EP1882753A1 - Alliage d'aluminium - Google Patents

Alliage d'aluminium Download PDF

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Publication number
EP1882753A1
EP1882753A1 EP06015671A EP06015671A EP1882753A1 EP 1882753 A1 EP1882753 A1 EP 1882753A1 EP 06015671 A EP06015671 A EP 06015671A EP 06015671 A EP06015671 A EP 06015671A EP 1882753 A1 EP1882753 A1 EP 1882753A1
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EP
European Patent Office
Prior art keywords
aluminium alloy
alloy
aluminium
percent
percentage
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EP06015671A
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German (de)
English (en)
Inventor
Iñaki Landa Sastre
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.)
Fagor Electrodomesticos SCL
Edertek S Coop
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Fagor Electrodomesticos SCL
Edertek S Coop
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Application filed by Fagor Electrodomesticos SCL, Edertek S Coop filed Critical Fagor Electrodomesticos SCL
Priority to EP06015671A priority Critical patent/EP1882753A1/fr
Priority to EP07014135.3A priority patent/EP1882754B1/fr
Publication of EP1882753A1 publication Critical patent/EP1882753A1/fr
Withdrawn legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
    • C22C21/04—Modified aluminium-silicon alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/043—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with silicon as the next major constituent

Definitions

  • the present invention relates to aluminium alloys. Particularly, the present invention is directed to an aluminium alloy which exhibits suitable tensile strength, yield strength and elongation percentage for its use to manufacture vehicular suspension parts.
  • Aluminium alloys are widely used as materials for various components of vehicles, industrial machines, airplanes, electric appliances for domestic use and other apparatus of various types.
  • Such aluminium alloys there are cast aluminium alloys, a representative of which is A356.
  • Such cast aluminium alloys are used in important durable parts requiring higher mechanical properties such as vehicle components, metal fittings for stringing and components of hydraulic systems, and in like applications.
  • Typical mechanical property values of the A356 alloy as treated by a T6 heat treatment are 250 MPa tensile strength, 200 MPa yield strength and 5 % elongation.
  • the A356 alloy has widespread applications for structural components in the automotive, aerospace, and general engineering industries because of their excellent castability, corrosion resistance, and, particularly, high strength-to-weight ratio in the heat-treated condition.
  • microstructures of alloy A356 are comprised of an aluminium matrix, which is strengthened by MgSi precipitates and, to a far lesser extent, by Si precipitates, and a dispersion of eutectic Al-Si particles and Fe-rich intermetallics.
  • the variables affecting the microstructure mainly include composition, solidification conditions, and heat treatment.
  • composition of A356 alloy comprises the following components: 91 to 93 wt % of Al; 6.5 to 7.5 wt % of Si; 0.20 to 0.40 wt % of Mg; 0 to 0.02 wt % of Cu; 0 to 0.20 wt % of Fe; 0 to 0.10 wt % of Mn; 0 to 0.20 wt % of Ti; and 0 to 0.10 wt % of Zn.
  • Another known aluminium die casting alloys for automotive structural applications have silicon contents between about 9-11 % by weight.
  • these alloys include C448 and Silafont 36.
  • the high Si content of these alloys results in brittle Al-Si eutectic networks in the as-cast condition.
  • these alloys need a high temperature solution heat treatment that serves, principally, to break down the eutectic network and to spheroidize the Si particles.
  • the solution heat treatment increases costs and also introduces part distortion which requires straightening or machining, which adds cost in the manufacturing process.
  • US 6364970 is directed to a hypoeutectic aluminium-silicon alloy.
  • the alloy according to the US 6364970 patent also known in industry as Silafont 36, contains an iron content of up to 0.15% by weight and a strontium refinement of 30 to 300 ppm (0.003 to 0.03% by weight). It has a high fracture strength resulting from the refined eutectic silicon phase and resulting from the addition of Sr to the alloy.
  • the alloy further contains 0.5 to 0.8% by weight manganese (Mn).
  • a material used for a vehicular suspension part such as a steering knuckle and a suspension arm is required to have high tensile strength, high yield strength, sufficient elongation percentage, as well as other technological properties such as corrosion resistance, low hot cracking, etc. Accordingly, it is desirable to provide an aluminium alloy with said properties.
  • the problem to be solved by the present invention is to provide an aluminium alloy with improved mechanical and technological properties suitable for vehicular suspension parts.
  • the solution is based on that the present inventors have found that an aluminium modified alloy containing silver and strontium in suitable amounts obtained by the process of the present invention, has an improved tensile strength, yield strength, and elongation percentage, and also suitable technological properties such as corrosion resistance and low hot cracking, compared to A356 aluminium alloy.
  • novel alloy of the present invention make it particularly suitable for durable components requiring higher mechanical properties such as vehicle components, particularly for suspension vehicle components such as steering knuckles and suspension arms. Furthermore, the new alloy is low in cost.
  • an aspect of the invention relates to an aluminium alloy which consists essentially of, by percentage of weight:
  • Another aspect of the invention relates to a process of making an aluminium alloy as described above, said method comprising (a) melting the raw materials, addition of alloying elements and auxiliary materials in suitable amounts to obtain the composition and properties of interest; (b) undergone the molten alloy thus obtained to a degassing process, and (c) introducing (pouring) the molten metal in a mould and reduce the temperature (cooling) until solidifying as rough casting parts.
  • Another aspect of the invention relates to a process of making an aluminium alloy having at least 300 MPa tensile strength, at least 230 MPa yield strength, and at least 9% elongation percentage, said method comprising submitting the aluminium alloy as defined above as rough casting part, to a T6 heat treatment which comprises homogenizing by heating in a temperature range of 500 to 600° C for 2 to 6 hours, followed by quenching and then age hardened by heating in a temperature range of 150 to 180 °C. From here on said improved aluminium alloy part is indistinctly named aluminium alloy casting part.
  • Another aspect of the invention relates to an aluminium alloy having at least 300 MPa tensile strength, at least 230 MPa yield strength, and at least 9% elongation percentage obtainable by the process described above.
  • Another aspect of the present invention relates to the use of the aluminium alloy casting described herein, as a vehicular suspension component.
  • vehicular suspension components such as steering knuckle and a suspension arms
  • a vehicular suspension component which is made from an aluminium alloy casting as described herein.
  • the precipitation hardening elements included in the alloy magnesium (Mg) and silicon (Si), are more finely dispersed in the alloy and precipitate.
  • the chemical composition for the aluminium alloy according to the present invention consists essentially 6.5 to 7.5 percent silicon, 0.2 to 0.4 percent magnesium, 0.1 to 0.2 percent titanium (Ti), at least 0.1 percent silver, 0.002 to 0.04 percent strontium, and the balance comprising aluminium and unavoidable impurities.
  • the aluminium alloy contains between 0.02 to 0.04 percent strontium.
  • the aluminium alloy contains, by percentage of weight, 0.2 percent silver.
  • the Ag is an essential element of the aluminium alloys of the present invention, due to its contribution to the increased fineness of the eutectic Si structure, the increased fineness of the needle iron (Fe) structure, and the increased uniformity and fineness of the precipitation hardening alloys of Mg, and Si which is suitable for improve the properties above mentioned.
  • the Ag content is at least 0.1 wt %.
  • the amount of the Ag added to the aluminium alloy is 0.2 wt %.
  • Ti is an element added for making the grains of the casting finer to improve the mechanical properties and mainly the ductility of the part.
  • the Ti content is defined as within a range from 0.1 to 0.2 wt %.
  • Mg is an essential hardening agent developed after heat treatment in Al-Si alloys.
  • the hardening phase Mg 2 Si is limited by solubility, which corresponds approximately until 0.7 % wherein maximum hardness is reached.
  • the Mg content is defined as within a range from 0.2 to 0.4 wt %.
  • Si is an essential element depositing together with Mg as Mg 2 Si by artificial aging to provide high strength (yield strength) for final products upon use. Its addition improves the flowability (castability), the hot strength, and other properties of the alloy. Alloys with less than 12% of Si are referred to as hypoeutectic, those with close to 12% Si as eutectic, and those with over 12% Si as hypereutectic. Modification of hypoeutectic alloys ( ⁇ 12% Si) is particularly advantageous in sand castings and can be effectively achieved through the addition of a controlled amount of sodium or strontium, which refines the eutectic phase.
  • the optimum range of Si depends on the process, e.g in sand castings amounts between 5 to 7 wt % , in die casting amounts between 7 to 9 wt %, in high pressure die casting between 8 to 12 wt %.
  • the addition of Si not only improves the mechanical properties, but also reduces the density and thermal expansion rate.
  • the Si content is defined as within the range from 6.5 to 7.5 wt %.
  • the aluminium alloy further comprises, by percentage of weight, 0.1 to 0.6 % of rare earth elements. More preferably, the aluminium alloy contains, by percentage of weight, 0.4 % of rare earth elements.
  • said rare earth element is at least one element selected from the group comprising La, Ce, Pr, Nb, Pm, Sm, Eu, Ga, Tb, Dy, Ho, Er, Tm, Yb, Lu, Y, and Sc. More preferred are those selected from the group consisting of La, Ce, Pr and Nd.
  • rare earth elements are eliminated as slag in refusions
  • the aluminium alloy contains, by percentage of weight, 0.1 percent silver and 0.4 percent of rare earth elements.
  • rare earth elements By adding slight amounts of rare earth elements the casting defects of the aluminium alloy casting are reduced, increased uniformity of structure and increased fineness of dispersion are achieved, and the strength of the aluminium alloy casting is strikingly improved. Furthermore, presence of rare earth elements contributes to make the grain size of the casting finer improving its strength and ductility, and modifies the eutectic structure of Al-Si alloys. Another advantage of the presence of rare earth elements in the aluminium alloys of the present invention, is that it reduces the costs, due to it permits to reduce the amount of Ag in the composition.
  • the alloys according to the present invention are substantially free of copper and iron.
  • substantially free means having no significant amount of that component purposely added to the alloy composition, it being understood that trace amounts of unavoidable impurities may find their way into a desired end product.
  • Copper substantially improves strength and hardness in the as-cast and heat-treated conditions. Alloys containing 4 to 6% Cu respond most strongly to thermal treatment. Copper generally reduces resistance to general corrosion and, in specific compositions and material conditions, stress corrosion susceptibility. Additions of copper also reduce hot tear resistance and decrease castability.
  • Iron improves hot tear resistance and decreases the tendency for die sticking or soldering in die casting. Increases in iron content are, however, accompanied by substantially decreased ductility. Iron reacts to form a myriad of insoluble phases in aluminium alloy melts, the most common of which are FeAl 3 , FeMnAl 6 and ⁇ -AlFeSi. These essentially insoluble phases are responsible for decrease in mechanical properties, such as elongation and tensile strength, especially at elevated temperature. As the fraction of insoluble phase increases with increased iron content, casting considerations as flowability and feeding characteristics are adversely affected. Iron participates in the formation of sludging phases with manganese, chromium and other elements.
  • the aluminium alloy of the present invention is substantially free of copper and iron, i.e. it has no significant amount of those components purposely added to the alloy composition, nevertheless it is understood that trace amounts of unavoidable impurities may find their way into a desired end product.
  • the content of iron in the aluminium alloys of the present invention is lower than 0.15 % wt.
  • the aluminium alloy described herein can be prepared by a process comprising (a) melting the raw materials, alloying elements and auxiliary materials in suitable amounts to obtain the composition and properties of interest; (b) undergone the molten alloy thus obtained to a degassing process, and (c) introducing (pouring) the molten metal in a mould and reduce the temperature until solidifying as rough casting parts.
  • the raw materials in solid state are introduced in the furnace as pure elements or as alloys of the components.
  • ingots of the aluminium alloy A356 basic composition
  • alloying elements are added, and then when the ingots are melt, the composition of the molten metal is analyzed and optionally, if necessary, the proportions of the components in the alloy are adjusted by adding suitable amounts of such components or alternatively diluted the molten by adding aluminium ingots and then adding suitable amounts of the components to adjust their proportion.
  • additives are added in order to achieve the suitable mechanical and technological properties.
  • additives are the modifying agent strontium and the refining agent titanium.
  • the modifying agent is used in order to achieve that the eutectic structure aluminium-silicon, which precipitates during the solidifying step of the part, shows a rounded shape, instead of a needle shape characteristic wherein no modifying is present.
  • the eutectic structure shows a needle shape, the mechanical properties are reduced, due to that those needles are prone to develop cracks, which reduce the ductility and strength of the material.
  • strontium effect is not permanent, their effect is enough to achieve rounded shapes of the eutectic structures.
  • the addition of strontium is performed by use of aluminium-strontium alloys.
  • the degassing process (b) is carried out by treating the molten alloy with dry nitrogen or dry argon.
  • the molten metal is introduced into a mould.
  • This step is known as pouring step.
  • Different pouring techniques are known in the art, gravity die casting, low pressure die casting and high pressure die casting.
  • the solidifying of the part generally leaving it to reduce the temperature, allows to taking out it from the mould without risk of breaking, marks, etc.
  • the product thus obtained, after deburring, is known as rough casting part. i.e. without any later treatment (generally thermal treatment).
  • the aluminium alloy according to the present invention In order to be used as vehicular suspension parts such as a steering knuckle and a suspension arms, the aluminium alloy according to the present invention must satisfy mechanical and technological properties such as tensile strength, yield strength, elongation percentage, corrosion resistance, and also low hot cracking.
  • T6 heat treatment is which gives best results.
  • another heat treatment known in the art such as T4, T5 heat treatments may also be suitable.
  • T6 heat treatment comprises 2 steps: homogenizing and quenching-age hardening.
  • homogenizing step what is done is to support the rough casting part to high temperature, in the range from about 500 to 600 °C, during a period of time that can be of the order of 2 to 6 hours.
  • the temperature is about 540 °C and the time 6 hours.
  • the part is quenched, i.e. is undergone to a sudden cooling.
  • the step from the homogenizing furnace to the quenching must be realized in an as short as possible period of time, since otherwise it would begin the selective precipitation. According to a preferred embodiment, this time is less than 15 seconds.
  • the quenched parts are introduced again in another treatment furnace, wherein it occurs the age-hardening step.
  • This age-hardening step is carried out at low temperature, preferably in the range of about 150 to 180 °C.
  • the age-hardening step gives the mechanical and technological properties to the casting part.
  • the casting part may be subjected to a shot-blasting step, to achieve a more bright superficial aspect.
  • the aluminium alloy thus obtained has at least 300 MPa tensile strength, at least 230 MPa yield strength, and at least 9% elongation percentage.
  • Example 1 Process of preparation of the aluminium alloy.
  • the raw materials in solid state were introduced in the furnace as pure elements and as ingots of alloys of the components.
  • Ingots of the aluminium alloy A356 (basic composition) were used.
  • the different proportions of the different components of the alloy were adjusted by adding suitable amounts of such components.
  • compositions thus obtained were: Composition A A356 alloy B Si 7% + Mg 0.3% + Ag 0,2% + Ti 0.1% + Sr 0.02% + Al balance C Si 7% + Mg 0.3% + Ag 0,1% + Ti 0.1% + Sr 0.02 + RE 0,2% + Al balance D Si 7% + Mg 0.3% + Ag 0,1% + Ti 0.1% + Sr 0.02 + RE 0,4% + Al balance RE: Rare earth elements
  • the molten alloy contains the composition of interest, it was undergone to a degassing process, by treating the molten alloy with dry nitrogen.
  • the molten metal was introduced into a mould by gravity pouring. After the mould filling, the molten metal in the mould was leaving to reduce the temperature, and then taking it out from the mould. The product thus obtained, as rough casting part, was deburred.
  • the product as rough casting part was undergone to a T6 heat treatment. During homogenizing step, the rough casting part was heated to 540 °C, during a period of time of 6 hours. Then, the part was quenched, wherein the step from the homogenizing furnace to the quenching was carried out in less than 15 seconds.
  • the quenched parts were introduced again in another treatment furnace, to carry out the age-hardening step.
  • This age-hardening step was carried out at 160 °C.
  • composition B The aluminium alloy castings of the invention, shown an improvement of their mechanical properties, when content of Ag is above 0.1%. Best results are obtained whit Ag 0.2% (composition B).
  • Example 3 Mechanical properties of tensile bars obtained in a mould with a step-shape.
  • tensile bars were prepared using the mould with a step-shape, as shows Figure 1.
  • tensile bars made from the aluminium alloy castings of example 1, were prepared from each area (2 per area), and the influence of thickness and improvement of results were determined. Parameters taken into account were composition and cooling speed when tests were running with and without refrigeration.
  • composition B of example 2 Aluminium alloy castings with Ag 0.2% (composition B of example 2), i.e. thin area bar (5), with external refrigeration, the mechanical properties resulted in a substantial improvement respect to A356 properties.
  • compositions C and D of example 2 shown an improvement in the mechanical properties respect to A356 properties.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
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EP06015671A 2006-07-27 2006-07-27 Alliage d'aluminium Withdrawn EP1882753A1 (fr)

Priority Applications (2)

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EP06015671A EP1882753A1 (fr) 2006-07-27 2006-07-27 Alliage d'aluminium
EP07014135.3A EP1882754B1 (fr) 2006-07-27 2007-07-19 Alliage d'aluminium

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Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102312137A (zh) * 2011-09-09 2012-01-11 中兴通讯股份有限公司 铝硅镁系铸造铝合金及铸造工艺
CN103290273A (zh) * 2013-05-14 2013-09-11 锡山区羊尖泓之盛五金厂 耐蚀铝合金
CN103451494A (zh) * 2013-08-16 2013-12-18 南昌大学 一种铝-硅-镱铸造铝合金及制备方法
CN103469022A (zh) * 2013-08-16 2013-12-25 南昌大学 一种铝-硅-钐铸造铝合金及制备方法
CN104294109A (zh) * 2014-10-23 2015-01-21 重庆大学 含钐和/或钆的耐热铸造铝合金及其制备方法
CN106676332A (zh) * 2016-10-25 2017-05-17 河北工业大学 一种铝合金复合细化‑变质剂及其制备方法和应用
CN111455231A (zh) * 2020-04-21 2020-07-28 昆明冶金研究院有限公司 一种复合稀土re铸造铝合金材料及其制备方法
WO2020246947A3 (fr) * 2019-06-05 2020-12-30 Cms Jant Ve Maki̇na Sanayi̇i̇ Anoni̇m Şi̇rketi̇ Alliage a356 présentant des propriétés mécaniques améliorées par apport d'alliage mère de cérium et de lanthane
CN113234970A (zh) * 2021-05-08 2021-08-10 昆明理工大学 一种含Er的高强韧铸造铝硅合金及其制备方法
CN114045407A (zh) * 2021-11-02 2022-02-15 山东博源精密机械有限公司 一种新能源汽车低偏析度电机转子微合金铝的制备方法及其制备的微合金铝
CN114525435A (zh) * 2022-01-20 2022-05-24 江西理工大学 一种添加Er和Pr的高强耐蚀Al-Zn-Mg-Cu合金及其制备方法
CN114855036A (zh) * 2022-05-26 2022-08-05 广东省科学院新材料研究所 一种高强高导热铸造铝合金及其制备方法与铝合金产品
CN116287891A (zh) * 2023-05-25 2023-06-23 小米汽车科技有限公司 一种免热处理压铸铝合金及其制备方法和应用

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CN1693508A (zh) * 2005-05-17 2005-11-09 郑州大学 一种用细晶铝锭制造的轮毂用铝合金及其制造方法
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EP1657319A1 (fr) * 2004-11-06 2006-05-17 Bayerische Motorenwerke Aktiengesellschaft Alliage d'aluminium
CN1693508A (zh) * 2005-05-17 2005-11-09 郑州大学 一种用细晶铝锭制造的轮毂用铝合金及其制造方法

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Cited By (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102312137B (zh) * 2011-09-09 2016-06-22 深圳市中兴康讯电子有限公司 铝硅镁系铸造铝合金及铸造工艺
CN102312137A (zh) * 2011-09-09 2012-01-11 中兴通讯股份有限公司 铝硅镁系铸造铝合金及铸造工艺
CN103290273A (zh) * 2013-05-14 2013-09-11 锡山区羊尖泓之盛五金厂 耐蚀铝合金
CN103290273B (zh) * 2013-05-14 2015-08-05 锡山区羊尖泓之盛五金厂 耐蚀铝合金
CN103451494A (zh) * 2013-08-16 2013-12-18 南昌大学 一种铝-硅-镱铸造铝合金及制备方法
CN103469022A (zh) * 2013-08-16 2013-12-25 南昌大学 一种铝-硅-钐铸造铝合金及制备方法
CN103469022B (zh) * 2013-08-16 2016-01-20 南昌大学 一种铝-硅-钐铸造铝合金及制备方法
CN103451494B (zh) * 2013-08-16 2016-04-20 南昌大学 一种铝-硅-镱铸造铝合金及制备方法
CN104294109A (zh) * 2014-10-23 2015-01-21 重庆大学 含钐和/或钆的耐热铸造铝合金及其制备方法
CN106676332A (zh) * 2016-10-25 2017-05-17 河北工业大学 一种铝合金复合细化‑变质剂及其制备方法和应用
WO2020246947A3 (fr) * 2019-06-05 2020-12-30 Cms Jant Ve Maki̇na Sanayi̇i̇ Anoni̇m Şi̇rketi̇ Alliage a356 présentant des propriétés mécaniques améliorées par apport d'alliage mère de cérium et de lanthane
CN111455231A (zh) * 2020-04-21 2020-07-28 昆明冶金研究院有限公司 一种复合稀土re铸造铝合金材料及其制备方法
CN113234970A (zh) * 2021-05-08 2021-08-10 昆明理工大学 一种含Er的高强韧铸造铝硅合金及其制备方法
CN114045407A (zh) * 2021-11-02 2022-02-15 山东博源精密机械有限公司 一种新能源汽车低偏析度电机转子微合金铝的制备方法及其制备的微合金铝
WO2023077668A1 (fr) * 2021-11-02 2023-05-11 山东博源精密机械有限公司 Procédé de préparation d'aluminium de microalliage de rotor de moteur à faible ségrégation de véhicule à nouvelles énergies et aluminium de microalliage préparé par ce procédé
CN114525435A (zh) * 2022-01-20 2022-05-24 江西理工大学 一种添加Er和Pr的高强耐蚀Al-Zn-Mg-Cu合金及其制备方法
CN114855036A (zh) * 2022-05-26 2022-08-05 广东省科学院新材料研究所 一种高强高导热铸造铝合金及其制备方法与铝合金产品
CN116287891A (zh) * 2023-05-25 2023-06-23 小米汽车科技有限公司 一种免热处理压铸铝合金及其制备方法和应用
CN116287891B (zh) * 2023-05-25 2023-08-08 小米汽车科技有限公司 一种免热处理压铸铝合金及其制备方法和应用

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