CN115679158A - Casting alloy - Google Patents

Casting alloy Download PDF

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Publication number
CN115679158A
CN115679158A CN202210897320.6A CN202210897320A CN115679158A CN 115679158 A CN115679158 A CN 115679158A CN 202210897320 A CN202210897320 A CN 202210897320A CN 115679158 A CN115679158 A CN 115679158A
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Prior art keywords
casting alloy
alloy
casting
iron
weight
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S·威斯纳
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Aluminum Rheinfeldon Alloy Co ltd
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Aluminum Rheinfeldon Alloy 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
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • C22C21/003Alloys based on aluminium containing at least 2.6% of one or more of the elements: tin, lead, antimony, bismuth, cadmium, and titanium
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D18/00Pressure casting; Vacuum casting
    • B22D18/04Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002Castings of light metals
    • B22D21/007Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22FCHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon

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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)
  • Induction Machinery (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Conductive Materials (AREA)
  • Sealing Battery Cases Or Jackets (AREA)

Abstract

The casting alloy of the invention is based on aluminium-iron-nickel and consists of the following elements: 0.8 to 3.0 wt.% iron, 0.1 to 3.5 wt.% nickel, 40 to 300ppm boron, 0 to 5 wt.% zinc, 0 to 5 wt.% tin, 0 to 3 wt.% copper, 0 to 1 wt.% manganese, 0 to 0.6 wt.% magnesium, 0 to 500ppm phosphorus, 0 to 0.4% silicon.

Description

Casting alloy
Technical Field
The invention relates to a casting alloy based on aluminium, iron and nickel with the addition of boron. The invention also relates to the use of the alloy for high pressure die casting or gravity die casting. The alloy of the invention is used for producing rotors and stators for electric motors and heat exchangers, cooling and heating elements in the electronics industry or in vehicle construction.
Background
The use of rotor aluminum (e.g., 99.7% aluminum by mass) in high pressure die casting has long been known. Typically, the metal body is placed in a die casting mold and an aluminum rotor or stator is cast inIn the metal body. In this way, difficulties in casting such alloys are avoided, in particular the tendency to stick to the steel, which would otherwise lead to rapid wear of the mould. Other typical disadvantages are high shrinkage, extremely high casting temperatures, poor machinability and particularly low strength (e.g. for Al alloys) 99.7 E, rp0.2 is 20-40 MPa).
For heat exchangers produced by high-pressure die casting, alloys of the AlSi type, for example the alloy AlSi, are generally used 9 Sr (Castasil-21). These alloy types are more castable than rotor aluminum. The tendency to stick to the casting mould, shrinkage, mould filling and casting temperature are all the more favourable. However, the lower electrical and thermal conductivity is disadvantageous compared to rotor aluminum. By heat treatment, an electrical conductivity of up to 28MS/m can be achieved, followed by a thermal conductivity of 190 (W/K m). The yield strength (Rp0.2) of the alloy is 80-100MPa.
The patent EP 3 235 916 B1 of the applicant discloses an AlMg 4 Fe 2 (castreduce-42) type alloy, preferably for crash related structural components in automotive construction. The metallurgical basis of this alloy is Al 3 And (4) eutectic crystallization of Fe. The conductivity is 16-17MS/m.
There are high conductivity and low strength aluminum alloys, or high strength and low conductivity alloys in the prior art.
Disclosure of Invention
It is an object of the present invention to address at least one of the disadvantages of the alloys known from the prior art.
It is an object of the alloy of the invention that the alloy has an electrical conductivity of preferably at least 23MS/m, more preferably more than 30 MS/m. At the same time, the alloy should provide high strength, preferably with an Rp0.2 of at least 74MPa, more preferably over 95MPa.
Another object is to provide an alloy composition having good castability.
Another object is to provide an alloy composition that does not require heat treatment while still maintaining the desired strength and electrical conductivity.
Another object is to provide an alloy composition suitable for machining, joining or corrosion resistance.
At least one of the above objects is solved by an alloy consisting of:
the alloy of the invention consists of the following substances:
iron (Fe) 0.8 to 3.0% by weight
Nickel (Ni) 0.1 to 3.5% by weight
Boron (B) 40 to 300ppm
Zinc (Zn) 0 to 5% by weight
0 to 5% by weight of tin (Sn)
Copper (Cu) 0 to 3% by weight
Manganese (Mn) 0 to 1 wt%
Magnesium (Mg) 0 to 0.6% by weight
Phosphorus (P) 0 to 500ppm
Silicon (Si) 0 to 0.4%
And 0 to 0.8 wt% of an element or group of elements selected from chromium (Cr), lithium (Li), vanadium (V), titanium (Ti), calcium (Ca), molybdenum (Mo) and zirconium (Zr), the balance being aluminum and unavoidable impurities.
In a preferred embodiment, the iron content is 1.0 to 2.5% by weight.
In another preferred embodiment, the iron content is 1.2 to 2.0 wt.%.
In another preferred embodiment, the iron content is 1.4 to 1.9% by weight.
In another preferred embodiment, the nickel content is from 0.3 to 3.0 wt.%.
In another preferred embodiment, the nickel content is from 0.8 to 2.0% by weight.
In another preferred embodiment, the boron content is from 70 to 200ppm.
In another preferred embodiment, the boron content is from 100 to 160ppm.
In another preferred embodiment, the boron content is from 80 to 150ppm.
In another preferred embodiment, the silicon content is 0 to 0.3 wt.%.
In another preferred embodiment, the copper content is from 0.2 to 3% by weight.
In another preferred embodiment, the copper content is 1.0-3.0%.
In another preferred embodiment, the zinc content is from 0 to 3% by weight of zinc.
In another preferred embodiment, the zinc content is from 0.5 to 4.0% by weight zinc.
In another preferred embodiment, the magnesium content is from 0 to 0.4% by weight magnesium.
In another preferred embodiment, the magnesium content is 0.2-0.4%.
In another preferred embodiment, the manganese content is 0 to 0.1 wt.%.
In another preferred embodiment, the tin content is from 0 to 2.5% by weight.
In another preferred embodiment, the tin content is from 0.2 to 2.5% by weight.
According to another aspect of the invention, the cast alloy is used for high pressure die casting, preferably for rotors and stators for electric motors and heat exchangers, cooling and heating elements in the electronics industry or vehicle construction.
A high-pressure die-cast product, preferably for rotors and stators of electric motors and heat exchangers, cooling and heating elements in the electronics industry or in vehicle construction, made from the cast alloy according to the invention.
The castability of the alloy according to the invention is achieved by adding the alloying elements iron and nickel so as to form a eutectic phase (which improves the castability of the alloy). In particular, al should be obtained 9 The FeNi phase, according to the literature, is produced in an ideal ternary system having a composition of 1.75wt% Fe and 1.25wt% Ni. In the case of alloy variants, al may also be present 3 Fe or Al 3 A Ni phase. Al (aluminum) 3 The Ni phase has a high Ni content and a low Fe content.
According to the invention, the Fe content should be high and with a smaller amount of Al 3 Fe eutectic crystal promotes Al together 9 And forming FeNi. This reduces the tendency for the alloy to stick and improves castability.
Al 9 FeNi、Al 3 Fe and Al 3 Three phases of Ni in the micrographAll showed very fine long fibers and had similar eutectic temperatures (640 ℃, 650 ℃ and 655 ℃). Thus, they are generated almost simultaneously and at almost the same location during the casting process, which may result in mixing of these phases. Industrially produced die-cast parts also exhibit a number of structural defects. Thus, the three phases (Al) 9 FeNi、Al 3 Fe and Al 3 Ni) are often difficult to distinguish in micrographs.
The alloy according to the invention is hardly reactive to heat treatment, as long as no further elements are added. Thermal treatment can have a positive effect on electrical and thermal conductivity. The metallurgical background is mainly the agglomeration of the additional elements and the coarsening of the phases, which results in a better conductivity of the α -Al.
The strength of the alloy may be increased by adding additional alloying elements.
In general, solid solution strengthening of the α -Al phase should be achieved. However, in general, such solid solution strengthening often leads to a reduction in conductivity, which is why even only certain elements are considered.
The Si content should not exceed 0.4% to ensure Si-free eutectic. To this level, it is expected that only the α -Al phase is enriched, which may slightly increase the strength.
The addition of about 40-300ppm boron results in a slight increase in conductivity. The metallurgical background is the formation of borides, which can reduce the negative effects of impurities. On the one hand, such borides can be expelled during degassing, and on the other hand, they can lead to an accumulation of impurities, resulting in a higher electrical conductivity (electrical and thermal conductivity).
The element for improving strength is Mg. It does not form a phase with Fe, has high solubility in α -Al, but has a negative effect on electrical conductivity (electrical and thermal conductivity). In addition, phases containing MgNi can form, which can interfere with Al 9 Formation of FeNi phase. Therefore, the alloy according to the invention should contain no or only a small amount of Mg, preferably at most 0.6%.
If Si is present in the alloy, mg is formed 2 Si phase (or one of its metastable variants), thereby increasing strength. Further heat treatment becomes possible。
Zn is known to increase the strength of the alloy according to the invention and its negative impact on electrical conductivity (electrical and thermal conductivity) is limited. However, if Mg is not added, the strength cannot be significantly improved. If Mg and Zn are added simultaneously, the material becomes hard and the strength increases.
Another strength-enhancing element in aluminum is Cu. Its negative impact on conductivity is less than Mg. However, only a small amount of Mg added to Cu can significantly improve the strength.
Other elements which may have a strength-increasing effect are Sn, mn, cr, li, V, ti, ca, ga, bi, mo and Zr.
Examples and comparative examples
In the following table, the alloy according to the invention and three prior art alloys AlMg are shown 4 Fe 2 、AlSi 9 Sr and Rotor Al 99.7 Different compositions of (a). Data are expressed in weight% (or ppm). At a Zn value of 0.01 or 0.02% or even lower, it is considered that no Zn is contained in the composition. At Si values of 0.03% or 0.04% or even lower, the composition may be considered to be free of Si.
For the high-pressure die-cast samples (C to E, I and J, P, R to T, V to Z), the mechanical parameters (Rm, rp0.2, A5) and the electrical conductivity were measured on a high-pressure die-cast plate having a thickness of 3 mm. Table 2 shows the average of at least 6 tensile tests or 5 conductivity measurements.
As comparative samples, two alloys of variants I and J, designated castreduce-42 and Castasil-21, known in the prior art are shown. Variant T is another known alloy, named Rotors-Al 99.7
The variants K to O refer to Gravity Die Casting (GDC). The relevant mechanical parameters UTS (ultimate tensile strength), YS (yield strength) and E (A) were measured using a Diez die with a diameter of 16mm 5 Elongation at break) of the resin. The conductivity of the cast and machined samples was measured separately. Table 3 shows the average of at least 5 tensile tests or 2 conductivity measurements.
TABLE 1
Figure BDA0003769423270000051
TABLE 1 (continuation)
Figure BDA0003769423270000052
Figure BDA0003769423270000061
The results obtained
High pressure die casting (HPC), state F
TABLE 2
Figure BDA0003769423270000062
Gravity Die Casting (GDC), state F Table 3
UTS[MPa] YS[MPa] E[%] Conductivity [ MS/m ]]
Variant K 100 55 26.0 33.2
Variants L 110 57 21.5 31.7
Variants M 129 63 18.4 32.4
Variant N 129 62 21.9 30.8
Modification O 169 72 7.8 25.4

Claims (16)

1. An aluminum-iron-nickel based casting alloy consisting of:
Figure FDA0003769423260000011
and 0 to 0.8% by weight of an element or group of elements selected from chromium, lithium, vanadium, titanium, calcium, molybdenum and zirconium, the balance being aluminium and unavoidable impurities.
2. A casting alloy as claimed in claim 1 characterised by 1.0 to 2.5 wt% iron.
3. A casting alloy as claimed in any one of the preceding claims characterised by 1.2 to 2.0 wt% iron.
4. The casting alloy of any preceding claim, characterized by 1.4 to 1.9 wt.% iron.
5. The casting alloy of any of the preceding claims, characterized by 0.3 to 3.0 wt.% nickel.
6. The casting alloy of any preceding claim, characterized by 0.8 to 2.0 wt.% nickel.
7. The casting alloy of any preceding claim, characterized by 70 to 200ppm boron.
8. The casting alloy of any preceding claim, characterized by 100 to 160ppm boron.
9. The casting alloy of any of the preceding claims, characterized by 0 to 0.3 wt.% silicon.
10. A casting alloy as claimed in any one of the preceding claims characterised by 0.2 to 3% by weight copper, for example 1.0 to 3.0% copper.
11. A casting alloy as claimed in any of the preceding claims characterised by 0 to 3 wt% zinc, for example 0.5 to 4.0 wt% zinc.
12. A casting alloy as claimed in any one of the preceding claims characterised by 0 to 0.4 wt% magnesium, for example 0.2 to 0.4 wt% magnesium.
13. The casting alloy of any preceding claim, characterized by 0 to 0.1 wt.% manganese.
14. The casting alloy of any preceding claim, characterized by 0 to 2.5 wt.% tin, such as 0.2 to 2.5 wt.% tin.
15. Use of the cast alloy according to any of the preceding claims for high pressure die casting, preferably for high pressure die casting of rotors and stators of electric motors and heat exchangers, cooling and heating elements in the electronics industry or in vehicle construction.
16. A high pressure die cast product, preferably for rotors and stators of electric motors and heat exchangers, cooling and heating elements in the electronics industry or in vehicle construction, made from the cast alloy according to any of the preceding claims 1 to 14.
CN202210897320.6A 2021-07-30 2022-07-28 Casting alloy Pending CN115679158A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP21188809.4A EP4124668A1 (en) 2021-07-30 2021-07-30 Cast alloy
EP21188809.4 2021-07-30

Publications (1)

Publication Number Publication Date
CN115679158A true CN115679158A (en) 2023-02-03

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US (1) US20230043878A1 (en)
EP (1) EP4124668A1 (en)
JP (1) JP2023021070A (en)
KR (1) KR20230019055A (en)
CN (1) CN115679158A (en)

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4080222A (en) * 1974-03-01 1978-03-21 Southwire Company Aluminum-iron-nickel alloy electrical conductor
JP4328927B2 (en) * 2000-03-13 2009-09-09 三菱樹脂株式会社 Aluminum alloy material with excellent electrical and thermal conductivity
US10822675B2 (en) * 2015-03-06 2020-11-03 NanoAL LLC High temperature creep resistant aluminum superalloys
EP3235916B1 (en) 2016-04-19 2018-08-15 Rheinfelden Alloys GmbH & Co. KG Cast alloy
CN108130456B (en) * 2017-12-22 2020-12-15 广州致远新材料科技有限公司 High-thermal-conductivity die-casting aluminum alloy material and preparation method thereof

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EP4124668A1 (en) 2023-02-01
US20230043878A1 (en) 2023-02-09
KR20230019055A (en) 2023-02-07

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