CN117026020A - Aluminum alloy ingot for producing integrated die casting by using recycled aluminum and production method thereof - Google Patents

Aluminum alloy ingot for producing integrated die casting by using recycled aluminum and production method thereof Download PDF

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Publication number
CN117026020A
CN117026020A CN202310955963.6A CN202310955963A CN117026020A CN 117026020 A CN117026020 A CN 117026020A CN 202310955963 A CN202310955963 A CN 202310955963A CN 117026020 A CN117026020 A CN 117026020A
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aluminum
alloy
intermediate alloy
casting
ingot
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Inventor
王欢
殷智
侯经韬
纪剑峰
刘立忠
张东
靳文刚
王文涛
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Xinjiang Joinworld Co Ltd
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Xinjiang Joinworld 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
    • C22C21/02Alloys based on aluminium with silicon as the next major constituent
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D7/00Casting ingots, e.g. from ferrous metals
    • B22D7/005Casting ingots, e.g. from ferrous metals from non-ferrous metals
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/02Making non-ferrous alloys by melting
    • C22C1/026Alloys based on aluminium
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/02Making non-ferrous alloys by melting
    • C22C1/03Making non-ferrous alloys by melting using master alloys
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/06Making non-ferrous alloys with the use of special agents for refining or deoxidising
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/20Recycling

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture And Refinement Of Metals (AREA)

Abstract

The invention discloses an aluminum alloy ingot for producing integrated die casting by using reclaimed aluminum and a production method thereof, belonging to the technical field of aluminum alloy. The aluminum alloy ingot production method comprises the following steps: (1) charging: spreading industrial silicon at the bottom of a smelting furnace, baking, adding waste aluminum materials into the smelting furnace to be melted into aluminum liquid, and adding aluminum-manganese intermediate alloy, aluminum-zirconium intermediate alloy, aluminum-molybdenum intermediate alloy, aluminum-boron intermediate alloy and aluminum-rare earth intermediate alloy into the aluminum liquid to be sufficiently melted; (2) refining: refining at 720-760 deg.C for 30-45min; (3) casting: casting at 720-760 ℃. The yield strength of the prepared aluminum alloy casting ingot is 130-150MPa, the tensile strength is 250-280MPa, the elongation is 10-14%, and the Fe content is below 0.15 wt.%.

Description

Aluminum alloy ingot for producing integrated die casting by using recycled aluminum and production method thereof
Technical Field
The invention relates to the technical field of aluminum alloy, in particular to an aluminum alloy ingot for producing integrated die casting by using reclaimed aluminum and a production method thereof.
Background
The aluminum alloy has the characteristics of energy conservation, environment friendliness, light weight, good corrosion resistance, long service life and the like, and is a preferred material for light weight (especially for new energy automobiles) of the existing automobiles. The Tesla integrated die-casting technology is a mainstream technology for manufacturing new energy automobile parts in the future, and a cast aluminum alloy ingot with low cost and high performance is required to be used as a base material of the cast aluminum alloy ingot to be matched with the development of the technology.
The energy of each ton of regenerated aluminum is saved by more than 3000kg of standard coal than that of electrolytic aluminum, and the energy can be saved by 20m 3 Reducing solid waste discharge by 20 tons and regenerating aluminum CO 2 The emission is only 2.1% of that of electrolytic aluminum, so that the regenerated aluminum is used for producing the heat treatment-free aluminum alloy material for automobiles, and the heat treatment-free aluminum alloy material is an ideal low-carbon and low-cost production mode.
The statistical results of the common secondary aluminum chemistry are shown in table 1 below.
TABLE 1
The regenerated aluminum has the characteristics of multiple types and impurity components, and the problem of component exceeding is frequently caused in the smelting process. Particularly, the enrichment of Fe element greatly limits the application of the regenerated aluminum. Fe easily forms a coarse needle-shaped phase in the as-cast aluminum alloy and easily causes cracking in the subsequent die casting, so that the Fe content control becomes a key technology for producing the heat-treatment-free aluminum alloy for the fields of automobiles and the like by using the regenerated aluminum.
The technical means for solving the problem of exceeding Fe content commonly used in the regenerated aluminum casting industry is as follows: 1) The regenerated aluminum is mixed with the original aluminum liquid to achieve the purpose of dilution, and the Fe element is reduced to be within an acceptable range, so that the treatment scheme has higher cost. 2) Mn, cr and other elements are added, then the iron phase morphology is controlled by controlling the modes of the superheat degree, the cooling speed and the like of the melt, the production process of the scheme is generally complex and is not suitable for mass industrialized production, the added elements do not increase the production cost, but the Fe content in the aluminum alloy is not reduced, the total amount of hard brittle compounds is increased, and the aluminum scrap is more difficult to regenerate by adding the elements as an impurity into aluminum continuously and accumulating the impurities. 3) And the physical methods such as a gravity sedimentation method, a centrifugal removal method, a filtering method, an electromagnetic separation method and the like are adopted, part of Fe is removed by utilizing the physical property difference of the iron-containing phase, other elements such as Mn and the like are also required to be introduced in the method, the relevance between the final Fe removal efficiency and the initial Fe content is large, and the Fe is difficult to continue to be removed after reaching a certain value.
Disclosure of Invention
In order to overcome the defects in the prior art, the invention aims to provide an aluminum alloy ingot for producing integrated die casting by using reclaimed aluminum and a production method thereof, wherein the Fe content in the produced heat-treatment-free aluminum alloy can be controlled below 0.15wt.%, and the product performance is good and stable by component design and combination of production processes; the addition proportion of the regenerated aluminum can reach 100%, the production mode is low-carbon and energy-saving, and the method is suitable for mass industrialized production application.
In order to achieve the above purpose, the technical scheme adopted by the invention is as follows:
the aluminum alloy ingot for producing integrated die casting by using the regenerated aluminum comprises the following chemical components in percentage by weight:
fe is less than or equal to 0.2 percent, si:7.0-10.0%, cu is less than or equal to 2.0%, mg:0.2-0.5%, mn:0.3-0.7%, sr:0.02-0.05%, mo:0.04-0.10%, RE:0.05-0.15%, zr:0.05-0.25%, B:0.03-0.06%, zn less than or equal to 1.0%, other single elements less than or equal to 0.05%, other elements less than or equal to 0.15% and the balance of Al.
The production method of the aluminum alloy ingot for producing integrated die casting by using the reclaimed aluminum comprises the following steps:
(1) Feeding: spreading industrial silicon at the bottom of a smelting furnace, baking at 790-810 ℃ for 15-30min, crushing, sieving, magnetically separating, preheating and depainting outsourcing the sorted waste aluminum materials, adding the waste aluminum materials into the smelting furnace, melting the waste aluminum materials into aluminum liquid, and adding the calculated and weighed aluminum-manganese intermediate alloy, aluminum-zirconium intermediate alloy, aluminum-molybdenum intermediate alloy, aluminum-boron intermediate alloy and aluminum-rare earth intermediate alloy into the aluminum liquid for full melting;
(2) Refining: refining at 720-760 ℃ for 30-45min by adopting inert gas current carrying refining agent (remelting type refining agent such as MK4844B, MK4844B in YS/T491-2020 standard) and standing for 30-40min after refining is finished, and removing surface slag;
(3) Casting: casting can be carried out at the temperature ranging from 720 ℃ to 760 ℃ after the components of the alloy liquid meet the requirements; adding AlSr10 intermediate alloy at the furnace hole by adopting on-line wire feeding, then carrying out gas removal and deslagging on aluminum liquid by on-line refining degassing equipment (the degassing efficiency is more than 50%) and double-stage plate type filtering equipment (the specification of a filter plate is 40ppi or more), and finally ensuring that the aluminum liquid enters an ingot casting machine at 680-700 ℃ to produce aluminum alloy casting ingots.
In the step (1), in the chemical composition of the waste aluminum material, fe is less than or equal to 0.5wt.%, cu is less than or equal to 2.0wt.%, and Zn is less than or equal to 1.0wt.%.
In the step (2), the aluminum-manganese intermediate alloy is AlMn20, the aluminum-strontium intermediate alloy is rolled AlSr10, the aluminum-zirconium intermediate alloy is AlZr10, the aluminum-molybdenum intermediate alloy is AlMo10, the aluminum-boron intermediate alloy is AlB5, the aluminum-rare earth intermediate alloy is AlRE10, and RE is one or more of La, ce and Er.
The prepared aluminum alloy casting ingot has the following properties: the yield strength is 130-150MPa, the tensile strength is 250-280MPa, and the elongation is 10-14%.
The design principle and the beneficial effects of the invention are as follows:
the invention mainly describes a production method for producing a heat-treatment-free aluminum alloy ingot by adopting reclaimed aluminum, which mainly has the innovation points that a form that a compound formed by main harmful element Fe in the reclaimed aluminum is settled at the bottom of a furnace is removed by boride treatment, so that the Fe content of a product is greatly reduced, and meanwhile, the product is matched with the refining, deterioration and strengthening effects of other alloy elements, so that the final product has excellent comprehensive mechanical properties, and has the main beneficial effects as follows:
1. the method adopts 100% of recycled aluminum raw materials for production, has low carbon and low cost, is simple and easy to operate, and is suitable for mass stable production.
2. Si content is 7-10%, and the excellent mold filling capability of the alloy in the die casting process is ensured.
3. Sr is used as a long-acting modifier, and eutectic Si in a lamellar or lath shape is changed into coral shape or spherical shape, so that the ductility of the alloy is enhanced.
4. The Fe content is controlled below 0.2%, so that the harm of Fe relative performance is reduced.
5. Mn element replaces Fe element to improve anti-sticking performance on one hand, and reduces harm of residual Fe to mechanical property on the other hand.
6. After the B element is added, the B element can firstly react with Fe to form Fe with larger density 2 The content of Fe in the regenerated aluminum is obviously reduced by settling the compound B to the furnace bottom, and the rest B provides a heterogeneous nucleation core through eutectic reaction in the casting process, so that the effects of refining grains and improving the product performance are achieved.
7. Mo element is dissolved in the body to increase the strength of the body and avoid generating a coarse second phase.
8. RE has the effect of removing (solid) hydrogen and refining, can reduce casting pinholes, has the effect of modifying Si, changes eutectic silicon from coarse needle sheets into short rod shapes, and improves the comprehensive performance of castings.
9. Mg forms Mg with Si 2 Si strengthening phase to increase alloy strength by natural aging.
10. Zr can refine grain structure, improve alloy heat resistance, and ensure mechanical property of the product at high temperature.
Detailed Description
For a further understanding of the present invention, the present invention is described below with reference to the following examples, which are intended to illustrate only the features and advantages of the present invention and are not intended to limit the scope of the claims of the present invention.
Example 1:
the embodiment is an aluminum alloy ingot for producing integrated die casting by using reclaimed aluminum and a production process thereof, wherein the production process of the aluminum alloy ingot is designed as follows:
1. the composition ratio of the final aluminum alloy ingot product is designed as follows: fe is less than or equal to 0.2 percent, si:7.0-10.0%, cu is less than or equal to 2.0%, mg:0.2-0.5%, mn:0.3-0.7%, sr:0.02-0.05%, mo:0.04-0.10%, RE:0.05-0.15%, zr:0.05-0.25%, B:0.03-0.06%, zn is less than or equal to 1.0%, the content of other single elements is less than or equal to 0.05%, and the total content of other elements is less than or equal to 0.15%. The balance being Al.
2. The equipment requirements are as follows: the main equipment is a crusher, a separator, a paint removing furnace, a smelting furnace, an ingot casting machine and an online wire feeder, and is provided with online refining equipment with the degassing efficiency of more than 50 percent and double-stage filtering equipment with the filter plate specification of more than or equal to 40 ppi.
3. The raw materials for production are shown in Table 2:
TABLE 2
4. The production process comprises the following steps:
spreading industrial silicon on the bottom of a smelting furnace, heating to 800 ℃ and baking for 20min, crushing and screening waste aluminum materials (waste aluminum wires, conducting plates, old aluminum foils, pop cans and automobile hub waste aluminum), preheating and depainting, adding the waste aluminum materials into the smelting furnace, sampling and analyzing that the Fe content is 0.39wt.% after the waste aluminum materials are melted, adding the calculated and weighed aluminum-manganese intermediate alloy, aluminum-zirconium intermediate alloy, aluminum-molybdenum intermediate alloy, magnesium ingots, aluminum-boron intermediate alloy and aluminum-rare earth intermediate alloy into aluminum liquid, and fully melting.
Refining: refining at 720-760 ℃ for 30-45min by adopting inert gas current carrying refining agent (MK 4844B type refining agent in YS/T491-2020 standard)), standing for 30-40min after refining, and removing the slag on the surface. The sampling analysis components are as follows: fe:0.14%, si:9.1%, cu:0.07%, mg:0.37%, mn:0.42%, mo:0.06%, la:0.04%, ce:0.02%, zr:0.09%, B:0.03%, zn:0.13%.
Casting: and (3) opening a furnace hole at 740 ℃ to start casting, adding an AlSr10 intermediate alloy with the Sr content of 0.036wt.% by adopting an online wire feeding at the outlet of the furnace hole, then carrying out degassing and deslagging on aluminum liquid by sequentially passing through an online refining degassing device and a two-stage plate type filtering device (the specification of a filter plate is 30ppi+50 ppi), and finally, feeding the aluminum liquid into an ingot casting machine at 685 ℃ to produce an aluminum alloy casting ingot.
And (3) checking the performance of the product: yield strength 148MPa, tensile strength 276MPa and elongation 12%.

Claims (5)

1. An aluminum alloy ingot for producing integrated die casting by using reclaimed aluminum is characterized in that: the aluminum alloy comprises the following chemical components in percentage by weight:
fe is less than or equal to 0.2 percent, si:7.0-10.0%, cu is less than or equal to 2.0%, mg:0.2-0.5%, mn:0.3-0.7%, sr:0.02-0.05%, mo:0.04-0.10%, RE:0.05-0.15%, zr:0.05-0.25%, B:0.03-0.06%, zn less than or equal to 1.0%, other single elements less than or equal to 0.05%, other elements less than or equal to 0.15% and the balance of Al.
2. The method for producing an aluminum alloy ingot for integrated die casting from recycled aluminum according to claim 1, wherein: the method comprises the following steps:
(1) Feeding: spreading industrial silicon at the bottom of a smelting furnace, baking at 790-810 ℃ for 15-30min, crushing, sieving, magnetically separating, preheating and depainting outsourcing the sorted waste aluminum materials, adding the waste aluminum materials into the smelting furnace, melting the waste aluminum materials into aluminum liquid, and adding the calculated and weighed aluminum-manganese intermediate alloy, aluminum-zirconium intermediate alloy, aluminum-molybdenum intermediate alloy, aluminum-boron intermediate alloy and aluminum-rare earth intermediate alloy into the aluminum liquid for full melting;
(2) Refining: refining at 720-760 ℃ for 30-45min by adopting inert gas current carrying refining agent, and after refining, standing for 30-40min, removing the slag on the surface;
(3) Casting: casting can be carried out at the temperature ranging from 720 ℃ to 760 ℃ after the components of the alloy liquid meet the requirements; adding AlSr10 intermediate alloy at the furnace hole by adopting on-line wire feeding, then carrying out gas removal and deslagging on aluminum liquid by on-line refining degassing equipment (the degassing efficiency is more than 50%) and double-stage plate type filtering equipment (the specification of a filter plate is 40ppi or more), and finally ensuring that the aluminum liquid enters an ingot casting machine at 680-700 ℃ to produce aluminum alloy casting ingots.
3. The method for producing an aluminum alloy ingot for integrated die casting from recycled aluminum according to claim 2, wherein: in the step (1), in the chemical composition of the waste aluminum material, fe is less than or equal to 0.5wt.%, cu is less than or equal to 2.0wt.%, and Zn is less than or equal to 1.0wt.%.
4. The method for producing an aluminum alloy ingot for integrated die casting from recycled aluminum according to claim 2, wherein: in the step (2), the aluminum-manganese intermediate alloy is AlMn20, the aluminum-strontium intermediate alloy is rolled AlSr10, the aluminum-zirconium intermediate alloy is AlZr10, the aluminum-molybdenum intermediate alloy is AlMo10, the aluminum-boron intermediate alloy is AlB5, the aluminum-rare earth intermediate alloy is AlRE10, and RE is one or more of La, ce and Er.
5. The method for producing an aluminum alloy ingot for integrated die casting from recycled aluminum according to claim 1, wherein: the prepared aluminum alloy casting ingot has the following properties: the yield strength is 130-150MPa, the tensile strength is 250-280MPa, and the elongation is 10-14%.
CN202310955963.6A 2023-08-01 2023-08-01 Aluminum alloy ingot for producing integrated die casting by using recycled aluminum and production method thereof Pending CN117026020A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN117821813A (en) * 2024-03-04 2024-04-05 鸿劲新材料研究(南通)有限公司 Aluminum alloy material for auxiliary frame of automobile and preparation method

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN117821813A (en) * 2024-03-04 2024-04-05 鸿劲新材料研究(南通)有限公司 Aluminum alloy material for auxiliary frame of automobile and preparation method
CN117821813B (en) * 2024-03-04 2024-04-26 鸿劲新材料研究(南通)有限公司 Aluminum alloy material for auxiliary frame of automobile and preparation method

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