiments thereof, it will be understood that the scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.
While the invention has been described in connection with specific embodiments thereof, it will be understood that the scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.
Claims (26)
1. An aluminum alloy suitable for high-pressure vacuum die casting operations, the aluminum alloy comprising, in weight percent:
between about 5.0 and less than 8.0 of Si;
between about 0.3 and about 0.6 of Mn;
between about 0.1 to about 0.6 Mg;
between about 0.003 to about 0.03 Sr;
between about 0.03 to about 0.15 Zr;
up to about 0.20 Fe;
up to about 0.10 Ti;
up to about 0.15 Mo; and the balance being aluminum and unavoidable impurities.
between about 5.0 and less than 8.0 of Si;
between about 0.3 and about 0.6 of Mn;
between about 0.1 to about 0.6 Mg;
between about 0.003 to about 0.03 Sr;
between about 0.03 to about 0.15 Zr;
up to about 0.20 Fe;
up to about 0.10 Ti;
up to about 0.15 Mo; and the balance being aluminum and unavoidable impurities.
2. The aluminum alloy of claim 1, comprising between about 6.0 to about 7.5 Si.
3. The aluminum alloy of claim 1 or 2, comprising between about 0.45 to about 0.60 Mn.
4. The aluminum alloy of any one of claims 1 to 3, comprising between about 0.15 and about 0.3 Mg.
5. The aluminum alloy of any one of claims 1 to 4, comprising between about 0.005 to about 0.02 Sr.
6. The aluminum alloy of any one of claims 1 to 5, comprising between about 0.05 and about 0.15 Zr.
7. The aluminum alloy of any one of claims 1 to 6, comprising between about 0.08 to about 0.20 Fe.
8. The aluminum alloy of any one of claims 1 to 7, comprising between about 0.03 and about 0.10 Ti.
9. The aluminum alloy of any one of claims 1 to 8, comprising between about 0.05 and about 0.15 Mo.
10. A foundry ingot comprising the aluminum alloy of any one of claims 1 to 9 for making an aluminum product with a high pressure vacuum die casting operation.
11. An aluminum cast product comprising the aluminum alloy of any one of claims 1 to 9 or made from the foundry ingot of claim 10.
12. A process for improving the quality index of an aluminum product comprising a modified aluminum alloy when compared to a corresponding aluminum product comprising a first aluminum alloy, the process comprising combining Zr with the first aluminum alloy to provide the modified aluminum alloy, wherein the first aluminum alloy comprises, in weight percent:
between about 5.0 and less than 8.0 of Si;
between about 0.3 and about 0.6 of Mn;
between about 0.1 to about 0.6 Mg;
between about 0.003 to about 0.03 Sr;
up to about 0.20 Fe;
up to about 0.10 Ti;
up to about 0.15 Mo; and the balance being aluminum and unavoidable impurities;
wherein the weight percent of Zr in the modified aluminum alloy is higher than about 0.03 and equal to and lower than about 0.15.
between about 5.0 and less than 8.0 of Si;
between about 0.3 and about 0.6 of Mn;
between about 0.1 to about 0.6 Mg;
between about 0.003 to about 0.03 Sr;
up to about 0.20 Fe;
up to about 0.10 Ti;
up to about 0.15 Mo; and the balance being aluminum and unavoidable impurities;
wherein the weight percent of Zr in the modified aluminum alloy is higher than about 0.03 and equal to and lower than about 0.15.
13. The process of claim 12, wherein the improved tensile property is yield strength.
14. The process of claim 12 or 13, wherein the modified aluminum alloy comprises between about 6.0 and about 7.5 Si.
15. The process of any one of claims 12 to 14, wherein the modified aluminum alloy comprises between about 0.45 and about 0.60 of Mn.
16. The process of any one of claims 12 to 15, wherein the modified aluminum alloy comprises between about 0.15 and about 0.3 Mg.
17. The process of any one of claims 12 to 16, wherein the modified aluminum alloy comprises between about 0.005 to about 0.02 Sr.
18. The process of any one of claims 12 to 17, wherein the modified aluminum alloy comprises between about 0.05 and about 0.15 Zr.
19. The process of any one of claims 12 to 18, wherein the modified aluminum alloy comprises between about 0.08 to about 0.20 Fe.
20. The process of any one of claims 12 to 19, wherein the modified aluminum alloy comprises between about 0.03 and about 0.10 Ti.
21. The process of any one of claims 12 to 20, wherein the modified aluminum alloy comprises between about 0.05 and about 0.15 Mo.
22. The process of any one of claims 12 to 21, wherein the aluminum product is a cast product and the process further comprises submitting the modified aluminum alloy to high pressure vacuum die casting to make the cast aluminum product.
23. An aluminum product obtainable by the process of any one of claims 12 to 22.
24. A process for making an aluminum product having an improved quality index, the process comprising working the aluminum alloy of any one of claims 1 to 11 or the foundry ingot of claim 12 in the aluminum product.
25. The process of claim 24, wherein the aluminum product is a cast product and the process further comprises submitting the aluminum alloy to high pressure vacuum die casting to make the cast product.
26. An aluminum product obtainable by the process of claim 24 or 25.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US201662343061P | 2016-05-30 | 2016-05-30 | |
| US62/343,061 | 2016-05-30 |
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| Publication Number | Publication Date |
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| CA2968224A1 true CA2968224A1 (en) | 2017-11-30 |
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ID=60477362
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
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| CA2968224A Abandoned CA2968224A1 (en) | 2016-05-30 | 2017-05-24 | Aluminum alloy for high-pressure vaccum die casting operations |
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Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108193096A (en) * | 2017-12-11 | 2018-06-22 | 南昌大学 | A kind of hypoeutectic silumin alloy of high-strength and high ductility and preparation method thereof |
| WO2021050674A1 (en) | 2019-09-10 | 2021-03-18 | Magna International Inc. | Aluminum alloy for high pressure die casting applications |
| CN115287485A (en) * | 2022-08-10 | 2022-11-04 | 帅翼驰新材料集团有限公司 | Method for manufacturing high-pressure cast aluminum alloy with performance improved after baking |
| CN115821127A (en) * | 2022-08-10 | 2023-03-21 | 帅翼驰新材料集团有限公司 | High pressure cast aluminum alloys with improved performance after baking |
| US12024759B2 (en) | 2020-09-10 | 2024-07-02 | Magna International Inc. | Aluminum alloy for high pressure die casting applications |
-
2017
- 2017-05-24 CA CA2968224A patent/CA2968224A1/en not_active Abandoned
Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108193096A (en) * | 2017-12-11 | 2018-06-22 | 南昌大学 | A kind of hypoeutectic silumin alloy of high-strength and high ductility and preparation method thereof |
| CN108193096B (en) * | 2017-12-11 | 2020-06-16 | 南昌大学 | High-strength high-toughness hypoeutectic aluminum-silicon casting alloy and preparation method thereof |
| WO2021050674A1 (en) | 2019-09-10 | 2021-03-18 | Magna International Inc. | Aluminum alloy for high pressure die casting applications |
| EP4028564A4 (en) * | 2019-09-10 | 2023-09-13 | Magna International Inc. | Aluminum alloy for high pressure die casting applications |
| US12024759B2 (en) | 2020-09-10 | 2024-07-02 | Magna International Inc. | Aluminum alloy for high pressure die casting applications |
| CN115287485A (en) * | 2022-08-10 | 2022-11-04 | 帅翼驰新材料集团有限公司 | Method for manufacturing high-pressure cast aluminum alloy with performance improved after baking |
| CN115821127A (en) * | 2022-08-10 | 2023-03-21 | 帅翼驰新材料集团有限公司 | High pressure cast aluminum alloys with improved performance after baking |
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