EP1400292A1 - Guss- Schmiedeteile aus Aluminium und Verfahren zu deren Herstellung - Google Patents

Guss- Schmiedeteile aus Aluminium und Verfahren zu deren Herstellung Download PDF

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Publication number
EP1400292A1
EP1400292A1 EP02256532A EP02256532A EP1400292A1 EP 1400292 A1 EP1400292 A1 EP 1400292A1 EP 02256532 A EP02256532 A EP 02256532A EP 02256532 A EP02256532 A EP 02256532A EP 1400292 A1 EP1400292 A1 EP 1400292A1
Authority
EP
European Patent Office
Prior art keywords
forging
forged
manufacturing
aluminum cast
forged product
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP02256532A
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English (en)
French (fr)
Inventor
Koji c/o Asahi Tec Corporation Kotani
Masatoshi Watanabe
Daisuke Machino
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Asahi Tec Corp
Hoei Industries Co Ltd
Original Assignee
Asahi Tec Corp
Hoei Industries Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to US10/235,995 priority Critical patent/US20040221931A1/en
Application filed by Asahi Tec Corp, Hoei Industries Co Ltd filed Critical Asahi Tec Corp
Priority to EP02256532A priority patent/EP1400292A1/de
Publication of EP1400292A1 publication Critical patent/EP1400292A1/de
Withdrawn legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/002—Hybrid process, e.g. forging following casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor

Definitions

  • the present invention relates to a method for manufacturing an aluminum cast-forged product in which forging is performed at a forging temperature higher than a general forging temperature of an aluminum alloy in a forging process to improve mechanical properties.
  • weight reduction techniques of an automobile are considered to be the most significant. It is because an automobile having reduced weight causes reduced load on a power source to allow reduction in fuel consumption of not only a gasoline engine but also of any power source.
  • a most approachable weight reduction technique is to change a material to be used to a weight reduction material. Typically, using an aluminum alloy material, many automobile parts such as an engine cylinder head or an engine cylinder block have been manufactured and used.
  • cast products are easy to manufacture, but there is a limit of improvement in mechanical strength.
  • forged products or squeeze cast products low speed injection molded products
  • the forged products or the squeeze cast products have a problem to be solved of high cost, and applications thereof are extremely limited.
  • the reasons why an aluminum forged product that uses a conventional A6061 alloy or the like and is preferably used for the suspension part for the automobile is high in cost include that the forged material per se is high in cost, and that the number of manufacturing steps is large. Further, for example, a squeeze cast product using an AC4CH alloy needs a large number of manufacturing steps and is low in injection speed, thus preventing an increase in productivity and cost reduction.
  • a manufacturing method by casting and forging (hereinafter also referred to as a casting and forging method) in which a material for forging (hereinafter also referred to as a forged material) is melted, cast, and cast to obtain a preform made of forged material, then the preform made of forged material is forged.
  • the casting and forging method according to embodiments of the present invention offer the following advantages, compared to a general forging method in which a forged material such as of a wrought material in the form of a round bar is bought, cut into a length according to a metal product to be produced, and then, for example, forged with a die.
  • unnecessary materials including burrs generated in a forging process can be repeatedly used as a starting material for a forged material to be melted.
  • burrs that are not used for producing a product account for at least appropriately 30% of a starting material before the die forging. That is, at most approximately 70% of the forged material are used for producing a product, causing a big waste. This waste can be saved.
  • the preform made of forged material obtained by casting can be formed into a shape to match a final product such that strength is increased by later forging but the forging process can be simplified.
  • the conventional forging method requires a step of cutting the forged material in the form of the round bar into the length according to the final product, and depending on shapes of the final product, requires a step of bending the forged material or a step of coarse forging before rough forging, but these steps can be omitted.
  • the present invention preferably provides a manufacturing method capable of reducing costs by using the above described casting and forging method and of producing an aluminum cast and forged product having improved mechanical properties compared to a conventional forging method.
  • the present invention may preferably provide an aluminum cast and forged product that has high tensile strength, high proof stress, and high elongation, and good mechanical properties, and is low in cost, using the manufacturing method capable of using recycled materials as a starting material and omitting processes.
  • the inventors have studied forging processes and found that a manufacturing method described below addresses the above described problem.
  • a method for manufacturing an aluminum cast-forged product which includes a step of casting a forged material of an aluminum alloy to obtain a preformmade of forgedmaterial, and a step of forging the preform made of forged material to obtain an aluminum cast-forged product, wherein said step of forging includes a step of heating the preform made of forged material at a temperature of from approximately 450°C to a melting point of the alloy.
  • a method for manufacturing an aluminum cast-forged product which includes a step of casting a forged material of an aluminum alloy to obtain a preformmade of forgedmaterial, a step of forging that includes a plural steps of forging the preform made of forged material to obtain an aluminum cast-forged product, wherein a first step of forging in said plural steps of forging is a step of forging the preform made of forged material by heating the preform made of forged material at a temperature of from approximately 450°C to a melting point of the alloy.
  • the step of forging may include a step of rough forging and a step of finish forging. It is preferable to carry out a step of rough forging by heating the preform made of forged material at a temperature of from approximately 450°C to a melting point of the alloy.
  • the step of rough forging is preferablyperformedbyheating the preform made of forged material at a temperature higher than a temperature in the step of finish forging.
  • the aluminum alloy preferably contains 0.2 to 2.
  • the forged material is preferably an aluminum alloy containing 0.4 to 0.8% by mass of silicon, 0.8 to 1.2% by mass of magnesium, 0.15 to 0.4% by mass of copper, and 0.04 to 0.35% by mass of chromium.
  • the aluminum alloy is one consisting essentially of 0.2 to 2. 5% by mass of silicon
  • the forged material is preferably an aluminum alloy containing 0.4 to 0.8% by mass of silicon, 0.8 to 1.2% by mass of magnesium, 0.15 to 0.4% by mass of copper, and 0.04 to 0.35% by mass of chromium.
  • a vehicle suspension part manufactured by the above-described method for manufacturing an aluminum cast-forged product.
  • the present invention provides an aluminum cast-forged product obtained by or obtainable by carrying out the manufacturing method of the invention.
  • the present invention relates to a method for manufacturing an aluminum cast-forged product obtained by forging a preform made of forged material obtained by casting a forged material of an aluminum alloy.
  • unnecessary burrs generated in forging can be included as a starting material, melted and cast.
  • No limit is placed on a shape of the preform made of forged material, and the preform made of forged material may be in the form of a round bar.
  • the preform made of forged material may have a shape so as to provide preferable machinability such that a final product obtains a strength increase effect by forging and a manufacturing process can be simplified.
  • a feature of the present invention is that a forging process is performed with the preform made of forged material heated to a temperature between approximately 450°C to a melting point.
  • the forging process includes a rough forging step and a finish forging step, and rough forging is preferably performed with the preform made of forged material heated to a temperature between approximately 450°C to a melting point.
  • the finish forging after the rough forging is preferably performed at a temperature lower than the temperature in the rough forging, for example, a temperature between approximately 370 to 450°C that are forging temperatures applied to a general aluminum alloy.
  • the method for manufacturing an aluminum cast-forged product according to the present invention can preferably producing a vehicle suspension part that is used in hostile environments and requires good mechanical properties, while reducing starting material costs and manufacturing costs.
  • Fig. 1 shows a block flow of an embodiment of a manufacturing process including the method for manufacturing an aluminum cast-forged product according to the present invention.
  • the manufacturing process of the aluminum cast and forged product includes, for example, a melting step 11 of melting a forged material 8 that is a starting material to obtain molten metal 3, a casting step 14 of casting the molten metal 3 to obtain a cast and cast preform made of forged material 6, a rough forging step 16 and a finish forging step 20 of forging the preform made of forged material 6 to obtain a forged material 4, and a trimming step 18 of trimming the forged material 4 to be a forged product.
  • the forged material 8 is an aluminum alloy containing 0.2 to 2.5% by mass of silicon. Taking Al-Mg-Si system heat treatment type aluminum alloy wrought material A6061 (hereinafter also simply referred to as an A6061 alloy) by the Japanese Industrial Standard H4140 as an example, the block flow in Fig. 1 will be described from the start.
  • the forged material 8 is not limited to the A6061 alloy.
  • the A6061 alloy contains, for example, 1.0% by mass of magnesium, 0.6% by mass of silicone, 0.25% by mass of copper, and 0.25% by mass of chromium in addition to pure aluminum as standard composition.
  • the forged material 8 may include unnecessary materials such as burr materials,burr receivers, or defectives, but in such as case, component analysis of the molten metal 3 obtained later by melting is preferably performed by emission spectrochemical analysis.
  • the forged material 8 is heated to be liquid metal, that is, the molten metal 3.
  • a fuel for heating may be any of liquid, solid, or gas.
  • An electrical heating source such as electrical resistance, electrical induction, or an arc, or an electronic heating method such as laser or electronic beam may be used.
  • a preferable melting furnace may be selected from furnaces of a crucible type, a channel type, a rotary type, or the like depending on heating methods.
  • the aluminum alloy can be melted with its temperature kept at approximately 680 to 780°C to obtain the molten metal 3.
  • the starting material includes the unnecessary materials such as the burr materials, it is preferable to clean the obtained molten metal 3 for reducing impurities.
  • the casting step 14 is a step of pouring the molten metal 3 into a mold, and after solidification, obtaining a cast product, that is, the preform made of forged material 6 as solid metal.
  • a preform made of forged material 6 having a shape similar to a shape of the final product can be obtained depending on molds, and it is preferable to determine the shape of the preform made of forged material 6 in view of a balance between an improvement effect of mechanical properties by later forging process and cost reduction by simplified forging process.
  • the low pressure casting is a method in which molten metal 3 is charged into a mold by low pressure by pressuring the molten metal 3 into a molten metal container by gas pressure, or vacuuming the molten metal 3 from the mold, and cast to obtain a cast product. It is preferable to inspect the preform made of forged material 6 obtained by casting for internal defects using, for example, a magnetic detector or an ultrasonic detector. It is because the forged material does not always have good castability, and confirming that there is no internal defect before die forging is preferable in terms of quality control.
  • the temperature of the material to be forged (preform made of forged material 6) required in the rough forging step 16 is preferably within a range between approximately 450°C to a melting point, which is higher than the general temperature.
  • a melting point of the A6061 alloy is approximately 652°C.
  • the temperature of the material to be forged is preferably lower than the temperature in the rough forging step 16, and for example, within a range between approximately 370 to 450°C generally required in forging the aluminum alloy. No limit is placed on means of the rough forging step 16 and the finish forging step 20, but when the A6061 alloy is used to produce a vehicle suspension part as the metal product 7, a pressing machine of 2000 to 4000 tons can be used.
  • the forging process is not limited to the two steps of the rough forging and the finish forging, but single forging is also preferable to simplify the manufacturing process.
  • the forged material 4 is cooled by, for example, a cooling step 17, and then separated into the forged product and the burr materials by, for example, the trimming step 18.
  • the forged product is then subjected to solution heat and aging treatment such as T3 to T6 by, for example, a heat treatment step 19 to improve the mechanical properties, thus becoming the final metal product 7.
  • solution heat and aging treatment such as T3 to T6 by, for example, a heat treatment step 19 to improve the mechanical properties, thus becoming the final metal product 7.
  • T4 and T6 treatments are desirable as heat treatment.
  • the preform made of forged material obtained by melting the starting material to obtain the molten metal and then casting can be formed into a shape similar to the shape of the final product rather than the round bar as the conventional forged material while obtaining the strength increasing effect by forging.
  • Main trace metals contained in the aluminum alloy used in casting and forging are silicon, magnesium, copper, and manganese.
  • Silicon is an element that, when contained, increases fluidity, reduces occurrence of shrinkage cavities, is precipitated as Mg 2 Si by being mixed with magnesium, and improves mechanical strength such as elongation, tensile strength, or proof stress.
  • the aluminum alloy preferably contains 0.4 to 0.8% by mass of silicon. Less than 0.2% by mass of silicon reduces castability from the molten metal, and more than 0.8% by mass of silicon reduces forging machinability, thus both are not preferable.
  • Magnesium is an element that, when contained, is precipitated in a matrix as Mg 2 Si by being mixed with silicon, and improves mechanical strength such as elongation, tensile strength, or proof stress.
  • the aluminum alloy preferably contains 0.8 to 1.2% by mass of magnesium. Less than 0.8% by mass of magnesium causes insufficient strength, and more than 1.2% by mass of magnesium is likely to cause casting defects, thus both are not preferable.
  • Copper is an element that, when contained, improves strength.
  • an Al-Cu or Al-Cu-Mg system precipitate can be obtained that is generated by aging treatment in which the forged product is cooled and then left at room temperature and crystals are precipitated over time.
  • the precipitate promotes the strength increase effect by precipitated Mg 2 Si as described above to increase strength.
  • the aluminum alloy preferably contains 0.15 to 0. 4% by mass of copper. Less than 0.15% by mass of copper does not increase strength, and more than 0.4% by mass of copper reduces corrosion resistance to prevent the strength from being kept over time, thus both are not preferable.
  • Chromium is an element that, when contained, restrains recrystallization of the aluminum alloy and growth of crystal grains. This causes texture in the aluminum alloy to be maintained in a fine manner to keep the strength.
  • the aluminum alloy When applied to the vehicle suspension part for an automobile or the like, the aluminum alloy preferably contains a trace amount of chromium, that is, 0 . 04 to 0.35% by mass of chromium, since the mechanical strength such as elongation, tensile strength, or proof stress needs to be held over time.
  • FIG. 2 shows an embodiment of the aluminum cast and forged product, and shows a knuckle steering of the vehicle suspension part.
  • An A6061 alloy material was prepared as a starting material, and the knuckle steering was manufactured by the following steps.
  • the starting material was melted at a predetermined melting temperature to obtain molten metal, and a preform made of forged material formed into a shape so as to provide desired machinability with respect to a shape of a final knuckle steering was cast at a predetermined casting temperature.
  • the preform made of forged material was forged with a die under predetermined rough forging load by a forging press at a rough forging temperature of 500°C (surface temperature) to obtain a rough forged product.
  • the rough forged product was again forged with a die under predetermined finish forging load by a forging press at a finish forging temperature of 430°C (surface temperature).
  • the forged product was trimmed, heated at 550°C for three hours as solution heat treatment using an atmosphere furnace, then cooled, and heated at 180°C for six hours as aging heat treatment to obtain the knuckle steering as a product.
  • the results of the example revealed that the aluminum cast and forged product produced by the method for manufacturing an aluminum cast-forged product according to the present invention has the mechanical properties superior in all of the tensile strength, the proof stress, and the elongation. Further, the results of the example in combination with the results of the comparative example revealed that the aluminum cast and forged product produced by the method for manufacturing an aluminum cast-forged product according to the present invention has the mechanical properties such that, in particular, elongation is remarkably improved with less variation, compared to the aluminum cast and forged product manufactured at the forging temperature lower than the temperature in the present invention.
  • the present invention can provide the aluminum cast and forged product that has high tensile strength, high proof stress, and high elongation, and good mechanical properties, using the manufacturing method capable of using recycled materials as the starting material, omitting processes, and reducing manufacturing costs.
  • the vehicle suspension part is widely supplied as the aluminum cast and forged product, the weight of the vehicle is reduced to achieve reduction in fuel cost, thus reducing discharged carbon dioxide and contributing to prevention of global warming.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Forging (AREA)
  • Vehicle Body Suspensions (AREA)
EP02256532A 2002-09-09 2002-09-20 Guss- Schmiedeteile aus Aluminium und Verfahren zu deren Herstellung Withdrawn EP1400292A1 (de)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US10/235,995 US20040221931A1 (en) 2002-09-09 2002-09-09 Aluminum cast -forged product and method for manufacturing aluminum cast-forged product
EP02256532A EP1400292A1 (de) 2002-09-09 2002-09-20 Guss- Schmiedeteile aus Aluminium und Verfahren zu deren Herstellung

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US10/235,995 US20040221931A1 (en) 2002-09-09 2002-09-09 Aluminum cast -forged product and method for manufacturing aluminum cast-forged product
EP02256532A EP1400292A1 (de) 2002-09-09 2002-09-20 Guss- Schmiedeteile aus Aluminium und Verfahren zu deren Herstellung

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2009006939A1 (de) 2007-07-09 2009-01-15 Bharat Forge Aluminiumtechnik Gmbh & Co. Kg Giessen-schmieden von knetlegierungen
CN102357628A (zh) * 2011-10-13 2012-02-22 北京机电研究所 铝合金枝杈类锻件成形的方法

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2473298B (en) * 2009-11-13 2011-07-13 Imp Innovations Ltd A method of forming a component of complex shape from aluminium alloy sheet

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS62187539A (ja) * 1986-02-13 1987-08-15 Asahi Tekko Kk アルミ鋳造後、鍛造の併用工法
JPH0673482A (ja) * 1992-08-26 1994-03-15 Honda Motor Co Ltd アルミニウム合金部材及びその製造方法
JPH1112675A (ja) * 1997-06-28 1999-01-19 Kobe Steel Ltd 熱間鍛造用アルミニウム合金及び熱間鍛造品の製造方法
EP0955113A1 (de) * 1998-05-04 1999-11-10 Emile Di Serio Verfahren zum Herstellen von Stücken aus Gusslegierungen , insbesondere aus Aluminium
JP2001107168A (ja) * 1999-10-06 2001-04-17 Kobe Steel Ltd 耐食性に優れた高強度高靱性アルミニウム合金鍛造材
JP2001105090A (ja) * 1999-10-06 2001-04-17 Yorozu Corp サスペンションリンクの製造方法
FR2803232A1 (fr) * 1999-12-29 2001-07-06 Serio Emile Di Procede perfectionne pour fabriquer des pieces en alliage leger

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP3695699B2 (ja) * 2000-10-11 2005-09-14 株式会社神戸製鋼所 アルミニウム合金製サスペンション部品のロール成形用素材の寸法決定方法およびアルミニウム合金製サスペンション部品の製造方法

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS62187539A (ja) * 1986-02-13 1987-08-15 Asahi Tekko Kk アルミ鋳造後、鍛造の併用工法
JPH0673482A (ja) * 1992-08-26 1994-03-15 Honda Motor Co Ltd アルミニウム合金部材及びその製造方法
JPH1112675A (ja) * 1997-06-28 1999-01-19 Kobe Steel Ltd 熱間鍛造用アルミニウム合金及び熱間鍛造品の製造方法
EP0955113A1 (de) * 1998-05-04 1999-11-10 Emile Di Serio Verfahren zum Herstellen von Stücken aus Gusslegierungen , insbesondere aus Aluminium
JP2001107168A (ja) * 1999-10-06 2001-04-17 Kobe Steel Ltd 耐食性に優れた高強度高靱性アルミニウム合金鍛造材
JP2001105090A (ja) * 1999-10-06 2001-04-17 Yorozu Corp サスペンションリンクの製造方法
FR2803232A1 (fr) * 1999-12-29 2001-07-06 Serio Emile Di Procede perfectionne pour fabriquer des pieces en alliage leger

Non-Patent Citations (4)

* Cited by examiner, † Cited by third party
Title
PATENT ABSTRACTS OF JAPAN vol. 012, no. 036 (M - 664) 3 February 1988 (1988-02-03) *
PATENT ABSTRACTS OF JAPAN vol. 018, no. 328 (C - 1215) 22 June 1994 (1994-06-22) *
PATENT ABSTRACTS OF JAPAN vol. 1999, no. 04 30 April 1999 (1999-04-30) *
PATENT ABSTRACTS OF JAPAN vol. 2000, no. 21 3 August 2001 (2001-08-03) *

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2009006939A1 (de) 2007-07-09 2009-01-15 Bharat Forge Aluminiumtechnik Gmbh & Co. Kg Giessen-schmieden von knetlegierungen
CN102357628A (zh) * 2011-10-13 2012-02-22 北京机电研究所 铝合金枝杈类锻件成形的方法

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