CN110603341A - Al-Mg-Si-Mn-Fe casting alloy - Google Patents

Al-Mg-Si-Mn-Fe casting alloy Download PDF

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CN110603341A
CN110603341A CN201980002032.6A CN201980002032A CN110603341A CN 110603341 A CN110603341 A CN 110603341A CN 201980002032 A CN201980002032 A CN 201980002032A CN 110603341 A CN110603341 A CN 110603341A
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aluminum casting
casting alloy
alloy
new aluminum
alloy includes
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严新炎
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Us Co Alcoa
Alcoa USA Corp
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Us Co Alcoa
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
    • C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002—Castings of light metals
    • B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/02—Casting exceedingly oxidisable non-ferrous metals, e.g. in inert atmosphere
    • B22D21/04—Casting aluminium or magnesium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/047—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with magnesium as the next major constituent

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Continuous Casting (AREA)
  • Mold Materials And Core Materials (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)

Abstract

Novel aluminum casting (cast) alloys are disclosed. The new aluminum casting alloy generally contains from 2.5 to 5.0 wt.% Mg, from 0.70 to 2.5 wt.% Si, from 0.40 to 1.50 wt.% Mn, from 0.15 to 0.60 wt.% Fe, optionally up to 0.15 wt.% Ti, optionally up to 0.10 wt.% Sr, optionally up to 0.15 wt.% of any of Zr, Sc, Hf, V, and Cr, with the remainder being aluminum and unavoidable impurities, wherein the Mg/Si ratio (in weight percent) is from 1.7 to 3.6. The new aluminum casting alloys may be high pressure die cast, for example, to form automotive parts. The new aluminum alloy may be provided, for example, in an F or T5 temper.

Description

Al-Mg-Si-Mn-Fe casting alloy
Background
Aluminum alloys can be used in a variety of applications. For example, aluminum casting (foundry) alloys are used in several tens of industries, including, for example, the automotive industry and the consumer electronics industry.
Disclosure of Invention
The present disclosure relates generally to new aluminum casting (cast) alloys and related products. The new aluminum casting alloys generally comprise (and in some cases consist of or consist essentially of) from 2.5 wt.% to 5.0 wt.% Mg, from 0.70 wt.% to 2.5 wt.% Si, from 0.40 wt.% to 1.5 wt.% Mn, from 0.10 wt.% to 0.60 wt.% Fe, optionally up to 0.15 wt.% Ti, optionally up to 0.10 wt.% Sr, and optionally up to 0.15 wt.% of any one of Zr, Sc, Hf, V, and Cr, with the balance being aluminum and unavoidable impurities, wherein the weight ratio of magnesium to silicon (Mg/Si) is from 1.7:1 to 3.6: 1. The new aluminum casting alloys may achieve improved combinations of properties, such as improved combinations of two or more of strength, ductility, castability, die welding resistance, and quality index (quality index).
i. Composition of
As noted above, the new aluminum casting alloys generally contain from 2.5 wt.% to 5.0 wt.% Mg. In one embodiment, the new aluminum casting alloy includes not greater than 4.75 wt.% Mg. In another embodiment, the new aluminum casting alloy includes not greater than 4.60 wt.% Mg. In one embodiment, the new aluminum casting alloy includes at least 2.75 wt.% Mg. In another embodiment, the new aluminum casting alloy includes at least 3.0 wt.% Mg.
As noted above, the new aluminum casting alloys generally contain from 0.70 wt.% to 2.5 wt.% Si. In one embodiment, the new aluminum casting alloy includes at least 0.80 wt.% Si. In another embodiment, the new aluminum casting alloy includes at least 0.90 wt.% Si. In yet another embodiment, the new aluminum casting alloy includes at least 0.95 wt.% Si. In another embodiment, the new aluminum casting alloy includes at least 1.00 wt.% Si. In yet another embodiment, the new aluminum casting alloy includes at least 1.05 wt.% Si. In another embodiment, the new aluminum casting alloy includes at least 1.10 wt.% Si. In yet another embodiment, the new aluminum casting alloy includes at least 1.15 wt.% Si. In another embodiment, the new aluminum casting alloy includes at least 1.20 wt.% Si. In one embodiment, the new aluminum casting alloy includes not greater than 2.4 wt.% Si. In another embodiment, the new aluminum casting alloy includes not greater than 2.3 wt.% Si. In yet another embodiment, the new aluminum casting alloy includes not greater than 2.2 wt.% Si. In another embodiment, the new aluminum casting alloy includes not greater than 2.1 wt.% Si. In yet another embodiment, the new aluminum casting alloy includes not greater than 2.0 wt.% Si.
As noted above, the weight ratio of magnesium to silicon in the new aluminum casting alloys is generally from 1.7:1 to 3.6:1 (wt.% Mg/wt.% Si). In one embodiment, the weight ratio of magnesium to silicon in the novel aluminum casting alloy is at least 1.8: 1. In another embodiment, the weight ratio of magnesium to silicon in the novel aluminum casting alloy is at least 1.85: 1. In one embodiment, the weight ratio of magnesium to silicon in the novel aluminum casting alloy is not greater than 3.6: 1. In another embodiment, the weight ratio of magnesium to silicon in the novel aluminum casting alloy is not greater than 3.5: 1.
In one embodiment, the new aluminum casting alloys comprise magnesium and silicon in amounts sufficient to facilitate the production of crack-free cast products (e.g., crack-free high pressure die cast products). A crack-free product is a product that is sufficiently crack-free that it can be used for its intended purpose. In one embodiment, the new aluminum casting alloy includes magnesium and silicon in amounts sufficient to achieve a hot cracking propensity index (HCTI), such as any low HCTI value disclosed herein, of no greater than 0.30.
As noted above, the new aluminum casting alloys generally contain from 0.40 wt.% to 1.5 wt.% Mn. In one embodiment, the new aluminum casting alloy includes at least 0.45 wt.% Mn. In another embodiment, the new aluminum casting alloy includes at least 0.50 wt.% Mn. In yet another embodiment, the new aluminum casting alloy includes at least 0.55 wt.% Mn. In another embodiment, the new aluminum casting alloy includes at least 0.60 wt.% Mn. In one embodiment, the new aluminum casting alloy includes not greater than 1.45 wt.% Mn. In another embodiment, the new aluminum casting alloy includes not greater than 1.40 wt.% Mn. In yet another embodiment, the new aluminum casting alloy includes not greater than 1.35 wt.% Mn. In another embodiment, the new aluminum casting alloy includes not greater than 1.30 wt.% Mn. In yet another embodiment, the new aluminum casting alloy includes not greater than 1.25 wt.% Mn. In another embodiment, the new aluminum casting alloy includes not greater than 1.20 wt.% Mn.
As noted above, the new aluminum casting alloys generally contain from 0.10 wt.% to 0.60 wt.% Fe. In one embodiment, the new aluminum casting alloy includes at least 0.12 wt.% Fe. In another embodiment, the new aluminum casting alloy includes at least 0.15 wt.% Fe. In yet another embodiment, the new aluminum casting alloy includes at least 0.20 wt.% Fe. In another embodiment, the new aluminum casting alloy includes at least 0.25 wt.% Fe. In yet another embodiment, the new aluminum casting alloy includes at least 0.30 wt.% Fe. In another embodiment, the new aluminum casting alloy includes at least 0.35 wt.% Fe. In one embodiment, the new aluminum casting alloy includes not greater than 0.55 wt.% Fe. In another embodiment, the new aluminum casting alloy includes not greater than 0.50 wt.% Fe. In yet another embodiment, the new aluminum casting alloy includes not greater than 0.45 wt.% Fe.
In one embodiment, the new aluminum casting alloy includes iron and manganese in amounts sufficient to promote the formation of alpha phase grains while limiting the formation of beta phase grains. In one embodiment, the new aluminum casting alloy includes not greater than 0.012 wt.% of a β -Al5FeSi compound, at least for reasons of iron content. In another embodiment, the new aluminum casting alloy includes not greater than 0.010 wt.% of a β -Al5FeSi compound. In yet another embodiment, the new aluminum casting alloy includes not greater than 0.008 wt.% of a β -Al5FeSi compound. In another embodiment, the new aluminum casting alloy includes not greater than 0.006 wt.% of a β -Al5FeSi compound. In yet another embodiment, the new aluminum casting alloy includes not greater than 0.004 wt.% of a β -Al5FeSi compound. In another embodiment, the new aluminum casting alloy includes not greater than 0.002 wt.% of a β -Al5FeSi compound. In yet another embodiment, the new aluminum casting alloy includes not greater than 0.001 wt.% of a β -Al5FeSi compound. In another embodiment, the new aluminum casting alloy includes not greater than 0.0005 wt.% of a β -Al5FeSi compound.
In one embodiment, the new aluminum casting alloy may comprise magnesium and silicon in amounts sufficient to meet the following requirements: (0.4567 × Mg-0.5) < ═ Si < (0.4567 × Mg + 0.2).
In one embodiment, the new aluminum casting alloy may comprise magnesium, silicon, manganese, and iron in amounts sufficient to meet the following requirements:
(1) (iii) wt.% Si ≦ (0.4567 (wt.% Mg) +0.2 (wt.% Mg) +0.25 (wt.% Fe), and
(2)wt.％Si≥(0.4567*(wt.％Mg)+0.2*(wt.％Mg)+0.25*(wt.％Fe)-0.6)。
as noted above, the new aluminum casting alloys may optionally include up to 0.15 wt.% Ti. In one embodiment, the new aluminum casting alloy includes at least 0.01 wt.% Ti. In another embodiment, the new aluminum casting alloy includes at least 0.03 wt.% Ti. In yet another embodiment, the new aluminum casting alloy includes at least 0.05 wt.% Ti. In another embodiment, the new aluminum casting alloy includes at least 0.07 wt.% Ti. In one embodiment, the new aluminum casting alloy includes not greater than 0.13 wt.% Ti. In another embodiment, the new aluminum casting alloy includes not greater than 0.115 wt.% Ti. In another embodiment, the new aluminum casting alloy includes not greater than 0.10 wt.% Ti. In one embodiment, the new aluminum casting alloys include an amount of titanium sufficient to promote grain refinement while limiting/avoiding the formation of primary (primary) titanium-containing particles. In some embodiments, titanium is included as an impurity in the new aluminum casting alloy.
As indicated above, the new aluminum casting alloys may optionally contain up to 0.10 wt.% Sr. In one embodiment, the novel aluminum casting alloy comprises an amount sufficient to promoteFeeding Mg2The modification of the Si eutectic simultaneously limits/avoids the formation of strontium in the amount of primary strontium containing particles. In one embodiment, the new aluminum casting alloy includes at least 0.005 wt.% Sr. In one embodiment, the new aluminum casting alloy includes not greater than 0.08 wt.% Sr. In another embodiment, the new aluminum casting alloy includes not greater than 0.05 wt.% Sr. In some embodiments, strontium is included as an impurity in the new aluminum casting alloy.
As noted above, the new aluminum casting alloys may optionally contain up to 0.15 wt.% of any of Zr, Sc, Hf, V, and Cr. In one embodiment, the new aluminum casting alloys include zirconium, scandium, hafnium, vanadium, and/or chromium in an amount sufficient to promote solid solution strengthening while limiting/avoiding formation of primary particles comprising zirconium, scandium, hafnium, vanadium, and chromium. In one embodiment, the new aluminum casting alloy includes at least 0.01 wt.% of any of Zr, Sc, Hf, V, and Cr. In another embodiment, the new aluminum casting alloy includes at least 0.03 wt.% of any of Zr, Sc, Hf, V, and Cr. In yet another embodiment, the new aluminum casting alloy includes at least 0.05 wt.% of any of Zr, Sc, Hf, V, and Cr. In one embodiment, the new aluminum casting alloy includes not greater than 0.10 wt.% of any of Zr, Sc, Hf, V, and Cr. In some embodiments, zirconium is included as an impurity in the new aluminum casting alloy. In some embodiments, scandium is included as an impurity in the new aluminum casting alloy. In some embodiments, hafnium is included as an impurity in the new aluminum casting alloy. In some embodiments, vanadium is included as an impurity in the new aluminum casting alloy. In some embodiments, chromium is included as an impurity in the new aluminum casting alloy.
The remainder of the new aluminum casting alloy is substantially aluminum and unavoidable impurities. In an embodiment, the new aluminum casting alloy includes not greater than 0.30 wt.% of unavoidable impurities, and wherein the new aluminum casting alloy includes not greater than 0.10 wt.% of any one of the unavoidable impurities. In another embodiment, the novel aluminum casting alloy includes not greater than 0.15 wt.% of unavoidable impurities, and wherein the novel aluminum casting alloy includes not greater than 0.05 wt.% of any one of the unavoidable impurities. In yet another embodiment, the novel aluminum casting alloy includes not greater than 0.10 wt.% of unavoidable impurities, and wherein the novel aluminum casting alloy includes not greater than 0.03 wt.% of any one of the unavoidable impurities.
ii processing
The new aluminum casting alloy may be cast using any suitable casting method. In one embodiment, the new aluminum casting alloy is a direct chill casting as an ingot or billet. In another embodiment, the new aluminum casting alloy is shape cast into a shape cast product (e.g., a complex shape cast product, such as a complex automotive part). In one embodiment, the shaped cast product is an automotive structural part. In another embodiment, the shape cast product is a door frame. In another embodiment, the shape cast product is a shock tower (shock tower). In another embodiment, the shaped cast product is a channel (tunnel) structure for an automobile.
In one embodiment, the shape casting comprises high pressure die casting. In another embodiment, the shape casting comprises permanent mold casting (permanent mold casting).
The new aluminum casting alloys do not require a solution heat treatment step. Thus, the new aluminium casting alloy may be provided in a suitable temper (temper) such as an F temper or a T5 temper.
iii. Properties
As indicated above, the new aluminum casting alloys may achieve improved combinations of properties, such as improved combinations of at least two of strength, ductility, castability, resistance to die welding, and quality index. Mechanical properties may be measured according to ASTM E8 and B557 (e.g., when directionally solidified). Castability can be measured using the HCTI method described herein. Resistance to die-welding can be tested by casting the alloy.
In one embodiment, the new aluminum casting alloy achieves an ultimate tensile strength of at least 200 MPa. In another embodiment, the new aluminum casting alloy achieves an ultimate tensile strength of at least 210 MPa. In yet another embodiment, the new aluminum casting alloy achieves an ultimate tensile strength of at least 220 MPa. In another embodiment, the new aluminum casting alloy achieves an ultimate tensile strength of at least 230 MPa.
In one embodiment, the new aluminum casting alloy achieves a tensile yield strength of at least 100 MPa. In another embodiment, the novel aluminum casting alloy achieves a tensile yield strength of at least 105 MPa. In yet another embodiment, the new aluminum casting alloy achieves a tensile yield strength of at least 110 MPa. In another embodiment, the new aluminum casting alloy achieves a tensile yield strength of at least 115 MPa. In another embodiment, the new aluminum casting alloy achieves a tensile yield strength of at least 120 MPa. In another embodiment, the new aluminum casting alloy achieves a tensile yield strength of at least 125 MPa. Any of the above tensile yield strength values can be achieved using any of the above ultimate tensile strength values.
In one embodiment, the new aluminum casting alloy achieves an elongation of at least 7%. In another embodiment, the new aluminum casting alloy achieves an elongation of at least 8%. In yet another embodiment, the new aluminum casting alloy achieves an elongation of at least 9%. In another embodiment, the new aluminum casting alloy achieves an elongation of at least 10%. In yet another embodiment, the new aluminum casting alloy achieves an elongation of at least 11%. In another embodiment, the new aluminum casting alloy achieves an elongation of at least 12%. In yet another embodiment, the new aluminum casting alloy achieves an elongation of at least 13%. In another embodiment, the new aluminum casting alloy achieves an elongation of at least 14%. In yet another embodiment, the new aluminum casting alloy achieves an elongation of at least 15%. In another embodiment, the new aluminum casting alloy achieves an elongation of at least 16% or greater. Any of the above elongation values can be achieved using any of the above ultimate tensile strength or tensile yield strength values.
In one embodiment, the new aluminum casting alloy achieves an HCTI of no greater than 0.30. In another embodiment, the new aluminum casting alloy achieves an HCTI of no greater than 0.25. In yet another embodiment, the new aluminum casting alloy achieves an HCTI of no greater than 0.20. In another embodiment, the new aluminum casting alloys achieve an HCTI of no greater than 0.15 or less.
In one embodiment, the new aluminum casting alloy is pressure die welded, wherein an as-cast aluminum alloy product is removed from the die without damaging the cast product and/or adhering to the die. Die sticking (die molding) can occur during high pressure die casting, where molten aluminum is welded (mold) to the die surface. In some embodiments, the novel aluminum casting alloys described herein may be cast without welding to a die.
These and other combinations of features are disclosed in the following detailed description.
Drawings
FIG. 1 is a graph showing the silicon content versus the hot cracking propensity index for the alloy of example 1.
FIG. 2 is a graph showing the silicon content versus the hot cracking propensity index for the alloy of example 2.
FIG. 3 is a graph showing the silicon content versus the hot cracking propensity index for the alloy of example 3.
FIG. 4 is a graph showing the manganese content versus the hot cracking propensity index for the alloy of example 4.
FIG. 5a is a graph showing beta phase content (shown in wt.%) as a function of Mn and Fe content based on ICME modeling; the amount of 3.6 wt.% Mg and 1.5 wt.% Si remained constant.
FIG. 5b is a graph showing alpha phase content (shown in wt.%) as a function of Mn and Fe content based on ICME modeling; the amount of 3.6 wt.% Mg and 1.5 wt.% Si remained constant.
FIG. 6 is a graph illustrating beta phase content (shown in wt.%) as a function of Fe content based on ICME modeling; the amounts of 3.6 wt.% Mg, 1.5 wt.% Si and 0.5 wt.% Mn were kept constant.
Fig. 7a is a graph showing the ultimate tensile strength (MPa) versus iron content (wt.%) for the alloy of example 6.
Fig. 7b is a graph showing elongation (%) versus iron content (wt.%) for the alloy of example 6.
Fig. 7c is a graph showing tensile yield strength (MPa) versus iron content (wt.%) for the alloy of example 6.
Fig. 7d is a graph showing the quality index (Q in MPa) versus the iron content (wt.%) of the alloy of example 6.
FIG. 8a is a graph showing HCI (calculated thermal cracking index) as a function of Si and Mg content based on ICME modeling; the amount of Mn of 0.70 wt.% and Fe of 0.25 wt.% was kept constant.
FIG. 8b is a graph showing the non-equilibrium solidification (solid) temperature range (deg.C) as a function of Si and Mg content based on ICME modeling; the amount of Mn of 0.70 wt.% and Fe of 0.25 wt.% was kept constant.
FIG. 8c is a graph showing HCI (calculated thermal cracking index) as a function of Si and Mn content based on ICME modeling; the amount of 4.0 wt.% Mg and 0.25 wt.% Fe remains constant.
FIG. 8d is a graph showing HCI (calculated thermal cracking index) as a function of Si and Fe content based on ICME modeling; the amount of 4.0 wt.% Mg and 0.70 wt.% Mn was kept constant.
Detailed Description
Example 1
Six aluminum alloys were cast into pencil probe (pencil probe) castings. The composition of the aluminum alloys is given in table 1 below.
TABLE 1 composition of alloy of example 1 (all values are in weight percent)
Five tests were performed for each alloy and at different joint sizes. The thermal cracking results are provided in table 2 below. In the following table, "C" means cracking during casting, "OK" means casting was successful and no cracking, and "NF" means that the pencil probe pattern was not completely filled. The hot cracking propensity index ("HCTI") of each alloy was calculated from the results. Table 2 also lists the calculated HCTI for each alloy.
The hot cracking propensity index (HCTI) of an alloy is defined as
If no fracture is found on any of the connecting rods (connection rod), the HCTI value will be 0. If a crack is found in all 7 tie bars (from 4mm to 16mm), the HCTI value will be 1. Thus, for a particular alloy, a smaller HCTI indicates a higher thermal cracking resistance.
TABLE 2 thermal cracking results for the alloy of example 1
FIG. 1 shows a graph of silicon content versus measured HCTI values. As shown, alloys having from about 1 to about 2 wt.% Si achieve improved resistance to thermal cracking at similar amounts of Fe, Mn, Mg, and Ti. The Mg/Si ratio of these alloys is from about 2.0 to 3.0. Alloy a4 with 1.56 wt.% Si had a Mg to Si ratio of 2.26.
Example 2
Four additional alloys were cast according to example 1 and their hot crack sensitivity was determined. Again, the silicon content was varied as in example 1, but using lower nominal amounts of magnesium and manganese. The composition of the alloy of example 2 is shown in table 3 below. HCTI results for the alloy of example 2 are shown in the following figure. Alloy B2 showed the best resistance to thermal cracking. The Mg/Si ratio of this alloy was about 2.65.
Table 3-composition of the alloy of example 2 (all values are in weight percent)
FIG. 2 shows the experimentally measured hot cracking propensity index for an Al-2.5Mg-1.1 Mn-x% Si alloy. Alloy B2 with 0.96 wt.% Si and 2.54 wt.% Mg showed the best resistance to thermal cracking. The Mg/Si ratio of this alloy was about 2.65.
Example 3
Four additional alloys were cast according to example 1 and their hot crack sensitivity was determined. Again, the silicon content was varied as in example 1, but a higher nominal amount of magnesium and a lower nominal amount of manganese were used. The composition of the alloy of example 3 is shown in table 4 below. The HCTI results for the example 3 alloy are shown in figure 3. As shown, HCTI for all alloys was generally good. Alloy C3 with a Mg/Si ratio of 2.22 achieved the lowest HCTI.
Table 4-composition of the alloy of example 3 (all values are in weight percent)
The results of examples 1-3 indicate that the Mg/Si (weight ratio) should be from about 1.7 to about 3.6, preferably from about 2.0 to about 3.0 to promote resistance to thermal cracking.
Example 4
Four additional alloys were cast according to example 1 and their hot crack sensitivity was determined. This time, the manganese content was varied, targeting a nominal magnesium amount of 3.6 wt.% and a nominal silicon amount of 1.5 wt.%. The composition of the alloy of example 4 is shown in table 5 below. The HCTI results for the example 4 alloy are shown in fig. 4. As shown, HCTI for all alloys was generally good. Alloy D4 with Mn of 1.20 wt.% achieved the best HCTI results.
TABLE 5 composition of alloy of example 4 (all values are in weight percent)
Example 5
Four additional alloys were cast according to example 1 and their hot crack sensitivity was determined. This time, the iron content was varied, targeting a nominal magnesium amount of 3.45 wt.%, a nominal silicon amount of 1.55 wt.%, and a nominal manganese amount of 0.90 wt.%. The composition of the alloy of example 5 is shown in table 6 below. HCTI results for the alloy of example 5 are shown in the following figure. As shown, HCTI for all alloys was generally good. Alloy E4 with 0.29 wt.% Fe achieved the best HCTI results.
TABLE 6 composition of alloy of example 5 (all values are in weight percent)
These results are unexpected. Iron adversely affects the mechanical properties of Al-Si cast alloys because it exists as large primary or pseudo-primary compounds that increase hardness but decrease ductility. In view of these improved HCTI results, modeling (ICME-integrated computational material engineering) was performed. These results show that by controlling the Fe and Mn content, the formation of harmful acicular beta-Al can potentially be avoided5FeSi. FIGS. 5a, 5b and 6 show manganese and iron contents and beta-Al5FeSi and alpha-Al15FeMn3Si2Correlation between volume fractions of phase particles (for Al-3.6Mg-1.5Si alloys). Addition of Mn to Al-Mg-Si alloys can promote alpha-Al15FeMn3Si2Formation of phase and limiting or preventing beta-Al5Formation of the FeSi phase. For example, using an increased amount of iron, an Al-3.6Mg-1.5Si alloy with Mn from 0.4 to 0.6 wt.% reduces β -Al5Amount of FeSi phase. As shown in fig. 6, by increasing the iron from 0.15 wt.% to 0.4 wt.%, β -Al5The amount of FeSi phase was reduced from about 0.018 wt.% to substantially 0 wt.%. Thus, due to the increase of iron in the alloy and beta-Al5A corresponding reduction in FeSi phase may enable alloys with improved properties (e.g., elongation).
Example 6
Eight additional alloys were cast by directional solidification. The iron content of all alloys varied. The first group (F) was targeted with a nominal amount of magnesium of 3.6 wt.%, a nominal amount of silicon of 1.5 wt.%, and a nominal amount of manganese of 0.90 wt.%. The second group (G) is targeted with a nominal amount of magnesium of 4.0 wt.%, a nominal amount of silicon of 1.7 wt.%, and a nominal amount of manganese of 0.65 wt.%. The composition of the alloy of example 6 is shown in table 7 below.
TABLE 6 composition of alloy of example 5 (all values are in weight percent)
The mechanical properties of the directionally solidified alloys were tested according to ASTM E8 and B557, the results of which are provided in table 7 below. The mechanical properties of the alloy of example 5 were also tested and those results are therefore also included in table 7. A quality index (Q) is also provided. (Q ═ UTS +150 × log (elongation)). Various graphs relating to these characteristics and alloy compositions are provided in fig. 7a-7 d.
TABLE 7-characteristics of alloys E1-E4, F1-F4 and G1-G4
Example 7 Experimental modeling
Based on the existing experiments, various aluminum alloy compositions were modeled. The results are shown in FIGS. 8a-8 b. These modeling results indicate that for Al-Mg-Si alloys targeting 0.7 wt.% Mn and 0.25 wt.% Fe, it may be useful to control magnesium and silicon such that (all values in weight percent): (0.4567 × Mg-0.5) < ═ Si < (0.4567 × Mg + 0.2).
Similar modeling was performed for additional aluminum alloys, as shown in FIGS. 8c-8 d. These modeling results indicate that as manganese or iron content increases, the silicon content needs to increase. These results further indicate that it may be useful to control magnesium, silicon, manganese and iron according to the following:
(0.4567*Mg+0.2*Mn+0.25*Fe–0.6)<＝Si<＝(0.4567*Mg+0.2*Mn+0.25*Fe)
while various embodiments of the present disclosure have been described in detail, it is apparent that modifications and adaptations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present disclosure.

Claims (37)

1. An aluminum casting alloy comprising:
from 2.5 to 5.0 wt.% Mg;
from 0.70 to 2.5 wt.% Si;
wherein the weight ratio of magnesium to silicon (wt.% Mg/wt.% Si) is from 1.7:1 to 3.6: 1;
from 0.40 to 1.5 wt.% Mn;
from 0.10 to 0.60 wt.% Fe;
optionally up to 0.15 wt.% Ti;
optionally up to 0.10 wt.% Sr;
optionally up to 0.15 wt.% of any of Zr, Sc, Hf, V and Cr;
the balance being aluminum and unavoidable impurities.
2. The aluminum casting alloy of claim 1, wherein the aluminum casting alloy includes not greater than 4.75 wt.% Mg or not greater than 4.60 wt.% Mg.
3. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes at least 2.75 wt.% Mg or at least 3.0 wt.% Mg.
4. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes at least 0.80 wt.% Si, or at least 0.90 wt.% Si, or at least 0.95 wt.% Si, or at least 1.00 wt.% Si, or at least 1.05 wt.% Si, or at least 1.10 wt.% Si, or at least 1.15 wt.% Si, or at least 1.20 wt.% Si.
5. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes not greater than 2.4 wt.% Si, or not greater than 2.3 wt.% Si, or not greater than 2.2 wt.% Si, or not greater than 2.1 wt.% Si, or not greater than 2.0 wt.% Si.
6. The aluminum casting alloy of any of the preceding claims, wherein the weight ratio of magnesium to silicon is at least 1.8:1, or wherein the weight ratio of magnesium to silicon is at least 1.85: 1.
7. The aluminum casting alloy of any of the preceding claims, wherein the weight ratio of magnesium to silicon is not greater than 3.6:1, or wherein the weight ratio of magnesium to silicon is not greater than 3.5: 1.
8. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes at least 0.45 wt.% Mn, or at least 0.50 wt.% Mn, or at least 0.55 wt.% Mn, or at least 0.60 wt.% Mn.
9. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes not greater than 1.45 wt.% Mn, or not greater than 1.40 wt.% Mn, or not greater than 1.35 wt.% Mn, or not greater than 1.30 wt.% Mn, or not greater than 1.35 wt.% Mn, or not greater than 1.20 wt.% Mn.
10. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes at least 0.12 wt.% Fe, or at least 0.15 wt.% Fe, or at least 0.20 wt.% Fe, or at least 0.25 wt.% Fe, or at least 0.30 wt.% Fe, or at least 0.35 wt.% Fe.
11. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes not greater than 0.55 wt.% Fe, or not greater than 0.50 wt.% Fe, or not greater than 0.45 wt.% Fe.
12. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes at least 0.01 wt.% Ti, or at least 0.03 wt.% Ti, or at least 0.05 wt.% Ti, or at least 0.07 wt.% Ti.
13. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes not greater than 0.13 wt.% Ti, or not greater than 0.115 wt.% Ti, or not greater than 0.10 wt.% Ti.
14. The aluminum casting alloy of any of the preceding claims, wherein the alloy includes not greater than 0.08 wt.% Sr or not greater than 0.05 wt.% Sr.
15. The aluminum casting alloy of any of the preceding claims, wherein the alloy includes at least 0.005 wt.% Sr.
16. The aluminum casting alloy of any of the preceding claims, wherein the alloy includes at least 0.01 wt.% of any of Zr, Sc, Hf, V, and Cr, or at least 0.03 wt.% of any of Zr, Sc, Hf, V, and Cr, or at least 0.05 wt.% of any of Zr, Sc, Hf, V, and Cr.
17. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes not greater than 0.30 wt.% of the unavoidable impurities, and wherein the aluminum casting alloy includes not greater than 0.10 wt.% of any one of the unavoidable impurities.
18. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes not greater than 0.15 wt.% of the unavoidable impurities, and wherein the aluminum casting alloy includes not greater than 0.05 wt.% of any one of the unavoidable impurities.
19. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes not greater than 0.10 wt.% of the unavoidable impurities, and wherein the aluminum casting alloy includes not greater than 0.03 wt.% of any one of the unavoidable impurities.
20. The aluminum casting alloy of any of the preceding claims, wherein (0.4567 x Mg-0.5 x Si (0.4567 x Mg + 0.2)).
21. The aluminum casting alloy of any of claims 1-19, wherein:
(1) wt.% Si ≦ (0.4567 ≦ (wt.% Mg) +0.2 ≦ (wt.% Mg) +0.25 ≦ (wt.% Fe), and
(2) wt. ％ Si ≥ (0.4567 * (wt. ％ Mg) + 0.2 * (wt. ％ Mg) + 0.25 * (wt. ％Fe)-0.6)。
22. the aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy realizes at least one of:
an ultimate tensile strength of at least 200 MPa;
a tensile yield strength of at least 110 MPa; and
an elongation of at least 10%.
23. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy realizes at least two of:
an ultimate tensile strength of at least 200 MPa;
a tensile yield strength of at least 110 MPa; and
an elongation of at least 10%.
24. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy realizes all of:
an ultimate tensile strength of at least 200 MPa;
a tensile yield strength of at least 110 MPa; and
an elongation of at least 10%.
25. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes not greater than 0.012 wt.% beta-Al5A FeSi compound, or not more than 0.010 wt.% of beta-Al5A FeSi compound, or not more than 0.008 wt.% of beta-Al5A FeSi compound, or not more than 0.006 wt.% of beta-Al5A FeSi compound, or not more than 0.004 wt.% of beta-Al5A FeSi compound, or not more than 0.002 wt.% of beta-Al5A FeSi compound, or not more than 0.001 wt.% of beta-Al5A FeSi compound or not more than 0.0005 wt.% beta-Al5A FeSi compound.
26. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy realizes a hot cracking propensity index of not greater than 0.30, or not greater than 0.25, or not greater than 0.20, or not greater than 0.15.
27. A high pressure die cast product made from any of the aluminum casting alloys of claims 1-26.
28. The high pressure die cast product of claim 27, wherein the high pressure die cast product is in an F temper or a T5 temper.
29. The high pressure die cast product of claim 27, wherein the high pressure die cast product is in the form of an automotive part.
30. The high pressure die cast product of claim 29 wherein the automotive part is a structural part.
31. The high pressure die cast product of claim 29, wherein the automotive component is a door frame or a shock tower or channel structure.
32. An aluminum casting alloy comprising:
from 3.0 to 4.60 wt.% Mg;
from 1.20 to 2.0 wt.% Si;
wherein the weight ratio of magnesium to silicon (wt.% Mg/wt.% Si) is from 1.85:1 to 3.5: 1;
from 0.60 to 1.20 wt.% Mn;
from 0.20 to 0.60 wt.% Fe;
optionally up to 0.15 wt.% Ti;
optionally up to 0.10 wt.% Sr; and
optionally up to 0.15 wt.% of any of Zr, Sc, Hf, V and Cr;
the balance being aluminum and unavoidable impurities.
33. The aluminum casting alloy of claim 32, wherein the aluminum casting alloy is in the form of a complex-shaped casting.
34. The aluminum casting alloy of claim 33, wherein the complex-shaped casting is an automotive part.
35. The aluminum casting alloy of claim 34, wherein the automotive component is a structural component.
36. The aluminum casting alloy of claim 34, wherein the automobile component is a door frame or a shock tower or channel structure.
37. The aluminum casting alloy of claim 32, comprising from 0.35 wt.% to 0.60 wt.% Fe.
CN201980002032.6A 2018-05-07 2019-05-06 Al-Mg-Si-Mn-Fe casting alloy Pending CN110603341A (en)

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