CN114346201B - Semi-solid manufacturing method suitable for aluminum alloy brake calipers - Google Patents
Semi-solid manufacturing method suitable for aluminum alloy brake calipers Download PDFInfo
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- CN114346201B CN114346201B CN202111607059.3A CN202111607059A CN114346201B CN 114346201 B CN114346201 B CN 114346201B CN 202111607059 A CN202111607059 A CN 202111607059A CN 114346201 B CN114346201 B CN 114346201B
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- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 63
- 239000007787 solid Substances 0.000 title claims abstract description 37
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 11
- 239000006104 solid solution Substances 0.000 claims abstract description 24
- 238000000034 method Methods 0.000 claims abstract description 22
- 238000001816 cooling Methods 0.000 claims abstract description 21
- 238000004512 die casting Methods 0.000 claims abstract description 20
- 230000008569 process Effects 0.000 claims abstract description 17
- 238000010791 quenching Methods 0.000 claims abstract description 15
- 230000000171 quenching effect Effects 0.000 claims abstract description 14
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 14
- 239000002002 slurry Substances 0.000 claims abstract description 12
- 238000005266 casting Methods 0.000 claims abstract description 7
- 238000002347 injection Methods 0.000 claims abstract description 7
- 239000007924 injection Substances 0.000 claims abstract description 7
- 239000000243 solution Substances 0.000 claims description 14
- 239000000956 alloy Substances 0.000 claims description 7
- 239000000463 material Substances 0.000 claims description 7
- 229910045601 alloy Inorganic materials 0.000 claims description 5
- 239000007790 solid phase Substances 0.000 claims description 3
- 238000007711 solidification Methods 0.000 claims description 3
- 230000008023 solidification Effects 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 abstract description 10
- 230000000052 comparative effect Effects 0.000 description 10
- 239000012071 phase Substances 0.000 description 10
- 239000002245 particle Substances 0.000 description 5
- 230000007547 defect Effects 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 238000004321 preservation Methods 0.000 description 3
- 230000006978 adaptation Effects 0.000 description 2
- 230000032683 aging Effects 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 230000018109 developmental process Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 238000005728 strengthening Methods 0.000 description 2
- 230000035882 stress Effects 0.000 description 2
- 238000010998 test method Methods 0.000 description 2
- 229910018125 Al-Si Inorganic materials 0.000 description 1
- 229910018520 Al—Si Inorganic materials 0.000 description 1
- 229910018565 CuAl Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000002159 abnormal effect Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000003153 chemical reaction reagent Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 239000002826 coolant Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000004134 energy conservation Methods 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000012827 research and development Methods 0.000 description 1
- 238000010099 solid forming Methods 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/007—Semi-solid pressure die casting
-
- 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
- C22C21/02—Alloys based on aluminium with silicon as the next major constituent
-
- 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
- C22F1/002—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working by rapid cooling or quenching; cooling agents used therefor
-
- 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
- C22F1/043—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 silicon as the next major constituent
Abstract
The invention discloses a semi-solid manufacturing method suitable for an aluminum alloy brake caliper, which comprises the following steps: pouring the semi-solid rheological slurry of the aluminum alloy into a casting machine injection chamber for die casting forming, arranging a gate at the position of the top center of the thickest caliper, controlling the speed of an in-gate to enable the semi-solid slurry to realize laminar flow filling, pressurizing and pressurizing after die casting filling, and finally carrying out multistage solid solution on the obtained caliper, wherein the multistage solid solution process comprises the following steps: solid-dissolving for 4 hours at 470 ℃, then heating to 500 ℃ for 2 hours and 40 minutes, then heating to 510 ℃ for 2 hours and 40 minutes, then quenching to room temperature by water, then placing at 170 ℃ for 10 hours, taking out, and finally cooling to room temperature by air. The aluminum alloy brake caliper prepared by the existing semi-solid die casting method is insufficient in tensile property, and the aluminum alloy brake caliper cannot have high tensile property and high elongation at the same time.
Description
Technical Field
The invention belongs to the technical field of aluminum alloy heat treatment, and particularly relates to a semi-solid manufacturing method suitable for an aluminum alloy brake caliper.
Background
Along with the increasingly urgent requirements of energy conservation and emission reduction of the automobile industry, light weight is a development trend of the automobile industry. The adoption of the light high-strength aluminum alloy parts to replace the traditional steel parts is an effective method for realizing the light weight of the automobile at present. More and more automobile structural members are made of aluminum alloy materials. The calipers are key stress structural members of the automobile chassis, and no application report of any aluminum alloy calipers is found under the condition of more severe stress conditions.
The solidification shrinkage rate of the semi-solid die casting is small, the defects of shrinkage cavity, loosening, die sticking and the like can be avoided, and various parts with thinner wall thickness, denser tissue and higher mechanical property can be prepared. The aluminum alloy is the most widely applied metal structural material in industry, and along with the development of society economy, the demands of high-strength, high-toughness and high-density aluminum alloy parts in the fields of automobiles, electronic appliances, high-end equipment and the like are rapidly increased. Semi-solid processing techniques for aluminum alloys have advanced to some extent, but still present certain problems. For example, research and development of aluminum alloys dedicated to semi-solid die casting technology is lacking.
At present, the aluminum alloy for semi-solid die casting is mainly Al-Si series cast aluminum alloy with the marks of ZL101, A356, ADC10, ADC12 and the like, and the cast aluminum alloy with the marks has good casting fluidity and machining performance, but when being used for semi-solid die casting, the aluminum alloy has low degree of sphericity of alpha-Al solid phase crystal grains, insufficient fluidity of semi-solid alloy slurry and difficulty in meeting the technological requirements of semi-solid die casting. For example, the semi-solid processing technology of aluminum alloy is simple and unscientific, resulting in lower strength and poorer plasticity of aluminum alloy, and is difficult to meet the requirements of fields such as automobiles, electronic appliances, high-end equipment and the like on high-strength, high-toughness and high-density semi-solid die-casting aluminum alloy parts. Therefore, the existing aluminum alloy for semi-solid die casting and the preparation method thereof still need to be improved and developed.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention provides a semi-solid manufacturing method suitable for an aluminum alloy brake caliper, so as to solve the problems that the aluminum alloy brake caliper prepared by the prior semi-solid die casting method has insufficient tensile property and cannot have high tensile property and high elongation at the same time.
In order to solve the technical problems, the invention is realized by the following technical scheme:
the invention provides a semi-solid manufacturing method suitable for an aluminum alloy brake caliper, which comprises the following steps of: pouring the semi-solid rheological slurry of the aluminum alloy into an injection chamber of a die casting machine for die casting forming, arranging a gate at the position of the top center of the thickest caliper, controlling the speed of an in-gate to enable the semi-solid slurry to realize laminar flow filling, pressurizing and pressurizing after die casting filling, and finally carrying out multistage solid solution on the obtained caliper, wherein the multistage solid solution process is characterized in that: solid-dissolving for 4 hours at 470 ℃, then heating to 500 ℃ for 2 hours and 40 minutes, then heating to 510 ℃ for 2 hours and 40 minutes, then quenching to room temperature by water, then placing at 170 ℃ for 10 hours, taking out, and finally cooling to room temperature by air.
Preferably, the water quench cooling rate is greater than 0.97 ℃/S.
Preferably, the maximum wall thickness of the aluminum alloy brake caliper reaches 60-80 mm.
The brake calipers bear larger braking torque, in order to improve the performance of parts and the reliability of products, the die castings of the semi-solid aluminum alloy calipers body are required to be subjected to solution treatment so as to improve the comprehensive mechanical property of the castings, the tensile strength is 408Mpa, in order to ensure the high-temperature strength of the calipers, 319s is adopted as the brand of the aluminum alloy material, and in the solution treatment, in order to control the solution time and obtain better solution effect, the solution temperature is usually hoped to be close to the CuAl in the alloy 2 The solid solution temperature of the phase is 506-509 ℃ and the solid solution temperature of the AL-Si phase is 520-526 ℃. However, the maximum wall thickness of the large-sized aluminum alloy brake caliper body part reaches 60-80 mm, and when single-stage solid solution is adopted, the solid solution temperature is set to be such that local hot stamping is usually caused to generate overburning, and the performance improvement is affected by uneven second-phase particle increase distribution, so that multistage solid solution and aging heat treatment are adopted.
Preferably, the semi-solid slurry is directly prepared by mechanical vibration in the solidification process of the aluminum alloy melt, and the solid phase fraction of the semi-solid slurry is between 50 and 60 percent.
Preferably, the aluminum alloy brake caliper comprises 5-6% of Si, 2.5-3.5% of Cu and 0.25-0.4% of Mg in percentage by mass. The aluminum alloy with Si content of 5-6% is easy to realize semi-solid forming, cu element and Mg element are effective strengthening elements in the aluminum alloy, and different second phase structures can be formed through heat treatment, so that the strength and hardness of the alloy are obviously improved.
Preferably, the in-gate speed is controlled to be between 0.2 and 5m/s, and the filling time is controlled to be between 0.1 and 2 s. Turbulent flow is easily generated when the mold filling speed is too high, and poor mold filling defect is easily generated when the mold filling speed is too low.
Preferably, the casting temperature is 630+/-2 ℃ and the temperature before punch injection is 35+/-2 ℃.
Preferably, the pressurizing and pressure building time after die casting and filling is less than 0.1s, and the pressure maintaining pressure is controlled to be 70-90MPa. Too long pressurization and pressure build time is unfavorable for feeding, too low pressure can not effectively feed, too high pressure is required to equipment, and the cost is increased.
Compared with the prior art, the low-temperature rapid curing composition prepared by the invention has the following beneficial effects:
1. the preparation method of the aluminum alloy caliper provided by the invention has the advantages of low energy consumption, low cost and high efficiency.
2. The tensile strength of the aluminum alloy caliper product prepared by the process is 405-410MPa, the yield strength of the aluminum alloy caliper product is 335-340MPa, and the elongation is 6-8%, so that the tensile strength and the yield strength of the aluminum alloy caliper product are greatly improved compared with those of the aluminum alloy caliper product prepared by the prior art.
Drawings
FIG. 1 is a microstructure morphology of a 319s large aluminum alloy caliper solution treated in accordance with example 1 of the present invention.
FIG. 2 is a graph showing the microstructure morphology of a 319s large aluminum alloy caliper solution treated in accordance with comparative example 1 of the present invention.
FIG. 3 is a graph showing the microstructure morphology of a 319s large aluminum alloy caliper solution treated in accordance with comparative example 2 of the present invention.
FIG. 4 is a microstructure morphology of a 319s large aluminum alloy caliper solution treated in accordance with comparative example 3 of the present invention.
FIG. 5 is a microstructure morphology of a 319s large aluminum alloy caliper solution treated in accordance with comparative example 4 of the present invention.
FIG. 6 is a graph of CCT of the 319s large aluminum alloy caliper of the present invention under various cooling conditions.
Detailed Description
In order that those skilled in the art will better understand the technical solution of the present invention, preferred embodiments of the present invention will be described below with reference to specific examples, but should not be construed as limiting the present patent, but merely as examples.
The test methods or test methods described in the following examples are all conventional methods unless otherwise specified; the reagents and materials, unless otherwise specified, are obtained from conventional commercial sources or prepared in conventional manner.
The following examples are given by way of example of 319s large aluminum alloy calipers.
Discussion of the Cooling Rate:
the cooling medium is adopted for quenching, and parts with different thicknesses need to be quenched by adopting different water temperatures and cooling modes such as: the cooling rate is controlled by immersing or spraying, so that the material is ensured to form a specific structure, and the mechanical properties of the material are ensured: as shown in the table below.
Influence of water temperature on cooling rates of aluminum alloys with different thicknesses
It can be seen that for large parts, it is difficult to obtain a large cooling rate. However, the material only needs to be cooled at a rate of more than 0.97 ℃/S to finish the quenching process.
As shown in fig. 6, in order to ensure that the cooling rate does not affect the formation of the strengthening phase related to the aluminum alloy, the cooling rate needs to be controlled, and the CCT diagram can be used for preliminary determination, and when the cooling rate is greater than 0.97 ℃/S, abnormal formation of the impurity phase can be avoided, thereby achieving improvement of performance.
Example 1
The aluminum alloy caliper product is prepared by adopting a semi-solid rheodie casting method, and the solid fraction of the semi-solid slurry is controlled to be about 54%. The specific alloy comprises the following components: 5.9% Si, 0.13% Te, 3.17% Cu, 0.002% Mn, 0.005% Ni, 0.349% Mg, 0.007% Ti and the balance Al. A top side feed mode is adopted. The multistage solid solution process comprises the following steps: and (3) solid-dissolving for 4 hours at 470 ℃, then heating to 500 ℃ for 2 hours and 40 minutes, then heating to 510 ℃ for 2 hours and 40 minutes, then water quenching to room temperature, wherein the water quenching cooling rate is more than 0.97 ℃/S, then placing at 170 ℃ and preserving heat for 10 hours, taking out, and finally air cooling to room temperature. As shown in fig. 1, the second phase particles are less, and the body performance of the aluminum alloy caliper product prepared by the process is as follows: the tensile strength is 410MPa, the yield strength is 340MPa, the elongation is 8%, and the performance requirement of the passenger car on the caliper product can be completely met.
Comparative example 1
The casting temperature is 630 ℃; the multistage solid solution process for the injection time 45s at the temperature of 35 ℃ before the punch injection comprises the following steps: and (3) carrying out solid solution for 4 hours at 470 ℃, then raising the temperature to 500 ℃ for 2 hours and 40 minutes, carrying out water quenching to room temperature, then placing at 170 ℃ for heat preservation for 10 hours, taking out, and finally carrying out air cooling to room temperature. As shown in fig. 2, the second phase particles are less, and the body performance of the aluminum alloy caliper product prepared by the process is as follows: the yield strength is 303MPa, the tensile strength is 380MPa, the elongation is 6.5%, and the performance requirement of the passenger car calipers is met.
Comparative example 2
The multistage solid solution process comprises the following steps: and (3) carrying out solid solution for 4 hours at 470 ℃, then raising the temperature to 510 ℃ for 2 hours and 40 minutes, carrying out water quenching to room temperature, then placing at 170 ℃ for heat preservation for 10 hours, taking out, and carrying out air cooling to room temperature. As shown in fig. 3, the second phase particles are less, and the body performance of the aluminum alloy caliper product prepared by the process is as follows: the yield strength is 310MPa, the tensile strength is 395MPa, the elongation is 6.2%, and the performance requirement of the passenger car calipers is met.
Comparative example 3
The multistage solid solution process comprises the following steps: and (3) carrying out solid solution for 4 hours at 470 ℃, then raising the temperature to 520 ℃ for 2 hours and 40 minutes, carrying out water quenching to room temperature, then placing at 170 ℃ for heat preservation for 10 hours, taking out, and finally carrying out air cooling to room temperature. As shown in fig. 4, a large number of overburden holes were found in the caliper, and the caliper was judged to be defective.
Comparative example 4
The multistage solid solution process comprises the following steps: solid-dissolving for 4 hours at 470 ℃, heating to 500 ℃ for 8 hours, quenching to room temperature, preserving heat for 10 hours at 170 ℃, taking out, and finally cooling to room temperature. As shown in FIG. 5, the second phase particles were found to be coarse, had a yield strength of 250MPa, a tensile strength of 315MPa, and an elongation of 4.3%.
Comparative example 5
The multistage solid solution process comprises the following steps: solid solution is carried out for 4 hours at 470 ℃, then the temperature is raised to 500 ℃ for 2 hours and 40 minutes, then the temperature is raised to 510 ℃ for 2 hours and 40 minutes, then water quenching is carried out to room temperature, then the mixture is placed at 150 ℃ for 10 hours, taken out, and finally air cooling is carried out to the room temperature. The tensile strength was only 335MPa.
Comparative example 6
The multistage solid solution process comprises the following steps: solid solution is carried out for 4 hours at 470 ℃, then the temperature is raised to 500 ℃ for 2 hours and 40 minutes, then the temperature is raised to 510 ℃ for 2 hours and 40 minutes, then water quenching is carried out to room temperature, then the mixture is placed at 190 ℃ for 10 hours, taken out, and finally air cooling is carried out to the room temperature. The maximum value is reached after aging for 8 hours at 190 ℃, the tensile strength is 400Mpa, and the cost is increased.
The foregoing is merely a preferred embodiment of the present invention, and it should be noted that the above-mentioned preferred embodiment should not be construed as limiting the invention, and the scope of the invention should be defined by the appended claims. It will be apparent to those skilled in the art that various modifications and adaptations can be made without departing from the spirit and scope of the invention, and such modifications and adaptations are intended to be comprehended within the scope of the invention.
Claims (5)
1. A semi-solid manufacturing method suitable for an aluminum alloy brake caliper, comprising the steps of: pouring the semi-solid rheological slurry of the aluminum alloy into an injection chamber of a die casting machine for die casting forming, arranging a gate at the position of the top center of the thickest caliper, controlling the speed of an in-gate to enable the semi-solid slurry to realize laminar flow filling, pressurizing and pressurizing after die casting filling, and finally carrying out multistage solid solution on the obtained caliper, wherein the multistage solid solution process is characterized in that: solid solution is carried out for 4 hours at 470 ℃, then the temperature is raised to 500 ℃ for 2 hours and 40 minutes, then the temperature is raised to 510 ℃ for 2 hours and 40 minutes, then water quenching is carried out to room temperature, then the solution is placed at 170 ℃ for 10 hours, and then the solution is taken out, and finally the solution is cooled to the room temperature;
the water quenching cooling rate is required to be greater than 0.97 ℃/S, the maximum wall thickness of the aluminum alloy brake caliper reaches 60-80 mm, 319S is adopted as the material mark of the aluminum alloy brake caliper, and the aluminum alloy brake caliper comprises the following specific alloy components in percentage by mass: 5.9% of Si, 0.13% of Te, 3.17% of Cu, 0.002% of Mn, 0.005% of Ni, 0.349% of Mg, 0.007% of Ti and the balance of Al.
2. Semi-solid manufacturing method suitable for aluminium alloy brake calipers according to claim 1, characterized in that: in the solidification process of the aluminum alloy melt, the semi-solid slurry is directly prepared through mechanical vibration, and the solid phase fraction of the semi-solid slurry is between 50 and 60 percent.
3. Semi-solid manufacturing method suitable for aluminium alloy brake calipers according to claim 1, characterized in that: the speed of the inner gate is controlled between 0.2 and 5m/s, and the filling time is controlled between 0.1 and 2 s.
4. Semi-solid manufacturing method suitable for aluminium alloy brake calipers according to claim 1, characterized in that: the temperature of the casting material is 630+/-2 ℃, and the temperature of the punch head before injection is 35+/-2 ℃.
5. Semi-solid manufacturing method suitable for aluminium alloy brake calipers according to claim 1, characterized in that: the pressurizing and pressure building time after die casting and filling is less than 0.1s, and the holding pressure is controlled to be 70-90MPa.
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