Summary of the invention
Purpose of the present invention is just for this needs, overcome the deficiency of the ADC12 diecasting aluminum-silicon alloy material existence of existing Japan, a kind of minicar engine cylinder body aluminium diecast alloy is provided, this aluminum alloy chemically optimizing components is reasonable, mechanical property is better than ADC12 height, processing performance, can satisfy the needs of G Engine Series cylinder body high-pressure casting technology and mechanical processing technique fully.
The main chemistry and the percentage composition of aluminum alloy materials of the present invention are: Cu1.5-3.0%, Si10.0-12.0%, Ng0.15-0.35%; The Al surplus; The content of impurity is: Zn≤0.90%, Fe≤0.90, Mn≤0.40%, Ni≤0.40%, Sn≤0.10%, Pb≤0.10%.
In the above-mentioned materials, the content of Chemical Composition Cu and Mg is chosen the comparison uniqueness, based on following reason:
Cu: when the Cu solid solution existed in the Al matrix or with the particulate state compound form, intensity, hardness, the mechanical behavior under high temperature that can significantly improve aluminium alloy were creep property, but unit elongation has reduction slightly; When Cu exists with netted compound form, will seriously reduce unit elongation, the intensity of aluminium alloy.
The chemical potential of Cu easily produces intergranular corrosion and stress corrosion than the Al height, and the solidity to corrosion that contains the Cu aluminium alloy reduces, when especially Cu exists with compound form, so the higher aluminium alloy of solidity to corrosion often limits the content of Cu.
In addition, the Al-Cu alloy has the solidification temperature range of broad, and the adding intensive of Cu reduces the flowing property of aluminium alloy, increases the hot cracking tendency of aluminium alloy.
Therefore, Cu content generally is controlled at 2~4%.
Magnesium Ng: the processing characteristics of the raising aluminium alloy of effect.
The Mg solid solution improves its hardness in the Al matrix, smear metal shortens, and is difficult for sticking cutter, and built-up edge reduces, and machined surface quality improves, and the wearing and tearing of cutter reduce.
Ng has reduced the electropotential of alloy, improves the solidity to corrosion of aluminium alloy.
Therefore, Mg content generally is controlled at 0.2~0.4%.
All the other impurity elements are chosen comparatively especially to be had:
Iron (Fe): it is the major impurity element in the aluminum silicon alloy, and it is mainly from furnace charge, crucible and melting instrument.To diecasting aluminum-silicon alloy, the high slightly Fe of content that allows Fe crosses low meeting because of content mold sticking takes place below 0.9, contains higher Fe and can make oxide film lose continuity, can improve mold sticking.In addition for the deleterious effect of eliminating the Fe phase can micro-Mn, Ni, Be etc. makes it exist with Chinese character shape complex compound form, eliminated the deleterious effect that original needle-like Fe weakens matrix mutually.Improve its disadvantageous effect to mechanical property, flowability, processibility.The content of Mn and Ni is about 0.4%.
They can form low melting point eutectic other impurity element Sn and Pd, and are totally unfavorable to thermal treatment, and the Sn of denier also can make the unit elongation after the thermal treatment significantly reduce, and therefore must limit the content of Sn, Pb below 0.10%.
Below be that aluminum alloy materials of the present invention (trade mark GYL-1) and the same type of material (ADC12) that Japan produces are contrasted:
The Chemical Composition contrast table
The trade mark | ????Cu | ????Si | ????Mg | ???Zn | ???Fe | ????Mn | ???AL | ????Ni | ????Sn | ????Pb |
?GYL-1 | ?1.5ˉ3.0?? | ?10.0ˉ12.0 | ???0.15ˉ0.35 | ??≤0.90 | ??≤0.90 | ??≤0.40 | Surplus | ??≤0.40 | ??≤0.10 | ?≤0.10 |
?ADC12 | ?1.5ˉ3.5 | ?9.6ˉ12.0 | ???≤0.30 | ??≤1.00 | ??≤1.30 | ??≤0.50 | Surplus | ??≤0.30 | ??≤0.30 | |
The mechanical property contrast table
The trade mark | State | ??σ
b(MPa)
| ????δ(%) |
??GYL-1 | Die casting | ????≥300 | ????≥1.5 |
??ADC12 | Die casting | ????147ˉ265 | ????0.7ˉ2.9 |
As seen, the chemical ingredients of this aluminium diecast alloy GYL-1 is more excellent, and tensile strength of mechanical property and unit elongation all are higher than ADC12.
Below be test and the detection case that this material is done:
1, show by cylinder body extrusion process test production practice: the comprehensive casting technique performance of GYL-1 die-cast aluminum alloy material is good.Concrete detected result
(1) casting dimension detects: cylinder block casting is through three-dimensional and scribing inspection, and satisfy ± 0.25mm accuracy requirement (CT6 level) little, the important mechanical workout position of casting deformation, and general casting dimension accuracy can reach the CT8 level, and basic symbols is closed drawing of rough casting requirement; Installation detects and meets JL472Q, JL474Q technology of gasoline engine standard; The die-cast rotor housing casting deformation is little, and process redundancy satisfies the machining dimension requirement.
(2) foundry goods anatomy: the inner quality of foundry goods mainly is the pore problem.Key is the size of pore, the position that what and pore exist.Analyse and observe the position specifying part position according to the drawing of rough casting and dissect sampling observation, the cylinder body die casting satisfies the related request that the drawing of rough casting proposes fully, has guaranteed that important position, mechanical workout hole pore-free exists.
(3) foundry goods appearance surfaces quality and qualified situation: aluminum alloy melt flowability good, the surface-brightening of die casting (roughness 1.6), profile not only attractive in appearance is complete, and the control of explanation press casting procedure better (is pressed chamber pressure, mould temperature, gate area, alloy temperature), the curdled appearance of foundry goods is normal, quality is even, the intensity height, alloy graining shrinks no decrepitation, and the macroscopic test quality satisfies the two class foundry goods requirements that the drawing of rough casting proposes.
(4) do not find decrepitation in the foundry goods of producing, the product stripping type is good.
Up to the present die casting production line accumulative total is produced 800 of cylinder block castings, and qualification rate reaches about 90%.Decrepitation is found at the end in the foundry goods of producing, and the product stripping type is good.
2, by the explanation of mechanical processing technique verification experimental verification: the mechanical processing technique of GYL-1 die-cast aluminum alloy material is functional.Mainly show as:
(1) step cover contacts with the Boring mill bearing and forms the crankshaft hole part, for heterotypic material is processed simultaneously.Cylinder body is not found distortion.
(2) cylinder body carries out leak test, because aluminium diecast alloy dense structure, and relatively evenly, leak test qualification rate height.
(3) cylinder body is because manufacturing procedure is many, and the situation of not finding the cramping distortion man-hour is located, added to the product clamping.
(4) surfacing after the testpieces machining is smooth, and surfaceness satisfies product requirement, particularly reaches the surfaceness Rz3.2 requirement of (being equivalent to Ra0.6), in addition have reach Ra 0.32.
(5) the testpieces machining reaches the high-precision requirement of product, particularly accuracy of form and position requirement, crankshaft hole circularity reach φ 0.008 in addition have reach φ 0.007.
(6) threaded hole of cylinder body is many, and former material bad tooth phenomenon occurs easily in the machine added-time, cause half-finished scrapping, and bad tooth phenomenon seldom appears in the cylinder body of this material, illustrates that the obdurability of this material is good.
Novel material is in the production process of batch machining, and every index that machine adds reaches the high-precision requirement of product, even exceeds a lot, and this shows this material excellent cutting performance, and dimensional stabilizing is good, and obdurability is good.
Through 500 hours working reliabilities close the frame test and. the entrucking road operation test, the running of an engine of novel alloy cylinder body assembling is good, cylinder body is ablated, distortion and seepage (oil, water) phenomenon, the complete machine performance index reach the company standard requirement.This petrol motor is qualified.
Show: novel alloy cylinder body working heat good stability, heat distortion amount is little; Under etches such as water, oil, steam, erosion resistance is preferably arranged; Has good fatigue resistance;
Working reliability bench testing in 500 hours: the GYL-1 cylinder body is in being assembled in the engine process, each component parts size no-float, through being assembled in JL472Q, JL474Q motoring run break-in inspection, do not find quality problems, after go through the test of 500 hours bed runs, the cylinder body working condition is normal, and seepage (oil, water) phenomenon does not take place, and running of an engine is good.After finishing, bench testing checks that the cylinder surface state is complete good.The crankcase planeness, the detected result of participating in the test front and back all meets the requirement of product design drawing, and abrasion loss shows novel alloy cylinder body good thermal stability in specialized range.Bench testing finishes in addition, and the crankcase cylinders bore dia is detected in the back, circle (post) degree detects, and abrasion loss is normal substantially.This is serious test to cylinder head with the thermal property of material.
The entrucking road operation test: the engine of GYL-1 cylinder body assembling and the star that is assemblied in Chang'an carry out 25000 kilometers road post-installation reviews tests in skid pad, Hainan, come and go in the way at whole road operation test and from Chongqing to Hainan, product is working properly good, the seepage phenomenon never takes place, and situation such as crackle, engine stripping inspection after test is finished, the test products surface is complete good.Cylinder body is being participated in the actual road test front and back, and principal dimensions such as relevant cylinder bore dia, circle (post) degree all are responsible for detection by relevant departments.Detected result shows: detect crankcase cylinders bore dia, the detection of circle (post) degree after the test, abrasion loss is normal substantially.The key technical indexes is all in product technology condition specialized range.
This shows that particularly Cu, Mg control is better to its main chemical compositions (Si, Cu, Mg) for aluminum alloy materials of the present invention, its detrimental impurity element control is strict; Obtain strength of alloy σ
b〉=300Mpa has enough strength and stiffness; Dimensional stability is better; Hot strength and resistance to sudden heating preferably; The working heat good stability, heat distortion amount is little; Under etches such as water, oil, steam, erosion resistance is preferably arranged; Have good fatigue resistance, can satisfy minicar engine cylinder body high-pressure casting technology and mechanical processing technique.The cost of alloy is low simultaneously.
Embodiment
Embodiment 1: one, batching composition
Batching is by following formula: W
i=A
i/ (1-E
i%) Wt calculates, in the formula:
A
iThe content X of each element in the alloy
i(%wt);
E
iThe burn out rate of each element during melting, it is as shown in the table;
The gross weight of Wt institute molten alloy;
W
iThe weight of each element in the melting once gross weight;
Melting loss of elements rate according to the form below:
Element aluminum silicon magnesium copper titanium
E
i(%〕3???1???15???5????15
Two, select following raw and auxiliary material for use: (if preparing 100 kilograms of alloys)
Aluminium ingot: 87 kilograms of industrial rafifinals;
Silicon: 11 kilograms of 1# silicon metals;
Master alloy: Al-50%Cu5 kilogram;
0.4 kilogram of metal pure magnesium ingot;
1 kilogram of refining agent and 0.5 kilogram of the agent of skimming etc.
Three, melting technology
The first step: adopt 20~30% talcum powder+5% water glass+suitable quantity of water and become coating;
Second step: all melting instruments are all in 250 ℃ of left and right sides paints and oven dry, in case increase iron in the fusion process;
The 3rd step: crucible is preheating to garnet, then the aluminium ingot after preheating is got 2/3 (58 kilograms) and put into crucible and melt;
The 4th step: when aluminium ingot is fused into starchiness, the silicon metal through preheating is pressed in the aluminium liquid for 9 kilograms, and 1/3 (29 kilograms) aluminium ingot of remainder is joined in the crucible, suppress the come-up of silicon;
The 5th step: material to be added all after the fusing, adds Al-Cu5 kilogram master alloy again, moltenly stirs after clear;
The 6th step: in 730 ℃ carry out refining at twice, skim after, rapidly 0.3 kilogram of MAG block is pressed in the aluminium liquid, molten skimming after clear left standstill 5~10min and got final product casting ingot-forming.
The Chemical Composition (mass percent) of the alloy material that obtains by above-mentioned technology is:
Cu?2.30、Si?10.90、Mg0.28、Zn?0.80、Fe?0.5、Mn0.17、Al?85.77、Ni0.06、Sb0.02。