EP1433552B1 - Pièce moulée composite en métal léger et son procédé de fabrication - Google Patents

Pièce moulée composite en métal léger et son procédé de fabrication Download PDF

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Publication number
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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EP
European Patent Office
Prior art keywords
light
alloy
intermediate layer
metal alloy
casting
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.)
Expired - Lifetime
Application number
EP20030025165
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German (de)
English (en)
Other versions
EP1433552A1 (fr
Inventor
Johann Wolf
Andreas Dr. Fent
Frank Dr. Doernenburg
Wolfram Wagener
Reinhard Jooss
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.)
Bayerische Motoren Werke AG
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Bayerische Motoren Werke AG
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Publication date
Application filed by Bayerische Motoren Werke AG filed Critical Bayerische Motoren Werke AG
Publication of EP1433552A1 publication Critical patent/EP1433552A1/fr
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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.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)

Claims (12)

  1. Procédé de fabrication d'une pièce moulée composite en métal léger selon lequel
    - on relie par fonte une pièce de départ en un premier alliage de métal léger à un second alliage de métal léger,
    - dans la zone de contact des alliages, on forme une couche de liaison et
    - avant de couler la pièce de départ (102), on la munit d'un revêtement (104),
    caractérisé en ce que
    - le premier alliage de métal léger (102, 202) est l'alliage d'aluminium AlSi17Cu4Mg, le second alliage de métal léger (206) est l'alliage Mg116Sr2 et le revêtement (104) est l'alliage aluminium-silicium AlSi12 et
    - au moins sur son côté extérieur, le revêtement (104) présente une structure poreuse de sorte que
    * pendant le procédé de coulée à haute température et sous pression élevée, le second alliage de métal léger (206) pénètre tout d'abord dans le revêtement poreux (104),
    * entre le premier et le second alliage de métal léger (202, 206), on forme une couche intermédiaire (204) ductile, déformable plastiquement, dans la pièce composite (200), et
    * on comprime cette couche intermédiaire contre le revêtement initialement poreux, l'alliage de magnésium (206) et la couche intermédiaire (204) étant reliés par une liaison par la matière.
  2. Procédé selon la revendication 1,
    caractérisé en ce que
    le revêtement (104) est appliqué par un procédé de pulvérisation à la flamme, notamment par pulvérisation à la flamme avec de la poudre ou du fil, par pulvérisation à l'arc électrique avec poudre et fil ou par pulvérisation au plasma.
  3. Procédé selon l'une des revendications précédentes,
    caractérisé en ce que
    le revêtement (104) a une épaisseur comprise entre 10 µm et 500 µm, notamment entre 100 µm et 140 µm.
  4. Procédé selon l'une des revendications précédentes,
    caractérisé en ce que
    le second alliage de métal léger (206) est relié par une opération de coulée au premier alliage de métal léger (102, 2002) à une température comprise entre 600°C et 800°C, notamment entre 680°C et 720°C, et sous une pression de 500 bar à 1200 bar et notamment à une pression comprise entre 850 bar et 900 bar.
  5. Procédé selon l'une des revendications précédentes,
    caractérisé en ce que
    pendant la coulée, le second alliage de métal léger (206) se fixe au revêtement poreux (104) en formant une couche intermédiaire (204) entre le premier et le second alliage de métal léger (202, 206) et comprime le revêtement (104).
  6. Pièce moulée composite en métal léger comprenant un premier alliage de métal léger (102, 202) ainsi qu'un second alliage de métal léger (206) relié à ce premier alliage,
    caractérisée en ce que
    - le premier alliage de métal léger (102, 202) est l'alliage d'aluminium AlSi17Cu4Mg et le second alliage de métal léger (206) est l'alliage MgA16SR2 à base de magnésium,
    - le premier et le second alliage de métal léger sont reliés par une couche intermédiaire (204) ductile, déformable plastiquement, et
    - la couche intermédiaire (204) est formée par la pénétration du second alliage de métal léger (206) dans le revêtement (104) tout d'abord poreux, formé d'aluminium-silicium AlSi12, le revêtement étant comprimé contre le revêtement initialement poreux, de façon que la couche intermédiaire (204) et le second alliage de métal léger (206) soient reliés par une liaison par la matière.
  7. Pièce moulée composite en métal léger selon la revendication 6,
    caractérisée en ce que
    la couche intermédiaire (204) est un alliage comprenant les éléments aluminium (Al), magnésium (Mg), silicium (Si), cuivre (Cu) et strontium (Sr).
  8. Pièce moulée composite en métal léger selon lune des revendications 6 ou 7,
    caractérisée en ce que
    la couche intermédiaire (204) a une épaisseur comprise entre 5 µm et 350 µm, notamment entre 70 µm et 120 µm.
  9. Pièce moulée composite en métal léger selon l'une des revendications 6 à 8,
    caractérisée en ce que
    la couche intermédiaire (204) a une dureté maximale de 400 HV, notamment comprise entre 250 HV à 350 HV.
  10. Pièce moulée composite en métal léger selon l'une des revendications 6 à 9,
    caractérisée en ce que
    la couche intermédiaire (204) a une ductilité d'au moins 0,05% en particulier d'au moins 0,1 %.
  11. Pièce moulée composite en métal léger selon l'une des revendications 6 à 10,
    caractérisée en ce que
    la couche intermédiaire (204) a une résistance à la traction Rm d'au moins 10 MPa et notamment d'au moins 20 MPa.
  12. Pièce moulée composite en métal léger selon l'une des revendications 6 à 11,
    caractérisée en ce que
    la couche intermédiaire (204) a une limite d'allongement Rp0,2 d'au moins 5 MPa en particulier d'au moins 10 MPa.
EP20030025165 2002-12-18 2003-11-04 Pièce moulée composite en métal léger et son procédé de fabrication Expired - Lifetime EP1433552B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE10259700 2002-12-18
DE2002159700 DE10259700A1 (de) 2002-12-18 2002-12-18 Verfahren zur Herstellung eines Leichtmetall-Verbundgussteil sowie Leichtmetall-Verbundgussteil

Publications (2)

Publication Number Publication Date
EP1433552A1 EP1433552A1 (fr) 2004-06-30
EP1433552B1 true EP1433552B1 (fr) 2009-05-06

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ID=32403998

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EP20030025165 Expired - Lifetime EP1433552B1 (fr) 2002-12-18 2003-11-04 Pièce moulée composite en métal léger et son procédé de fabrication

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EP (1) EP1433552B1 (fr)
DE (2) DE10259700A1 (fr)
ES (1) ES2322700T3 (fr)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102009013625A1 (de) 2009-03-11 2010-09-16 Elgan-Diamantwerkzeuge Gmbh & Co. Kg Verfahren zur Feinbearbeitung von Bohrungen, Bearbeitungswerkzeug und Bearbeitungsmaschine hierfür sowie Werkstück
CN103372641A (zh) * 2012-04-28 2013-10-30 宇宙钢丝绳有限公司 一种钢丝绳绳头浇铸方法

Family Cites Families (11)

* Cited by examiner, † Cited by third party
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 (fr) * 1955-09-29
JPS4946215B1 (fr) * 1970-04-02 1974-12-09
CH682307A5 (fr) * 1991-02-05 1993-08-31 Alusuisse Lonza Services Ag
JP3078411B2 (ja) * 1992-11-12 2000-08-21 株式会社ユニシアジェックス 複合アルミニウム部材の製造方法
DE19745725A1 (de) * 1997-06-24 1999-01-07 Ks Aluminium Technologie Ag Verfahren zum Herstellen eines Verbundgussteils
WO1998058755A1 (fr) * 1997-06-24 1998-12-30 Ks Aluminium-Technologie Ag Procede de production d'une piece de fonte composite
DE19733205B4 (de) * 1997-08-01 2005-06-09 Daimlerchrysler Ag Beschichtung für eine Zylinderlauffläche einer Hubkolbenmaschine aus einer übereutektischen Aluminium/Siliziumlegierung, Spritzpulver zu deren Herstellung und deren Verwendung
US6443211B1 (en) * 1999-08-31 2002-09-03 Cummins Inc. Mettallurgical bonding of inserts having multi-layered coatings within metal castings
DE10019793C1 (de) * 2000-04-20 2001-08-30 Federal Mogul Friedberg Gmbh Zylinderlaufbuchse für Verbrennungskraftmaschinen und Herstellungsverfahren

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Publication number Publication date
ES2322700T3 (es) 2009-06-25
EP1433552A1 (fr) 2004-06-30
DE50311494D1 (de) 2009-06-18
DE10259700A1 (de) 2004-07-15

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