EP0218035A1 - Alliages pour application à des températures élevées, à base d'aluminium contenant du silicium et obtenus par solidification rapide - Google Patents

Alliages pour application à des températures élevées, à base d'aluminium contenant du silicium et obtenus par solidification rapide Download PDF

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Publication number
EP0218035A1
EP0218035A1 EP86110835A EP86110835A EP0218035A1 EP 0218035 A1 EP0218035 A1 EP 0218035A1 EP 86110835 A EP86110835 A EP 86110835A EP 86110835 A EP86110835 A EP 86110835A EP 0218035 A1 EP0218035 A1 EP 0218035A1
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EP
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Prior art keywords
ranges
aluminum
article
alloys
alloy
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Ceased
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EP86110835A
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German (de)
English (en)
Inventor
Colin Mclean Adam
Richard Lister Bye
Santosh Kumar Das
David John Skinner
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Allied Corp
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Allied Corp
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Publication of EP0218035A1 publication Critical patent/EP0218035A1/fr
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/002—Making metallic powder or suspensions thereof amorphous or microcrystalline
    • B22F9/008—Rapid solidification processing
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0408—Light metal alloys
    • C22C1/0416—Aluminium-based alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C45/00—Amorphous alloys
    • C22C45/08—Amorphous alloys with aluminium as the major constituent

Definitions

  • the invention relates to aluminum based, Silicon containing, alloys having strength, ductility and toughness at ambient and elevated temperatures and relates to powder products produced from such alloys. More particularly, the invention relates to Al-Fe-Si alloys that have been rapidly solidified from the melt and thermomechanically processed into structural components having a combination of high strength, ductility and fracture toughness.
  • the invention provides an aluminum based alloy consisting essentially of the formula Al bal Fe a Si b X c , wherein X is at least one element selected from the group consisting of Mn, V, Cr, Mo, W, Nb, Ta, "a” ranges from 2.0 to 7.5 at%, “b” ranges form 0.5 to 3.0 at%, “c” ranges from 0.05 to 3.5 at% and the balance is aluminum plus incidental impurities, with the proviso that the ratio ⁇ Fe + X ⁇ :Si ranges from about 2.0:l to 5.0:l.
  • the alloys of the invention are subjected to rapid solidification processing, which modifies the alloy microstructure.
  • the rapid solidification processing method is one wherein the alloy is placed into the molten state and then cooled at a quench rate of at least about l05 to l07°C/sec. to form a solid substance.
  • this method should cool the molten metal at a rate of greater than about l06°C/sec, ie. via melt spinning, spat cooling or planar flow casting which forms a solid ribbon or sheet.
  • These alloys have an as cast microstructure which varies from a microeutectic to a microcellular structure, depending on the specific alloy chemistry. In alloys of the invention the relative proportions of these structures is not critical.
  • Consolidated articles are produced by compacting particles composed of an aluminum based alloy consisting essentially of the formula Al bal Fe a Si b X c , wherein X is at least one element selected from the group consisting of Mn, V, Cr, Mo, W, Nb, Ta, "a” ranges from 2.0 to 7.5 at%, “b” ranges from 0.5 to 3.0 at%, “c” ranges from 0.05 to 3.5 at% and the balance is aluminum plus incidental impurities, with the proviso that the ratio ⁇ Fe + X ⁇ :Si ranges from about 2.0:l to 5.0:l.
  • the particles are heated in a vacuum during the compacting step to a pressing temperataure varying from about 300 to 500°C, which minimizes coarsening of the dispersed, intermetallic phases.
  • the particles are put in a can which is then evacuated, heated to between 300°C and 500°C, and then sealed.
  • the sealed can is heated to between 300°C and 500°C in ambient atmosphere and compacted.
  • the compacted article is further consolidated by conventionally practiced methods such as extrusion, rolling or forging.
  • the consolidated article of the invention is composed of an aluminum solid solution phase containing a substantially uniform distribution of dispersoid intermetallic phase precipitates of approximate composition Al12 (Fe, X)3Si. These precipitates are fine intermetallics measuring less than l00nm. in all linear dimensions thereof. Alloys of the invention, containing these fine dispersed intermetallics are able to tolerate the heat and pressure associated with conventional consolidation and forming techniques such as forging, rolling, and extrusion without substantial growth or coarsening of these intermetallics that would otherwise reduce the strength and ductility of the consolidated article to unacceptably low levels.
  • the alloys can be used to produce near net shape articles, such as wheels, by forging, semi-finished articles, such as T-sections, by extrusion, and plate or sheet products by rolling that have a combination of strength and good ductility both at ambient temperature and at elevated temperatures of about 350°C.
  • the articles of the invention are more suitable for high temperature structural applications such as gas turbine engines, missiles, airframes, landing wheels etc.
  • the alloys of the invention consist essentially of the formula Al bal Fe a Si b X c , wherein X is at least one element selected from the group consisting of Mn, V, Cr, Mo, W, Nb, Ta, "a" ranges from 2.0 to 7.5 at%, “b” ranges from 0.5 to 3.0 at%, “c” ranges from 0.05 to 3.5 at% and the balance is aluminum plus incidental impurities, with the proviso that the ratio ⁇ Fe + X ⁇ :Si ranges from about 2.0:l to 5.0:l.
  • the rapid solidification processing typically employs a casting method wherein the alloy is placed into a molten state and then cooled at a quench rate of at least about l05 to l07°C/sec. on a rapidly moving casting substrate to form a solid ribbon or sheet.
  • This process should provide provisos for protecting the melt puddle from burning, excessive oxidation and physical disturbances by the air boundary layer carried with along with a moving casting surface.
  • this protection can be provided by a shrouding apparatus which contains a protective gas; such as a mixture of air or Co2 and SF6, a reducing gas, such as CO or an inert gas; around the nozzle.
  • the shrouding apparatus excludes extraneous wind currents which might disturb the melt puddle.
  • the as-cast alloy of the present invention may have a microeutectic microstructure or a microcellular microstructure.
  • Rapidly solidified alloys having the Al bal Fe a Si b X c composition (with the ⁇ Fe + X ⁇ :Si ratio proviso) described above have been processed into ribbons and then formed into particles by conventional comminution devices such as pulverizers, knife mills, rotating hammer mills and the like.
  • the comminuted powder particles have a size ranging from about -40 to 200 mesh, US standard sieve size.
  • the particles are placed in a vacuum of less than l0 ⁇ 4 torr (l.33 ⁇ l0 ⁇ 2 Pa.) preferably less than l0 ⁇ 5 torr (l.33 ⁇ l0 ⁇ 3 Pa.), and then compacted by conventional powder metallurgy techniques.
  • the particles are heated at a temperature ranging from about 300 to 550°C, preferably ranging from about 325 to 450°C, minimizing the growth or coarsening of the intermetallic phases therein.
  • the heating of the powder particles preferably occurs during the compacting step.
  • Suitable powder metallurgy techniques include direct powder extrusion by putting the powder in a can which has been evacuated and sealed under vacuum, vacuum hot compaction, blind die compaction in an extrusion or forging press, direct and indirect extrusion, conventional and impact forging, impact extrusion and combinations of the above.
  • the compacted consolidated article of the invention is composed of a substantially homogeneous dispersion of very small intermetallic phase precipitates within the aluminum solid solution matrix.
  • these intermetallic precipitates can be provided with optimized combinations of size, eg. diameter, and interparticle spacing. These characteristics afford the desired combination of high strength and ductility.
  • the precipitates are fine, usually sperical in shape, measuring less than about l00nm. in all linear dimentions thereof.
  • the volume fraction of these fine intermetallic precipitates ranges from about l0 to 50%, and preferably, ranges from about 20 to 35% to provide improved properties. Volume fractions of coarse intermetallic precipitates (ie. precipitates measuring more than about l00nm.
  • Figure 3(a) shows a transmission electron micrograph of a consolidated article of the invention (with composition Al 90.99 Fe 5.61 V 1.59 Si 1.81 ) that contains a substantially homogeneous dispersion of very small intermetallic phase precipitates, these dispersed intermetallic precipitates are generally spherical in shape and measure less than l00nm. in all dimensions thereof.
  • Figure 3(b) shows a transmission electron micrograph of a consolidated article of the same composition as shown in Figure 3(a) except that the Si content is zero (composition Al 92.8 Fe 5.61 V 1.59 ), and therefore outside the scope of the invention.
  • micrograph shows a dispersion of intermetallic phase precipitates that have different compositions than those shown in Figure 3(a). These dispersed intermetallic precipitates are generally polygonal or needle shaped and of a size such that they are deleterious to the mechanical properties (strength, ductility).
  • compositions of the fine intermetallic precipitates found in the consolidated article of the invention is approximately Al12(Fe,X)3Si.
  • this intermetallic composition represents about 80% of the fine dispersed intermetallic precipitates found in the consolidated article.
  • the addition of one or more of the elements listed as X when describing the alloy composition as the formula Al bal Fe a Si b X c (with the ⁇ Fe + X ⁇ :Si ratio of 2:l to 5:l) stabilize this metastable ternary intermetallic precipitate resulting in a general composition of about Al12(Fe, X)3Si.
  • Figure 4 To distinguish this intermetallic precipitate from ones with compositions close to this, reference is made to Figure 4.
  • the partial X-ray diffraction trace reveals the structure and lattice parameter of the intermetallic phase precipitate and of the aluminum matrix of a consolidated article of the invention.
  • the prefered stabilized intermetallic precipitate has a structure that is cubic (either body-­centered or primative cubic) and a lattice parameter that is about l.25 to l.28nm.
  • Further Figure 5 reveals the essential difference between alloys of the invention (Si containing alloys) and those outside the scope of the invention.
  • the differential scanning calorimetry trace shows the decomposition of the as-cast structure of alloy Al 90.99 Fe 5.61 V 1.59 Si 1.81 of the invention; (peak labled “A") into the preferred intermetallic precipitate of composition about Al12(Fe, V)3Si.
  • the other DSC trace shows the decomposition of an as-cast Al 92.8 Fe 5.61 V 1.59 alloy outside the scope of the invention; (peaks labled "B” and “C”) into the poygonal and needle shaped precipitates that are deleterious to the mechanical properties.
  • Alloys of the invention containing this fine dispersed intermetallic precipitate, are able to tolerate the heat and pressure of conventional powder metallurgy techniques without excessive growth or coarsening of the intermetallics that would otherwise reduce the strength and ducility of the consolidated article to unacceptably low levels.
  • alloys of the invention are able to withstand unconventionally high processing temperatures and withstand long exposure times at high temperataures during processing. Such temperatures and times are encountered during the production at near net-shape articles by forging and sheet or plate by rolling, for example.
  • Reference to Figure 6 illustrates the difference in thermal stability of a consolidated article of the invention (Al-Fe-V-Si alloy) and a consolidated article outside the scope of the invention (Al-Fe-V alloy).
  • alloys of the invention are particularly useful for forming high strength consolidated aluminum alloy articles.
  • the alloys are particularly advantageous because they can be compacted over a broad range of consolidation temperatures and still provide the desired combinations of strength and ductility in the compacted article.
  • Figure 7 demonstrates the essential differences between a consolidated article of the invention with one that is outside the scope of the invention.
  • the alloy containing Al 93.87 Fe 4.0 V 1.09 Si 1.04 when cast and consolidated using the methods of the invention has a microstructure as shown by transmission electron microscopy that exhibits a very fine dispersion of, generally spherical, intermetallic phase precipitates which imparts strength and ductility to the consolidated article of the invention.
  • These very fine intermetallic precipitates are those described in the body of the invention and have a ocmposition that is about Al12 (Fe, V)3 Si.
  • the alloy containing Al 94.91 Fe 4.0 V 1.09 when cast and consolidated within the conditions of the invention shows a transmission electron microstructure that exhibits polygonal or needle shaped intermetallic precipitates which imparts lower strength and very low ductility.
  • Table 3 shows the mechanical properties of specific alloys measured in uniaxial tension at a strain rate of approximately 5 ⁇ l0 ⁇ 4/sec. and at various elevated temperatures. Each selected alloy powder was vacuum hot pressed at a temperature of 350°C for l hr. to produce a 95 to l00% density preform slug. These slugs were extruded into rectangular bars with an extrusion ratio of l8:l at 385 to 400°C after holding at that temperature for l hr.
  • Selected alloys of the invention are capable of producing consolidated articles which have high strength at very high elevated temperatures e.g. 900°F.
  • Table 4 below shows the elevated strength of an Al 90.66 Fe 6.34 V 0.68 Si 2.32 alloy article consolidated by vacuum hot compaction at 350°C, and subsequently extruded at 400°C with an extrusion ratio of l8:l.
  • This alloy has a strength at 900°F which is l000% higher than conventional aluminum alloys. This is a further demonstration of the improved thermal stability of the preferred intermetallic precipitate that is formed in the consolidated articles of the invention.
  • the alloys of the invention are capable of producing consolidated articles which have high fracutre toughness when measured at room temperature.
  • Table 5 shows the fracture toughness for selected consolidated articles of the invention.
  • Each of the powder articles were consolidated by vacuum hot compaction at 350°C and subsequently extruded at 385°C at an extrusion ratio of l8:l.
  • Fracture toughness measurements were made on compact tension (CT) specimens of the consolidated articles of the invention under the ASTM E399 standard.
  • the alloys of the invention are capable of producing consolidated articles which have the form of a sheet having a width of at least 0.5" and a thickness of at least 0.0l0".
  • Table 6 shows the room temperature strength and ductility of selected consolidated sheet articles of the invention.
  • Such sheet was produced by vacuum hot pressing powder, followed by forging into approximately 1 ⁇ 2" thick plate, heating such forged plate to 400°C and then rolling into 0.l0 inch sheet. During this extensive thermal cycling the dispersed intermetallic precipitates may grow somewhat. Under these conditions the size of the dispersed intermetallic precipitates will be less than 500 nm, in any linear dimension thereof.
  • Table 7 shows the room temperature mechanical properties of specific alloys of the invention that have been consolidated by forging.
  • Each selected alloy powder was vacuum hot pressed at a temperature of 350°C for l hr. to provide a 95 to l00% density preform slug.
  • These slugs were subsequently forged at a temperature from about 450°C to 500°C after holding at that temperature for l hr.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Crystallography & Structural Chemistry (AREA)
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EP86110835A 1985-10-02 1986-08-05 Alliages pour application à des températures élevées, à base d'aluminium contenant du silicium et obtenus par solidification rapide Ceased EP0218035A1 (fr)

Applications Claiming Priority (2)

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US78277485A 1985-10-02 1985-10-02
US782774 1985-10-02

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EP0218035A1 true EP0218035A1 (fr) 1987-04-15

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JP (1) JPS6311639A (fr)
AU (1) AU587487B2 (fr)
NO (1) NO168899C (fr)

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1988007592A1 (fr) * 1987-03-30 1988-10-06 Allied-Signal Inc. Alliages d'aluminium solidifies rapidement et contenant du silicium, pour applications aux temperatures elevees
WO1988009825A1 (fr) * 1987-06-05 1988-12-15 Allied-Signal Inc. Alliage d'aluminium/vanadium/silicium/fer solidifie rapidement
EP0303100A1 (fr) * 1987-08-12 1989-02-15 Ykk Corporation Alliages d'aluminium à haute résistance et résistant à la chaleur, et procédé pour la fabrication d'articles façonnés avec ces alliages
WO1989006287A2 (fr) * 1988-01-11 1989-07-13 Allied-Signal Inc. Composites a matrice metallique a base d'aluminium
WO1990002210A1 (fr) * 1988-08-31 1990-03-08 Allied-Signal Inc. Extrusion, commandee par frottement, d'alliages a base d'aluminium a haute temperature se solidifiant rapidement
WO1992001078A1 (fr) * 1990-07-06 1992-01-23 Allied-Signal Inc. Alliages d'aluminum a temperature elevee et a base de silicium, de fer et d'aluminium
WO1992019780A2 (fr) * 1991-04-29 1992-11-12 Allied-Signal Inc. Alliages pour brasure a solidification rapide a base d'aluminium et de germanium
WO1992022398A1 (fr) * 1991-06-10 1992-12-23 Allied-Signal Inc. Alliage de brasage a solidification rapide a base d'aluminium et de magnesium
EP0445114B1 (fr) * 1988-04-15 1994-05-18 AlliedSignal Inc. Traitement thermomecanique d'alliages a base d'aluminium a temperature elevee rapidement solidifies
EP0638657A1 (fr) * 1993-08-09 1995-02-15 Honda Giken Kogyo Kabushiki Kaisha Procédé de forgeage de poudre d'alliage d'aluminium à haute limite d'élasticité et tenacité

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4347076A (en) * 1980-10-03 1982-08-31 Marko Materials, Inc. Aluminum-transition metal alloys made using rapidly solidified powers and method
EP0100287A1 (fr) * 1982-07-06 1984-02-08 CNRS, Centre National de la Recherche Scientifique Alliages amorphes ou microcristallins à base d'aluminium
EP0136508A2 (fr) * 1983-10-03 1985-04-10 AlliedSignal Inc. Alliages aluminium-métaux de transition ayant une haute résistance à température élevée
EP0143727A2 (fr) * 1983-11-29 1985-06-05 Cegedur Societe De Transformation De L'aluminium Pechiney Alliages à base d'aluminium présentant une grande stabilité à chaud

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4347076A (en) * 1980-10-03 1982-08-31 Marko Materials, Inc. Aluminum-transition metal alloys made using rapidly solidified powers and method
EP0100287A1 (fr) * 1982-07-06 1984-02-08 CNRS, Centre National de la Recherche Scientifique Alliages amorphes ou microcristallins à base d'aluminium
EP0136508A2 (fr) * 1983-10-03 1985-04-10 AlliedSignal Inc. Alliages aluminium-métaux de transition ayant une haute résistance à température élevée
EP0143727A2 (fr) * 1983-11-29 1985-06-05 Cegedur Societe De Transformation De L'aluminium Pechiney Alliages à base d'aluminium présentant une grande stabilité à chaud

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1988007592A1 (fr) * 1987-03-30 1988-10-06 Allied-Signal Inc. Alliages d'aluminium solidifies rapidement et contenant du silicium, pour applications aux temperatures elevees
WO1988009825A1 (fr) * 1987-06-05 1988-12-15 Allied-Signal Inc. Alliage d'aluminium/vanadium/silicium/fer solidifie rapidement
EP0303100A1 (fr) * 1987-08-12 1989-02-15 Ykk Corporation Alliages d'aluminium à haute résistance et résistant à la chaleur, et procédé pour la fabrication d'articles façonnés avec ces alliages
WO1989006287A2 (fr) * 1988-01-11 1989-07-13 Allied-Signal Inc. Composites a matrice metallique a base d'aluminium
WO1989006287A3 (fr) * 1988-01-11 1989-09-21 Allied Signal Inc Composites a matrice metallique a base d'aluminium
EP0445114B1 (fr) * 1988-04-15 1994-05-18 AlliedSignal Inc. Traitement thermomecanique d'alliages a base d'aluminium a temperature elevee rapidement solidifies
WO1990002210A1 (fr) * 1988-08-31 1990-03-08 Allied-Signal Inc. Extrusion, commandee par frottement, d'alliages a base d'aluminium a haute temperature se solidifiant rapidement
WO1992001078A1 (fr) * 1990-07-06 1992-01-23 Allied-Signal Inc. Alliages d'aluminum a temperature elevee et a base de silicium, de fer et d'aluminium
WO1992019780A3 (fr) * 1991-04-29 1992-12-23 Allied Signal Inc Alliages pour brasure a solidification rapide a base d'aluminium et de germanium
US5286314A (en) * 1991-04-29 1994-02-15 Alliedsignal Inc. Rapidly solidified aluminum-germanium base brazing alloys
WO1992019780A2 (fr) * 1991-04-29 1992-11-12 Allied-Signal Inc. Alliages pour brasure a solidification rapide a base d'aluminium et de germanium
WO1992022398A1 (fr) * 1991-06-10 1992-12-23 Allied-Signal Inc. Alliage de brasage a solidification rapide a base d'aluminium et de magnesium
US5332455A (en) * 1991-06-10 1994-07-26 Alliedsignal Inc. Rapidly solidified aluminum-magnesium base brazing alloys
EP0638657A1 (fr) * 1993-08-09 1995-02-15 Honda Giken Kogyo Kabushiki Kaisha Procédé de forgeage de poudre d'alliage d'aluminium à haute limite d'élasticité et tenacité
US5498393A (en) * 1993-08-09 1996-03-12 Honda Giken Kogyo Kabushiki Kaisha Powder forging method of aluminum alloy powder having high proof stress and toughness

Also Published As

Publication number Publication date
NO863525D0 (no) 1986-09-03
NO168899C (no) 1992-04-15
JPS6311639A (ja) 1988-01-19
NO168899B (no) 1992-01-06
AU6116486A (en) 1987-04-09
NO863525L (no) 1987-04-03
AU587487B2 (en) 1989-08-17

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