CN104141077B - Wear-resistant alloy with complex microstructure - Google Patents

Wear-resistant alloy with complex microstructure Download PDF

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CN104141077B
CN104141077B CN201410269993.2A CN201410269993A CN104141077B CN 104141077 B CN104141077 B CN 104141077B CN 201410269993 A CN201410269993 A CN 201410269993A CN 104141077 B CN104141077 B CN 104141077B
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alloy
range
particles
amount
wear
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CN104141077A (en
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姜熙三
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Modern Auto Co Ltd
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Modern Auto Co Ltd
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    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • C22C21/10Alloys based on aluminium with zinc as the next major constituent

Abstract

A wear resistant alloy having a complex microstructure is provided. The microstructure includes zinc (Zn) in a range of about 28 wt% to about 38 wt%, tin (Sn) in a range of about 1 wt% to about 3 wt%, silicon (Si) in a range of about 6.2 wt% to about 9.4 wt%, and aluminum (Al) in balance.

Description

Wear-resistant alloy with complex microstructure
Technical Field
The present invention relates to aluminum alloys for vehicle parts that may require wear resistance and self-lubricity and methods of making the same. Specifically, the present invention provides an aluminum alloy having a complex microstructure comprising wear resistant particles and self-lubricating soft particles.
Background
As aluminum alloys, hypereutectic aluminum-iron (Al-Fe) alloys containing about 13.5 to about 18 or 12 wt% silicon (Si) and about 2 to about 4 wt% copper (Cu) are commonly used in the automotive industry. Since such a conventional hypereutectic Al-Fe alloy has a microstructure having primary silicon (Si) particles therein having a size of about 30 μm to about 50 μm, it may have improved wear resistance relative to a pure Al-Fe alloy, and thus, it is generally used for vehicle parts, such as a suspension fork, a rear cover, a swash plate, and the like, which may require wear resistance. Examples of commercial alloys may include: r14 alloy (produced by ryobi corporation, japan), K14 alloy similar to R14 alloy, a390 for monolithic (monoblock) or aluminum lining, and the like.
However, these hypereutectic alloys may have problems such as low castability, low impact resistance, and the like due to their high silicon content. In addition, it may be difficult to adjust the size and distribution of silicon (Si) particles, and manufacturing hypereutectic alloys may be more costly than other general aluminum alloys due to specially developed procedures.
Meanwhile, Al — Sn alloy may be another example of a self-lubricating aluminum alloy for vehicle components. The Al-Sn alloy may include about 8 wt% to about 15 wt% tin (Sn), and further include a microstructure of self-lubricating soft tin (Sn) particles that may reduce friction. Therefore, the Al — Sn alloy can be used as a base material for a metal bearing used in a high friction contact surface. However, the Al — Sn alloy may not be suitable for structural vehicle components due to low strength (e.g., about 150MPa or less), although strength may be enhanced by silicon (Si) content.
The above description provided as related art to the present invention is only for the purpose of aiding understanding of the background of the present invention and is not to be construed as being included in the related art already known to those skilled in the art.
Disclosure of Invention
The present invention can provide a technical solution to the above-mentioned problems. Accordingly, in one aspect, the present invention provides a novel high strength wear resistant alloy having a microstructure that is obtainable from hard and soft particles thereof. In particular, the novel alloy may have wear resistance from hypereutectic Al-Si and self-lubricity from Al-Sn alloys.
In one exemplary embodiment, the present invention provides a wear resistant alloy having a complex microstructure, which may include: zinc (Zn) in a range of about 28 wt% to about 38 wt%; tin (Sn) in a range of about 1 wt% to about 3 wt%; silicon (Si) in a range of about 6.2 wt% to about 9.4 wt%; and the balance aluminum (Al). The wear resistant alloy may further include copper (Cu) in a range of about 1 wt% to about 3 wt%. The wear resistant alloy may also include magnesium (Mg) in a range of about 0.3 wt% to about 0.8 wt%. In addition, the wear resistant alloy may include copper (Cu) in a range of about 1 wt% to about 3 wt% and magnesium (Mg) in a range of about 0.3 wt% to about 0.8 wt%.
In another exemplary embodiment, the present invention provides a wear resistant alloy having a complex microstructure, which may include: zinc (Zn) in a range of about 28 wt% to about 38 wt%; bismuth (Bi) in a range of about 1 wt% to about 3 wt%; silicon (Si) in a range of about 6.2 wt% to about 9.4 wt%; and the balance aluminum (Al).
Drawings
The above and other objects, features and advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
fig. 1 is an exemplary graph showing a correlation between a friction coefficient and a tin (Sn) content (wt%) or a zinc (Zn) content (wt%) in a wear-resistant alloy having a complex microstructure according to an exemplary embodiment of examples and comparative examples for soft particles.
Detailed Description
It should be understood that the term "vehicle" or "vehicular" or other similar terms as used herein include automobiles in general, such as passenger vehicles including Sport Utility Vehicles (SUVs), buses, trucks, various commercial vehicles, watercraft including a variety of boats and ships, aircraft, and the like, and include hybrid vehicles, electric vehicles, plug-in hybrid electric vehicles, hydrogen-powered vehicles, and other alternative fuel vehicles (e.g., fuels derived from resources other than petroleum). As referred to herein, a hybrid vehicle is a vehicle having two or more power sources, for example, a vehicle having gasoline power and electric power.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.
As used herein, unless otherwise indicated herein or otherwise evident from the context, the term "about" is understood to be within the normal tolerance of the art, e.g., within 2 standard deviations of the mean. "about" can be understood as being within 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, 0.1%, 0.05% or 0.01% of the stated value. Unless otherwise clear from the context, all numbers provided herein are modified by the term "about".
Hereinafter, various exemplary embodiments of the present invention will be described in detail. The present invention relates to novel alloys having complex microstructures that can contain both hard and soft particles.
In certain embodiments of the conventional aluminum alloy, the alloying elements for forming the self-lubricating particles may include tin (Sn), lead (Pb), bismuth (Bi), zinc (Zn), and the like. Since these alloying elements do not react with aluminum, intermetallic compounds are not formed and their phases can be separated. In addition, these alloying elements may have a relatively low melting point and have self-lubricity to form a lubricating film when partially melted under severe friction conditions.
Among the above four alloying elements, lead (Pb) may be the most suitable element for forming self-lubricating particles when considering both self-lubricity and cost. However, lead is prohibited for use in vehicles because it is classified as a harmful metal element. In this regard, tin (Sn) may be most widely used instead of Pb, while bismuth (Bi) may occasionally be used instead of Sn. In contrast, zinc (Zn) may be disadvantageous due to its rather high melting point and rather low self-lubricity compared to Sn and Bi. However, Zn can be added in relatively high amounts based on its lower cost. Therefore, Zn can be used to form soft particles and partially replace expensive Sn or Bi in consideration of cost competitiveness.
In addition, Si or Fe may be an alloying element for forming hard particles. Si or Fe may cause eutectic reaction with Al and form angular hard particles when added in a predetermined amount or more. In one example of an aluminum alloy, Si may form hard particles and primary silicon particles may be formed. Further, Si may provide wear resistance when added to the Al-Si binary alloy in an amount of about 12.6 wt% or more. However, when Si is added together with Zn, which is an element for forming soft particles, the Si content may vary depending on the Zn content to form hard particles. For example, when the Zn content is about 10 wt%, the Si content may be a minimum of about 7 wt% to a maximum of about 14 wt%. When the Si content is less than the minimum amount of 7 wt%, hard particles may not be formed; when the Si content is greater than the maximum amount of about 14 wt%, the size of the hard particles may be significantly increased, thereby negatively affecting mechanical properties and wear resistance.
In the Al-Fe alloy, Fe may be an impurity. However, when the Al-Fe binary alloy does not contain Si and Fe is added in an amount of about 0.5 wt% or less, wear-resistant Al-Fe intermetallic compound particles may be formed, thereby providing wear resistance to the Al-Fe alloy. In contrast, when Fe is added in an amount of about 3 wt% or more, intermetallic compound particles may be excessively formed, thereby deteriorating mechanical properties and increasing a melting point.
In addition, alloying elements used to strengthen exemplary aluminum alloys may include Cu and Mg. Cu can effectively form an intermetallic compound and improve strength by a chemical reaction of Cu with Al. The effect of Cu varies depending on the Cu content, casting/cooling conditions, or heat treatment conditions. Mg can effectively form an intermetallic compound and improve strength by a chemical reaction of Mg with Si or Zn. The effect of Mg will also vary based on Mg content, casting/cooling conditions or heat treatment conditions.
Hereinafter, the present invention will be described in detail in exemplary embodiments.
In one exemplary embodiment, the aluminum alloy may include aluminum (Al) as a main component, and further include zinc (Zn) in a range of about 28 wt% to about 38 wt%; tin (Sn) in a range of about 1 wt% to about 3 wt%; copper (Cu) in a range of about 1 wt% to about 3 wt%; magnesium (Mg) in a range of about 0.3 wt% to about 0.8 wt%; and silicon (Si) in a range of about 6.2 wt% to about 9.4 wt% for forming the hard particles. When zinc (Zn) is added in an amount of less than about 28 wt%, sufficient Zn soft particles may not be formed, and thus it may be difficult to obtain sufficient self-lubricity. When zinc (Zn) is added in an amount of more than about 38 wt%, the solidus line of the aluminum alloy may become very low, thereby deteriorating casting conditions.
In addition, tin (Sn) may have higher self-lubricity than zinc (Zn). When tin (Sn) is added in an amount of less than 1 wt%, a sufficient amount of Sn soft particles may not be formed, and thus it may be difficult to compensate for insufficient self-lubricity of Zn soft particles. When tin (Sn) is added in an amount of more than 3 wt%, the additional self-lubricating effect may be insufficient compared to the increase in cost, thereby limiting the amount thereof.
Silicon (Si) may form hard particles. When silicon (Si) is added in an amount of less than about 6.2 wt%, primary Si hard particles may not be sufficiently formed, for example, less than about 0.5 wt%, and thus it may be difficult to ensure wear resistance. When silicon (Si) is added in an amount of more than about 9.4 wt%, primary Si hard particles may be excessively formed, for example, more than about 5 wt%, and thus these hard particles may be coarsened, thereby adversely affecting wear resistance and mechanical properties.
Copper (Cu) may improve mechanical properties, and may be added in an amount of about 1 wt% or more to ensure sufficient mechanical properties. However, when copper (Cu) is added in an amount of more than 3 wt%, other elements and intermetallic compounds may be formed, so that mechanical properties of the aluminum alloy are deteriorated, and thus, the amount of copper (Cu) may be limited. Alternatively, magnesium (Mg) may be added in an amount of about 0.3 wt% or more instead of copper (Cu), and also mechanical properties of the aluminum alloy may be additionally improved. However, when magnesium (Mg) is added in an amount of about 0.8 wt%, a compound that deteriorates the mechanical characteristics of the aluminum alloy may be formed, and thus the amount of magnesium (Mg) may be limited.
The low friction characteristics of the Al-Zn-Sn alloy according to the exemplary embodiment of the present invention have been evaluated for soft particles. As shown in fig. 1, exemplary alloys of examples and comparative examples were prepared while varying the amounts of Zn and Sn, and then the friction coefficient variation of the alloys was measured. As a result, the exemplary 1Sn-28Zn alloy of the example may obtain desired low friction characteristics, for example, a friction coefficient of about 0.150 or less, at about 1 wt% Sn, while the exemplary 1Sn-26Zn alloy of the comparative example may obtain undesired results. Therefore, when Zn is added in an amount of about 28 wt% or more based on about 1 wt% or more of Sn, desired low friction characteristics may be obtained. In addition, when the amounts of Sn and Zn are increased, satisfactory low friction characteristics can be obtained. The results of the evaluation of wear resistance and mechanical properties of the exemplary Al-35Zn-1Sn-xSi alloys of the examples and comparative examples are given in Table 1 below.
TABLE 1
In the table, in the exemplary Al-35Zn-1Sn-xSi alloy of the comparative example (which may contain about 0.8 wt% of Si), Si particles in the form of hard particles may be formed in an amount of about 0.2 wt%, and thus it may be difficult to obtain sufficient wear resistance. In contrast, when Si is included in an amount of about 9.6 wt%, Si particles in the form of hard particles may be excessively formed, for example, above about 5 wt%, whereby the Si particles may be coarsened and segregated. Further, when the amount of Si is about 6.2 wt% to about 9.4 wt%, Si hard particles may be formed in an amount of about 5 wt% at the maximum, and thus sufficient wear resistance is obtained.
In addition, the strength of an exemplary Al-35Zn-1Sn-xSi alloy may range from about 350MPa to about 355MPa depending on the amount of Si, and thus such an alloy may be used as a structural material for vehicle parts. An aluminum alloy according to another exemplary embodiment of the present invention may include: zinc (Zn) in a range of about 28 wt% to about 38 wt%; bismuth (Bi) in a range of about 1 wt% to about 3 wt%; silicon (Si) in a range of about 6.2 wt% to about 9.4 wt%; the balance being aluminum (Al). Specifically, bismuth (Bi) may be used as a material having strong self-lubricity instead of tin (Sn).
As described above, the wear-resistant alloy having a complex microstructure according to the exemplary embodiment of the present invention may have both wear resistance of the hypereutectic Al-Si alloy and self-lubricity of the Al-Sn alloy, thus achieving high strength and improved wear resistance.
Although the exemplary embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.

Claims (5)

1. A wear resistant alloy having a complex microstructure comprising:
zinc (Zn) in a range of 28 wt% to 38 wt%;
tin (Sn) in a range of 1 wt% to 3 wt%;
silicon (Si) in a range of 6.2 wt% to 9.4 wt%; and
the balance of aluminum (Al),
wherein the alloy forms primary silicon particles by a eutectic reaction,
wherein the alloy has a coefficient of friction of 0.150 or less.
2. The wear resistant alloy of claim 1, further comprising copper (Cu) in a range of 1 wt% to 3 wt%.
3. The wear resistant alloy of claim 1, further comprising magnesium (Mg) in a range of 0.3 wt% to 0.8 wt%.
4. The wear resistant alloy of claim 1, further comprising copper (Cu) in a range of 1 wt% to 3 wt% and magnesium (Mg) in a range of 0.3 wt% to 0.8 wt%.
5. A wear resistant alloy having a complex microstructure comprising:
zinc (Zn) in a range of 28 wt% to 38 wt%;
bismuth (Bi) in a range of 1 to 3 wt%;
silicon (Si) in a range of 6.2 wt% to 9.4 wt%; and
the balance of aluminum (Al),
wherein the alloy forms primary silicon particles by a eutectic reaction,
wherein the alloy has a coefficient of friction of 0.150 or less.
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JP6415098B2 (en) 2018-10-31
US20140334971A1 (en) 2014-11-13
CN104141077A (en) 2014-11-12
JP2014218746A (en) 2014-11-20
KR20140132154A (en) 2014-11-17

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