EP1433552B1 - Light metal composite casting and method for the production thereof - Google Patents
Light metal composite casting and method for the production thereof Download PDFInfo
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- EP1433552B1 EP1433552B1 EP20030025165 EP03025165A EP1433552B1 EP 1433552 B1 EP1433552 B1 EP 1433552B1 EP 20030025165 EP20030025165 EP 20030025165 EP 03025165 A EP03025165 A EP 03025165A EP 1433552 B1 EP1433552 B1 EP 1433552B1
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- Prior art keywords
- light
- alloy
- intermediate layer
- metal alloy
- casting
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- 238000005266 casting Methods 0.000 title claims description 39
- 238000000034 method Methods 0.000 title claims description 17
- 239000002905 metal composite material Substances 0.000 title description 12
- 238000004519 manufacturing process Methods 0.000 title description 5
- 229910001092 metal group alloy Inorganic materials 0.000 claims description 30
- 239000011248 coating agent Substances 0.000 claims description 26
- 238000000576 coating method Methods 0.000 claims description 26
- 239000002131 composite material Substances 0.000 claims description 18
- 229910000838 Al alloy Inorganic materials 0.000 claims description 14
- 229910000861 Mg alloy Inorganic materials 0.000 claims description 14
- 229910045601 alloy Inorganic materials 0.000 claims description 13
- 239000000956 alloy Substances 0.000 claims description 13
- 239000011777 magnesium Substances 0.000 claims description 13
- 239000000463 material Substances 0.000 claims description 12
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 11
- 229910052749 magnesium Inorganic materials 0.000 claims description 11
- 229910052782 aluminium Inorganic materials 0.000 claims description 6
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 6
- 239000000843 powder Substances 0.000 claims description 6
- 239000010949 copper Substances 0.000 claims description 5
- 238000010285 flame spraying Methods 0.000 claims description 5
- 238000007750 plasma spraying Methods 0.000 claims description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 2
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 2
- 229910052802 copper Inorganic materials 0.000 claims description 2
- 229910052710 silicon Inorganic materials 0.000 claims description 2
- 239000010703 silicon Substances 0.000 claims description 2
- 238000005507 spraying Methods 0.000 claims description 2
- 229910052712 strontium Inorganic materials 0.000 claims description 2
- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 claims description 2
- 238000005058 metal casting Methods 0.000 claims 8
- 229910000789 Aluminium-silicon alloy Inorganic materials 0.000 claims 2
- 239000004411 aluminium Substances 0.000 claims 1
- 230000035515 penetration Effects 0.000 claims 1
- 238000011161 development Methods 0.000 description 5
- 230000018109 developmental process Effects 0.000 description 5
- 239000011856 silicon-based particle Substances 0.000 description 4
- 238000002485 combustion reaction Methods 0.000 description 3
- 238000001000 micrograph Methods 0.000 description 3
- 229910001366 Hypereutectic aluminum Inorganic materials 0.000 description 2
- 238000005422 blasting Methods 0.000 description 2
- 238000004512 die casting Methods 0.000 description 2
- 230000000977 initiatory effect Effects 0.000 description 2
- 229910001234 light alloy Inorganic materials 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 230000007704 transition Effects 0.000 description 2
- 229910001018 Cast iron Inorganic materials 0.000 description 1
- 229910000676 Si alloy Inorganic materials 0.000 description 1
- CSDREXVUYHZDNP-UHFFFAOYSA-N alumanylidynesilicon Chemical compound [Al].[Si] CSDREXVUYHZDNP-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 239000010431 corundum Substances 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
- 238000011282 treatment Methods 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/0081—Casting in, on, or around objects which form part of the product pretreatment of the insert, e.g. for enhancing the bonding between insert and surrounding cast metal
Definitions
- the invention relates according to the preamble of claim 1, a method for producing a light metal composite casting. Furthermore, the invention relates to a light metal composite casting according to the preamble of claim 6.
- Out DE-A-197 46 167 a light metal component of magnesium die-casting is known in which in a growing area a threaded bush made of hardened aluminum during casting of the light metal component is partially enclosed by this. Out DE-A-197 46 167 It is known to coat the inserts in order to increase the adhesion between the insert and the casting material.
- the materials are light alloys, for example based on aluminum or magnesium, a temperature-related reaction occurs on the surface of the starting part during the casting process; The result is a bonding layer, which consists of a combination of the two materials.
- Such aluminum- or magnesium-based materials form a tie layer containing a high proportion of brittle magnesium phases, for example Al12Mg17; These phases disadvantageously cause a low mechanical strength of the connecting layer.
- one of the cast materials is a hypereutectic aluminum alloy, such as AlSi17Cu4Mg
- a hypereutectic aluminum alloy such as AlSi17Cu4Mg
- the invention has for its object to provide a method for producing a light metal composite casting mentioned above, which advantageously allows a compound of an initial part, which is formed essentially of a first light metal alloy, with a second light metal alloy by casting.
- an insulating, ductile intermediate layer should be formed, which on the one hand sufficient Strength and a sufficient line limit has to compensate for stresses between the two composite materials by plastic deformation and on the other a crack initiation, for example, on sharp aluminum particles of an aluminum alloy and crack propagation through brittle phases of a magnesium alloy by a separation of the Si particles from the magnesium phases prevented.
- a light metal composite casting comprising a first light metal alloy, in particular an aluminum alloy, as well as a second light metal alloy connected thereto, in particular a magnesium alloy, is to be provided, which has such an intermediate layer in the connection region between the light metal alloys.
- the output part is provided with a coating which during the casting process at high temperature and high pressure between the first and second light metal alloy in the composite casting forms a ductile, plastically deformable intermediate layer.
- the object is achieved according to the features of claim 6, wherein a ductile, plastically deformable intermediate layer between the first and second light metal alloy is formed.
- the first light metal alloy is an aluminum alloy, the second Alloy alloy a magnesium alloy and the coating an aluminum-silicon alloy.
- the aluminum alloy is preferably the alloy AlSi17Cu4Mg with the designation A390 and the magnesium alloy is the alloy MgAl6Sr2 with the designation AJ62 or alloys which are similar in each case at least in the relevant properties.
- the coating is applied by means of a flame spraying method, in particular by flame spraying with powder or wire, arc spraying with powder or wire or plasma spraying.
- the coating has a thickness of about 10 to 500 .mu.m, in particular from about 100 to 140 .mu.m.
- An at least on the outside porous structure of the coating has proven to be very favorable, which is compressed during the casting process and with which the second light metal alloy combines to form an intermediate layer between the first and second light metal alloys.
- the second light metal alloy at a temperature of about 600 to 800 ° C, in particular at about 680 ° C to 720 ° C and under a pressure of about 500 to 1200 bar, in particular about 850 to 900 bar, connected to the first light alloy in the casting process.
- the intermediate layer is formed by an alloy with the elements aluminum (Al), magnesium (Mg), silicon (Si), copper (Cu) and strontium (Sr).
- the intermediate layer of the light metal composite casting has a thickness of about 5 to 350 .mu.m, in particular from about 70 to 120 .mu.m, a hardness of at most 400 HV, in particular from about 250 to 350 HV, a ductility of at least 0.05 %, in particular of at least 0.1%, a tensile strength R m of at least 10 MPa, in particular of at least 20 Mpa, and a yield strength R p0.2 of at least 5 MPa, in particular of at least 10 MPa.
- an initial part made of an aluminum alloy such as AlSi17Cu4Mg with the designation A390, is produced by casting by means of gravity die casting.
- This output part which may well be in several parts and optionally provided on the outside with an example waffle-like structure pattern is surface-treated in a subsequent operation.
- a mechanical blasting treatment is carried out with a blasting medium such as corundum.
- a blasting medium such as corundum.
- other or further, for example, chemical surface treatments are performed.
- the output part is provided with a coating, in the present case an alloy of AlSi12 type is used and by means of a flame spraying method, in particular by flame spraying with powder or wire, arcing with powder or wire or plasma spraying is applied.
- the coating is primarily mechanically connected to the output part due to micro-region connections and at least on the outside has a porous structure;
- the coating has a thickness of about 10 to 500 .mu.m, in particular from about 100 to 140 .mu.m.
- the coated starting part is preheated to a temperature of about 400 to 550 ° C, in particular to about 480 ° C, to avoid cracks and to ensure a better connection of the subsequently applied magnesium casting.
- connection of the coated starting part takes place in a casting tool, in which the output part is inserted, wherein between the tool and the output part one or more mold spaces are formed, in which a molten casting material is introduced.
- the output part can be held in places on the tool wall adjacent and / or medium resolvable core elements.
- the coated starting part with a molten magnesium alloy such as MgAl6Sr2 with the designation AJ62, in the casting process at a temperature of about 600 to 800 ° C, especially at about 680 ° C to 720 ° C and under a pressure of about 500 up to 1200 bar, in particular about 850 to 900 bar connected, wherein the molten magnesium alloy combines very beneficial with the porous coating and the coating at the same time under the high pressure to about 70 to 90%, in particular to about 80% of their original thickness is compressed. Temperature and pressure caused a cohesive connection between the magnesium alloy and the coated output part.
- a molten magnesium alloy such as MgAl6Sr2 with the designation AJ62
- Fig. 2 shows a micrograph of a composite aluminum casting 200 from the hypereutectic aluminum alloy AlSi17Cu4Mg A390 and the magnesium alloy MgAl6Sr2 with the name AJ62 with intermediate layer. It can be seen how the molten magnesium alloy 206 has penetrated into the porous coating (212) and under pressure, the intermediate layer 204 has been formed. The intermediate layer 204 is compressed with respect to the original porous coating, with the magnesium alloy 206 and the intermediate layer 204 being adhesively bonded to one another. The transition from the intermediate layer 204 to the aluminum alloy 202 of the Output parts is much less fluent, which shows the more form-fitting nature of this connection.
- an insulating, ductile intermediate layer is formed which, on the one hand, has sufficient strength and a sufficient distance limit to compensate for stresses between the two composite materials by plastic deformation and, on the other hand, initiation of cracking, for example, on the sharp-edged silicon particles 208 of the aluminum alloy 202 and crack propagation by brittle phases of the magnesium alloy 206 prevented by a separation of the Si particles 208 of the magnesium phases.
- connection method according to the invention is particularly suitable for the production of the crankcase of internal combustion engines, in the light metal composite casting is therefore a crankcase for an internal combustion engine.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
- Manufacture Of Alloys Or Alloy Compounds (AREA)
- Cylinder Crankcases Of Internal Combustion Engines (AREA)
Description
Die Erfindung betrifft gemäß dem Oberbegriff des Anspruches 1 ein Verfahren zur Herstellung eines Leichtmetall-Verbundgussteils. Ferner betrifft die Erfindung ein Leichtmetall-Verbundgussteil gemäß dem Oberbegriff des Anspruches 6.The invention relates according to the preamble of claim 1, a method for producing a light metal composite casting. Furthermore, the invention relates to a light metal composite casting according to the preamble of claim 6.
Verfahren zur Herstellung von Verbundgussteilen sind allgemein bekannt. Beispielsweise beschreibt die
Aus
Bei Verbundgussteilen, bei welchen ein Ausgangsgussteil aus einem ersten Gusswerkstoff in einem Gießprozess mit einem weiteren Gusswerkstoff verbunden wird, entsteht demgemäss ein Verbund zwischen den Materialien, wobei im Kontaktbereich eine Verbindungsschicht gebildet wird.In composite castings, in which an output casting of a first casting material in a casting process with another casting material Accordingly, a bond between the materials is formed, wherein in the contact region, a bonding layer is formed.
Insbesondere falls es sich bei den Materialien um Leichtmetalllegierungen, beispielsweise auf Aluminium- oder Magnesiumbasis, handelt, kommt es während des Gießprozesses temperaturbedingt zu einer Reaktion an der Oberfläche des Ausgangsteils; es entsteht eine Verbindungsschicht, die aus einer Kombination der beiden Materialien besteht.In particular, if the materials are light alloys, for example based on aluminum or magnesium, a temperature-related reaction occurs on the surface of the starting part during the casting process; The result is a bonding layer, which consists of a combination of the two materials.
Derartige Materialien auf Aluminium- oder Magnesiumbasis bilden eine Verbindungsschicht, welche einen hohen Anteil an spröden Magnesium-Phasen, beispielsweise Al12Mg17, enthält; diese Phasen bewirken nachteiligerweise eine geringe mechanische Belastbarkeit der Verbindungsschicht.Such aluminum- or magnesium-based materials form a tie layer containing a high proportion of brittle magnesium phases, for example Al12Mg17; These phases disadvantageously cause a low mechanical strength of the connecting layer.
Des weiteren kommt es, insbesondere falls es sich bei einem der Gusswerkstoffe um eine übereutektische Aluminiumlegierung, wie AlSi17Cu4Mg, handelt, bei Verbundgussteilen zu einer verstärkten Rissneigung, so dass aufgrund thermischer und/oder mechanischer Beanspruchungen am Übergang bzw. in der Verbindungsschicht ausgehend von den dort vorhandenen kantigen Si-Partikel Risse entstehen, die den werkstofflichen Verbund zerstören.Furthermore, in particular if one of the cast materials is a hypereutectic aluminum alloy, such as AlSi17Cu4Mg, in the case of composite cast parts an increased tendency to crack occurs, so that, due to thermal and / or mechanical stresses at the transition or in the connecting layer, starting from there existing edged Si particles cracks, which destroy the composite material.
Der Erfindung liegt die Aufgabe zugrunde, ein Verfahren zur Herstellung eines eingangs genannten Leichtmetall-Verbundgussteils bereitzustellen, welches in vorteilhafter Weise eine Verbindung eines Ausgangsteiles, welches im wesentlichen aus einer ersten Leichtmetalllegierung gebildet ist, mit einer zweiten Leichtmetalllegierung durch Gießen ermöglicht.The invention has for its object to provide a method for producing a light metal composite casting mentioned above, which advantageously allows a compound of an initial part, which is formed essentially of a first light metal alloy, with a second light metal alloy by casting.
Zwischen den Leichtmetalllegierungen soll eine isolierende, duktile Zwischenschicht gebildet werden, welche zum einen eine ausreichende Festigkeit sowie eine ausreichende Streckengrenze besitzt, um Spannungen zwischen den beiden Verbundmaterialien durch plastische Deformation auszugleichen und zum anderen eine Rissinitiierung beispielsweise an scharfkantigen Silizium-Partikeln einer Aluminiumlegierung und eine Rissfortsetzung durch spröde Phasen einer Magnesiumlegierung durch eine Trennung der Si-Partikel von den Magnesium-Phasen verhindert.Between the light metal alloys an insulating, ductile intermediate layer should be formed, which on the one hand sufficient Strength and a sufficient line limit has to compensate for stresses between the two composite materials by plastic deformation and on the other a crack initiation, for example, on sharp aluminum particles of an aluminum alloy and crack propagation through brittle phases of a magnesium alloy by a separation of the Si particles from the magnesium phases prevented.
Ferner soll ein Leichtmetall-Verbundgussteil umfassend eine erste Leichtmetalllegierung, insbesondere eine Aluminiumlegierung, sowie eine mit dieser verbundene zweite Leichtmetalllegierung, insbesondere eine Magnesiumlegierung, bereitgestellt werden, welches im Verbindungsbereich zwischen den Leichtmetalllegierungen eine derartige Zwischenschicht aufweist.Furthermore, a light metal composite casting comprising a first light metal alloy, in particular an aluminum alloy, as well as a second light metal alloy connected thereto, in particular a magnesium alloy, is to be provided, which has such an intermediate layer in the connection region between the light metal alloys.
Die Lösung der Aufgabe erfolgt hinsichtlich des Verfahrens mit den Merkmalen des Anspruchs 1, wobei gemäß des zugrunde liegenden Gedankens vor dem Gießen das Ausgangsteil mit einer Beschichtung versehen wird, welche während des Gießprozesses bei hoher Temperatur und unter hohem Druck zwischen erster und zweiter Leichtmetalllegierung im Verbundgussteil eine duktile, plastisch deformierbare Zwischenschicht bildet.The object is achieved with regard to the method with the features of claim 1, wherein according to the underlying idea prior to casting the output part is provided with a coating which during the casting process at high temperature and high pressure between the first and second light metal alloy in the composite casting forms a ductile, plastically deformable intermediate layer.
In Hinblick auf das Leichtmetall-Verbundgussteil wird die Aufgabe gemäß den Merkmalen des Anspruch 6 gelöst, wobei eine duktile, plastisch deformierbare Zwischenschicht zwischen erster und zweiter Leichtmetallegierung gebildet ist.With regard to the light metal composite casting, the object is achieved according to the features of claim 6, wherein a ductile, plastically deformable intermediate layer between the first and second light metal alloy is formed.
Vorteilhafte Ausgestaltungen und Weiterbildungen des Verfahrens sowie des Leichtmetall-Verbundgussteils sind mit den Unteransprüchen angegeben.Advantageous embodiments and further developments of the method and of the light metal composite casting are specified by the subclaims.
Gemäß einer besonders vorteilhaften Weiterbildung des Verfahrens ist die erste Leichtmetalllegierung eine Aluminiumlegierung, die zweite Leichtmetalllegierung eine Magnesiumlegierung und die Beschichtung eine Aluminium-Silizium-Legierung. Insbesondere handelt es sich bei der Aluminiumlegierung bevorzugterweise um die Legierung AlSi17Cu4Mg mit der Bezeichnung A390 und bei der Magnesiumlegierung um die Legierung MgAl6Sr2 mit der Bezeichnung AJ62 oder um jeweils zumindest in den relevanten Eigenschaften ähnliche Legierungen.According to a particularly advantageous development of the method, the first light metal alloy is an aluminum alloy, the second Alloy alloy a magnesium alloy and the coating an aluminum-silicon alloy. In particular, the aluminum alloy is preferably the alloy AlSi17Cu4Mg with the designation A390 and the magnesium alloy is the alloy MgAl6Sr2 with the designation AJ62 or alloys which are similar in each case at least in the relevant properties.
Besonders bevorzugt ist es, wenn die Beschichtung mittels eines Flammspritzverfahrens, insbesondere durch Flammspritzen mit Pulver oder Draht, Lichtbogenspritzen mit Pulver oder Draht oder Plasmaspritzen, aufgebracht wird. Zweckmäßigerweise weist die Beschichtung eine Dicke von ca. 10 bis 500 µm, insbesondere von ca. 100 bis 140 µm, auf.It is particularly preferred if the coating is applied by means of a flame spraying method, in particular by flame spraying with powder or wire, arc spraying with powder or wire or plasma spraying. Conveniently, the coating has a thickness of about 10 to 500 .mu.m, in particular from about 100 to 140 .mu.m.
Als sehr günstig hat sich eine zumindest außenseitig poröse Struktur der Beschichtung erwiesen, welche während des Gießprozesses komprimiert wird und mit welcher' sich die zweite Leichtmetalllegierung unter Bildung einer Zwischenschicht zwischen erster und zweiter Leichtmetalllegierung verbindet.An at least on the outside porous structure of the coating has proven to be very favorable, which is compressed during the casting process and with which the second light metal alloy combines to form an intermediate layer between the first and second light metal alloys.
Gemäß einer besonders zweckmäßigen Weiterbildung des erfindungsgemäßen Verfahrens wird die zweite Leichtmetallegierung bei einer Temperatur von ca. 600 bis 800°C, insbesondere bei ca. 680°C bis 720°C und unter einem Druck von ca. 500 bis 1200 bar, insbesondere ca. 850 bis 900 bar, im Gießprozess mit der ersten Leichtmetallegierung verbunden.According to a particularly advantageous embodiment of the method according to the invention, the second light metal alloy at a temperature of about 600 to 800 ° C, in particular at about 680 ° C to 720 ° C and under a pressure of about 500 to 1200 bar, in particular about 850 to 900 bar, connected to the first light alloy in the casting process.
Bei einer besonders zu bevorzugenden Ausgestaltung des erfindungsgemäßen Leichtmetall-Verbundgussteils ist die Zwischenschicht durch eine Legierung mit den Elementen Aluminium (Al), Magnesium (Mg), Silizium (Si), Kupfer (Cu) und Strontium (Sr) gebildet.In a particularly preferred embodiment of the light metal composite casting according to the invention, the intermediate layer is formed by an alloy with the elements aluminum (Al), magnesium (Mg), silicon (Si), copper (Cu) and strontium (Sr).
Vorteilhafterweise weist die Zwischenschicht des Leichtmetall-Verbundgussteils eine Dicke von ca. 5 bis 350 µm, insbesondere von ca. 70 bis 120 µm, eine Härte von höchstens 400 HV, insbesondere von ca. 250 bis 350 HV, eine Duktilität von wenigstens 0,05 %, insbesondere von wenigstens 0,1 %, eine Zugfestigkeit Rm von wenigstens 10 MPa, insbesondere von wenigstens 20 Mpa, sowie eine Dehngrenze Rp0,2 von wenigstens 5 MPa, insbesondere von wenigstens 10 MPa, auf.Advantageously, the intermediate layer of the light metal composite casting has a thickness of about 5 to 350 .mu.m, in particular from about 70 to 120 .mu.m, a hardness of at most 400 HV, in particular from about 250 to 350 HV, a ductility of at least 0.05 %, in particular of at least 0.1%, a tensile strength R m of at least 10 MPa, in particular of at least 20 Mpa, and a yield strength R p0.2 of at least 5 MPa, in particular of at least 10 MPa.
Nachfolgend wird eine besonders zu bevorzugende Weiterbildung des erfindungsgemäßen Verfahrens sowie ein Leichtmetall-Verbundgussteil näher erläutert, dabei zeigen schematisch und beispielshaft
- Figur 1
- ein Schliffbild eines Ausgangsteiles aus einer Aluminiumlegierung mit einer Beschichtung,
- Figur 2
- ein Schliffbild eines Leichtmetall-Verbundgussteiles aus einer Aluminiumlegierung und einer Magnesiumlegierung mit Zwischenschicht.
- FIG. 1
- a micrograph of an aluminum alloy starting part with a coating,
- FIG. 2
- a microsection of a light metal composite casting of an aluminum alloy and a magnesium alloy with intermediate layer.
Einer besonders zu bevorzugenden Weiterbildung des erfindungsgemäßen Verfahrens zufolge wird in einem ersten Schritt ein Ausgangsteil aus einer Aluminiumlegierung wie AlSi17Cu4Mg mit der Bezeichnung A390 gießtechnisch im Kokillenguss hergestellt.According to a particularly preferred development of the method according to the invention, in a first step an initial part made of an aluminum alloy, such as AlSi17Cu4Mg with the designation A390, is produced by casting by means of gravity die casting.
Diese Ausgangsteil, welches durchaus auch mehrteilig sein kann und gegebenenfalls außenseitig mit einem beispielsweise waffelartigen Strukturmuster versehen ist, wird in einem folgenden Arbeitsgang oberflächenbehandelt. Gemäß der vorliegend beschriebenen Weiterbildung des Verfahrens wird eine mechanische Strahlbehandlung mit einem Strahlmittel wie Korund durchgeführt. Alternativ oder zusätzlich können jedoch auch andere bzw. weitere beispielsweise auch chemische Oberflächenbehandlungen durchgeführt werden.This output part, which may well be in several parts and optionally provided on the outside with an example waffle-like structure pattern is surface-treated in a subsequent operation. According to the development of the method described herein, a mechanical blasting treatment is carried out with a blasting medium such as corundum. Alternatively or additionally However, other or further, for example, chemical surface treatments are performed.
Wiederum in einem folgenden Arbeitsgang wird das Ausgangsteil mit einer Beschichtung versehen, wobei vorliegend eine Legierung von Typ AlSi12 zur Anwendung kommt und mittels eines Flammspritzverfahrens, insbesondere durch Flammspritzen mit Pulver oder Draht, Lichtbögenspritzen mit Pulver oder Draht oder Plasmaspritzen, aufgebracht wird.Again, in a subsequent operation, the output part is provided with a coating, in the present case an alloy of AlSi12 type is used and by means of a flame spraying method, in particular by flame spraying with powder or wire, arcing with powder or wire or plasma spraying is applied.
Die Beschichtung ist mit dem Ausgangsteil primär mechanisch aufgrund von Verbindungen im Mikrobereich verbunden und weist zumindest außenseitig eine poröse Struktur auf; die Beschichtung weist eine Dicke von ca. 10 bis 500 µm, insbesondere von ca. 100 bis 140 µm, auf.The coating is primarily mechanically connected to the output part due to micro-region connections and at least on the outside has a porous structure; The coating has a thickness of about 10 to 500 .mu.m, in particular from about 100 to 140 .mu.m.
Das beschichtete Ausgangsteil wird zur Vermeidung von Rissen und um eine bessere Anbindung des nachfolgend aufzubringenden Magnesiumgusses zu gewährleisten, auf eine Temperatur von ca. 400 bis 550°C, insbesondere auf ca. 480°C, vorgewärmt.The coated starting part is preheated to a temperature of about 400 to 550 ° C, in particular to about 480 ° C, to avoid cracks and to ensure a better connection of the subsequently applied magnesium casting.
Die Verbindung des beschichteten Ausgangsteils erfolgt in einem Gusswerkzeug, in welches das Ausgangsteil eingelegt wird, wobei zwischen Werkzeug und Ausgangsteil ein oder mehrere Formräume gebildet sind, in welche ein schmelzflüssiger Gusswerkstoff eingebracht wird. Das Ausgangsteils kann dabei Stellenweise an der Werkzeugwand anliegend und/oder mittel auflösbarer Kernelemente gehalten sein.The connection of the coated starting part takes place in a casting tool, in which the output part is inserted, wherein between the tool and the output part one or more mold spaces are formed, in which a molten casting material is introduced. The output part can be held in places on the tool wall adjacent and / or medium resolvable core elements.
Vorliegend wir das beschichtete Ausgangsteil mit einer schmelzflüssigen Magnesiumlegierung, wie MgAl6Sr2 mit der Bezeichnung AJ62, im Gießprozess bei einer Temperatur von ca. 600 bis 800°C, insbesondere bei ca. 680°C bis 720°C und unter einem Druck von ca. 500 bis 1200 bar, insbesondere ca. 850 bis 900 bar, verbunden, wobei die schmelzflüssige Magnesiumlegierung sich sehr vorteilhaft mit der porösen Beschichtung verbindet und die Beschichtung zugleich unter dem hohen Druck auf ca. 70 bis 90%, insbesondere auf ca. 80%, ihrer ursprünglichen Dicke komprimiert wird. Temperatur- und Druckbedingt entsteht zwischen der Magnesiumlegierung und dem beschichteten Ausgangsteil eine stoffschlüssige Verbindung.In the present case, the coated starting part with a molten magnesium alloy, such as MgAl6Sr2 with the designation AJ62, in the casting process at a temperature of about 600 to 800 ° C, especially at about 680 ° C to 720 ° C and under a pressure of about 500 up to 1200 bar, in particular about 850 to 900 bar connected, wherein the molten magnesium alloy combines very beneficial with the porous coating and the coating at the same time under the high pressure to about 70 to 90%, in particular to about 80% of their original thickness is compressed. Temperature and pressure caused a cohesive connection between the magnesium alloy and the coated output part.
Ein Schliffbild 100 eines gegossenen Ausgangsteiles 102 aus der Aluminiumlegierung AlSi17Cu4Mg mit der Bezeichnung A390, welches in Vorbereitung für eine gießtechnische Verbindung mit einer Leichtmetalllegierung bereits mit einer Beschichtung 104 aus AlSi12 versehen ist, ist in
Zwischen der Aluminiumlegierung 202 und der Magnesiumlegierung 206 ist eine isolierende, duktile Zwischenschicht gebildet, welche zum einen eine ausreichende Festigkeit sowie eine ausreichende Streckengrenze besitzt, um Spannungen zwischen den beiden Verbundmaterialien durch plastische Deformation auszugleichen und zum anderen eine Rissinitiierung beispielsweise an den scharfkantigen Silizium-Partikeln 208 der Aluminiumlegierung 202 und eine Rissfortsetzung durch spröde Phasen der Magnesiumlegierung 206 durch eine Trennung der Si-Partikel 208 von den Magnesium-Phasen verhindert.Between the
Das erfindungsgemäße Verbindungsverfahren eignet sich in besonderem Maße für die Herstellung vom Kurbelgehäusen von Brennkraftmaschinen, bei dem Leichtmetall-Verbundgussteil handelt es sich dementsprechend um ein Kurbelgehäuse für eine Brennkraftmaschine.The connection method according to the invention is particularly suitable for the production of the crankcase of internal combustion engines, in the light metal composite casting is therefore a crankcase for an internal combustion engine.
Claims (12)
- A method of producing a composite light-metal casting, wherein- a starting part made of a first light-metal alloy is connected to a second light-metal alloy by casting and- a connecting layer is formed in the contact region between the alloys and- before casting, the starting part (102) is given a coating (104),characterised in that- the first light-metal alloy (102, 202) is the aluminium alloy AlSi17Cu4Mg, the second light-metal alloy (206) is the magnesium-based alloy MgAl6Sr2 and the coating (104) is the aluminium silicon alloy AlSi12, and- the coating (104) is given a porous structure, at least on the outside, so that- during the casting process at high temperature and high pressure, the second light-metal alloy (206) penetrates into the initially porous coating (104) and- a ductile plastically deformable intermediate layer (204) formed between the first and the second light-metal alloy (202, 206) is compressed relative to the initially porous coating, wherein the magnesium alloy (206) and the intermediate layer (204) are connected to one another via the material.
- A method according to claim 1, characterised in that the coating (104) is applied by flame spraying, especially with powder or wire, or by arc spraying with powder or wire or by plasma spraying.
- A method according to any of the preceding claims, characterised in that the coating (104) has a thickness of 10 to 500 µm, especially 100 to 140 µm.
- A method according to any of the preceding claims, characterised in that the second light-metal alloy (206) is connected to the first light-metal alloy (102, 202) at a temperature of 600 to 800°C, especially at about 680 to 720°C, and at a pressure of 500 to 1200 bar, especially 850 to 900 bar, in the casting process.
- A method according to any of the preceding claims, characterised in that during the casting process the second light-metal alloy (206) is connected to the porous coating (104), forming an intermediate layer (204) between the first and the second light-metal alloy (202, 206), and the coating (104) is compressed.
- A composite light-metal casting comprising a first light-metal alloy (102, 202) connected to a second light-metal alloy (206), characterised in that- the first light-metal alloy (102, 202) is the aluminium alloy AlSi17Cu4Mg and the second light-metal alloy (206) is the magnesium-based alloy MgAl6Sr2 and- the first and the second light-metal alloy are connected by a ductile, plastically deformable intermediate layer (204), wherein- the intermediate layer (204) is formed by penetration of the second light-metal alloy (206) into the initially porous layer (104) of the aluminium-silicon alloy AlSi12, wherein the coating is compressed relative to the initially porous coating, so that the intermediate layer (204) and the second light-metal alloy (206) are connected to one another via the material.
- A composite light-metal casting according to claim 6, characterised in that the intermediate layer (204) is made from an alloy containing the elements aluminium (Al), magnesium (Mg), silicon (Si), copper (Cu) and strontium (Sr).
- A composite light-metal casting according to claim 6 or claim 7, characterised in that the intermediate layer (204) has a thickness of 5 to 350 µm, especially 70 to 120 µm.
- A composite light-metal casting according to any of claims 6 to 8, characterised in that the intermediate layer (204) has hardness up to 400 HV, especially 250 to 350 HV.
- A composite light-metal casting according to any of claims 6 to 9, characterised in that the intermediate layer (204) has a ductility of at least 0.05%, especially at least 0.1 %.
- A composite light-metal casting according to any of claims 6 to 10, characterised in that the intermediate layer (204) has a tensile strength Rm of at least 10 MPa, especially at least 20 MPa.
- A composite light-metal casting according to any of claims 6 to 11, characterised in that the intermediate layer (204) has a proof strength Rp0.2 of at least 5 MPa, especially at least 10 MPa.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE10259700 | 2002-12-18 | ||
| DE2002159700 DE10259700A1 (en) | 2002-12-18 | 2002-12-18 | Process for producing a light metal composite casting and light metal composite casting |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| EP1433552A1 EP1433552A1 (en) | 2004-06-30 |
| EP1433552B1 true EP1433552B1 (en) | 2009-05-06 |
Family
ID=32403998
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| EP20030025165 Expired - Lifetime EP1433552B1 (en) | 2002-12-18 | 2003-11-04 | Light metal composite casting and method for the production thereof |
Country Status (3)
| Country | Link |
|---|---|
| EP (1) | EP1433552B1 (en) |
| DE (2) | DE10259700A1 (en) |
| ES (1) | ES2322700T3 (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102009013625A1 (en) | 2009-03-11 | 2010-09-16 | Elgan-Diamantwerkzeuge Gmbh & Co. Kg | Method for fine machining of bores, machining tool and processing machine therefor as well as workpiece |
| CN103372641A (en) * | 2012-04-28 | 2013-10-30 | 宇宙钢丝绳有限公司 | Steel wire rope head casting method |
Family Cites Families (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB689224A (en) * | 1950-04-03 | 1953-03-25 | Aluminium Lab Ltd | Process for the production of light-metal castings having metallic inserts |
| GB747137A (en) * | 1953-03-06 | 1956-03-28 | Metallgesellschaft Ag | Method of producing compound castings between a metal or alloy and magnesium or magnesium alloys |
| NL97314C (en) * | 1955-09-29 | |||
| JPS4946215B1 (en) * | 1970-04-02 | 1974-12-09 | ||
| CH682307A5 (en) * | 1991-02-05 | 1993-08-31 | Alusuisse Lonza Services Ag | |
| JP3078411B2 (en) * | 1992-11-12 | 2000-08-21 | 株式会社ユニシアジェックス | Method for manufacturing composite aluminum member |
| DE19745725A1 (en) * | 1997-06-24 | 1999-01-07 | Ks Aluminium Technologie Ag | Method of making a composite casting |
| WO1998058755A1 (en) * | 1997-06-24 | 1998-12-30 | Ks Aluminium-Technologie Ag | Method for producing a composite casting part |
| DE19733205B4 (en) * | 1997-08-01 | 2005-06-09 | Daimlerchrysler Ag | Coating for a cylinder surface of a reciprocating engine of a hypereutectic aluminum / silicon alloy, spray powder for their production and their use |
| US6443211B1 (en) * | 1999-08-31 | 2002-09-03 | Cummins Inc. | Mettallurgical bonding of inserts having multi-layered coatings within metal castings |
| DE10019793C1 (en) * | 2000-04-20 | 2001-08-30 | Federal Mogul Friedberg Gmbh | Cylinder liner for internal combustion engines and manufacturing processes |
-
2002
- 2002-12-18 DE DE2002159700 patent/DE10259700A1/en not_active Ceased
-
2003
- 2003-11-04 DE DE50311494T patent/DE50311494D1/en not_active Expired - Lifetime
- 2003-11-04 ES ES03025165T patent/ES2322700T3/en not_active Expired - Lifetime
- 2003-11-04 EP EP20030025165 patent/EP1433552B1/en not_active Expired - Lifetime
Also Published As
| Publication number | Publication date |
|---|---|
| DE10259700A1 (en) | 2004-07-15 |
| EP1433552A1 (en) | 2004-06-30 |
| DE50311494D1 (en) | 2009-06-18 |
| ES2322700T3 (en) | 2009-06-25 |
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