CN101365817A - A high crashworthiness al-si-mg alloy and methods for producing automotive casting - Google Patents
A high crashworthiness al-si-mg alloy and methods for producing automotive casting Download PDFInfo
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Abstract
The present invention provides a casting having increased crashworthiness including an an aluminum alloy of about 6.0 wt % to about 8.0 wt % Si; about 0.12 wt % to about 0.25 wt % Mg; less than or equal to about 0.35 wt % Cu; less than or equal to about 4.0 wt % Zn; less than or equal to about 0.6 wt % Mn; and less than or equal to about 0.15 wt % Fe, wherein the cast body is treated to a T5 or T6 temper and has a tensile strength ranging from 100 MPa to 180 MPa and has a critical fracture strain greater than 10%. The present invention further provides a method of forming a casting having increased crashworthiness.
Description
The cross reference of related application
[0001] the present invention requires the right of the U.S. Provisional Patent Application 60/731,046 submitted on October 28th, 2005, by reference with the full content of this application with openly incorporate this paper into, as elaboration fully in this article.
Invention field
[0002] the present invention relates to be suitable for the cast aluminium alloy that automobile is used.Especially, the present invention relates to have the Al-Si-Mg casting alloy of the collision performance that is suitable for the automobile application.
Background of invention
[0003] because aluminium alloy provides low density, good intensity and erosion resistance, so it is highly suitable for body frame structure for automotive.In addition, aluminium alloy can be used for improving vehicle frame rigidity and performance.In addition, it is believed that the aluminium vehicle frame keeps usually conventional steel frame vehicle design relevant intensity and the crashworthiness many with recuperation.
[0004] significant consideration of aluminium automotive body structure comprises and reduces gross combination weight and/or improve vehicle performance bonded crashworthiness.Use crashworthiness reflection vehicle bears a certain amount of collision impact under the situation of unacceptable distortion that does not suffer objective railway carriage or compartment or passenger's excessive deceleration ability for automobile.When being subjected to impacting, structure should be out of shape in the mode of regulation; The strain energy of distortion that structure absorbed is answered the kinetic energy of balance-impact; Should keep the complete of objective railway carriage or compartment; And primary structure is answered so that the minimized mode of passenger's deceleration is pushed.
[0005] demand to the higher collision performance of automobile aluminum casting parts improves greatly, particularly, include but not limited to: support, node (for example A post, B post, C post etc.), collision box (crashbox), cross member, subframe and engine support for body structure; Or the like.But, even the most frequently used cast aluminium alloy A356 also has poor extrudability under the T6 state.A sign of crashworthiness is the critical breaking strain (CFS) as the Yeh exploitation.Referring to " the The development of an Aluminum Failure Model forCrashworthiness Design " of J.R.Yeh, report number 99-016, on March 11st, 1999.Critical breaking strain (CFS) or A356-T6 are about 5-6%.Usually, collision sensing unit and the required critical breaking strain (CFS) of application are about 10% or bigger.
[0006] therefore, the cast component that needs new alloy and thermal treatment to have isostatic intensity and crashworthiness in order to manufacturing.
Summary of the invention
[0007] the invention provides the Al-Si-Mg base alloy that is suitable for gravity or low pressure permanent mold, Hpdc or sand mold casting, this alloy has tensile strength and the critical breaking strain (CFS) that is suitable for the automobile application, includes but not limited to frame part.
[0008] in one embodiment, the present invention comprises the invention Al-Si-Mg base alloy that is used for gravity or low pressure permanent mold, Hpdc, sand mold casting or similar casting technique, and wherein the foundry goods of being made by Al-Si-Mg alloy of the present invention is realizing that about 100MPa extremely is suitable for F, T5 or T6 state in the elongation of yield strength, 10% to 20% scope of about 180MPa scope and at least 10% the critical breaking strain (CFS).Widely, Al-Si-Mg alloy composition of the present invention mainly is made of following composition:
About 6.0wt% is to the Si of about 8.0wt%;
About 0.12wt% is to the Mg of about 0.25wt%;
The Cu that is less than or equal to about 0.35wt%;
The Zn that is less than or equal to about 4.0wt%;
The Mn that is less than or equal to about 0.6wt%;
The Fe that is less than or equal to about 0.15wt%; With
The aluminium of surplus and impurity.
[0009] in one embodiment of the invention, provide the Al-Si-Mg alloy to be used for vacuum head-free casting (VRC)/pressure head-free casting (PRC), permanent mold or sand mold casting, it comprises the Si of about 6.5wt% to about 7.5wt%; About 0.12wt% is to the Mg of about 0.20wt%; Less than the Mn of about 0.15wt%, preferably less than the Mn of about 0.05wt%; With the Fe less than about 0.10wt%, wherein surplus comprises Al and impurity.
[0010] in another embodiment of the invention, provide the Al-Si-Mg alloy to be used for Hpdc or Alcoa evacuated die-casting process (AVDC), and this alloy comprise the Si of about 6.5wt% to about 7.5wt%; About 0.12wt% is to the Mg of about 0.20wt%; About 0.5wt% is to the Mn of about 0.6wt%; With the Fe less than 0.10wt%, wherein surplus comprises Al and impurity.The Mn content that increases reduces the welding of casting mold in the castingprocesses, and wherein Mn content reduces the tendency that foundry goods adheres to casting mold.
[0011] in a preferred embodiment, the scope of Si content is 6.5wt% to 7.5wt%, and the scope of Mg content is that about 0.12wt% is to about .19wt%.
[0012] in another aspect of this invention in, the technology that merges Al-Si-Mg alloy composition of the present invention produces a kind of foundry goods, when casting and when handling to T5 or T6 state this foundry goods have the tensile strength suitable and greater than the critical breaking strain (CFS) of A356 with A356.A356 has the composition of Al-7Si-0.35Mg usually, and when being heat-treated to T5 or T6 state, has the tensile yield strength (TYS) of 190MPa to 240MPa and 5% to 6% critical breaking strain (CFS).
[0013] scope of target capabilities is depended in this alloy thermal treatment of technology of the present invention, and comprises natural aging, T4, T5, T6 and T7.
[0014] the foundry goods complicacy allows shape of product to reach and has the equal or higher rigidity target capabilities of steel design now.
The accompanying drawing summary
[0015] Fig. 1 has described stress-strain curve.
[0016] Fig. 2 (side-view) has described three point bending test.
[0017] Fig. 3 a-3d illustrates the pliability test sample of handling to the T5 state.
[0018] Fig. 4 a-4d illustrates the pliability test sample of handling to the T6 state.
[0019] Fig. 5 has described the graphic representation of the bending property of the high pressure die castings that is made of the aluminium alloy in the scope of the invention.
DESCRIPTION OF THE PREFERRED
[0020] the invention provides the casting alloy with the high isostatic strength that is applicable to automobile casting and crashworthiness forms.Widely, casting alloy of the present invention comprises:
The Si of 6.0wt%-8.0wt%,
The Mg of 0.12wt%-0.25wt%,
Less than the Cu of 0.35wt%,
Less than the Zn of 4.0wt%,
Mn less than 0.6wt%;
Less than the Fe of 0.15wt%,
At least a silica modifier,
At least a grain refining element and
The aluminium of surplus and impurity.
[0021] all herein component percentages all are weight percentage (wt%), unless otherwise noted.When any digital scope of the value of mentioning, these scopes should be understood to include each numeral and/or the part between described stated range minimum and the maximum value.For example, the scope of about 6.0wt% to 8.0wt%Si will clearly comprise about 6.1,6.2 and all intermediate values of 6.3wt%, reach always and comprise the Si of 8.0wt%.Term " impurity " means any pollutent of melt, comprises from the element of casting equipment leaching.The tolerable limit of impurity is less than 0.05wt% for each impurity component, and content of impurities is less than 0.15wt%.
[0022] cast aluminium alloy of the present invention has certain Mg concentration, and this Mg concentration increases critical breaking strain (CFS) when having excess silicon.Though silicon increases castability by promote high workability and low-shrinkage in casting alloy, the silicone content that increases causes silicon grain to form, and described silicon grain causes cast body to have low crashworthiness.In one embodiment, select Mg concentration of the present invention, in metallic solution, produce the Mg of suitable proportion so that in casting alloy is provided
2Si precipitate, and do not have too much precipitate to form at grain boundary place, described casting alloy produce the tensile strength that is suitable for the automobile application and more than or equal to 10% critical breaking strain (CFS) when standing precipitation-hardening.
[0023] critical breaking strain (CFS) is a value that is used for characterizing crashworthiness.CFS can be derived by engineering stress-strain curve, and described engineering stress-strain curve is produced by tested alloy sample.Can use quasistatic free bend test (ASTME190), quasistatic squeeze test, quasistatic axial compression or quasistatic three-point bending to determine stress-strain curve.
[0024] uses as stress-strain curve depicted in figure 1, can determine the engineering strain (ε under the ultimate load
m) 10, the engineering stress (δ under the ultimate load
m) 15 and crushing load under engineering stress (δ
f) 20, then the following equation of their substitutions is provided engineering refinement strain (ε
L, eng):
ε
t，eng＝ε
m，/2+(1-(ε
m，/2))x(1-(δ
f/δ
m))
[0025] uses engineering refinement strain (ε by following equation then
L, eng) derive critical breaking strain (CFS):
CFS＝-ln(1-ε
l，eng)
[0026] common, the high material of CFS value material property lower than the CFS value under gross distortion is better.Usually, when being characterised in that the CFS value is lower than 10%, existing material and alloy composition meet with serious cracking in squeeze test.
[0027] in one embodiment, crashworthiness alloy composition of the present invention comprises the Al-Si-Mg base alloy that is suitable for gravity or low pressure permanent mold or sand mold casting, and this alloy has following compositing range (all by weight percentage):
The Si of 6.0wt% to 8.0wt%,
The Mg of 0.12wt% to 0.25wt%,
Less than the Cu of 0.35wt%,
Less than the Zn of 4.0wt%,
Less than the Mn of 0.6wt% and
Fe less than 0.15wt%.
[0028] in another embodiment, crashworthiness alloy composition of the present invention comprises the Al-Si-Mg alloy that is applicable to Hpdc, wherein the weight percent of manganese can be increased to 0.55 to prevent the pressing mold welding, the possibility of alloys adhesion casting mold during the manganese content that wherein the increases reduction castingprocesses.
[0029] can increase the Cu level in the casting alloy so that increase the strength property of alloy.But, Cu content is increased to greater than 0.35wt% and may disadvantageous effect be arranged to ductility.Can increase Zn content so that reduce the susceptibility of alloy to solidification rate.Increasing that Zn content uses for the foundry goods of bigger thickness can be effective especially, and wherein, it is significantly different that foundry goods bosom part and the foundry goods of direct contact mo(U)ld face are partly compared solidification rate.
[0030] alloy composition of the present invention can also comprise Si properties-correcting agent and grain-refining agent.In one embodiment, can comprise in the above-mentioned alloy composition that content is less than or equal to the Si properties-correcting agent of 0.02wt% amount, wherein said Si properties-correcting agent is selected from Ca, Na, Sr and Sb.In one embodiment, grain-refining agent can comprise TiB2 TiB
2Or titanium carbide TiC.If as grain-refining agent, the boron concentration in the alloy can be in the scope of 0.0025wt% to 0.05wt% so with TiB2.Equally, if with titanium carbide as grain-refining agent, the carbon concentration in the alloy can be in the scope of 0.0025wt% to 0.05wt%.Typical grain-refining agent is to comprise TiC or TiB
2Aluminium alloy.
[0031] one aspect of the present invention is the method that is formed foundry goods by above-mentioned alloy composition, and this method comprises specific thermal treatment.The scope and the type of target capabilities are depended in this alloy thermal treatment, and relate to natural aging, T4, T5, T6 and T7 state.In one embodiment, T5 thermal treatment generally includes lasting 1/2 hour to 10 hours the time period of artificial aging processing under about 150 ℃ to 250 ℃ temperature.
[0032] common, T6 handles and comprises three stage processing, continues about 1/2 hour under the temperature since 450 ℃ to 550 ℃ to about 6 hours solution heat treatment.After the solution heat treatment, use air quenching, pressure air quenching, the quenching of liquid mist or liquid-immersed quenching to carry out quench treatment.Notice, as long as foundry goods does not deform or unrelieved stress is not guided to cast(ing) surface, just quench rates can be increased,, just quench rates can be reduced as long as the per-cent of perhaps staying in the supersaturated solution of separating out element is not subjected to big negative impact so that significantly reduces casting strength.After the quenching, to peak strength, wherein ag(e)ing process is with to handle to the T5 state employed ag(e)ing process similar with the foundry goods artificial aging.
[0033] T4 handles and generally includes three stage processing that are similar to T6, but the final stage in T4 handles, foundry goods is by natural aging, and in T6 thermal treatment, foundry goods is by artificial aging under the temperature that improves.More specifically, the fs of T4 processing is preferably and continues about 1/2 hour under 450 ℃ to the 550 ℃ temperature to about 6 hours solution heat treatment.After the solution heat treatment, use air quenching, pressure air quenching, the quenching of liquid mist or liquid-immersed quenching to carry out quench treatment.After the quenching, with auswittering.
[0034] T7 thermal treatment is similar to T6, and comprises solution heat treatment, quenching and ageing treatment step.With wherein carry out the T6 opposite states of artificial aging step to peak strength, the heat treated ageing treatment step of T7 continues until overaging, wherein in certain embodiments, though the overaging of foundry goods has negative impact to intensity, it advantageously improves erosion resistance.
[0035] the casting complicacy allows shape of product to reach and has the equal or higher rigidity target capabilities of steel design now.
[0036] target Al-Si-Mg alloy provides the foundry goods that is suitable for impact applications with combining of manufacture method.
[0037] in one embodiment, the vacuum head-free casting of this alloy/pressure head-free casting (VRC/PRC) provides processing parameter very flexibly, it allows any part of casting, wherein said mo(u)lded piece can have 3mm or bigger wall thickness, and its medium casting can be solid or hollow.
[0038] vacuum head-free casting (VRC)/pressure head-free casting (PRC) technology is suitable for the batch process of high integrality aluminium vapor chassis and sprung parts.VRC/PRC is a low-pressure casting process, and wherein in certain embodiments, pressure can be about 6.0Psi.In VRC/PRC, casting mold is positioned on the Sealing furnace and casting cavity is connected to melt by (one or more) feed-pipe.Exert pressure to stove by the rare gas element of application examples such as Ar melt is introduced die cavity.In the stove of VRC/PRC equipment, keep the constant melt level, avoid the reverse surge (back-surges) that in more conventional lp system, experiences sometimes.
[0039] a plurality of filling pipes (stem stalk (stalks)) provide the ideal Metal Distribution in die cavity.The a plurality of filling points that combine with close-coupled between casting mold and the bath surface allow lower metal temperature, hydrogen and oxide contaminant are minimized and provide the maximum of easy constriction zone to supply with in casting.Described a plurality of filling pipe also allows to have in the casting mold a plurality of but still die cavity independently.The thermal control of careful ordering makes that being back to the foundry goods of filling pipe from end solidifies rapidly, and described filling pipe serves as the charging rising head subsequently.
[0040] in another embodiment of the present invention, can in using, die casting utilize described alloy, and described die casting is preferably Hpdc, for example Alcoa evacuated die-casting process (AVDC).Title is the U.S. Patent No. 5 of " Vacuum Die-Casting Machine with Apparatus and Methodfor Controlling Pressure Behind the Piston ", 246, describe more going through of AVDC in 055, incorporated this patent integral body into this paper by reference.
[0041] die casting be with at a high speed and high pressure molten metal is injected the technology in preferred casting mold (pressing mold) chamber of making by high-quality steel.Under ideal conditions, metal did not solidify before the chamber was full of.
[0042] Alcoa evacuated die-casting process (AVDC) is a kind of form of Hpdc, wherein AVDC preferably finds time whole compression mold cavities and injection system (shot system) during with the melt suction spray tube (shot tube) under the vacuum at it, under high pressure melt is injected pressing mold then.AVDC significantly reduces the atmosphere in (preferably removing) injection system and the compression mold cavities.For this reason, preferably will spray and compression mold cavities system excellent sealing to avoid suction ambient air under high vacuum.Compare big at least one order of magnitude of high vacuum that the vacuum that AVDC produces may provide than typical die casting with typical die casting.If remove the atmosphere in injection system and the compression mold cavities basically, then in the filling process of chamber, can realize seldom to there not being air to mix with molten metal and to bring into wherein.
[0043] compares with the low-voltage vacuum head-free casting (VRC) that about 6Psi pressure is provided/pressure head-free casting (PRC), the big several magnitude of pressure that the high-pressure ratio VRC/PRC casting operation that AVDC produces produces, and in certain embodiments, the pressure that AVDC provides is about 10Ksi or bigger.
[0044] in one embodiment, when alloy of the present invention is used in the VRC/PRC foundry goods that can not expect, it provides the suitable bending property of foundry goods (for example AVDC foundry goods) that forms with Hpdc, and when comparing by the foundry goods of VRC/PRC preparation, the significant advantage of bending property is present in the alloy of casting by Hpdc usually.
Therefore [0045] AVDC provides the solidification rate higher than VRC/PRC usually, causes foundry goods to have littler grain-size, littler particle size and littler dendrite interval, and these all help bigger ductility and bigger bending property.By utilizing casting alloy of the present invention to obtain unexpectedly to use the VRC/PRC foundry engieering to form suitable bending property in the foundry goods, wherein Mg content is adjusted so that reduce Mg
2The Si particulate forms, simultaneously by utilizing core to reduce casting thickness so that wall thickness less than 6mm is provided, be preferably 4.0mm and be as thin as 2.0mm, as long as castability is not subjected to harmful effect.
[0046] following examples are provided in case further specify the present invention and proof by some advantages of its generation.Be not intended to limit the present invention to disclosed specific embodiment.
Embodiment 1: critical breaking strain
[0047] prepares the foundry goods of representing three kinds of alloy compositions in the alloy composition of the present invention by directional freeze casting mold and permanent mold.An example of permanent mold system comprises vacuum head-free casting/pressure head-free casting.The composition of each alloy sample of being tested is provided in the Table I, wherein by the preparation of directional freeze casting mold, sample B and C are prepared by the slush casting that the vacuum head-free casting/the pressure head-free casting utilizes core to provide wall thickness to be about 4mm under industrial scale sample A under laboratory scale.
The composition of Table I alloy
| Alloy composition | Si | Mg | Cu | Zn | Fe |
| A | 7.05 | 0.1 | 0 | 2.57 | 0.02 |
| B | 7.03 | 0.16 | 0.35 | 0 | 0.06 |
| C | 7.01 | 0.177 | 0 | 0.0025 | 0.087 |
[0048] after the casting, uses the air cooling sample.No matter it is casting technique how, equal substantially from the solidification rate of the cast structure of directional freeze casting mold and permanent mold.Then cast structure is heat-treated to F, T5 or T6 state.T5 thermal treatment comprises the artificial aging that continues 1/2 hour to 10 hours under about 150 ℃ to 250 ℃ temperature.T6 handles to comprise and continues under 450 ℃ to the 550 ℃ temperature to continue 1/2 hour to 10 hours artificial aging under extremely about 6 hours solution heat treatment in about 1/2 hour, liquid hardening and 150 ℃ to 250 ℃ temperature.After the thermal treatment, foundry goods is machined to test sample and according to ASTM B557 it is carried out tension test.(referring to ASTM B557: the aluminium of tension test deformation and casting and magnesium-alloy material).Ultimate tensile strength, yield tensile strength and the elongation of listed alloy among the recorder I then.For each alloy of listing in the Table I provides stress-strain curve, can determine critical breaking strain (CFS) thus.Then critical breaking tenacity (CFS), ultimate breaking strength (UTS), tensile yield strength (TYS) and elongation are recorded in the Table II.
The tensile property of Table II alloy and CFS
| Alloy | Experimental scale | State | TYS(MPa) | UTS(MPa) | E(％) | CFS(％) | |
| A | The laboratory | T5 | 122 | 204 | 18 | - | |
| B | The laboratory | T5 | 150 | 232 | 10 | - | |
| C | Factory | F | 90 | 200 | 14 | - | |
| | Factory | T5 | 144 | 218 | 10 | 7 | |
| | Factory | T5 | 110 | 190 | 14 | 10 | |
| C | Factory | T6 | 166 | 256 | 14 | 14 | |
| | Factory | T6 | 135 | 227 | 16 | 24 | |
| | Factory | T6 | 180 | 270 | 10 | 9 |
[0049] result shows the suitable combination that can come to realize at the Al-Si-Mg alloy that is used for the automobile application intensity and crashworthiness by control alloy composition and thermal treatment.In alloy of the present invention, observe high ductibility and high critical breaking strain usually.T5 and T6 state all increase the intensity of alloy.But when comparing with the T5 state, to increase the reduction of observed ductility and critical fracture toughness property slower along with intensity in the T6 state.
Example II: the visual inspection of crackle in the pliability test
[0050], it is handled to T5 and T6 state carry out pliability test and crackle visual inspection then then with preparing the VRC/PRC foundry goods as alloy composition C listed in the Table I.Foundry goods be by the preparation of (VRC)/(PRC) foundry engieering as mentioned above and use core so that the wall thickness of about 4.0mm to be provided.The thermal treatment explanation of describing among heat treated temperature of T5 and T6 and the embodiment 1 is similar.Change the heat treatment period section so that test bending property for the change intensity of particular alloy.Table III shows casting sample and thermal treatment.
The composition of Table III alloy and state
| Sample | Experimental scale | State | TYS(MPa) | CFS(％) | |
| 1 | | T5 | 144 | 7 | |
| 2 | | T5 | 110 | 10 | |
| 3 | | T6 | 135 | 24 | |
| 4 | | T6 | 180 | 9 |
[0051] sample 1 and 2 is handled the state to T5, wherein the aging time of sample 1 is greater than the aging time of sample 2.Sample 3 and 4 is handled the state to T6, and wherein the aging time of sample 4 is greater than the aging time of sample 3.
[0052] after the thermal treatment, sample machine is processed into test board 30a, 30b, its length is about 60mm, and width is about 30mm, and thickness is about 2mm.
[0053] also lists herein according to method measurement tensile yield strength (TYS) and the critical breaking tenacity (CFS) described among the embodiment 1 so that compare with visual pliability test.
[0054] with reference to Fig. 2, pliability test and three point bending test are similar, and wherein basic point 25 has cylindrical geometries, have wedge geometry and load nose (loading nose) 35.In mechanism, load wedge and contact (test board before the distortion represents that with Reference numeral 30a the test board after the distortion is represented with Reference numeral 30b) with the medullary ray of test board 30a, 30b, plate 30a, 30b are out of shape with respect to basic point.The distortion of test board 30a, 30b continues to the summit A1 place formation about 15 ° angle α 1 of the plate 30b of distortion with respect to the displacement D1 of plane p1, the plate 30a before described plane p1 passes summit A1 and is parallel to distortion.
[0055] after the pliability test, sample is carried out the crackle visual inspection.The showing to compare with the sample that does not show crackle of crackle is not suitable for the sample of impact applications.
[0056] with reference to Fig. 3 a and 3b, the diagram of sample 1 is provided, wherein test board is deformed into 15 ° of angles, and visible crack is arranged on the curved surface.Particularly, sample 1 comprises the alloy composition C of T5 state, and its aging time provides the TYS of about 144MPa.
[0057], provide the diagram of sample 2 to show that wherein test board is deformed into 15 ° of angles, does not have tangible visible crack on curved surface with reference to Fig. 3 c and 3d.Particularly, sample 2 comprises the alloy composition C under the T5 state, and its aging time provides the TYS of about 110MPa, wherein is used to prepare the aging time of the aging time of sample 2 less than sample 1.Comparative sample 1 and 2 increased TYS though show to increase aging time, thereby also increased crackle the crashworthiness that reduces takes place to cause.
[0058], provide the diagram of sample 3 to show that wherein test board is deformed into 15 ° of angles, does not have tangible visible crack on curved surface with reference to Fig. 4 a and 4b.Particularly, sample 3 comprises the alloy composition C under the T6 state, and its aging time provides the TYS of about 135MPa.
[0059], provide the diagram of sample 4 to show that wherein test board is deformed into 15 ° of angles, and visible crack is arranged on curved surface with reference to Fig. 4 c and 4d.Particularly, sample 4 comprises the alloy composition C under the T6 state, and its aging time provides the TYS of about 180MPa, wherein is used to prepare the aging time of sample 4 greater than the aging time that is used to prepare sample 3.Comparative sample 3 and 4 is though show that increasing aging time has increased TYS, has reduced crashworthiness.
[0060] be also noted that in the pliability test process crackle and less than having dependency between 10% the critical breaking strain.Particularly,, notice, find visible crack in less than 10% alloy and heat treated pliability test being characterized as critical breaking strain, such as sample 1 and 4 with reference to Table III, Fig. 3 a-3d and Fig. 4 a-4d.
EXAMPLE III: the bending property of Hpdc and vacuum head-free casting (VRC)/pressure head-free casting (PRC) relatively
[0061] use the preparation of vacuum head-free casting/pressure head-free casting and Hpdc to represent the test sample of alloy composition of the present invention.Go forward side by side line bend test of test board 30a, 30b is heat-treated, is machined to test sample.Alloy composition is made of the Mn of the Mg of the Si of about 9.0-10.0wt%, about 0.2wt%, about 0.5-0.6wt% and the aluminium and the impurity of surplus.
[0062] use core casting VRC/PRC test sample so that the wall thickness of about 4.0mm is provided.The thickness of die casting test sample is about 2.5mm.
[0063] test sample that forms with the VRC/PRC casting technique is heat-treated the state to T6.T6 handles and is included in the artificial aging that continues about 1/2 hour to 6 hours solution heat treatment, liquid hardening under 450 ℃ to the 550 ℃ temperature and continue 1/2 hour to 10 hours under 150 ℃ to 250 ℃ temperature.
[0064] also the test sample that uses Hpdc to form is heat-treated to peak strength, comprise higher slightly aging temp, be about 250 ℃ to 300 ℃.After the thermal treatment, test sample is machined to test board 30a, the 30b of the about 2.0mm of thickness.
[0065] VRC/PRC foundry goods and high pressure die castings are carried out pliability test.With reference to Fig. 2, pliability test and three point bending test are similar, and wherein basic point 25 has cylindrical geometries, load nose 35 and have wedge geometry.In mechanism, load the medullary ray of nose 35 contact test plate 30a, 30b, test board 30a, 30b are out of shape with respect to basic point.The distortion of test board 30a, 30b continues until the generation that visually confirms crackle.When crackle takes place, be applied to the power and the bending angle of foundry goods.
[0066] power that is applied to foundry goods is by loading the power that nose 35 applies.With reference to Fig. 2, destruction angle (failure angle) is the angle a1 when visually confirming crackle.Destroy angle a1 and be from the plate 30b of distortion with respect to the summit A1 measurement of the displacement D1 of plane p1, described plane p1 passes summit A1 and is parallel to test board 30a before the distortion.The VRC/PRC foundry goods that is formed by alloy of the present invention and the destruction angle a1 and the power of high pressure die castings are recorded in the Table IV.
Table IV: the comparison of Hpdc and VRC/PRC bending property
| Sample | Power (N) | Destroy the angle | Castmethod |
| 1 | 1386 | 44 | VRC/PRC |
| 2 | 1369 | 46 | VRC/PRC |
| 3 | 986 | 52 | VRC/PRC |
| 4 | 895 | 51 | VRC/ |
| 5 | 1018 | 53 | Hpdc |
| 6 | 1044 | 54 | |
| 7 | 1039 | 50 | Hpdc |
| 8 | 1039 | 53 | |
| 9 | 1059 | 53 | |
| 10 | 882 | 45 | Hpdc |
| 11 | 813 | 40 | Hpdc |
| 12 | 1008 | 51 | Hpdc |
| 13 | 928 | 48 | Hpdc |
| 14 | 940 | 47 | Hpdc |
[0067] as shown in Table IV, the bending property of the bending property of VRC/PRC foundry goods and high pressure die castings is suitable.Particularly, the destruction angle of the VRC/PRC foundry goods of record (sample 1-4 number) is 44-52 °, and the destruction angle of the high pressure die castings of record (sample 6-14 number) is 40-54 °.
[0068] Fig. 5 has described the graphic representation of the bending property of the high pressure die castings sample that writes down (sample 6-14 number) in the diagram demonstration Table IV, wherein the y axle is drawn the power (N) that applies by loading nose 35, and displacement (mm) expression is by the displacement of the power that loads nose in the generation of place, test board 30b summit.Each data line of drawing is represented test sample, and wherein for clarity sake, data line is shifted along the x axle.Region representation on every curve causes the power and the displacement of visible crack in BENDING PROCESS, the region representation under every curve does not cause the power and the displacement of visible crack.
[0069] though the present invention has been shown particularly and it has been described according to its preferred embodiment, but it will be apparent to those skilled in that, can under the situation that does not break away from the spirit and scope of the present invention, can make aforementioned in form and details and other change.Therefore intention is to the invention is not restricted to definite form and the details that institute describes and illustrates, but falls within the scope of the appended claims.
Claims (21)
1. Al-Si-Mg alloy of the present invention, it comprises:
About 6.0wt% is to the Si of about 8.0wt%;
About 0.12wt% is to the Mg of about 0.25wt%;
The Cu that is less than or equal to about 0.35wt%;
The Zn that is less than or equal to about 4.0wt%;
The Mn that is less than or equal to about 0.6wt%;
The Fe that is less than or equal to about 0.15wt%; With
The aluminium of surplus and impurity.
2. Al-Si-Mg alloy as claimed in claim 1 also comprises at least a silica modifier that is less than or equal to the 0.02wt% amount, and wherein said at least a silica modifier comprises Ca, Na, Sr, Sb or its combination.
3. Al-Si-Mg alloy as claimed in claim 1 also comprises the grain-refining agent that is less than or equal to the 0.1wt% amount, and wherein said at least a grain-refining agent comprises TiB
2Or TiC.
4. Al-Si-Mg alloy as claimed in claim 1, wherein the scope of Mn content is 0.5wt% to 0.6wt%.
5. Al-Si-Mg alloy as claimed in claim 1, wherein the scope of Si content is 6.5wt% to 7.5wt%, and the scope of Mg content is that 0.12wt% is to about 0.19wt%.
6. foundry goods, it comprises:
The cast body that comprises the alloy composition of following composition:
About 6.0wt% is to the Si of about 8.0wt%;
About 0.12wt% is to the Mg of about 0.25wt%;
The Cu that is less than or equal to about 0.35wt%;
The Zn that is less than or equal to about 4.0wt%;
The Mn that is less than or equal to about 0.6wt%; With
The Fe that is less than or equal to about 0.15wt%.
7. foundry goods as claimed in claim 6, wherein said cast body are in F, T5, T6 or T7 state, and have the tensile strength in 100MPa to the 180MPa scope, and have the critical breaking strain greater than 10%.
8. foundry goods as claimed in claim 6, the elongation of wherein said cast body equals 10% to 20%.
9. foundry goods as claimed in claim 6, wherein said alloy composition also comprise at least a Si properties-correcting agent that is less than or equal to the 0.02wt% amount, and wherein said at least a Si properties-correcting agent comprises Ca, Na, Sr, Sb or its combination.
10. foundry goods as claimed in claim 6, wherein said alloy composition also comprise at least a grain-refining agent that amount is less than or equal to 0.1wt%, and wherein said at least a grain-refining agent is selected from Ti, B and C.
11. foundry goods as claimed in claim 6, wherein said cast body has the plate geometrical shape, and wherein said cast body does not demonstrate visible crack when being deformed into 15 degree angles in three point test.
12. a castmethod comprises:
Melt with the alloy composition that comprises following composition is provided:
About 6.0wt% is to the Si of about 8.0wt%;
About 0.12wt% is to the Mg of about 0.25wt%;
The Cu that is less than or equal to about 0.35wt%;
The Zn that is less than or equal to about 4.0wt%;
The Mn that is less than or equal to about 0.6wt%; With
The Fe that is less than or equal to about 0.15wt%;
Described melt casting is become cast body; With
Described cast body is heat-treated.
13. comprising, method as claimed in claim 12, wherein said thermal treatment handle to F, T5, T6 or T7 state.
14. method as claimed in claim 12, wherein said handle to be included in to the T5 state carry out artificial aging under about 150 ℃ to 250 ℃ temperature and continue about 1/2 hour to about 10 hours time period.
15. method as claimed in claim 13, the wherein said processing to carrying out solution heat treatment under the T6 state is included in 450 ℃ to 550 ℃ temperature continues about 1/2 hour to about 6 hours time period, quench and artificial aging to peak strength.
16. being included in to handle under about 150 ℃ to 250 ℃ temperature, method as claimed in claim 13, wherein said artificial aging to peak strength continue about 1/2 hour to about 10 hours time period.
17. method as claimed in claim 13, the wherein said processing to carrying out solution heat treatment under the T7 state is included in 450 ℃ to 550 ℃ temperature continues about 1/2 hour to about 6 hours period, quenches and artificial overaging.
18. method as claimed in claim 13 also comprises by the AVDC method and casting.
19. method as claimed in claim 13, wherein Mn content is less than 0.15wt%, and comprises by vacuum head-free casting/pressure head-free casting and casting.
20. method as claimed in claim 19 also comprises and utilizes core to combine so that about 6mm or littler wall thickness are provided with vacuum head-free casting/pressure head-free casting.
21. method as claimed in claim 19, wherein said cast body are in F, T5, T6 or T7 state, and have the tensile strength in 100MPa to the 180MPa scope, and have the critical breaking strain greater than 10%.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US73104605P | 2005-10-28 | 2005-10-28 | |
| US60/731,046 | 2005-10-28 | ||
| US11/553,236 | 2006-10-26 |
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