EP2261384A2 - Aluminiumlegierung mit hoher Korrosionsbeständigkeit für Sand- und Dauerformverfahren - Google Patents
Aluminiumlegierung mit hoher Korrosionsbeständigkeit für Sand- und Dauerformverfahren Download PDFInfo
- Publication number
- EP2261384A2 EP2261384A2 EP10164100A EP10164100A EP2261384A2 EP 2261384 A2 EP2261384 A2 EP 2261384A2 EP 10164100 A EP10164100 A EP 10164100A EP 10164100 A EP10164100 A EP 10164100A EP 2261384 A2 EP2261384 A2 EP 2261384A2
- Authority
- EP
- European Patent Office
- Prior art keywords
- percent
- weight
- aluminum
- alloy
- casting
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 229910000838 Al alloy Inorganic materials 0.000 title claims description 20
- 238000005260 corrosion Methods 0.000 title abstract description 14
- 230000007797 corrosion Effects 0.000 title abstract description 14
- 239000004576 sand Substances 0.000 title abstract description 11
- 238000000034 method Methods 0.000 title abstract description 8
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 38
- 239000000956 alloy Substances 0.000 claims abstract description 38
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 31
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 31
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 26
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 claims abstract description 15
- 229910052748 manganese Inorganic materials 0.000 claims abstract description 15
- 239000011572 manganese Substances 0.000 claims abstract description 15
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 14
- 239000010703 silicon Substances 0.000 claims abstract description 14
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 13
- 229910052802 copper Inorganic materials 0.000 claims abstract description 13
- 239000010949 copper Substances 0.000 claims abstract description 13
- 229910052742 iron Inorganic materials 0.000 claims abstract description 13
- 238000004519 manufacturing process Methods 0.000 claims 1
- 238000005266 casting Methods 0.000 abstract description 15
- 238000007528 sand casting Methods 0.000 abstract description 10
- 238000010120 permanent mold casting Methods 0.000 abstract description 9
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 10
- 238000004512 die casting Methods 0.000 description 10
- 238000005476 soldering Methods 0.000 description 5
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 239000004411 aluminium Substances 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 229910052749 magnesium Inorganic materials 0.000 description 2
- 239000011777 magnesium Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000001939 inductive effect Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 230000035945 sensitivity Effects 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- 239000011135 tin Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
Classifications
-
- 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
Definitions
- This invention relates to aluminum alloys; particularly, to aluminum casting alloys; and more particularly, to aluminum casting alloys used for sand and permanent mold casting processes.
- Components formed from casting of known aluminum alloys may not be sufficiently resistant to corrosion for certain automotive applications.
- United States Patent US 6,733,726 B2 provides for an aluminum alloy that is suitable for die-casting components for automotive applications.
- the aluminum die casting alloy is characterized by a very low copper content, a manganese content that is sufficient to enhance the stability of the alloy and have a positive influence on the strength properties, and a silicon content that is sufficient to impart excellent fluidity, hot tear resistance and feeding characteristics for good die-castability.
- the aluminum die casting alloy contains about 4.5 to about 12 percent silicon by weight, at least 87 percent aluminum by weight, about 0.25 percent to about 0.5 percent manganese by weight, and a maximum of 0.08 percent copper by weight.
- the resulting aluminum alloy has improved corrosion resistance and excellent strength characteristics; however, the alloy is formulated mainly for die-casting processes in which the alloy is subjected to high gauge pressure for introducing molten alloy into the die-cast dies.
- Sand and permanent mold casting may be a more cost efficient alternative to die-casting for forming certain components. As compared to die-casting, both sand and permanent mold casting processes require very low to no gauge pressure in introducing the molten aluminum alloy into the mold.
- Sand casting is a process in which molten metal is poured into a mold formed of sand under gravity or low pressure or in vacuum and held until the alloy is cooled and solidified.
- Permanent mold casting is similar to sand casting except that the mold is typically formed of a metal that has a higher melting point than the alloy that is poured into the mold.
- Components formed from sand and permanent mold casting can be heat treated to obtain the desired mechanical properties. Components formed from aluminum alloys designed for die casting cannot be heat treated, and therefore requires the alloy formulation be tailored to provide the desired mechanical properties in an as-cast component.
- an aluminum casting alloy best suited for sand and permanent mold casting processes, in which the alloy is highly resistant to corrosion yet exhibits adequate strength similar to that of the aluminum alloy for die-casting as disclosed in US 6,733,726 B2 . It is also desirable to have an aluminum casting alloy that is amenable to heat treatment. It is still further desirable to have an aluminum casting alloy that has a reduced natural affinity for the aluminium to attack and dissolve the tooling steel, a condition referred to as soldering. It is an object of the present invention to provide an aluminum alloy with the above mentioned advantages.
- This invention is directed to aluminum alloys having improved corrosion resistance and excellent strength characteristics for sand and permanent mold casting processes.
- An aluminum-based alloy in accordance with the present invention comprises at least about 87 percent aluminum by weight; from about 4.0 percent to about 8.5 percent silicon by weight; from about 0.25 percent to about 0.5 percent manganese by weight; a maximum of about 0.08 percent copper by weight; and from about 0.2 percent to about 0.8 percent iron by weight.
- the aluminum alloys of this invention are characterized by a very low copper content, a manganese content that is sufficient to input excellent strength properties, a silicon content that is suitable for fluid flow of molten alloy into a mold under normal gravity, and an iron content sufficient to minimize soldering of metallic molds.
- the lower silicon content provides for improved mechanical properties, while the lower iron content provides for increased strength and better creep characteristics at moderately elevated temperatures and improved ductility.
- an aluminum casting alloy having improved corrosion resistance and excellent sand and permanent casting properties includes a relatively low copper content that is effective to achieve enhanced corrosion resistance, in conjunction with a relatively lower silicon content for improved mechanical properties, and a lower iron content to increase tensile strength and ductility as well as to reduce shrinkage and soldering.
- the aluminum alloys of this invention typically have a silicon content of from about 4.0 percent by weight to about 8.5 percent by weight; preferably between about 4.0 to about 7.0 percent by weight.
- Iron is preferably added to the aluminum alloys of this invention to decrease the tendency for mold sticking or soldering during casting.
- a suitable amount of iron is from about 0.2 percent to about 0.8 percent by weight.
- Conventional aluminum casting alloys typically contain relatively high amounts of copper in order to improve the machinability, strength, and hardness of the casting.
- copper reduces resistance to general corrosion, and therefore, is present in the aluminum alloys of this invention in relatively low amounts, if at all.
- the aluminum alloys of this invention typically contain 0.08 percent copper by weight or less, and more preferably 0.05 percent or less.
- Aluminum casting alloys have an aluminum content of about 86 percent by weight or less.
- the most commonly used aluminum die casting alloy (alloy 380.0) contains from about 79 to about 83 percent aluminum by weight.
- the aluminum alloys of this invention for sand and permanent mold casting have a relatively high (more than 87 percent by weight) aluminum content, and as a result, exhibit a thermal conductivity that is about 20 percent greater than that of alloy 380.0.
- Manganese is present in an amount from about 0.25 to about 0.5 percent by weight to enhance strength, and more preferably from about 0.3 to about 0.5, with about 0.40 percent manganese being most preferred. These levels of manganese have been found to compensate, at least in part, for the relatively low levels of copper, to enhance strength properties without significantly adversely affecting corrosion resistance.
- Magnesium, nickel, zinc and tin may be present in the alloy in relatively minor amounts, preferably about 1.5 percent or less, more preferably about 1 percent or less, and even more preferably about 0.6 percent or less.
- the aluminum alloys of this invention use lower silicon and higher iron and manganese contents, as compared to known aluminum alloys, to increase strength and control the grain structure.
- An advantage of having higher manganese content is the increase in the sensitivity of heat treating in obtaining the desired properties.
- Another advantage of having higher manganese content is that the manganese combines with magnesium to insure a greater degree of stability to the alloy.
- the higher iron aids in reducing the natural affinity for aluminium to attack and dissolve tooling steel, a condition referred to as soldering.
- the alloy of the present invention has a lower range limit for the silicon content, and a lower range for the iron content.
- Lower iron content has been found to reduce shrinkage and increases tensile strength and ductility.
- Lower silicon provides improved mechanical and elongation properties.
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
- Prevention Of Electric Corrosion (AREA)
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US12/480,912 US20100310414A1 (en) | 2009-06-09 | 2009-06-09 | High corrosion resistance aluminum alloy for sand and permanent mold processes |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| EP2261384A2 true EP2261384A2 (de) | 2010-12-15 |
Family
ID=42782054
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| EP10164100A Withdrawn EP2261384A2 (de) | 2009-06-09 | 2010-05-27 | Aluminiumlegierung mit hoher Korrosionsbeständigkeit für Sand- und Dauerformverfahren |
Country Status (3)
| Country | Link |
|---|---|
| US (1) | US20100310414A1 (de) |
| EP (1) | EP2261384A2 (de) |
| CN (1) | CN101921936A (de) |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6733726B2 (en) | 2001-02-05 | 2004-05-11 | Delphi Technologies, Inc. | High corrosion resistance aluminum alloy |
Family Cites Families (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CH297680A (de) * | 1942-05-07 | 1954-03-31 | Lurgi Thermie Gmbh | Verfahren zur Herstellung einer Aluminium-Silizium-Legierung. |
| JPH01283335A (ja) * | 1988-05-10 | 1989-11-14 | Showa Alum Corp | 真空用アルミニウム合金 |
| WO1998010109A1 (fr) * | 1996-09-03 | 1998-03-12 | Toyota Jidosha Kabushiki Kaisha | Alliage, alliage d'aluminium et element d'alliage d'aluminium ayant une excellente resistance a la fatigue thermique |
| US6376375B1 (en) * | 2000-01-13 | 2002-04-23 | Delphi Technologies, Inc. | Process for preventing the formation of a copper precipitate in a copper-containing metallization on a die |
| US6586110B1 (en) * | 2000-07-07 | 2003-07-01 | Delphi Technologies, Inc. | Contoured metal structural members and methods for making the same |
| DE60231046D1 (de) * | 2001-07-25 | 2009-03-19 | Showa Denko Kk | Aluminiumlegierung mit hervorragender zerspanbarkeit und aluminiumlegierungsmaterial und herstellungsverfahren dafür |
| JP4053793B2 (ja) * | 2002-03-08 | 2008-02-27 | 古河スカイ株式会社 | 熱交換器用アルミニウム合金複合材の製造方法とアルミニウム合金複合材 |
| CN101120894B (zh) * | 2006-08-08 | 2010-05-12 | 上海市机械制造工艺研究所有限公司 | 制造假肢膝关节中有关部件的工艺方法 |
| CN101338392B (zh) * | 2008-08-07 | 2011-08-03 | 中铝河南铝业有限公司 | 一种热轧法生产铝合金药用箔的方法 |
-
2009
- 2009-06-09 US US12/480,912 patent/US20100310414A1/en not_active Abandoned
-
2010
- 2010-05-27 EP EP10164100A patent/EP2261384A2/de not_active Withdrawn
- 2010-06-08 CN CN2010101988481A patent/CN101921936A/zh active Pending
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6733726B2 (en) | 2001-02-05 | 2004-05-11 | Delphi Technologies, Inc. | High corrosion resistance aluminum alloy |
Also Published As
| Publication number | Publication date |
|---|---|
| CN101921936A (zh) | 2010-12-22 |
| US20100310414A1 (en) | 2010-12-09 |
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| STAA | Information on the status of an ep patent application or granted ep patent |
Free format text: STATUS: THE APPLICATION HAS BEEN WITHDRAWN |
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| 18W | Application withdrawn |
Effective date: 20160531 |