CN118028667A - Die-casting aluminum alloy material, preparation method thereof and automobile structural member - Google Patents
Die-casting aluminum alloy material, preparation method thereof and automobile structural member Download PDFInfo
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Abstract
The present disclosure relates to a die-casting aluminum alloy material, a preparation method thereof, and an automobile structural member, wherein the die-casting aluminum alloy material comprises: 8.5 to 13 weight percent of Si,0.1 to 1 weight percent of Mn,0 to 0.5 weight percent of Fe,1.5 to 3 weight percent of Cu,0.5 to 2 weight percent of Mg,1.0 to 2.5 weight percent of Zn,0.02 to 0.5 weight percent of Ti,0.02 to 0.08 weight percent of Sr,0.02 to 0.1 weight percent of Zr,0 to 0.1 weight percent of Ni, less than 0.1 weight percent of impurities and the balance of Al. The method can improve the yield strength, the tensile strength and the elongation of the die-casting material under the condition of no heat treatment; and improves the high temperature performance and creep resistance of the die casting material; and can satisfy the body performance demand of electric drive casing.
Description
Technical Field
The disclosure relates to the technical field of die-casting aluminum alloy, in particular to a die-casting aluminum alloy material, a preparation method thereof and an automobile structural member.
Background
Aluminum alloy is widely applied to the die-casting shell of the motor with the advantages of small density, good heat conduction and flow property and the like. The die-cast aluminum alloy material most used in the industry currently is AlSiCu-series alloy.
Along with the development of new energy automobiles, the electric drive industry also continuously pursues the extremely high power density, and the influence is extremely high in requirements on light weight and high power. The electric drive shell using the high-strength die-casting aluminum alloy is accordingly produced, the requirements of light weight and high power can be simultaneously met through the high-strength high-yield electric drive shell, the local thinning design can bring weight reduction benefit through the high-strength, the strength performance required by high power and high torque can be met through the high strength, and even under the current power torque requirement of the highest-performance electric drive, the yield strength performance of the electric drive shell body is required to be more than 240MPa, so that the development of the ultrahigh-strength heat-treatment-free aluminum alloy for the electric drive shell is necessary.
In addition, the performance of the conventional aluminum alloy is the performance of the tested die-cast or poured test bar or test piece, the performance of the conventional aluminum alloy and the performance tested on the parts are greatly different, and no clear corresponding relation exists. Therefore, in order to reflect the performance of the material on the actual parts more truly, the body performance of the electric drive housing should be more focused, i.e. sampling test is performed on the body of the component. Meanwhile, the working condition temperature of the motor can reach 120 ℃ at most, and the motor can be even higher under certain designs, so that the high-temperature performance is also necessary on the premise of examining the room-temperature performance of the material. For the mechanical properties of metals, a common test method is a unidirectional tensile test at normal temperature, and a stress-strain curve is obtained. However, in the fields of energy, chemical industry, metallurgy, aerospace and the like, a large number of parts must be in service for a long time under the high temperature condition, for example, the operation parameters of the ultra-supercritical thermal power unit of a power plant can reach 26.25MPa and 600 ℃. For the metal materials used under the high temperature condition, if the mechanical properties under normal temperature short-time static load are taken as the design material selection basis, the mechanical properties of the materials can be obviously changed under the high temperature service environment. Under the condition that the working stress is smaller than the yield strength of the material at the working temperature, the material can also generate slow and continuous plastic deformation (namely creep phenomenon) in the long-term service process, so that in order to prevent the motor from creep failure during long-term working, the creep resistance of the material needs to be further inspected.
Disclosure of Invention
The invention aims to provide a die-casting aluminum alloy material, a preparation method thereof and an automobile structural part, which can improve the yield strength, the tensile strength and the elongation of the die-casting material under the condition of no heat treatment, and meet the performance requirement of a body of an electric drive shell; the high temperature performance and creep resistance of the die casting material can also be improved.
In order to achieve the above object, a first aspect of the present disclosure provides a die cast aluminum alloy material including, based on a total weight of the die cast aluminum alloy material: 8.5 to 13 weight percent of Si,0.1 to 1 weight percent of Mn,0 to 0.5 weight percent of Fe,1.5 to 3 weight percent of Cu,0.5 to 2 weight percent of Mg,1.0 to 2.5 weight percent of Zn,0.02 to 0.5 weight percent of Ti,0.02 to 0.08 weight percent of Sr,0.02 to 0.1 weight percent of Zr,0 to 0.1 weight percent of Ni, less than 0.1 weight percent of impurities and the balance of Al.
Optionally, the die-casting aluminum alloy material further contains Bi element; preferably, the die cast aluminum alloy material includes 0.01 to 0.1 wt% of Bi based on the total weight of the die cast aluminum alloy material.
Optionally, the die cast aluminum alloy material comprises, based on the total weight of the die cast aluminum alloy material: 8.8 to 12 weight percent of Si,0.2 to 0.8 weight percent of Mn,0 to 0.5 weight percent of Fe,1.5 to 3.0 weight percent of Cu,0.03 to 0.1 weight percent of Bi,0.5 to 2.0 weight percent of Mg,1.3 to 2.3 weight percent of Zn,0.02 to 0.5 weight percent of Ti,0.02 to 0.08 weight percent of Sr,0.02 to 0.1 weight percent of Zr,0 to 0.1 weight percent of Ni, less than 0.1 weight percent of impurities and the balance of Al.
Optionally, in the die-casting aluminum alloy material, the content ratio of Cu element to Bi element is 40 or less, and optionally, the content ratio of Cu element to Ni element is 50 or less.
Optionally, the die cast aluminum alloy material does not contain Mo.
Optionally, the bulk properties of the die-cast aluminum alloy material include: the yield strength is 240MPa or more, the tensile strength is 320MPa or more, and the elongation is 1.5% or more.
A second aspect of the present disclosure provides a method of preparing a die-cast aluminum alloy material, comprising the steps of:
S1, smelting an alloy raw material mixture in a smelting furnace to obtain a first alloy melt, wherein the alloy raw material mixture comprises the following components: 8.5 to 13 weight percent of Si,0.1 to 1 weight percent of Mn,0 to 0.5 weight percent of Fe,1.5 to 3 weight percent of Cu,0.5 to 2 weight percent of Mg,1.0 to 2.5 weight percent of Zn,0.02 to 0.5 weight percent of Ti,0.02 to 0.08 weight percent of Sr,0.02 to 0.1 weight percent of Zr,0 to 0.1 weight percent of Ni, less than 0.1 weight percent of impurities and the balance of Al;
s2, carrying out degassing treatment, refining treatment and first slag skimming treatment on the first alloy melt in a middle converter to obtain a second alloy melt;
s3, carrying out heat preservation treatment and second slag skimming treatment on the second alloy melt in a side furnace to obtain a third alloy melt;
And S4, performing die casting treatment on the third alloy melt.
Optionally, in step S1, the smelting process conditions include: the smelting temperature is 740-760 ℃, the smelting atmosphere temperature is 700-950 ℃, and the smelting time is 3-13 h.
Optionally, in step S2, the degassing treatment conditions include: the degassing revolution is 400-500 r/min, the pressure of a degassing gas source is 0.35-0.45 MPa, the degassing temperature is 760-770 ℃, and the degassing time is 8-10 min;
The refining process includes: introducing nitrogen with refining agent powder into the first melt after degassing treatment to perform first refining, and introducing nitrogen with refining agent powder again to perform second refining
The first skimming process includes removing dross with a skimming tool.
Optionally, in step S3, the conditions of the incubation include: the heat preservation temperature is 660-680 ℃ and the heat preservation time is 30-40 min;
The second drossing process includes removing dross using a drossing tool.
Optionally, in step S4, the conditions of the die casting process include: the casting pressure is above 60MPa, the high speed is above 3.5m/s, the vacuum degree is below 100mbar, the temperature of molten aluminum is 660-680 ℃, the temperature after die spraying is above 120-150 ℃, and the injection delay time is below 1 s.
A third aspect of the present disclosure provides a die cast aluminum alloy material prepared according to the method of the second aspect of the present disclosure.
A fourth aspect of the present disclosure provides an automotive structural member comprising a die cast aluminum alloy material that is a heat treatment free die cast aluminum alloy material according to the first or third aspect of the present disclosure.
Through the technical scheme, the die-casting aluminum alloy material, the preparation method thereof and the automobile structural part are provided, the aluminum alloy material realizes the effects of composite modification and fine grain reinforcement of the die-casting aluminum alloy material by exploring the element proportion content of the alloy material through alloying control and AI model iteration, and the material which is suitable for a motor shell and has the comprehensive optimal strength and elongation is obtained; the performance of the die-casting aluminum alloy disclosed by the invention is fully verified on a motor shell mould, and the body sampling performance can be realized at the position of the motor cylinder wall (namely the position with the highest strength required by the motor), and the die-casting aluminum alloy material has higher strength and elongation; the Cu content is lower, and the corrosion resistance is better from the viewpoint of alloy; the high-temperature performance and creep resistance of the die-casting aluminum alloy material are improved to a certain extent, and the die-casting aluminum alloy material is suitable for an application environment in which an electric drive is positioned on a chassis; the die-casting aluminum alloy disclosed by the invention can achieve the performance of other conventional alloys after heat treatment without heat treatment, can save cost and reduce carbon emission without heat treatment, and has great benefits for the dimensional accuracy of parts; the die-casting aluminum alloy disclosed by the invention has the advantages that the cost is lower, the components do not contain rare earth, compared with other high-strength aluminum alloys, the iron content requirement is relatively low, the use of reclaimed materials is facilitated, and the cost is further reduced.
Additional features and advantages of the present disclosure will be set forth in the detailed description which follows.
Drawings
The accompanying drawings are included to provide a further understanding of the disclosure, and are incorporated in and constitute a part of this specification, illustrate the disclosure and together with the description serve to explain, but do not limit the disclosure. In the drawings:
FIG. 1 illustrates a flow diagram of a method of making a die cast aluminum alloy material of the present disclosure;
Fig. 2 shows a motor housing and sampling location for bulk sampling of die cast aluminum alloy of the present disclosure.
Description of the reference numerals
1-Body sampling position.
Detailed Description
Specific embodiments of the present disclosure are described in detail below with reference to the accompanying drawings. It should be understood that the detailed description and specific examples, while indicating and illustrating the disclosure, are not intended to limit the disclosure.
A first aspect of the present disclosure provides a die cast aluminum alloy material, based on a total weight of the die cast aluminum alloy material, the die cast aluminum alloy material comprising: 8.5 to 13 weight percent of Si (silicon), 0.1 to 1 weight percent of Mn (manganese), 0 to 0.5 weight percent of Fe (iron), 1.5 to 3 weight percent of Cu (copper), 0.5 to 2 weight percent of Mg (magnesium), 1.0 to 2.5 weight percent of Zn (zinc), 0.02 to 0.5 weight percent of Ti (titanium), 0.02 to 0.08 weight percent of Sr (strontium), 0.02 to 0.1 weight percent of Zr (zirconium), 0 to 0.1 weight percent of Ni (nickel), less than 0.1 weight percent of impurities and the balance of Al (aluminum).
The die-casting aluminum alloy material realizes the effects of composite modification and fine grain reinforcement by controlling alloying and iterating an AI model and fumbling the proportioning contents of Cu, mg, ni, zr, zn and other alloy elements, and obtains a material which is suitable for a motor shell and has comprehensively optimal strength and elongation; the performance of the die-casting aluminum alloy disclosed by the invention is fully verified on a motor shell mould, and the body sampling performance can be realized at the position of the motor cylinder wall (namely the position with the highest strength required by the motor), and the die-casting aluminum alloy material has higher strength and elongation; the Cu content is lower, and the corrosion resistance is better from the viewpoint of alloy; the high-temperature performance and creep resistance of the die-casting aluminum alloy material are improved to a certain extent, and the die-casting aluminum alloy material is suitable for an application environment in which an electric drive is positioned on a chassis; the die-casting aluminum alloy disclosed by the invention can achieve the performance of other conventional alloys after heat treatment without heat treatment, can save cost and reduce carbon emission without heat treatment, and has great benefits for the dimensional accuracy of parts; the die-casting aluminum alloy disclosed by the invention has the advantages that the cost is lower, the components do not contain rare earth, and compared with other high-strength aluminum alloys, the iron content requirement is low, the use of reclaimed materials is facilitated, and the cost is further reduced.
In the present disclosure, the impurities may include Cr (chromium), sn (tin), pb (lead), etc., and the total amount of impurities in the die-cast aluminum alloy material provided in the present disclosure is 0.1 wt% or less.
In a preferred embodiment, the die-cast aluminum alloy material further contains Bi (bismuth) element; preferably, the die cast aluminum alloy material includes 0.01 to 0.1 wt% of Bi based on the total weight of the die cast aluminum alloy material.
In a preferred embodiment, the diecast aluminum alloy material does not contain Mo (molybdenum). The inventor of the present disclosure found that there are some technical difficulties in adding molybdenum powder: firstly, the adding amount of the molybdenum powder is proper, and the excessive molybdenum powder can cause the aluminum alloy to become brittle; secondly, the uniformity of the distribution of the molybdenum powder is critical to the performance of the aluminum alloy, and if the distribution is uneven, the strength and toughness of the aluminum alloy material can be reduced. The die-casting aluminum alloy material provided by the disclosure does not add metallic element Mo, can avoid the defects caused by metallic Mo, and is beneficial to reducing cost.
Silicon: the alloy is a main element of most aluminum alloys, can improve the fluidity of the alloy at high temperature and improve the tensile strength of the alloy, but the plasticity is reduced, when the silicon content in the alloy exceeds the eutectic composition and impurities such as copper, iron and the like are more, free silicon is generated, the hardness of the free silicon is high, and the cutter is severely worn during processing. In addition, in high silicon aluminum alloys, silicon is generally present in the aluminum alloy in a coarse needle structure, so that the mechanical properties of the alloy are reduced. Through researches and growths of the inventor, the optimal interval for controlling the Si content in the die-casting aluminum alloy material is 8.5-13 wt%, so that the requirement of a motor shell on certain elongation can be met, the impact resistance is achieved, and the strength of the alloy material can be improved to a higher level.
Iron: the higher the iron content, the better the recyclability of the material and the better the demolding effect. However, when the iron content is too high, brittle needle-shaped phases can be generated, and the performance is unfavorable, the upper limit of the Fe content in the die-casting aluminum alloy material is controlled to be 0.5 wt%, so that the die-casting aluminum alloy material has a high stripping recovery effect and can ensure the excellent performance of the material.
Copper: copper is an important alloy element, has a certain solid solution strengthening effect, and in addition, the aged CuAl 2 has an obvious ageing strengthening effect. The inventor of the present disclosure has found that controlling the copper content in the die-casting aluminum alloy to be between 1.5 and 3.0 wt% can improve the aging strengthening effect of the alloy while simultaneously giving consideration to the corrosion resistance of the alloy material, which is superior to the conventional alloy A380 and ADC 12.
Bismuth: the addition of Cu can form a strengthening phase CuAl 2, but the form of CuAl 2 has great influence on the performance, and through a great amount of experiments and researches, the inventor finds that the alpha-Al/CuAl 2 binary eutectic in an alloy material can be gradually converted into a uniform and fine short lamellar structure from a coarse radial state by adding a certain amount of bismuth element (0.01-0.10 wt%), and the long needle-shaped form of eutectic silicon is converted into a needle-shaped point, so that the strength performance, the high-temperature performance and the creep resistance of the material are improved.
Magnesium: the strength limit, the elastic limit, the fatigue limit and the hardness of the alloy can be improved by adding a small amount of magnesium into the high-silicon aluminum alloy; however, the presence of magnesium increases the tendency of the alloy to oxidize during smelting and holding. Magnesium is an element for obviously improving strength, and the common addition of Mg and Cu has complex strengthening phases such as Q-Al 5Mg8Si6Cu2 besides CuAl 2 and Mg 2 Si phases, and the heat-resistant temperature of the alloy can reach 250 ℃ after a plurality of second phases are combined. The inventor of the present disclosure has developed an intensive study for the magnesium content, and can control the Mg content to be 0.5 to 2 wt%, so that the elongation of the die-casting aluminum alloy material can be controlled to meet the basic requirements of the motor housing, and at the same time, the present disclosure has a good strength improving effect, and the disadvantage that the elongation is low due to the excessively high magnesium content is avoided.
Zinc: the zinc alloy has good casting forming performance and mechanical property, the zinc content is controlled to be 1.0-2.5 wt%, and adverse effects of increased alloy hot cracking tendency and reduced corrosion resistance caused by zinc can be avoided;
Titanium: as an effective nucleating agent in the aluminum alloy, the titanium content is controlled within the range of 0.02-0.5 wt%, so that the grain size of the aluminum alloy can be obviously refined, and the room-temperature mechanical property and the aluminum alloy rolling property are improved; meanwhile, the Al 3 Ti phase has the characteristics of high melting point and high hardness, and the high-temperature strength of the aluminum alloy can be improved.
Strontium: is an effective eutectic silicon nodulizer, and the addition of 0.02 to 0.08 weight percent of Sr can change eutectic silicon from needle shape to fiber shape, thereby being beneficial to improving the strength performance and toughness of the die casting material.
Zirconium: (Al, si) 3 Zr particles are easy to form in the alloy, the heterogeneous nucleation point of alpha-Al is easy to become, grains are refined, the alloy strength and elongation are synchronously improved, the die-casting aluminum alloy material disclosed by the invention comprises 0.02-0.1 wt% of zirconium, the adverse effects of coarsening of (Al, si) 3 Zr particles and high-content Zr on the alloy performance can be avoided, and meanwhile, the beneficial effects of thermally stable phase Al 3 Zr on the high-temperature performance of the aluminum alloy material can be exerted.
Manganese: manganese can enable flaky or needle-shaped crystal structures of iron in aluminum alloy to be changed into fine crystal shapes, and the existence of manganese can reduce harmful effects of iron.
Nickel: the addition of a proper amount of Ni (0-0.1 wt%) in the aluminum alloy material can improve the high-temperature mechanical properties of the aluminum alloy, and the formed Al 7Cu4 Ni intermetallic compound can also increase the stability of the microstructure at high temperature.
In a preferred embodiment, the die cast aluminum alloy material comprises, based on the total weight of the die cast aluminum alloy material:
8.8 to 12 weight percent of Si,0.2 to 0.8 weight percent of Mn,0 to 0.5 weight percent of Fe,1.5 to 3.0 weight percent of Cu,0.03 to 0.1 weight percent of Bi,0.5 to 2.0 weight percent of Mg,1.3 to 2.3 weight percent of Zn,0.02 to 0.5 weight percent of Ti,0.02 to 0.08 weight percent of Sr,0.02 to 0.1 weight percent of Zr,0 to 0.1 weight percent of Ni, less than 0.1 weight percent of impurities and the balance of Al. The content ratio of the die-casting aluminum alloy material provided by the embodiment is favorable for further improving the performance of the aluminum alloy material.
In a preferred embodiment, the die-cast aluminum alloy material has a content ratio of Cu element to Bi element of 40 or less, and optionally, a content ratio of Cu element to Ni element of 50 or less. The present inventors have found that when the ratio of the Cu element to the Bi element and the content of the Cu element to the Ni element in the die-cast aluminum alloy is within the optimized range provided by the present embodiment, the die-cast aluminum alloy material can have more excellent strength properties, high temperature properties, creep resistance properties, and the like.
In one embodiment, the bulk properties of the die cast aluminum alloy material include (at room temperature): the yield strength is more than 240MPa, the tensile strength is more than 320MPa, and the elongation is more than 1.5%; preferably, the yield strength is 250MPa or more, the tensile strength is 330MPa or more, and the elongation is 3% or more. The body performance of the die-casting aluminum alloy material can meet the aim of electric drive extreme power torque.
In the present disclosure, the bulk properties of the die-cast aluminum alloy material refer to: and taking out a tensile sample meeting the requirements on the part in practical application, and performing a tensile test to obtain the strength performance of the part body. The bulk sampling may be performed by: firstly, a part body is obtained through a die casting process, a region conforming to a tensile sample is marked, then a sample block marked in the front is obtained through cutting, and a standard tensile sample is obtained from the sample block in a linear cutting slow wire-moving mode.
In a specific embodiment, the die-cast aluminum alloy material has a plate die sample having a yield strength of 250MPa or more, a tensile strength of 320MPa or more, and an elongation of 2% or more at 120 ℃. The test performance of the conventional ADC12 aluminum alloy material under the same condition is as follows: the yield strength is more than 180MPa, the tensile strength is more than 270MPa, and the elongation is more than 2%. Comparing the aluminum alloy disclosed by the disclosure with the existing ADC12 aluminum alloy in the transverse direction, the die-casting aluminum alloy material provided by the disclosure has better high-temperature performance.
In a specific embodiment, the aluminum alloy die cast material has a die cast flat die specimen total strain of 0.155%. The total strain of the test performance of the ADC12 under the same condition is 0.200%, and the transverse comparison of the two materials proves that the die-casting aluminum alloy material provided by the disclosure has better creep resistance.
A second aspect of the present disclosure provides a method of preparing a die-cast aluminum alloy material, comprising the steps of:
S1, smelting an alloy raw material mixture in a smelting furnace to obtain a first alloy melt, wherein the alloy raw material mixture comprises the following components: 8.5 to 13 weight percent of Si,0.1 to 1 weight percent of Mn,0 to 0.5 weight percent of Fe,1.5 to 3 weight percent of Cu,0.5 to 2 weight percent of Mg,1.0 to 2.5 weight percent of Zn,0.02 to 0.5 weight percent of Ti,0.02 to 0.08 weight percent of Sr,0.02 to 0.1 weight percent of Zr,0 to 0.1 weight percent of Ni, less than 0.1 weight percent of impurities and the balance of Al;
s2, carrying out degassing treatment, refining treatment and first slag skimming treatment on the first alloy melt in a middle converter to obtain a second alloy melt;
s3, carrying out heat preservation treatment and second slag skimming treatment on the second alloy melt in a side furnace to obtain a third alloy melt;
And S4, performing die casting treatment on the third alloy melt.
The method for preparing the die-casting aluminum alloy can obtain the high-strength aluminum alloy material without heat treatment, and avoids the defects of reduction of production efficiency, increase of production cost, additional carbon emission and the like caused by introducing heat treatment.
The preparation of the method adopts smelting equipment (including smelting furnace, transfer furnace, machine side furnace and the like) to melt the alloy ingot (or perform furnace washing operation) and the qualification of component detection is determined. Wherein the smelting equipment is of a conventional device structure in the field.
In a preferred embodiment, the alloy raw material mixture comprises:
8.8 to 12 weight percent of Si,0.2 to 0.8 weight percent of Mn,0 to 0.5 weight percent of Fe,1.5 to 3.0 weight percent of Cu,0.03 to 0.1 weight percent of Bi,0.5 to 2.0 weight percent of Mg,1.3 to 2.3 weight percent of Zn,0.02 to 0.5 weight percent of Ti,0.02 to 0.08 weight percent of Sr,0.02 to 0.1 weight percent of Zr,0 to 0.1 weight percent of Ni, less than 0.1 weight percent of impurities and the balance of Al. The die-casting aluminum alloy material prepared from the optimized alloy raw material provided by the implementation has better strength performance and elongation, and the high-temperature performance and creep resistance of the material are further improved.
In one embodiment, in step S1, the smelting conditions include: the smelting temperature is 740-760 ℃, the smelting atmosphere temperature is 700-950 ℃, and the smelting time is 3-13 h; preferably, the smelting temperature is 745-755 ℃, the smelting atmosphere temperature is 750-850 ℃, and the smelting time is 5-8 h.
In one embodiment, in step S2, the degassing conditions include: the degassing revolution is 400-500 r/min, the pressure of a degassing gas source is 0.35-0.45 MPa, the degassing temperature is 760-770 ℃, and the degassing time is 8-10 min; preferably, the degassing revolution is 450-500 r/min, the pressure of a degassing gas source is 0.4-0.45 MPa, the degassing temperature is 765-770 ℃, and the degassing time is 9-10 min;
the refining process includes: introducing nitrogen with refining agent powder into the degassed first melt to perform first refining treatment, and introducing nitrogen with refining agent powder again to perform second refining treatment; wherein, the refining agent adopts the variety conventionally selected in the field and can be obtained through common commercial channels;
the first skimming process includes removing dross with a skimming tool.
In one embodiment, in step S3, the conditions of the heat preservation process include: the heat preservation temperature is 660-680 ℃ and the heat preservation time is 30-40 min; preferably, the heat preservation temperature is 670-680 ℃ and the heat preservation time is 35-40 min;
The second drossing process includes removing dross using a drossing tool.
In one embodiment, in step S4, the die casting apparatus is a force DC2500 die casting machine, and the conditions of the die casting process include: the casting pressure is above 60MPa, the high speed is above 3.5m/s, the vacuum degree is below 100mbar, the temperature of molten aluminum is 660-680 ℃, the temperature after die spraying is above 120-150 ℃, and the injection delay time is below 1 s. Preferably, the casting pressure is 80-100 MPa, the high-speed is more than 4.5m/s, the vacuum degree is 50-60 mbar, the temperature of aluminum liquid is 670-680 ℃, the temperature after die spraying is 140-150 ℃, and the injection delay time is less than 1 s.
In one embodiment, the method further comprises: performing first component detection treatment on the first alloy melt obtained in the step S1; when the result of the first component detection processing meets a first condition, the first alloy melt is subjected to a step S2;
Performing second component detection treatment on the second alloy melt obtained in the step S2; when the result of the second component detection processing meets a second condition, the second alloy melt is subjected to a step S3;
Performing third component detection treatment on the third alloy melt obtained in the step S3; when the result of the third component detection processing meets a third condition, the third alloy melt is subjected to step S4;
optionally, the first condition, the second condition, and the third condition each independently include:
The alloy melt comprises the following components: 8.5 to 13 weight percent of Si,0.1 to 1 weight percent of Mn,0 to 0.5 weight percent of Fe,1.5 to 3 weight percent of Cu,0.5 to 2 weight percent of Mg,1.0 to 2.5 weight percent of Zn,0.02 to 0.5 weight percent of Ti,0.02 to 0.08 weight percent of Sr,0.02 to 0.1 weight percent of Zr,0 to 0.1 weight percent of Ni, less than 0.1 weight percent of impurities and the balance of Al; preferably 8.8 to 12 wt% Si,0.2 to 0.8 wt% Mn,0 to 0.5 wt% Fe,1.5 to 3.0 wt% Cu,0.03 to 0.1 wt% Bi,0.5 to 2.0 wt% Mg,1.3 to 2.3 wt% Zn,0.02 to 0.5 wt% Ti,0.02 to 0.08 wt% Sr,0.02 to 0.1 wt% Zr,0 to 0.1 wt% Ni,0.1 wt% or less impurity and the balance Al. In the preparation process, the composition of the alloy melt obtained in each step is detected, so that the composition of the final alloy material can be ensured to meet the requirements.
A third aspect of the present disclosure provides a cast aluminum alloy material prepared according to the method of the second aspect of the present disclosure.
A fourth aspect of the present disclosure provides an automotive structural member comprising a die cast aluminum alloy material that is a heat treatment free die cast aluminum alloy material according to the first or third aspect of the present disclosure.
Further, the automotive structural members include parts that are die cast and that have high strength and high yield requirements for the parts themselves, including but not limited to motor housings, motor end caps, reducer housings, and the like. As shown in fig. 2, the motor housing of the structure shown in fig. 2, in which the body sampling position 1 is on the motor housing.
The invention is illustrated in further detail by the following examples. The starting materials used in the examples are all available commercially.
Example 1
In this example, aluminum alloy materials were prepared according to the alloy raw material compositions listed in table 1, provided that:
(1) Placing the prepared alloy ingot into a smelting furnace, setting the smelting temperature to 750 ℃, the smelting atmosphere temperature to 850 ℃, the smelting time to 8 hours, fully melting, detecting whether the components of the alloy ingot meet the requirements (detecting by an OES (optical emission spectroscopy) component detection method after a small part of molten liquid is scooped to be solidified), and performing the next operation after the components are qualified;
(2) Transferring the molten alloy solution to a transfer furnace, degassing, refining and slagging-off, wherein the conditions of the degassing treatment include: the degassing revolution is 450r/min, the pressure of a degassing gas source is 0.4MPa, the temperature is 765 ℃ and the time is 10min; the conditions of the refining treatment include: adding a refining agent to perform first refining at 760 ℃, introducing nitrogen with refining agent powder again to perform second refining treatment, uniformly and slightly stirring in the refining process, and standing for 10 minutes; skimming the scum by utilizing a skimming tool; detecting whether the components meet the requirements, and performing the next operation after the components are qualified;
(3) Transferring the alloy solution of the middle converter to a side furnace, preserving heat, and simultaneously carrying out slag skimming treatment, wherein the heat preservation temperature is 680 ℃ and the heat preservation time is 30min, detecting whether the components of the alloy solution meet the requirements, and carrying out the next operation after the alloy solution is qualified;
S4: die casting is carried out, and die casting parameters comprise: the tonnage of the press is 2500Ton, the casting pressure is above 60MPa, the high-speed is 3.5m/s, the vacuum degree is 60mbar, the temperature of aluminum liquid is 660 ℃, the temperature after die spraying is 150 ℃, and the injection delay time is 1s.
Examples 2 to 7
Examples 2 to 7 refer to the preparation method in example 1, and differ from example 1 in that: the aluminum alloy materials were prepared according to the alloy raw material compositions listed in table 1, and the rest was the same as in example 1.
Example 8
This example prepares an alloy raw material mixture according to the raw material formulation in example 1, and differs from example 1 in that the preparation process conditions are changed:
(1) Placing the prepared alloy ingot into a smelting furnace, setting the smelting temperature to 790 ℃, the smelting atmosphere temperature to 850 ℃, the smelting time to 10 hours, fully melting, detecting whether the components meet the requirements, and performing the next operation after the components are qualified;
(2) Transferring the molten alloy solution to a transfer furnace, degassing, refining and slagging-off, wherein the conditions of the degassing treatment include: the degassing revolution is 380r/min, the pressure of a degassing gas source is 0.3MPa, the temperature is 780 ℃ and the time is 3min; the conditions of the refining treatment include: adding a refining agent at 780 ℃ to perform first refining treatment, introducing nitrogen with refining agent powder again to perform second refining treatment, simultaneously carrying out uniform slight stirring, standing for 3 minutes, and skimming scum by using a skimming tool; detecting whether the components meet the requirements, and performing the next operation after the components are qualified;
(3) Transferring the alloy solution of the middle converter to a side furnace, preserving heat, and simultaneously carrying out slag skimming treatment, wherein the heat preservation temperature is 680 ℃ and the heat preservation time is 1h; detecting whether the components meet the requirements, and performing the next operation after the components are qualified;
s4: die casting is carried out, and die casting parameters comprise: the tonnage of the press is 3000Ton, the casting pressure is above 60MPa, the high-speed is 3m/s, the vacuum degree is 100mbar, the temperature of aluminum liquid is 680 ℃, the temperature after die spraying is 150 ℃, and the injection delay time is 1s.
Comparative examples 1 to 9
Comparative examples 1 to 9 reference the preparation method in example 1, which differs from example 1 in that: the aluminum alloy materials were prepared according to the alloy raw material compositions listed in table 1, and the rest was the same as in example 1.
Comparative example 10
This comparative example was prepared with reference to the formulation and preparation process in example 1 of CN116752018a to obtain an aluminum alloy material.
TABLE 1
Wherein, "-" means no addition or no presence in the alloy formulation; in the data of the ratio between the contents of Cu/Bi and Cu/Ni, "-" means that the calculated result could not be obtained because the Bi or Ni content was 0 (the result could be considered as infinity).
Test example 1
The test example was used for bulk sampling and mechanical property testing of the products prepared in the above examples and comparative examples.
The method for sampling the body comprises the following steps: firstly, a part body is obtained through a die casting process, a region which accords with a tensile sample is marked, then a sample block marked in the front is obtained through cutting, and a standard tensile sample is obtained from the sample block in a linear cutting slow wire-moving mode; the sample specification is a small-size test according to ASTME8, the thickness is the actual thickness of the body, about 5-6 mm, and a tensile sample is taken.
Test methods for yield strength, tensile strength and elongation of bulk samples reference standard GB/T228.1-2021 metallic materials tensile test part 1: room temperature test method. The test results are listed in table 2 below.
TABLE 2
From the data in table 2 above, it can be seen that:
Comparing examples 1-7 with comparative examples 1-10, it is clear that the alloy preparation is not performed by adopting the metal proportion provided by the disclosure in comparative examples 1-10, and the heat treatment-free die casting aluminum alloy materials obtained in examples 1-7 have higher yield strength and tensile strength and better comprehensive performance while ensuring higher elongation.
As can be seen from a comparison of examples 1-2 with examples 3-7, the alloy compositions of examples 1-2 are within the preferred ranges provided by the present disclosure, and the yield strength, tensile strength, and elongation of the aluminum alloy materials obtained in examples 1-2 are higher than those of examples 3-7.
Comparing example 3 with example 4, the aluminum alloy material of example 4 was not added with metallic Bi, the metallic Bi was added to example 3, and the strength properties of the aluminum alloy material obtained in example 3 were superior to those of example 4;
as can be seen from comparing example 3 with example 2, the alloy composition of example 2 is within the preferred range provided by the present disclosure, and the mass ratio of Cu element to Bi element is not higher than 40, the strength properties and elongation of example 2 are more excellent than example 3;
comparing example 2 with example 1, it is known that the alloy composition of example 1 is within the preferred range provided by the present disclosure, and the mass ratio of Cu element to Ni element in example 1 is not higher than 50, and the yield strength and tensile strength of the aluminum alloy material obtained in example 1 are significantly improved compared with those of the aluminum alloy material of example 2;
comparing example 1 with example 8, it can be seen that the aluminum alloy material prepared according to the optimized process conditions provided in the present disclosure in example 1 has higher yield strength, tensile strength and elongation.
Test example 2
This test example was used to conduct high temperature performance tests on the aluminum alloy material products prepared in examples 1 to 7 and comparative example 1 (ADC 12 alloy) and comparative example 10.
The test bar 120 ℃ mechanical property testing method comprises the following steps: reference is made to GB/T228.2-2015 section 2 of Metal Material tensile test: high temperature test method, using electrohydraulic servo fatigue tester Landmark370.25.
The test results are listed in table 3 below.
TABLE 3 Table 3
From the data in table 3 above, it can be seen that:
Comparing examples 1 to 7 with comparative examples 1 and 10, the alloy materials obtained in examples 1 to 7 have higher yield strength and tensile strength on the basis of ensuring higher elongation under the test condition of 120 ℃, i.e., the high-temperature performance of the aluminum alloy materials obtained in examples 1 to 7 according to the method provided by the disclosure is better;
comparing examples 1-2 with examples 3-7, it is evident that the alloy compositions of examples 1-2 are within the preferred ranges provided by the present disclosure, and that the aluminum alloy materials obtained in examples 1-2 have better high temperature performance than examples 3-7, and can simultaneously achieve both strength performance and elongation;
Comparing example 3 with example 4, the aluminum alloy material of example 4 was not added with metallic Bi, the metallic Bi was added to example 3, and the high temperature performance of the aluminum alloy material obtained in example 3 was better than that of example 4;
As can be seen from comparing example 3 with example 2, the alloy composition of example 2 is within the preferred range provided by the present disclosure, and the mass ratio of Cu element to Bi element is not higher than 40, the high temperature performance of example 2 is more excellent than example 3;
As can be seen from comparing example 2 with example 1, the alloy composition of example 1 is within the preferred range provided by the present disclosure, and the mass ratio of Cu element to Ni element in example 1 is not higher than 50, the high temperature performance of the aluminum alloy material obtained in example 1 is significantly superior to that of the aluminum alloy material of example 2.
Test example 3
This test example was used to conduct a flat die creep resistance test on the aluminum alloy material products prepared in example 1 and comparative examples 1 (ADC 12 alloy) and 10 above.
The creep resistance test method of the flat die comprises the following steps: referring to GB/T2039, test method for uniaxial tensile creep test of metal materials, the test temperature is 120 ℃, the initial load is 90MPa, the creep time is 100h, and the equipment is a creep tester RDL-10.
The test results are listed in table 4 below.
TABLE 4 Table 4
| Flat plate mold results | Total strain/% |
| Example 1 | 0.155 |
| Comparative example 1 | 0.200 |
| Comparative example 10 | 0.179 |
As can be seen from the data in table 4 above, the aluminum alloy material provided in example 1 has a smaller total strain and better creep resistance than comparative examples 1 and 10.
The preferred embodiments of the present disclosure have been described in detail above with reference to the accompanying drawings, but the present disclosure is not limited to the specific details of the embodiments described above, and various simple modifications may be made to the technical solutions of the present disclosure within the scope of the technical concept of the present disclosure, and all the simple modifications belong to the protection scope of the present disclosure.
In addition, the specific features described in the foregoing embodiments may be combined in any suitable manner, and in order to avoid unnecessary repetition, the present disclosure does not further describe various possible combinations.
Moreover, any combination between the various embodiments of the present disclosure is possible as long as it does not depart from the spirit of the present disclosure, which should also be construed as the disclosure of the present disclosure.
Claims (13)
1. A die cast aluminum alloy material, characterized in that the die cast aluminum alloy material comprises, based on the total weight of the die cast aluminum alloy material: 8.5 to 13 weight percent of Si,0.1 to 1 weight percent of Mn,0 to 0.5 weight percent of Fe,1.5 to 3 weight percent of Cu,0.5 to 2 weight percent of Mg,1.0 to 2.5 weight percent of Zn,0.02 to 0.5 weight percent of Ti,0.02 to 0.08 weight percent of Sr,0.02 to 0.1 weight percent of Zr,0 to 0.1 weight percent of Ni, less than 0.1 weight percent of impurities and the balance of Al.
2. The die-cast aluminum alloy material according to claim 1, characterized in that the die-cast aluminum alloy material further contains a Bi element; preferably, the die cast aluminum alloy material includes 0.01 to 0.1 wt% of Bi based on the total weight of the die cast aluminum alloy material.
3. The die cast aluminum alloy material as claimed in claim 2, wherein the die cast aluminum alloy material comprises, based on the total weight of the die cast aluminum alloy material: 8.8 to 12 weight percent of Si,0.2 to 0.8 weight percent of Mn,0 to 0.5 weight percent of Fe,1.5 to 3.0 weight percent of Cu,0.03 to 0.1 weight percent of Bi,0.5 to 2.0 weight percent of Mg,1.3 to 2.3 weight percent of Zn,0.02 to 0.5 weight percent of Ti,0.02 to 0.08 weight percent of Sr,0.02 to 0.1 weight percent of Zr,0 to 0.1 weight percent of Ni, less than 0.1 weight percent of impurities and the balance of Al.
4. The die-cast aluminum alloy material according to claim 1, wherein the ratio of the content of Cu element to the content of Bi element in the die-cast aluminum alloy material is 40 or less, optionally 50 or less.
5. The die cast aluminum alloy material according to any one of claims 1 to 4, characterized in that the die cast aluminum alloy material does not contain Mo.
6. The die cast aluminum alloy material as claimed in claim 1, wherein the bulk properties of the die cast aluminum alloy material include: the yield strength is 240MPa or more, the tensile strength is 320MPa or more, and the elongation is 1.5% or more.
7. A method of making a die-cast aluminum alloy material, comprising the steps of:
S1, smelting an alloy raw material mixture in a smelting furnace to obtain a first alloy melt, wherein the alloy raw material mixture comprises the following components: 8.5 to 13 weight percent of Si,0.1 to 1 weight percent of Mn,0 to 0.5 weight percent of Fe,1.5 to 3 weight percent of Cu,0.5 to 2 weight percent of Mg,1.0 to 2.5 weight percent of Zn,0.02 to 0.5 weight percent of Ti,0.02 to 0.08 weight percent of Sr,0.02 to 0.1 weight percent of Zr,0 to 0.1 weight percent of Ni, less than 0.1 weight percent of impurities and the balance of Al;
s2, carrying out degassing treatment, refining treatment and first slag skimming treatment on the first alloy melt in a middle converter to obtain a second alloy melt;
s3, carrying out heat preservation treatment and second slag skimming treatment on the second alloy melt in a side furnace to obtain a third alloy melt;
And S4, performing die casting treatment on the third alloy melt.
8. The method according to claim 7, wherein in step S1, the conditions of the smelting process include: the smelting temperature is 740-760 ℃, the smelting atmosphere temperature is 700-950 ℃, and the smelting time is 3-13 h.
9. The method according to claim 7, wherein in step S2, the conditions of the degassing treatment include: the degassing revolution is 400-500 r/min, the pressure of a degassing gas source is 0.35-0.45 MPa, the degassing temperature is 760-770 ℃, and the degassing time is 8-10 min;
The refining process includes: introducing nitrogen with refining agent powder into the first melt after degassing treatment to perform first refining, and introducing nitrogen with refining agent powder again to perform second refining
The first skimming process includes removing dross with a skimming tool.
10. The method according to claim 7, wherein in step S3, the conditions of the incubation treatment include: the heat preservation temperature is 660-680 ℃ and the heat preservation time is 30-40 min;
The second drossing process includes removing dross using a drossing tool.
11. The method according to claim 7, wherein in step S4, the conditions of the die casting process include: the casting pressure is above 60MPa, the high speed is above 3.5m/s, the vacuum degree is below 100mbar, the temperature of molten aluminum is 660-680 ℃, the temperature after die spraying is above 120-150 ℃, and the injection delay time is below 1 s.
12. A die cast aluminum alloy material produced by the method according to any one of claims 7 to 11.
13. An automotive structural member comprising a die-cast aluminum alloy material as claimed in any one of claims 1 to 6 and 12.
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