EP1466038B1 - Magnesium-zirconium alloying - Google Patents
Magnesium-zirconium alloying Download PDFInfo
- Publication number
- EP1466038B1 EP1466038B1 EP03700086A EP03700086A EP1466038B1 EP 1466038 B1 EP1466038 B1 EP 1466038B1 EP 03700086 A EP03700086 A EP 03700086A EP 03700086 A EP03700086 A EP 03700086A EP 1466038 B1 EP1466038 B1 EP 1466038B1
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- EP
- European Patent Office
- Prior art keywords
- zirconium
- magnesium
- sponge
- particles
- master alloy
- 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
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- QRNPTSGPQSOPQK-UHFFFAOYSA-N magnesium zirconium Chemical compound [Mg].[Zr] QRNPTSGPQSOPQK-UHFFFAOYSA-N 0.000 title claims description 33
- 238000005275 alloying Methods 0.000 title claims description 30
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims abstract description 189
- 229910052726 zirconium Inorganic materials 0.000 claims abstract description 169
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims abstract description 76
- 229910052749 magnesium Inorganic materials 0.000 claims abstract description 76
- 239000011777 magnesium Substances 0.000 claims abstract description 75
- 239000002245 particle Substances 0.000 claims abstract description 69
- 229910000861 Mg alloy Inorganic materials 0.000 claims abstract description 22
- 229910045601 alloy Inorganic materials 0.000 claims description 48
- 239000000956 alloy Substances 0.000 claims description 48
- 238000000034 method Methods 0.000 claims description 29
- 238000005266 casting Methods 0.000 claims description 6
- 150000001875 compounds Chemical class 0.000 claims description 6
- OMQSJNWFFJOIMO-UHFFFAOYSA-J zirconium tetrafluoride Chemical class F[Zr](F)(F)F OMQSJNWFFJOIMO-UHFFFAOYSA-J 0.000 claims description 6
- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 claims description 4
- 239000011248 coating agent Substances 0.000 claims description 4
- 238000000576 coating method Methods 0.000 claims description 4
- 239000011737 fluorine Substances 0.000 claims description 4
- 229910052731 fluorine Inorganic materials 0.000 claims description 4
- 238000002156 mixing Methods 0.000 claims description 4
- 239000002344 surface layer Substances 0.000 claims description 2
- 238000003756 stirring Methods 0.000 abstract description 27
- 239000000155 melt Substances 0.000 abstract description 23
- 238000001000 micrograph Methods 0.000 abstract description 13
- KRHYYFGTRYWZRS-UHFFFAOYSA-N Fluorane Chemical compound F KRHYYFGTRYWZRS-UHFFFAOYSA-N 0.000 abstract description 10
- 238000007670 refining Methods 0.000 abstract description 9
- 238000000879 optical micrograph Methods 0.000 abstract 1
- 238000007792 addition Methods 0.000 description 28
- 239000002253 acid Substances 0.000 description 12
- 238000004458 analytical method Methods 0.000 description 8
- 238000004519 manufacturing process Methods 0.000 description 8
- 230000008569 process Effects 0.000 description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 8
- 239000000843 powder Substances 0.000 description 7
- -1 zirconium halides Chemical class 0.000 description 7
- 230000007246 mechanism Effects 0.000 description 6
- DUNKXUFBGCUVQW-UHFFFAOYSA-J zirconium tetrachloride Chemical class Cl[Zr](Cl)(Cl)Cl DUNKXUFBGCUVQW-UHFFFAOYSA-J 0.000 description 6
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 5
- 239000012535 impurity Substances 0.000 description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 5
- 238000002360 preparation method Methods 0.000 description 5
- 239000000126 substance Substances 0.000 description 5
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 4
- 238000013459 approach Methods 0.000 description 4
- 150000004820 halides Chemical class 0.000 description 4
- 239000010410 layer Substances 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 229910052751 metal Inorganic materials 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- 229910017604 nitric acid Inorganic materials 0.000 description 4
- 230000003647 oxidation Effects 0.000 description 4
- 238000007254 oxidation reaction Methods 0.000 description 4
- 239000010959 steel Substances 0.000 description 4
- 229910052782 aluminium Inorganic materials 0.000 description 3
- 229910052799 carbon Inorganic materials 0.000 description 3
- 239000007795 chemical reaction product Substances 0.000 description 3
- 230000003247 decreasing effect Effects 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 238000002474 experimental method Methods 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- 150000002739 metals Chemical class 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 229910052710 silicon Inorganic materials 0.000 description 3
- 229910052845 zircon Inorganic materials 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- WCUXLLCKKVVCTQ-UHFFFAOYSA-M Potassium chloride Chemical compound [Cl-].[K+] WCUXLLCKKVVCTQ-UHFFFAOYSA-M 0.000 description 2
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 description 2
- 229910001093 Zr alloy Inorganic materials 0.000 description 2
- 229910007932 ZrCl4 Inorganic materials 0.000 description 2
- 239000012300 argon atmosphere Substances 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 239000003638 chemical reducing agent Substances 0.000 description 2
- 239000000460 chlorine Substances 0.000 description 2
- 238000011109 contamination Methods 0.000 description 2
- 238000004090 dissolution Methods 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 238000000227 grinding Methods 0.000 description 2
- 229910052735 hafnium Inorganic materials 0.000 description 2
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 description 2
- 229910052739 hydrogen Inorganic materials 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 229910052757 nitrogen Inorganic materials 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 238000006722 reduction reaction Methods 0.000 description 2
- 239000004576 sand Substances 0.000 description 2
- PUZPDOWCWNUUKD-UHFFFAOYSA-M sodium fluoride Chemical compound [F-].[Na+] PUZPDOWCWNUUKD-UHFFFAOYSA-M 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 229910052718 tin Inorganic materials 0.000 description 2
- 239000011701 zinc Substances 0.000 description 2
- VXEGSRKPIUDPQT-UHFFFAOYSA-N 4-[4-(4-methoxyphenyl)piperazin-1-yl]aniline Chemical compound C1=CC(OC)=CC=C1N1CCN(C=2C=CC(N)=CC=2)CC1 VXEGSRKPIUDPQT-UHFFFAOYSA-N 0.000 description 1
- 229910018137 Al-Zn Inorganic materials 0.000 description 1
- 229910018573 Al—Zn Inorganic materials 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 229910003910 SiCl4 Inorganic materials 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 229910001297 Zn alloy Inorganic materials 0.000 description 1
- 229910007998 ZrF4 Inorganic materials 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- 238000003483 aging Methods 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- WDIHJSXYQDMJHN-UHFFFAOYSA-L barium chloride Chemical compound [Cl-].[Cl-].[Ba+2] WDIHJSXYQDMJHN-UHFFFAOYSA-L 0.000 description 1
- 229910001626 barium chloride Inorganic materials 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000005587 bubbling Effects 0.000 description 1
- 239000002775 capsule Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 150000003841 chloride salts Chemical class 0.000 description 1
- 229910052801 chlorine Inorganic materials 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000007865 diluting Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000004508 fractional distillation Methods 0.000 description 1
- 239000012634 fragment Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 230000002401 inhibitory effect Effects 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- RBTARNINKXHZNM-UHFFFAOYSA-K iron trichloride Chemical compound Cl[Fe](Cl)Cl RBTARNINKXHZNM-UHFFFAOYSA-K 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 230000003389 potentiating effect Effects 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 238000011946 reduction process Methods 0.000 description 1
- 230000004044 response Effects 0.000 description 1
- 239000011833 salt mixture Substances 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- FDNAPBUWERUEDA-UHFFFAOYSA-N silicon tetrachloride Chemical compound Cl[Si](Cl)(Cl)Cl FDNAPBUWERUEDA-UHFFFAOYSA-N 0.000 description 1
- 239000005049 silicon tetrachloride Substances 0.000 description 1
- 239000011780 sodium chloride Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- 238000009834 vaporization Methods 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 150000003755 zirconium compounds Chemical class 0.000 description 1
- 229910001928 zirconium oxide Inorganic materials 0.000 description 1
- XLMQAUWIRARSJG-UHFFFAOYSA-J zirconium(iv) iodide Chemical compound [Zr+4].[I-].[I-].[I-].[I-] XLMQAUWIRARSJG-UHFFFAOYSA-J 0.000 description 1
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
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- 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
- C22C1/02—Making non-ferrous alloys by melting
- C22C1/03—Making non-ferrous alloys by melting using master alloys
-
- 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
- C22C1/02—Making non-ferrous alloys by melting
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23G—CLEANING OR DE-GREASING OF METALLIC MATERIAL BY CHEMICAL METHODS OTHER THAN ELECTROLYSIS
- C23G1/00—Cleaning or pickling metallic material with solutions or molten salts
- C23G1/02—Cleaning or pickling metallic material with solutions or molten salts with acid solutions
- C23G1/10—Other heavy metals
- C23G1/106—Other heavy metals refractory metals
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B26/00—Obtaining alkali, alkaline earth metals or magnesium
- C22B26/20—Obtaining alkaline earth metals or magnesium
- C22B26/22—Obtaining magnesium
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B34/00—Obtaining refractory metals
- C22B34/10—Obtaining titanium, zirconium or hafnium
- C22B34/14—Obtaining zirconium or hafnium
Definitions
- the present invention relates to the addition of zirconium to pure magnesium or magnesium alloys and to a method of preparation of magnesium-zirconium (Mg-Zr) alloys, including Mg-Zr master alloys.
- Mg-Zr magnesium-zirconium
- Zirconium is a potent grain refiner for magnesium alloys which contain negligible amounts of elements with which zirconium forms stable compounds such as Al, Si, Fe, Ni, Co, Sn and Sb. Zirconium additions of about 1% by weight to such magnesium alloys can readily cause the grain size to decrease by 80% or more under normal cooling rates.
- the exceptional grain refining ability makes zirconium an important alloying element for magnesium alloys that are not based on alloying with Al and Si.
- zirconium containing Mg-RE-Zn alloys such as EZ33 (Mg-3.3RE-2.7Zn-0.6Zr) and ZE41 (Mg-1.2RE-4.2Zn-0.7Zr) offer a specific combination of elevated temperature and room temperature properties which are not readily achievable with the Mg-Al-Zn alloys.
- zirconium-rich cores that exist in most of the magnesium grains. These zirconium-rich cores are believed to be the products of peritectic solidification. In order to achieve excellent grain refinement in commercial production, it is desirable to dissolve the full zirconium content (ie, about 0.6%) in a magnesium melt.
- Zr-rich Mg-Zr master alloys are generally made by chemical reduction by magnesium of salt mixtures based on zirconium fluorides or zirconium chlorides.
- MEL Magnesium Elektron Ltd
- Zirmax trade mark
- a similar type of Mg-Zr master alloy was developed in the United States at about the same time based on a chloride salt reduction process.
- Zirmax type master alloys remain the primary zirconium alloying material used for the commercial production of zirconium-containing magnesium alloys.
- Zirmax contains approximately 33% zirconium and 67% magnesium and most of the zirconium is present as various sizes of zirconium particles (mostly in the range of submicron to 10 ⁇ m) in a magnesium matrix.
- Iodide zirconium sheet rolled to about 127 - 254 ⁇ m (0.005-0.010 in.) and cut into 6.35mm (1 ⁇ 4-in.) squares was added in a manner similar to that used for the fused lump zirconium. It was stirred for several minutes in the ladle. It was found that after 65 minutes of holding at temperature, the resultant soluble zirconium content merely reached 0.1% with 1% zirconium addition.
- the use of zirconium powder was evaluated by adding it in various ways because zirconium powder is pyrophoric and some means of protecting the powder from oxidation had to be applied.
- zirconium powder was pelleted with various binders, zirconium powder was enclosed in tight magnesium capsules, zirconium powder was compacted with magnesium powder, and zirconium powder was used in the form of sintered zirconium powder briquettes.
- the solubility of zirconium in magnesium is influenced by the presence of a third element. It was reported that with the presence of Zn at a level around 3-4%, the solubility of Zr in magnesium could be increased from 0.6% to slightly over 0.7% and 5% zinc increases the solubility of Zr in magnesium to about 0.8%.
- the sponge was essentially ground with the average size being reduced to about 12.7 ⁇ m or 0.0005 in.
- the results showed that zirconium sponge produced a soluble zirconium content of about 0.62-0.66% in Mg-5Zn alloys with 3% zirconium addition after 3-4 minutes stirring. With 1% zirconium sponge addition, soluble zirconium contents in the range of 0.32 to 0.52% were achieved.
- the authors found that the alloying efficiency decreased when the sponge fragments were decreased in size because when the particles became finer powder, the material burned up before it could be submerged beneath the melt. Therefore, some means of protecting the powder from oxidation had to be applied.
- zirconium particles therefore have a strong tendency to settle in a magnesium melt unless stirred vigorously. The larger the particle, the faster it settles to the bottom of the melt. For example, a 15-micron zirconium particle has been found to fall at approximately 40 mm/min to the bottom of a magnesium melt at 780 °C and is therefore difficult to maintain such particles suspended in a melt at this temperature. By contrast, when the particle size is smaller than 3 microns, it can be readily suspended in as magnesium melt at the same temperature.
- Passivity as "Lack of response of metal or mineral surface to chemical attack such as would take place with a clean, newly exposed surface. Due to various causes, including insoluble film produced by ageing, oxidation, or contamination; run-down of surface energy at discontinuity lattices; adsorbed layers."
- the terms "depassivate”, “depassivated” and “depassivating” are to be understood to have meanings derived from the foregoing definition of "passivity”.
- the present invention provides a method for treating zirconium metal, the method comprising chemically depassivating the zirconium metal.
- the zirconium metal is zirconium sponge with the method forming treated zirconium sponge.
- the zirconium sponge may be chemically depassivated by treatment with a source of fluoride ions.
- the source of fluoride ions may be hydrofluoric acid.
- the source of fluoride ions may be a mixture of hydrofluoric acid and nitric acid.
- the hydrofluoric acid preferably has a concentration between 0.1% and 50%, more preferably between 0.1% and 5%, and most preferably between 0.1% and 2.5%, with the acid concentrations calculated as shown later in this specification. These acid concentration ranges correspond respectively to about 0.05 - 25 molar, 0.05 - 2.5 molar and 0.05 - 1.25 molar. Efficacy at concentrations less than 0.1% HF, for example 0.07% (about 0.035 molar), has been demonstrated.
- the zirconium sponge may be treated with a solution containing fluoride ions to form treated zirconium sponge.
- the zirconium sponge is preferably a porous agglomerate of zirconium grains.
- the sponge is formed by the Kroll process.
- the sponge comprises zirconium with only incidental impurities.
- Hafnium is a common impurity in zirconium.
- Fe, Ni, Al, Si, C, Co, Sn and Sb are undesirable as they are alloying inhibiting and their total concentration is preferably less than 1% and, more preferably less than 0.5%.
- the zirconium sponge is in the physical form of small particles and each particle has a porous structure.
- these zirconium sponge particles have the following properties:
- treatment of zirconium sponge in accordance with the present invention has been found to improve the ability of molten magnesium/magnesium alloy to dissolve zirconium and to form a melt containing substantially evenly distributed particles of zirconium.
- the present invention as given in the claims provides zirconium sponge comprising an agglomerate of zirconium particles and having a surface layer containing fluorine containing compounds at least partially coating at least some of the particles.
- the fluorine containing compounds are preferably zirconium fluoride compounds and may be compounds of the formula ZrxFy.nH 2 O.
- the present invention provides a method of manufacturing a magnesium-zirconium master alloy, the method comprising the steps of:
- the sponge is mixed with the molten magnesium/magnesium alloy by stirring.
- the present invention provides a magnesium-zirconium master alloy manufactured by a method according to the present invention.
- the master alloy contains 10%-50%, more preferably 20%-40%, zirconium in magnesium/magnesium alloy.
- at least 90% of the zirconium particles in the master alloy are sized less than 5 ⁇ m, more preferably less then 3 ⁇ m.
- the average particle size is less than 5 ⁇ m.
- the present invention provides a process for preparing a magnesium-zirconium master alloy containing dissolved zirconium and zirconium particles in the substantial absence of halide inclusions wherein 90% of the zirconium particles are sized less then 5 ⁇ m, preferably less than 3 ⁇ m.
- the master alloy is cast as ingots, which term is to be understood to include briquettes, pellets and the like.
- the present invention provides a method of adding zirconium as an alloying element to molten magnesium/magnesium alloy, the method comprising mixing a magnesium-zirconium master alloy according to the present invention with the molten magnesium/magnesium alloy.
- the amount of zirconium added to the molten magnesium/magnesium alloy is greater than that required to saturate the magnesium/magnesium alloy with zirconium at the temperature of the melt.
- the present invention provides a magnesium alloy containing zirconium prepared by a method according to the present invention.
- Figures 1(a)-(c) are micrographs illustrating the grain refining ability of as-received and untreated zirconium sponge when added to pure magnesium at 730 °C. All three micrographs are of the same magnification.
- Figure 1(a) is pure magnesium
- Figure 1(b) is after addition of 1wt% untreated zirconium sponge followed by 30 minutes of manual stirring
- Figure 1(c) is after addition of a further 1wt% untreated zirconium sponge followed by a further 30 minutes of manual stirring.
- Figures 2(a)-(c) are micrographs illustrating the grain refining ability of as-received and untreated zirconium sponge when added to pure magnesium at 780 °C. All threemicrographs are of the same magnification as in Figures 1(a)-(c) .
- Figure 2(a) is pure magnesium
- Figure 2(b) is after addition of 1wt°s untreated zirconium sponge followed by two minutes of manual stirring and then 30 minutes holding at 780°C
- Figure 2(c) is after a further holding of 210 minutes at 780°C.
- Figures 3(a)-(c) are micrographs illustrating the grain refining ability of treated zirconium sponge of the present invention when added to pure magnesium at 680 °C. All three micrographs are of the same magnification as in the previous figures.
- Figure 3(a) is pure magnesium
- Figure 3(b) is after addition of 1 wt% treated zirconium sponge followed by 20 minutes of manual stirring
- Figure 3(c) is after a further 10 minutes of manual stirring.
- Figures 4(a)-(c) are micrographs illustrating the grain refining ability of treated zirconium sponge of the present invention when added to pure magnesium at 730 °C. All three micrographs are of the same magnification as in the previous figures.
- Figure 4(a) is pure magnesium
- Figure 4(b) is after addition of 1 wt% treated zirconium sponge followed by 30 minutes manual stirring
- Figure 4(c) is after 30 minutes of holding and then a further two minutes of manual stirring.
- Figures 5(a)-(c) are micrographs illustrating the grain refining ability of treated zirconium sponge of the present invention when added to pure magnesium at 800 °C. All micrographs are of the same magnification as in the previous figures.
- Figure 5(a) is pure magnesium
- Figure 5(b) is after addition of 1 wt% treated zirconium sponge followed by 30 minutes of manual stirring
- Figure 5(c) is after 30 minutes of holding and then a further two minutes of manual stirring.
- Figure 6 is a photograph showing the physical form of untreated (as received) zirconium sponge particles as used in one embodiment of the present invention.
- Figure 7 is a micrograph showing a view of a typical microstructure of the zirconium sponge particles shown in Figure 6 after treatment in accordance with the present invention.
- Figure 8 is a micrograph showing a view of an alternative microstructure for the zirconium sponge particles shown in Figure 6 after treatment in accordance with the present invention.
- Figure 9 is a schematic diagram illustrating a method of adding treated zirconium sponge to molten magnesium.
- Figures 10 and 11 show typical views of the microstructure of an ingot of master alloy produced according to the present invention.
- Figures 12 and 13 show typical views of commercially available Zirmax master alloy.
- Figures 14 and 15 show typical views of the microstructure of an ingot of master alloy produced according to the present invention.
- Figure 16 is a micrograph showing reaction products left on zirconium sponge particles after treatment in accordance with the present invention.
- the sponge was added, without treatment in accordance with the present invention, to two samples of molten magnesium at 730 and 780 °C respectively.
- Cone samples ( ⁇ 30 ⁇ 20 ⁇ 25 mm) were collected at different times and examination showed little evidence of grain refinement (see Fig. 1 and Fig. 2 ) even when the melt was held at 780°C for 2 to 6 hours.
- Wet chemical analyses of the soluble zirconium contents in the samples using 15% HCl acid showed negligible zirconium contents ( ⁇ 0.05%).
- Zirconium sponge identical to that used in the Comparative Trial above was first immersed in an acid solution which was prepared in the following manner: 45ml of concentrated nitric acid (68.5%-69.5%) and 45ml of concentrated hydrofluoric acid (50%) were combined and diluted in water to a total of 1000ml. This gave an acid solution of approximately 3% HNO 3 and 2% HF, which equates to approximately 1.1 molar HF and 0.5 molar HNO 3 .
- the zirconium sponge was left in this acid solution for 5 minutes. Bubbling was observed which indicated that the acid had probably at least partially removed the ZrO 2 layer and was dissolving some of the zirconium metal underneath. After removal from the acid solution the zirconium sponge was rinsed in ethanol and dried under heating lamps at approximately 50°C for 60 minutes. Water was also found to be a suitable rinsing agent.
- the treated zirconium sponge used in preparing the alloys depicted in Figures 3-5 was prepared by immersing zirconium sponge identical to that used in the Comparative Trial in a HF solution for 5 minutes followed by rinsing in water and drying.
- the HF solution was prepared by diluting 45ml of concentrated HF(50%) in water to a total of 1,000mls to give approximately 2.25% HF which equates to approximately 1 molar HF.
- Treated zirconium sponge was prepared by immersing zirconium sponge identical to that used in the Comparative Trial in a 2% HF solution for 4 minutes followed by rinsing in water and drying. The reaction products of the treatment are evident as the white phases on the sponge particles in Figure 16 .
- XPS analyses of treated and untreated sponge particles gave the results set out in Table 1 below.
- the treated particles were immersed in 0.5% HF solution for 4 minutes, rinsed with water and dried. For each analysis given, information was collected from a depth of 5 nanometers or 10 atomic layers on the surfaces of six different large particles.
- Table 1 XPS analyses of treated and untreated sponge particles Sponge Particles Surface composition in atom percentage C O Zr Fe Si F Cl Mg Hf Untreated 30.5 49.2 16.2 1.1 3.0 0 0 0 0 Treated particles 10.3 43.3 14.9 1.3 2.3 27.8 0 0 0 (black) Treated particles 26.0 41.1 15.6 1.1 1.7 27.4 0 0 0 (grey)
- O is present in the form of ZrO 2 in all three cases studied and the detected F in the treated particles is present in the form of Zr x F y .nH 2 O, such as ZrF 4 .
- the approach avoided the treated sponge being trapped in the dross and avoided the treated sponge not being wetted by the melt.
- the sponge could be added to the melt in various other ways, such as by adding a compact of sponge particles, providing that it is successfully introduced below the surface.
- the zirconium sponge particles can be directly added to the melt under certain circumstances.
- cover gas such as 1% SF 6 (balance: 49.5% CO 2 and 49.5% dry air)
- the concentration of oxygen above the surface of the magnesium melt is therefore very low
- the sponge particles can be successfully added directly providing it is done quickly.
- the zirconium sponge particles can be added at a height of 800 mm away from the melt surface through a steel funnel, where the bottom of the funnel is placed just above the melt surface. This allows the sponge particles to quickly get into the melt without being oxidised. This has been proved to be a very convenient way of adding small ( ⁇ 5mm) zirconium sponge particles to magnesium melts.
- the melt was left for a couple of minutes to reheat to the correct temperature and was then stirred for 30 minutes. Three temperatures were used: 680°C, 730°C and 800°C. Cone samples were collected at different times after the addition of the treated zirconium sponge.
- Figures 3 to 5 show a typical view of the grain structures achieved from the three tests, respectively.
- the soluble zirconium content reached 0.56% at both 730°C and 800°C after 30 min. stirring. This is very close to the solubility limit of zirconium, ie, 0.6 wt%, in molten pure magnesium.
- the soluble zirconium contents achievable by addition of the same amount of zirconium from Zirmax master alloy have been reported as generally less than 0.5% and are typically around 0.4% at 720°C - see Y. Tamura, N. Kono, T. Motegi and E. Sato, "Grain refining mechanism and casting structure of Mg-Zr alloys", Journal of Japan Institute of Light Metals, 1998, Vol. 48, No. 4, pp. 185-189 .
- the use of pretreated zirconium sponge showed a better recovery compared with the use of the Zirmax master alloy.
- a solution of 0.4% HF was prepared by adding 40ml of 10% HF to 960ml of water.
- Zirconium sponge identical to that used in the Comparative Trial was immersed in the 0.4% HF at room temperature for 5 minutes and then rinsed in water and dried. The dry treated zirconium sponge were stored in a plastic bag.
- FIGs 7 and 8 show typical views of the microstructure of the treated zirconium sponge. Owing to the gradual dissolution of the porous structure, each zirconium sponge particle will eventually be disintegrated into many fine zirconium particles sized about 2-3 ⁇ m. Production of a suspension of fine zirconium particles in the melt is enhanced by maintaining gentle stirring throughout.
- the magnesium-zirconium melt produced as described above can be cast into different moulds, preferably into chill moulds.
- the height of each ingot is not much greater than 500 mm unless the mould employed has an excellent chilling effect.
- a low casting temperature such as 680 °C or lower is preferred. Cover gas should be used during casting.
- FIGs 10 and 11 show typical views of the microstructure of the ingot produced according to the above description with 25% zirconium addition.
- the white phases are zirconium particles.
- Figures 12 and 13 show typical views of MEL's Zirmax master alloy. As can be seen, the zirconium particles present in the master alloy of the present invention are in general smaller than those present in Zirmax. Small zirconium particles are always highly preferred as discussed earlier.
- a magnesium-zirconium master alloy containing approximately 50wt% zirconium was prepared by adding 440g of treated zirconium sponge particles to 440g of molten magnesium at 700°C with slow manual stirring for 90 minutes.
- Figures 14 and 15 are typical views of the microstructure of an ingot cast on completion of the stirring in which the grey particles are zirconium and the white phases are magnesium.
- Magnesium-zirconium master alloy containing approximately 25wt% zirconium (prepared in accordance with the present invention) was added to a crucible containing 30kg of molten magnesium at 730°C.
- the master alloy was preheated to approximately 175°C prior to addition to the crucible and sufficient master alloy was added to give a zirconium addition of approximately 1wt%.
- the melt was stirred with a mechanical stirrer at 150rpm for 5 minutes. Thereafter, the melt was allowed to settle for 15 minutes and a 30mm thick plate sample (160mm x 140mm) was then sand cast at 730°C. A plate sample of the pure magnesium was also sand cast at 730°C prior to addition of the master alloy.
- the pure magnesium plate sample had an average grain size of approximately 10,000 ⁇ m. After alloying with the master alloy the resultant plate sample had an average grain size of 98 ⁇ m, a soluble zirconium content of 0.49% and a total zirconium content of 0.58%.
Abstract
Description
- The present invention relates to the addition of zirconium to pure magnesium or magnesium alloys and to a method of preparation of magnesium-zirconium (Mg-Zr) alloys, including Mg-Zr master alloys.
- Zirconium is a potent grain refiner for magnesium alloys which contain negligible amounts of elements with which zirconium forms stable compounds such as Al, Si, Fe, Ni, Co, Sn and Sb. Zirconium additions of about 1% by weight to such magnesium alloys can readily cause the grain size to decrease by 80% or more under normal cooling rates. The exceptional grain refining ability makes zirconium an important alloying element for magnesium alloys that are not based on alloying with Al and Si. For example, zirconium containing Mg-RE-Zn alloys such as EZ33 (Mg-3.3RE-2.7Zn-0.6Zr) and ZE41 (Mg-1.2RE-4.2Zn-0.7Zr) offer a specific combination of elevated temperature and room temperature properties which are not readily achievable with the Mg-Al-Zn alloys.
- The solubility of zirconium in molten pure magnesium is approximately 0.6%, which slightly increases with increasing melt temperature. It has been reported that the most characteristic feature of the microstructure of a magnesium alloy that contains more than a few tenths per cent soluble zirconium is the zirconium-rich cores that exist in most of the magnesium grains. These zirconium-rich cores are believed to be the products of peritectic solidification. In order to achieve excellent grain refinement in commercial production, it is desirable to dissolve the full zirconium content (ie, about 0.6%) in a magnesium melt.
- Over the decades various approaches to introducing zirconium into molten magnesium have been explored, including:
- (a) alloying with different forms of zirconium metal;
- (b) alloying with zirconium sponge;
- (c) alloying with Zn-Zr master alloys;
- (d) alloying with ZrO2;
- (e) alloying with various zirconium halides or complex halides or a mixture of halides and/or complex halides with different salts such as NaCl, KCl, BaCl2, NaF, KF, etc; and
- (f) alloying with Mg-Zr master alloys.
- The advantages and disadvantages of each of these approaches have been discussed in detail by Saunders and Strieter (W. P. Saunders and F. P. Strieter, "Alloying Zirconium to Magnesium", Transactions of the American Foundrymen's Society, 1952, Vol. 60, pp. 581-594) and Emley (E. F. Emley, "Principles of Magnesium Technology", Pergamon Press, Oxford, 1966, pp. 127-155). Since about 1960, only Mg-Zr master alloys have been in widespread commercial use as sources of zirconium for alloying with magnesium. These Zr-rich Mg-Zr master alloys are generally made by chemical reduction by magnesium of salt mixtures based on zirconium fluorides or zirconium chlorides. A master alloy, developed by Magnesium Elektron Ltd (MEL) in about 1945 via chemical reduction of a complex zirconium fluoride by molten magnesium, has been long known as Zirmax (trade mark). A similar type of Mg-Zr master alloy was developed in the United States at about the same time based on a chloride salt reduction process.
- Zirmax type master alloys remain the primary zirconium alloying material used for the commercial production of zirconium-containing magnesium alloys. Zirmax contains approximately 33% zirconium and 67% magnesium and most of the zirconium is present as various sizes of zirconium particles (mostly in the range of submicron to 10 µm) in a magnesium matrix.
- Prior to Zirmax type master alloys becoming a standard source of zirconium for the production of zirconium-containing magnesium alloys, alloying with various forms of zirconium metal were investigated.
- Sauerwald published work on alloying zirconium metal powder to magnesium in 1947 (V. F. Sauerwald, "Dus Zustandsdiagram Magnesium-Zirkonnium", Zeitschrift fur anorganische Chemie., 1947, Band 255, pp. 212-220). He added 5 wt% zirconium metal powder to magnesium under an argon atmosphere at various temperatures between 680 and 1100°C- Soluble zirconium contents exceeding 0.5 wt% (samples were digested in HCl acids) were obtained at all temperatures tested. In the same year, Ball reported work (C. J. P. Ball, "Metallurgia", 1947, Vol. 35, pp. 125-129; 211) stating that metallic zirconium dissolves in magnesium under an argon atmosphere at 900-1100 °C but that it was a difficult and costly process. Operating at such temperatures is not commercially feasible in view of vaporisation of magnesium. Emley reported in 1948 (E. F. Emley, "Discussions of the Faraday Society", 1948-49, Vol. 47, No. 4, pp. 219) that as zirconium metal powder is expensive and highly inflammable, it is natural to consider the possibility of alloying by a reducible zirconium compound.
- In 1952, Saunders and Strieter reported their investigations in which different forms of metallic zirconium, (ie, zirconium sponge, fused zirconium, iodide-decomposed ductile zirconium, and zirconium powder) were investigated as zirconium alloying materials for magnesium at 760 °C (1400 F). The fused lump zirconium was added as 6.35-mm (¼-in.) pieces in a small steel ladle and stirred in the ladle with a steel rod. No apparent solution had occurred after 30 minutes of stirring. Analysis of the melt showed a result of 0.03% soluble zirconium content with 1% zirconium addition. Iodide zirconium sheet, rolled to about 127 - 254µm (0.005-0.010 in.) and cut into 6.35mm (¼-in.) squares was added in a manner similar to that used for the fused lump zirconium. It was stirred for several minutes in the ladle. It was found that after 65 minutes of holding at temperature, the resultant soluble zirconium content merely reached 0.1% with 1% zirconium addition. The use of zirconium powder was evaluated by adding it in various ways because zirconium powder is pyrophoric and some means of protecting the powder from oxidation had to be applied. Zirconium powder was pelleted with various binders, zirconium powder was enclosed in tight magnesium capsules, zirconium powder was compacted with magnesium powder, and zirconium powder was used in the form of sintered zirconium powder briquettes. In general, with 3% zirconium addition to a Mg-5Zn melt, the resultant zirconium content was reported as varying between 0.7 and 0.85%. The solubility of zirconium in magnesium is influenced by the presence of a third element. It was reported that with the presence of Zn at a level around 3-4%, the solubility of Zr in magnesium could be increased from 0.6% to slightly over 0.7% and 5% zinc increases the solubility of Zr in magnesium to about 0.8%.
- According to Saunders and Strieter, of the various metallic forms of zirconium tested, alloying with zirconium sponge demonstrated the most promising results. The zirconium sponge used was made by the Kroll process
- ((a) zirconium tetrachloride is produced by the action of chlorine and carbon on a zirconium oxide such as baddeleyite (ZrO2) of zircon (ZrSiO4 ZrO2+2Cl2+2C (900°C) → zrCl4+2CO, or ZrSiO4+4Cl2+4 (900°C)→ZrCl4+SiCl4+4CO;
- (b) the resultant zirconium tetrachloride is separated from iron trichloride (from iron impurities) and silicon tetrachloride (if present) by fractional distillation; and
- (c) the purified zirconium tetrachloride is reduced by reaction with molten magnesium under argon to produce "zirconium sponge" - ZrCl4+2Mg (1100°C) →Zr+2MgCl2) .
- In their experiments, the sponge was essentially ground with the average size being reduced to about 12.7 µm or 0.0005 in. The results showed that zirconium sponge produced a soluble zirconium content of about 0.62-0.66% in Mg-5Zn alloys with 3% zirconium addition after 3-4 minutes stirring. With 1% zirconium sponge addition, soluble zirconium contents in the range of 0.32 to 0.52% were achieved. Furthermore, the authors found that the alloying efficiency decreased when the sponge fragments were decreased in size because when the particles became finer powder, the material burned up before it could be submerged beneath the melt. Therefore, some means of protecting the powder from oxidation had to be applied.
- Despite the excellent alloying results demonstrated by the work of Saunders and Strieter with Kroll process zirconium sponge, alloying zirconium sponge to magnesium was in general limited to laboratory scales. As realised and pointed out by Saunders and Strieter, "an important disadvantage in the commercial use of sponge in the magnesium alloying field is the rather laborious effort required to alloy the material". This laborious effort apparently refers to the grinding process because the alloying process employed, ie, 3-4 minutes of stirring, was plainly simple. In addition, the unavoidable contamination problem arising from the grinding process is another important disadvantage in the commercial use of zirconium sponge.
GB 734 614 - In Principles of Magnesium Technology, Emley similarly commented about alloying zirconium metal to magnesium: "pure zirconium metal is expensive by any route and very inflammable in powder form, and for these reasons, coupled with the ease with which it becomes contaminated with oxygen, hydrogen and nitrogen, the approach via zirconium metal is not obviously the best".
- Experiments have indicated that in commercial production of magnesium alloys, when Zirmax is dissolved into a magnesium melt at commercially useful addition rates, undissolved zirconium particles can be readily observed in the microstructure of the magnesium alloy produced (Ma Qian, L. Zheng, D. Graham, D. H. StJohn and M. T. Frost, "Settling of undissolved zirconium particles in pure magnesium melts", Journal of Light Metals, 2001, Vol. 1, No.3, pp. 157-165 and Y. Tamura, N. Kono, T. Motegi and E. Sato, "Grain refining mechanism and casting structure of Mg-Zr alloys", Journal of Japan Institute of Light Metals, 1998, Vol. 48, No. 4, pp. 185-189). Many of these residual (undissolved) zirconium particles have an average size of around 5 µm.
- The density of zirconium is 6.5gcm-3 whereas the density of molten magnesium is 1.6gcm-3. zirconium particles therefore have a strong tendency to settle in a magnesium melt unless stirred vigorously. The larger the particle, the faster it settles to the bottom of the melt. For example, a 15-micron zirconium particle has been found to fall at approximately 40 mm/min to the bottom of a magnesium melt at 780 °C and is therefore difficult to maintain such particles suspended in a melt at this temperature. By contrast, when the particle size is smaller than 3 microns, it can be readily suspended in as magnesium melt at the same temperature.
- Chambers Science and Technology Dictionary (1991) defines "passivity" as "Lack of response of metal or mineral surface to chemical attack such as would take place with a clean, newly exposed surface. Due to various causes, including insoluble film produced by ageing, oxidation, or contamination; run-down of surface energy at discontinuity lattices; adsorbed layers..." Throughout this specification, the terms "depassivate", "depassivated" and "depassivating" are to be understood to have meanings derived from the foregoing definition of "passivity".
- The present invention which is given in the claims provides a method for treating zirconium metal, the method comprising chemically depassivating the zirconium metal. The zirconium metal is zirconium sponge with the method forming treated zirconium sponge. The zirconium sponge may be chemically depassivated by treatment with a source of fluoride ions. The source of fluoride ions may be hydrofluoric acid. The source of fluoride ions may be a mixture of hydrofluoric acid and nitric acid.
- The hydrofluoric acid preferably has a concentration between 0.1% and 50%, more preferably between 0.1% and 5%, and most preferably between 0.1% and 2.5%, with the acid concentrations calculated as shown later in this specification. These acid concentration ranges correspond respectively to about 0.05 - 25 molar, 0.05 - 2.5 molar and 0.05 - 1.25 molar. Efficacy at concentrations less than 0.1% HF, for example 0.07% (about 0.035 molar), has been demonstrated.
- The zirconium sponge may be treated with a solution containing fluoride ions to form treated zirconium sponge.
- The zirconium sponge is preferably a porous agglomerate of zirconium grains. Preferably, the sponge is formed by the Kroll process.
- Preferably, the sponge comprises zirconium with only incidental impurities. Hafnium is a common impurity in zirconium. In contrast, Fe, Ni, Al, Si, C, Co, Sn and Sb are undesirable as they are alloying inhibiting and their total concentration is preferably less than 1% and, more preferably less than 0.5%.
- Preferably, the zirconium sponge is in the physical form of small particles and each particle has a porous structure. Preferably, these zirconium sponge particles have the following properties:
- the particles have an average size between 0.1 to 10 mm, more preferably between 0.5 and 5mm
- the particles have a minimum size of 0.5mm, more preferably 1mm, and a maximum size of 10mm, more preferably 5mm
- density of sponge = 5.2-6.3g/cm3, more preferably 5.5-5.8g/cm3
- porosity of sponge (1 - density of sponge/density of solid zirconium) = 0.08-0.2, more preferably 0.11-0.15.
- the void sizes on a polished transverse section of each zirconium sponge particle are in general between 5 and 60 µm.
- As compared with untreated (as received) zirconium sponge, treatment of zirconium sponge in accordance with the present invention has been found to improve the ability of molten magnesium/magnesium alloy to dissolve zirconium and to form a melt containing substantially evenly distributed particles of zirconium.
- The present invention as given in the claims provides zirconium sponge comprising an agglomerate of zirconium particles and having a surface layer containing fluorine containing compounds at least partially coating at least some of the particles. The fluorine containing compounds are preferably zirconium fluoride compounds and may be compounds of the formula ZrxFy.nH2O.
- The present invention provides a method of manufacturing a magnesium-zirconium master alloy, the method comprising the steps of:
- (a) mixing treated zirconium sponge according to the third aspect of the present invention or zirconium sponge according to the fourth aspect of the present invention with molten magnesium/magnesium alloy to form a magnesium-zirconium melt containing dissolved zirconium and zirconium particles; and
- (b) casting the magnesium-zirconium melt to solidify as the magnesium-zirconium master alloy.
- Preferably, the sponge is mixed with the molten magnesium/magnesium alloy by stirring.
- The present invention provides a magnesium-zirconium master alloy manufactured by a method according to the present invention. Preferably, the master alloy contains 10%-50%, more preferably 20%-40%, zirconium in magnesium/magnesium alloy. Preferably, at least 90% of the zirconium particles in the master alloy are sized less than 5µm, more preferably less then 3µm. Preferably, the average particle size is less than 5µm.
- The present invention provides a process for preparing a magnesium-zirconium master alloy containing dissolved zirconium and zirconium particles in the substantial absence of halide inclusions wherein 90% of the zirconium particles are sized less then 5µm, preferably less than 3µm.
- Preferably, the master alloy is cast as ingots, which term is to be understood to include briquettes, pellets and the like.
- The present invention provides a method of adding zirconium as an alloying element to molten magnesium/magnesium alloy, the method comprising mixing a magnesium-zirconium master alloy according to the present invention with the molten magnesium/magnesium alloy.
- Preferably, the amount of zirconium added to the molten magnesium/magnesium alloy is greater than that required to saturate the magnesium/magnesium alloy with zirconium at the temperature of the melt.
- The present invention provides a magnesium alloy containing zirconium prepared by a method according to the present invention.
- In order that the invention may be more fully understood there will now be described, by way of example only, preferred embodiments and other elements of the present invention with reference to the below mentioned accompanying illustrations.
-
Figures 1(a)-(c) are micrographs illustrating the grain refining ability of as-received and untreated zirconium sponge when added to pure magnesium at 730 °C. All three micrographs are of the same magnification.Figure 1(a) is pure magnesium,Figure 1(b) is after addition of 1wt% untreated zirconium sponge followed by 30 minutes of manual stirring, andFigure 1(c) is after addition of a further 1wt% untreated zirconium sponge followed by a further 30 minutes of manual stirring. -
Figures 2(a)-(c) are micrographs illustrating the grain refining ability of as-received and untreated zirconium sponge when added to pure magnesium at 780 °C. All threemicrographs are of the same magnification as inFigures 1(a)-(c) .Figure 2(a) is pure magnesium,Figure 2(b) is after addition of 1wt°s untreated zirconium sponge followed by two minutes of manual stirring and then 30 minutes holding at 780°C, andFigure 2(c) is after a further holding of 210 minutes at 780°C. -
Figures 3(a)-(c) are micrographs illustrating the grain refining ability of treated zirconium sponge of the present invention when added to pure magnesium at 680 °C. All three micrographs are of the same magnification as in the previous figures.Figure 3(a) is pure magnesium,Figure 3(b) is after addition of 1 wt% treated zirconium sponge followed by 20 minutes of manual stirring, andFigure 3(c) is after a further 10 minutes of manual stirring. -
Figures 4(a)-(c) are micrographs illustrating the grain refining ability of treated zirconium sponge of the present invention when added to pure magnesium at 730 °C. All three micrographs are of the same magnification as in the previous figures.Figure 4(a) is pure magnesium,Figure 4(b) is after addition of 1 wt% treated zirconium sponge followed by 30 minutes manual stirring, andFigure 4(c) is after 30 minutes of holding and then a further two minutes of manual stirring. -
Figures 5(a)-(c) are micrographs illustrating the grain refining ability of treated zirconium sponge of the present invention when added to pure magnesium at 800 °C. All micrographs are of the same magnification as in the previous figures.Figure 5(a) is pure magnesium,Figure 5(b) is after addition of 1 wt% treated zirconium sponge followed by 30 minutes of manual stirring, andFigure 5(c) is after 30 minutes of holding and then a further two minutes of manual stirring. -
Figure 6 is a photograph showing the physical form of untreated (as received) zirconium sponge particles as used in one embodiment of the present invention. -
Figure 7 is a micrograph showing a view of a typical microstructure of the zirconium sponge particles shown inFigure 6 after treatment in accordance with the present invention. -
Figure 8 is a micrograph showing a view of an alternative microstructure for the zirconium sponge particles shown inFigure 6 after treatment in accordance with the present invention. -
Figure 9 is a schematic diagram illustrating a method of adding treated zirconium sponge to molten magnesium. -
Figures 10 and 11 show typical views of the microstructure of an ingot of master alloy produced according to the present invention. -
Figures 12 and 13 show typical views of commercially available Zirmax master alloy. -
Figures 14 and 15 show typical views of the microstructure of an ingot of master alloy produced according to the present invention. -
Figure 16 is a micrograph showing reaction products left on zirconium sponge particles after treatment in accordance with the present invention. - An untreated (as received) zirconium sponge in the physical form of zirconium sponge particles of size 1-10 mm diameter was selected. The major impurity in the sponge was hafnium. The impurity concentrations were:
Hf = 0.8% approx Fe+Cr = 0.1% C = 0.004% H = 0.001% N = 0.002% - The sponge was added, without treatment in accordance with the present invention, to two samples of molten magnesium at 730 and 780 °C respectively. Cone samples (φ30×20×25 mm) were collected at different times and examination showed little evidence of grain refinement (see
Fig. 1 andFig. 2 ) even when the melt was held at 780°C for 2 to 6 hours. Wet chemical analyses of the soluble zirconium contents in the samples using 15% HCl acid showed negligible zirconium contents (< 0.05%). - Zirconium sponge identical to that used in the Comparative Trial above was first immersed in an acid solution which was prepared in the following manner: 45ml of concentrated nitric acid (68.5%-69.5%) and 45ml of concentrated hydrofluoric acid (50%) were combined and diluted in water to a total of 1000ml. This gave an acid solution of approximately 3% HNO3 and 2% HF, which equates to approximately 1.1 molar HF and 0.5 molar HNO3.
- The zirconium sponge was left in this acid solution for 5 minutes. Bubbling was observed which indicated that the acid had probably at least partially removed the ZrO2 layer and was dissolving some of the zirconium metal underneath. After removal from the acid solution the zirconium sponge was rinsed in ethanol and dried under heating lamps at approximately 50°C for 60 minutes. Water was also found to be a suitable rinsing agent.
- The treated zirconium sponge used in preparing the alloys depicted in
Figures 3-5 was prepared by immersing zirconium sponge identical to that used in the Comparative Trial in a HF solution for 5 minutes followed by rinsing in water and drying. The HF solution was prepared by diluting 45ml of concentrated HF(50%) in water to a total of 1,000mls to give approximately 2.25% HF which equates to approximately 1 molar HF. - An alternative acid solution which was successfully used was 0.07-0.25% HF. This is a very dilute HF acid solution and is readily handled.
- Treated zirconium sponge was prepared by immersing zirconium sponge identical to that used in the Comparative Trial in a 2% HF solution for 4 minutes followed by rinsing in water and drying. The reaction products of the treatment are evident as the white phases on the sponge particles in
Figure 16 . - Although it is thought that successful treatment involves the dissolution or some physical removal of oxide from the Zr surface, we do not wish to be bound by any theory as to why such treatment is effective.
- XPS analyses of treated and untreated sponge particles gave the results set out in Table 1 below. The treated particles were immersed in 0.5% HF solution for 4 minutes, rinsed with water and dried. For each analysis given, information was collected from a depth of 5 nanometers or 10 atomic layers on the surfaces of six different large particles.
Table 1 XPS analyses of treated and untreated sponge particles Sponge Particles Surface composition in atom percentage C O Zr Fe Si F Cl Mg Hf Untreated 30.5 49.2 16.2 1.1 3.0 0 0 0 0 Treated particles 10.3 43.3 14.9 1.3 2.3 27.8 0 0 0 (black) Treated particles 26.0 41.1 15.6 1.1 1.7 27.4 0 0 0 (grey) - According to the energy level detected for each element, O is present in the form of ZrO2 in all three cases studied and the detected F in the treated particles is present in the form of ZrxFy.nH2O, such as ZrF4.
- In all of the experiments conducted it was observed that the weight of the sponge particles decreased with increasing treatment time in the acid solution until all of the particles disappeared or the HF was consumed.
- Although we did not wish to be bound by any theory, it is presently thought that the mechanism is that the treatment results in the oxide film on each sponge particle being partially or totally removed and a layer of reaction products (possibly ZrxFy.nH2O), either continuous or discontinuous, being formed on the particles. Owing to the formation of the ZrxFy.nH2O patches or coating on the sponge particles, oxidation of zirconium beneath these patches or the coating would be prevented after treatment. It is thought that the patches then dissolve into molten magnesium, leaving parts of the zirconium surface exposed to the molten magnesium thereby providing fresh contact sites for the molten magnesium. BSE images have revealed that there are many tiny channels in each sponge particle which provides an explanation for the disintegration of the sponge particles.
- The above proposed mechanism is offered only as a possible explanation of the experimental results and there could be other mechanism(s). The present invention may incorporate but is not to be considered limited by the mechanism described.
- A hole was machined into a small piece of magnesium ingot and the required pieces of treated zirconium sponge were placed into the hole as illustrated in
Figure 9 . This piece of ingot was then quickly submerged below the magnesium melt surface. This allowed the treated zirconium sponge to be introduced directly to the melt without the possibility of it remaining on the surface of the melt. The approach avoided the treated sponge being trapped in the dross and avoided the treated sponge not being wetted by the melt. The sponge could be added to the melt in various other ways, such as by adding a compact of sponge particles, providing that it is successfully introduced below the surface. - It has been found that, alternatively, the zirconium sponge particles can be directly added to the melt under certain circumstances. An example is if the magnesium melt surface is protected with cover gas such as 1% SF6 (balance: 49.5% CO2 and 49.5% dry air), and the concentration of oxygen above the surface of the magnesium melt is therefore very low, the sponge particles can be successfully added directly providing it is done quickly. For example, the zirconium sponge particles can be added at a height of 800 mm away from the melt surface through a steel funnel, where the bottom of the funnel is placed just above the melt surface. This allows the sponge particles to quickly get into the melt without being oxidised. This has been proved to be a very convenient way of adding small (< 5mm) zirconium sponge particles to magnesium melts.
- After addition of the treated zirconium sponge at a rate of 1% by weight, the melt was left for a couple of minutes to reheat to the correct temperature and was then stirred for 30 minutes. Three temperatures were used: 680°C, 730°C and 800°C. Cone samples were collected at different times after the addition of the treated zirconium sponge.
-
Figures 3 to 5 show a typical view of the grain structures achieved from the three tests, respectively. - Results of wet chemical analysis are summarised in Table 2 which lists the wet chemical analysis results of soluble zirconium contents in samples taken from all three alloying tests.
Table 2 Soluble and total zirconium contents of samples by wet chemical analysis (%) Alloying temperatures 680°C
1 wt% sponge addition730°C
1 wt% sponge addition800°C
1 wt% sponge additionSoluble* Total** Soluble Total Soluble Total Before addition < 0.005 < 0.005 < 0.005 <0.005 <0.005 <0.005 30 min. stirring 0.48 0.93 0.56 0.76 0.54 0.92 A further 30 min. holding 0.56 0.85 0.56 0.66 Restirring for 2 min. 0.56 0.97 0.57 0.74 * Soluble: 15% HCl ** Total: 50% HCl + 6% HF - As can be seen, the soluble zirconium content reached 0.56% at both 730°C and 800°C after 30 min. stirring. This is very close to the solubility limit of zirconium, ie, 0.6 wt%, in molten pure magnesium. The soluble zirconium contents achievable by addition of the same amount of zirconium from Zirmax master alloy have been reported as generally less than 0.5% and are typically around 0.4% at 720°C - see Y. Tamura, N. Kono, T. Motegi and E. Sato, "Grain refining mechanism and casting structure of Mg-Zr alloys", Journal of Japan Institute of Light Metals, 1998, Vol. 48, No. 4, pp. 185-189. The use of pretreated zirconium sponge showed a better recovery compared with the use of the Zirmax master alloy.
- A solution of 0.4% HF was prepared by adding 40ml of 10% HF to 960ml of water. Zirconium sponge identical to that used in the Comparative Trial was immersed in the 0.4% HF at room temperature for 5 minutes and then rinsed in water and dried. The dry treated zirconium sponge were stored in a plastic bag.
- After four weeks of storage, 300g of the treated zirconium sponge particles were added to 30kg of pure magnesium at 680°C and stirred. Chill bar samples (25mm in diameter) were cast prior to addition of the treated zirconium sponge particles, after 30 minutes of stirring, and after 60 minutes of stirring.
- Very good grain refinement was achieved after 30 minutes of stirring. The soluble and total zirconium contents were 0.38% and 0.69% respectively after 30 minutes of stirring which increased to 0.42% and 0.81% respectively after 60 minutes of stirring.
- A total of 150g of treated zirconium sponge particles in the size range of approximately 1-3mm was added to a 550g magnesium melt at 730°C. The nominal addition of zirconium was approximately 25 wt%. These zirconium particles were added in two batches. Stirring was applied throughout the whole alloying process. The melt was cast into a steel ingot mould after 60 minutes of stirring.
-
Figures 7 and8 show typical views of the microstructure of the treated zirconium sponge. Owing to the gradual dissolution of the porous structure, each zirconium sponge particle will eventually be disintegrated into many fine zirconium particles sized about 2-3µm. Production of a suspension of fine zirconium particles in the melt is enhanced by maintaining gentle stirring throughout. - The magnesium-zirconium melt produced as described above can be cast into different moulds, preferably into chill moulds. Preferably the height of each ingot is not much greater than 500 mm unless the mould employed has an excellent chilling effect. Where possible, a low casting temperature such as 680 °C or lower is preferred. Cover gas should be used during casting.
-
Figures 10 and 11 show typical views of the microstructure of the ingot produced according to the above description with 25% zirconium addition. The white phases are zirconium particles.Figures 12 and 13 show typical views of MEL's Zirmax master alloy. As can be seen, the zirconium particles present in the master alloy of the present invention are in general smaller than those present in Zirmax. Small zirconium particles are always highly preferred as discussed earlier. - A magnesium-zirconium master alloy containing approximately 50wt% zirconium was prepared by adding 440g of treated zirconium sponge particles to 440g of molten magnesium at 700°C with slow manual stirring for 90 minutes.
Figures 14 and 15 are typical views of the microstructure of an ingot cast on completion of the stirring in which the grey particles are zirconium and the white phases are magnesium. - Magnesium-zirconium master alloy containing approximately 25wt% zirconium (prepared in accordance with the present invention) was added to a crucible containing 30kg of molten magnesium at 730°C. The master alloy was preheated to approximately 175°C prior to addition to the crucible and sufficient master alloy was added to give a zirconium addition of approximately 1wt%.
- Following addition of the master alloy, the melt was stirred with a mechanical stirrer at 150rpm for 5 minutes. Thereafter, the melt was allowed to settle for 15 minutes and a 30mm thick plate sample (160mm x 140mm) was then sand cast at 730°C. A plate sample of the pure magnesium was also sand cast at 730°C prior to addition of the master alloy. The pure magnesium plate sample had an average grain size of approximately 10,000µm. After alloying with the master alloy the resultant plate sample had an average grain size of 98µm, a soluble zirconium content of 0.49% and a total zirconium content of 0.58%.
- It is to be understood that where the word "comprise", and variations such as "comprises" and "comprising", are used in this specification, unless the context requires otherwise such use is intended to imply the inclusion of a stated feature or features but is not to be taken as excluding the presence of other feature or features.
Claims (8)
- A method of preparing a magnesium-zirconium master alloy comprising the steps of:(a) mixing (i) zirconium sponge comprising an agglomerate of zirconium particles and having a surface layer containing fluorine containing compounds at least partially coating at least some of the particles, with (ii) molten magnesium/magnesium alloy to form a magnesium-zirconium melt containing dissolved zirconium and zirconium particles; and(b) casting the magnesium-zirconium melt to solidify as the magnesium-zirconium master alloy.
- A method as claimed in claim 1, wherein 90% of the zirconium particles in the magnesium-zirconium master alloy are sized less than 5µm.
- A method as claimed in claim 1 or 2, wherein the magnesium-zirconium master alloy contains 10-50% by weight zirconium.
- A method as claimed in claim 1 or 2, wherein the magnesium-zirconium master alloy contains 20-40% by weight zirconium.
- A method as claimed in any one of the preceding claims wherein 90% of the zirconium particles in the magnesium-zirconium master alloy are sized less than 3µm.
- A method as claimed in any one of the preceding claims wherein the fluorine containing compounds are zirconium fluoride compounds.
- A method as claimed in claim 6 wherein the zirconium fluoride compounds have the formula ZrxFy.nH2O and x, y and n are integers.
- A method of adding zirconium as an alloying element to molten magnesium/magnesium alloy, the method comprising mixing a magnesium-zirconium master alloy prepared by the method as claimed in any one of the preceding claims with the molten magnesium/magnesium alloy.
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
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AUPS004302 | 2002-01-18 | ||
AUPS004202 | 2002-01-18 | ||
AUPS0042A AUPS004202A0 (en) | 2002-01-18 | 2002-01-18 | Magnesium-zirconium master alloys and their manufacture |
AUPS0043A AUPS004302A0 (en) | 2002-01-18 | 2002-01-18 | Metal alloying process |
PCT/AU2003/000053 WO2003062492A1 (en) | 2002-01-18 | 2003-01-20 | Magnesium-zirconium alloying |
Publications (4)
Publication Number | Publication Date |
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EP1466038A1 EP1466038A1 (en) | 2004-10-13 |
EP1466038A4 EP1466038A4 (en) | 2006-07-19 |
EP1466038B1 true EP1466038B1 (en) | 2009-12-02 |
EP1466038B9 EP1466038B9 (en) | 2010-07-14 |
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EP03700086A Expired - Lifetime EP1466038B9 (en) | 2002-01-18 | 2003-01-20 | Magnesium-zirconium alloying |
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US (1) | US20050161121A1 (en) |
EP (1) | EP1466038B9 (en) |
CN (1) | CN100393912C (en) |
AT (1) | ATE450634T1 (en) |
AU (1) | AU2003201396B2 (en) |
DE (1) | DE60330309D1 (en) |
TW (1) | TW200302285A (en) |
WO (1) | WO2003062492A1 (en) |
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US7988946B2 (en) * | 2005-06-30 | 2011-08-02 | Compagnie Europeenne Du Zirconium-Cezus | Method for recycling zirconium tetrafluoride into zirconia |
US20080216924A1 (en) * | 2007-03-08 | 2008-09-11 | Treibacher Industrie Ag | Method for producing grain refined magnesium and magnesium-alloys |
CN101358359B (en) * | 2008-08-27 | 2010-07-21 | 哈尔滨工程大学 | Method for directly preparing Mg-Zr alloy by MgCl2, K2ZrF6 and ZrO2 electrolysis |
CN101845564B (en) * | 2010-04-28 | 2011-06-29 | 娄底市兴鑫合金有限公司 | Secondary smelting method for producing magnesium-zirconium intermediate alloy |
CN109182855B (en) * | 2018-08-22 | 2019-11-08 | 厦门火炬特种金属材料有限公司 | A kind of deformable low bulk magnesium alloy |
CN111272797B (en) * | 2020-03-09 | 2021-06-25 | 中南大学 | Mineral exploration method for judging mineralization of granite body by using zircon |
CN113063873B (en) * | 2021-03-29 | 2023-05-12 | 中国船舶重工集团公司第七二五研究所 | Method for measuring chlorine content in zirconium sponge |
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GB734614A (en) * | 1952-01-22 | 1955-08-03 | Aluminum Co Of America | Improvements in or relating to master alloys and method of making same |
GB1239863A (en) * | 1968-05-13 | 1971-07-21 | Euratom | Treatment of zirconium and its alloys by chemical displacement |
JPS5141639A (en) * | 1974-10-05 | 1976-04-08 | Kobe Steel Ltd | Jirukoniumu mataha jirukoniumugokin aruiha chitan mataha chitangokinseihinno sanaraihoho |
DE3234671C1 (en) * | 1982-09-18 | 1983-06-01 | Dornier System Gmbh, 7990 Friedrichshafen | Process for coating hydrogen storage material with palladium |
DD211811A1 (en) * | 1982-12-03 | 1984-07-25 | Leipzig Galvanotechnik | METHOD FOR THE STAINLESS TREATMENT OF ZIRCONIUM AND ZIRCONIUM ALLOYS |
US4751048A (en) * | 1984-10-19 | 1988-06-14 | Martin Marietta Corporation | Process for forming metal-second phase composites and product thereof |
FR2601379A1 (en) * | 1986-07-09 | 1988-01-15 | Commissariat Energie Atomique | STRIPPING PRODUCT FOR STEEL PARTS AND STRIPPING METHOD USING THE SAME |
SU1678075A1 (en) * | 1989-05-29 | 1995-11-27 | Березниковский филиал Всесоюзного научно-исследовательского и проектного института титана | Method of producing pig master alloy magnesium-neodymium-zirconium |
SU1822592A3 (en) * | 1991-04-03 | 1995-04-30 | Соликамский магниевый завод | Method for zirconium introduction into magnesium |
JPH10280063A (en) * | 1997-04-04 | 1998-10-20 | Toyota Central Res & Dev Lab Inc | Method for adding zirconium to magnesium alloy |
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2003
- 2003-01-20 EP EP03700086A patent/EP1466038B9/en not_active Expired - Lifetime
- 2003-01-20 WO PCT/AU2003/000053 patent/WO2003062492A1/en active Search and Examination
- 2003-01-20 CN CNB038047934A patent/CN100393912C/en not_active Expired - Fee Related
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- 2003-01-20 AU AU2003201396A patent/AU2003201396B2/en not_active Ceased
- 2003-01-20 US US10/501,704 patent/US20050161121A1/en not_active Abandoned
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DE60330309D1 (en) | 2010-01-14 |
EP1466038A4 (en) | 2006-07-19 |
TW200302285A (en) | 2003-08-01 |
EP1466038A1 (en) | 2004-10-13 |
CN1639389A (en) | 2005-07-13 |
WO2003062492A1 (en) | 2003-07-31 |
ATE450634T1 (en) | 2009-12-15 |
EP1466038B9 (en) | 2010-07-14 |
US20050161121A1 (en) | 2005-07-28 |
CN100393912C (en) | 2008-06-11 |
AU2003201396B2 (en) | 2007-08-23 |
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