EP2374905B1 - Manufacturing method of magnesium based alloy for high temperature - Google Patents

Manufacturing method of magnesium based alloy for high temperature Download PDF

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Publication number
EP2374905B1
EP2374905B1 EP11159526.0A EP11159526A EP2374905B1 EP 2374905 B1 EP2374905 B1 EP 2374905B1 EP 11159526 A EP11159526 A EP 11159526A EP 2374905 B1 EP2374905 B1 EP 2374905B1
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Prior art keywords
magnesium
cao
alloy
magnesium alloy
mri153
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German (de)
English (en)
French (fr)
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EP2374905A3 (en
EP2374905A2 (en
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Shae K Kim
Jung Ho Seo
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Emk Co Ltd
Korea Institute of Industrial Technology KITECH
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Emk Co Ltd
Korea Institute of Industrial Technology KITECH
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Priority claimed from KR1020100028157A external-priority patent/KR101147650B1/ko
Priority claimed from KR1020100135979A external-priority patent/KR101367892B1/ko
Application filed by Emk Co Ltd, Korea Institute of Industrial Technology KITECH filed Critical Emk Co Ltd
Priority to PL11159526T priority Critical patent/PL2374905T3/pl
Publication of EP2374905A2 publication Critical patent/EP2374905A2/en
Publication of EP2374905A3 publication Critical patent/EP2374905A3/en
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C23/00—Alloys based on magnesium
    • C22C23/02—Alloys based on magnesium with aluminium as the next major constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002—Castings of light metals
    • B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
    • 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
    • C22C1/06—Making non-ferrous alloys with the use of special agents for refining or deoxidising

Definitions

  • the present invention relates to a manufacturing method for magnesium-based alloy for high temperature.
  • Magnesium with a specific gravity of 1.7 is not only the lightest element among commercially available metals, but its specific strength and specific stiffness are also superior to those of iron and aluminum.
  • excellent mechanical properties can be obtained when manufacturing magnesium products by a die casting process. Therefore, magnesium is currently being applied to various fields, such as portable electronic components, aircrafts and sporting goods, etc., with mainly focusing on the field of automobile components. When magnesium alloys are applied to the automobile components, 30 % of a weight reduction can be achieved.
  • Typical magnesium alloys among the currently available commercial magnesium alloys for die casting applications are magnesium (Mg)-aluminum (Al) based alloys such as AZ91D, AM50 and AM60. These magnesium alloys are low priced and have good castability as compared to other alloys for the die casting applications. Particularly, high strength can be obtained by forming a ⁇ -Mg 17 Al 12 phase during solidification at room temperature.
  • Mg magnesium
  • Al aluminum-aluminum
  • magnesium alloys for high temperature are largely classified into magnesium alloys for die casting applications and magnesium alloys for sand casting applications, which depend on alloy compositions and manufacturing methods caused by differences in use temperatures of target components.
  • a proper characteristic required for the magnesium alloy for high temperature is castability that is appropriate for die casting, and corrosion and oxidation resistances are also required.
  • development of magnesium alloys excluding high-priced additive elements is required in terms of cost.
  • magnesium alloys having high addition ratios of rare earth elements are disadvantageous in an aspect of cost.
  • alkaline earth metals e.g., calcium (Ca) and strontium (Sr)
  • WO 2010/032893 A1 disclose a method that is related to the method of the present invention.
  • the present invention provides a manufacturing method for a magnesium-based alloy for high temperaturecalcium oxide (CaO) is added into a molten magnesium to reduce the CaO, the reduced Ca from the CaO reacts with Mg or A1 to form a phase, and formation of a thermally unstable ⁇ -Mg 17 Al 12 phase can be suppressed so that high-temperature strength and deformation resistance can be improved.
  • CaO high temperaturecalcium oxide
  • the present invention also provides a manufacturing method for a magnesium-based alloy for high temperature, in which CaO is added into the magnesium alloy such that ductility and strength can be improved at the same time by improving internal soundness of casting such as reduction of oxides, inclusions and pores or the like.
  • each Mg alloy is generally determined according to the temperature of an environment where products are used.
  • the use environment temperature is often classified into 90 °C, 120 °C and 150 °C, etc.
  • the present invention also provides a magnesium-based alloy for high temperature which can be used at high temperatures of 120 °C or more and 175 °C or more including a temperature of 90 °C or more.
  • a method of manufacturing a magnesium-based alloy for high temperature includes: melting magnesium (Mg) or magnesium alloy into a liquid phase; adding 0.5 % to 4.0 % by weight of calcium oxide (CaO) onto a surface of a melt in which the magnesium or magnesium alloy is melted; exhausting the CaO through surface stirring to allow the CaO not to remain in the magnesium or magnesium alloy through a surface reduction reaction between the melt and the CaO; and forming a compound by reacting at least a portion of calcium (Ca) produced by the surface reduction reaction in the magnesium or magnesium alloy, wherein the surface stirring is carried out for between 1 second and 60 minutes per 0.1 % by weight of the calcium oxide added, wherein the surface stirring is performed in the upper layer portion of which a depth is about 20% of a total depth of the melt from the surface thereof.
  • the method may include adding the CaO 1.4 times the weight of a final Ca target composition onto the surface of the melt in which the magnesium or the magnesium alloy is melted.
  • the CaO may be added in the range of 1.0 to 3.5 wt %.
  • the Ca may be produced in the range of 0.8 to 2.4 wt %.
  • a final composition of the Mg alloy may include 6.0 to 8.0 wt % of aluminum (Al), 0.1 to 0.3 wt % of manganese (Mn), 0.2 to 0.3 wt % of strontium (Sr), less than 0.04 wt % of zinc (Zn), less than 0.9 wt % of tin (Sn), and a balance being Mg.
  • the compound formed may include at least one of Mg 2 Ca, Al 2 Ca and (Mg, Al) 2 Ca.
  • a magnesium-based alloy for high temperature is characterized in that the magnesium-based alloy is manufactured by adding 0.5 % to 4.0 % by weight of CaO into a molten magnesium or magnesium alloy, and partially or wholly exhausting the CaO through a surface reduction reaction of the CaO, wherein the magnesium-based alloy contains a compound formed through combination of Ca with Mg or other alloying elements in the magnesium-based alloy to thereby have larger high-temperature mechanical properties as compared to a Mg alloy having the same composition manufactured by directly adding Ca.
  • the high-temperature mechanical properties may be high-temperature yield strength or high-temperature tensile strength.
  • the CaO may be added in the range of 1.0 to 3.5 wt %.
  • the Ca may be produced in the range of 0.8 to 2.4 wt %.
  • a final composition of the Mg alloy may include 6.0 to 8.0 wt % of Al, 0.8 to 2.4 wt% of Ca, 0.1 to 0.3 wt % of Mn, 0.2 to 0.3 wt % of Sr, less than 0.04 wt % of Zn, less than 0.9 wt % of Sn, and a balance being Mg.
  • the compound formed may include at least one of Mg 2 Ca, Al 2 Ca and (Mg, Al) 2 Ca.
  • a magnesium-based alloy for high temperature is characterized in that the magnesium-based alloy is manufactured by adding 0.5 % to 4.0 % by weight of CaO into a molten magnesium or magnesium alloy, and partially or wholly exhausting through a reduction reaction of the CaO, wherein the magnesium-based alloy contains a compound formed through combination of Ca with Mg or other alloying elements in the magnesium-based alloy to thereby have lower high-temperature elongation and high-temperature creep strain as compared to a Mg alloy having the same composition manufactured by directly adding Ca.
  • the CaO may be added in the range of 1.0 to 3.5 wt%.
  • the Ca may be produced in the range of 0.8 to 2.4 wt%.
  • a final composition of the Mg alloy may include 6.0 to 8.0 wt% of aluminum (Al), 0.1 to 0.3 wt% of manganese (Mn), 0.2 to 0.3 wt% of strontium (Sr), less than 0.04 wt% of zinc (Zn), less than 0.9 wt% of tin (Sn), and a balance being Mg.
  • the compound formed may include at least one of Mg 2 Ca, Al 2 Ca and (Mg, Al) 2 Ca.
  • a magnesium-based alloy for high temperature is characterized in that the Mg-based alloy is manufactured through addition of CaO into a molten magnesium or magnesium alloy and a surface reduction reaction of the CaO, wherein strength and elongation of room-temperature mechanical properties are increased at the same time as compared to a Mg alloy having the same composition manufactured by directly adding Ca.
  • high-temperature creep strain is reduced by suppressing deformation at high temperature. Therefore, high-temperature creep resistance is increased.
  • a manufacturing method of a new alloy by adding CaO into molten magnesium and an alloy thereof are used to solve problems arising when calcium is added to magnesium and overcome limitations of physical properties.
  • FIG. 1 is a flowchart illustrating a manufacturing method of a magnesium-based alloy according to the present invention.
  • the manufacturing method of the magnesium-based alloy according to the present invention includes the steps of: forming a magnesium-based melt (Step S1); adding an alkaline earth metal oxide (CaO in the present invention) (Step S2); stirring the magnesium-based melt (Step S3); exhausting the alkaline earth metal oxide (Step S4); allowing the alkaline earth metal (Ca in the present invention) to react with the magnesium-based melt (Step S5); casting (Step S6); and solidifying (Step S7).
  • Step S4 of exhausting the alkaline earth metal oxide and Step S5 of allowing the alkaline earth metal to react with the magnesium-based melt are divided into the separate steps for convenience of description, two steps S4 and S5 occur almost at the same time. That is, when supplying of the alkaline earth metal starts in Step S4, Step S5 is initiated.
  • Step S1 of forming the magnesium-based melt magnesium or a magnesium alloy are put into a crucible, and heated at a temperature ranging from 400 °C to 800 °C under a protective gas atmosphere. Then, the magnesium alloy in the crucible is melted to form the magnesium-based melt.
  • temperature for melting magnesium or a magnesium alloy means the melting temperature of pure magnesium and the melting temperature of the magnesium alloy.
  • the melting temperatures may be different depending on alloy type.
  • CaO is added in the state where magnesium or the magnesium alloy is completely melted.
  • a temperature at which a solid phase is sufficiently melted to exist in a complete liquid phase is enough for the melting temperature of magnesium or the magnesium alloy.
  • work is necessary to maintain a molten magnesium in the temperature range with sufficient margin by considering the fact that the temperature of the molten magnesium is decreased due to the addition of CaO.
  • the molten magnesium alloy when the temperature is less than 400 °C, the molten magnesium alloy is difficult to be formed. On the contrary, when the temperature is more than 800 °C, there is a risk that the magnesium-based melt may be ignited.
  • a molten magnesium is generally formed at a temperature of 600 °C or more, whereas a molten magnesium alloy may be formed at a temperature ranging from 400 °C or more to 600 °C or less. In general, many cases in metallurgy show that a melting point decreases as alloying proceeds.
  • the magnesium used in Step S1 of forming the magnesium-based melt may be any one selected from pure magnesium, a magnesium alloy, and equivalents thereof.
  • the magnesium alloy may be any one selected from AZ91D, AM20, AM30, AM50, AM60, AZ31, AS41, AS31, AS21X, AE42, AE44, AX51, AX52, AJ50X, AJ52X, AJ62X, MRI153, MRI 230, AM-HP2, magnesium-Al, magnesium-Al-Re, magnesium-Al-Sn, magnesium-Zn-Sn, magnesium-Si, magnesium-Zn-Y, and equivalents thereof; however, the present invention is not limited thereto. Any magnesium alloy that is generally available in industries may be used.
  • Step S2 of adding the alkaline earth metal oxide CaO in the form of powder is added onto a surface of the molten magnesium.
  • CaO is in the powder form for accelerating a reaction with the magnesium alloy.
  • CaO may be added in a powder state so as to increase a surface area for efficient reaction.
  • the additive is too fine, that is, less than 0.1 ⁇ m in size, the additive is liable to be scattered by vaporized magnesium or hot wind, thereby making it difficult to input the additive into a furnace.
  • the additives are agglomerated to each other, and thus clustered while not being easily mixed with liquid molten metal.
  • an ideal particle size should not exceed 500 ⁇ m. More preferably, the particle size may be 200 ⁇ m or less.
  • CaO is used as an alkaline earth metal oxide added into the molten.
  • An input amount of the alkaline earth meal oxide is determined by a final target alloy composition. That is, an amount of CaO may be determined by performing a back-calculation according to a desired amount of Ca to be alloyed into a magnesium alloy.
  • the input amount of the alkaline earth metal oxide is in the range of 0.5 wt% to 4.0 wt%.
  • Excellent high-temperature mechanical properties could be obtained when the input amount of the alkaline earth metal oxide was 4.0 wt% or less. Improvement of the above properties was not relatively large when the input amount was less than 0.5 wt%.
  • the composition is in the range of 1.0 wt% to 3.5 wt%.
  • the excellent high-temperature mechanical properties mean relatively high yield strength and tensile strength at high temperature, and relatively low elongation and creep strain, at high temperature.
  • the input amount of calcium oxide (CaO) should be adjusted such that calcium formed by reduction of CaO is included in the range of 0.8 wt% to 2.4 wt% in the final magnesium alloy.
  • Step S3 the molten magnesium is stirred for 1 second to 60 minutes per 0.1 wt% of the added CaO.
  • the stirring time depends on the volume of the molten magnesium and the input amount of CaO.
  • the oxide powders of a required amount may be input at once. However, to accelerate the reaction and reduce agglomeration possibility, it is preferable that the oxide powders be re-input after a predetermined time elapses from a first input time, or the oxide powders are grouped into several batches of appropriate amounts and the batches are input in sequence.
  • the stirring may be generally performed by generating an electromagnetic field using a device capable of applying electromagnetic fields around the furnace holding the molten magnesium, thus enabling the convection of the molten magnesium to be induced.
  • artificial stirring may be performed on the molten magnesium from the outside.
  • the stirring may be performed in such a manner that the input CaO powders are not agglomerated.
  • the ultimate purpose of the stirring in the present invention is to induce the reduction reaction between the molten magnesium and added powders properly.
  • the stirring time may vary with the temperature of a molten metal and the state (pre-heating state or the like) of powders added.
  • the stirring may continue to be performed in principle until the powders are not observed on the surface of the molten magnesium. Since the powders are lower in specific gravity than the molten magnesium so that they float on the molten magnesium in a steady state, it can be indirectly determined that the powders and the molten magnesium sufficiently react when the powders are not observed on the molten magnesium any longer.
  • the term "sufficiently react" means that all of the CaO powders substantially react with the molten magnesium and are exhausted.
  • the CaO powders are not observed on the molten magnesium, possibilities of existing in the molten magnesium may not be excluded. Therefore, the CaO powders that do not float yet should be observed for a predetermined holding time after the stirring time, and the holding time may be necessary to complete the reaction of the CaO powders that did not react with the molten magnesium yet.
  • the stirring is effective when it is performed at the same time with the input of the oxide powders.
  • the stirring may start after the oxide powders receive heat from the molten magnesium and reach a predetermined temperature or higher, which enables acceleration of the reaction.
  • the stirring continues to be performed until the added oxide powders are not observed on the surface of the molten magnesium. After the calcium oxide is completely exhausted through the reaction, the stirring is finished.
  • the calcium oxide when the calcium oxide is input into the molten magnesium, the calcium oxide does not sink into the molten magnesium but float on the surface of the molten magnesium due to a difference in specific gravity.
  • the present invention it is important to create a reaction environment where the oxide reacts on the surface rather than inside the molten magnesium. To this end, it is important not to forcibly stir the oxide floating on the surface of the molten magnesium into the molten magnesium. It is important to uniformly spread the calcium oxide on the molten magnesium surface exposed to air. More preferably, it is important to supply the oxide in such a way as to coat the entire surface of the molten magnesium with the oxide.
  • the stirring inducing the foregoing surface reaction is denoted as surface stirring. That is, Ca, which is produced by a reduction reaction (surface reduction reaction) of the CaO added onto the surface of the molten Mg, acts as an alloying element of Mg or Mg alloys.
  • the stirring methods used herein were the stirring of the upper layer portion of molten magnesium alloy, the stirring of the inside of the molten magnesium alloy, and the rest method was no stirring. According to various stirring conditions, when comparing the case of the stirring of only the upper layer portion with the cases of no stirring and the stirring of the inside of the molten magnesium alloy, the smallest residual amount of the calcium oxide was observed in the case of the stirring of only the upper layer portion, that is, the final residual amounts of the calcium oxide were 0.001 wt%, 0.002 wt% and 0.005 wt% as the calcium oxide was added 5 wt%, 10 wt% and 15 wt%, respectively.
  • An oxygen component of the calcium oxide is substantially removed above the surface of the molten magnesium alloy by the stirring the upper layer portion of molten magnesium alloy.
  • the stirring is performed at an upper layer portion of which a depth is 20 % of a total depth of the molten magnesium from the surface. If the depth is beyond 20 %, the surface reaction according to a preferred example of the present invention is rarely generated. More preferably, the stirring may be performed in an upper layer portion of which a depth is 10 % of the total depth of the molten magnesium from the surface.
  • the substantially floating calcium oxide is induced to be positioned in an upper layer portion of which a depth is 10 % of an actual depth of the molten magnesium, thereby minimizing the turbulence of the molten magnesium.
  • Step S4 of exhausting the alkaline earth metal oxide through the reaction between the molten magnesium and the added calcium oxide, the calcium oxide is completely exhausted so as not to remain in the magnesium alloy at least partially or substantially. It is preferable that all the calcium oxide input in the present invention is exhausted by a sufficient reaction. However, even if some portions do not react and remain in the alloy, it is also effective if these do not largely affect physical properties.
  • the exhausting of calcium oxide includes removing an oxygen component from the alkaline earth metal oxide.
  • the oxygen component is removed in the form of oxygen gas (O 2 ) or in the form of dross or sludge through combination with magnesium or alloying components in the molten magnesium.
  • the oxygen component is substantially removed out from the top surface of the molten magnesium by stirring the upper layer portion of the molten magnesium.
  • FIG. 3 is a schematic view exemplarily showing dissociation of calcium oxide through stirring of an upper layer portion of molten magnesium according to the present invention.
  • Step S5 of allowing the alkaline earth metal to react with the molten magnesium calcium produced by the exhaustion of the calcium oxide reacts with the molten magnesium alloy so as not to at least partially or substantially remain in the magnesium alloy.
  • the calcium produced by the exhaustion is compounded with at least one of magnesium, aluminum, and other alloying elements (components) in the magnesium alloy, and is thus not left remaining.
  • a compound refers to an intermetallic compound obtained through bonding between metals.
  • the added calcium oxide is exhausted by removing the oxygen component through the reaction with the magnesium alloy, i.e., the molten magnesium alloy, and the produced calcium makes a compound with at least one of magnesium in the magnesium alloy, aluminum, and other alloying elements in the molten magnesium alloy. Therefore, the formed calcium will not remain at least partially or substantially in the magnesium alloy.
  • step S5 of exhausting the alkaline earth metal oxide there occur many flint flashes during the reduction reaction of the alkaline earth metal oxide on the surface of the molten magnesium.
  • the flint flashes may be used as an index for confirming whether the reduction reaction is completed or not.
  • the alkaline earth metal oxide added may not be fully exhausted. That is, the tapping of the molten magnesium is performed after the flint flashes, which can be used as an index for indirectly measuring the reduction reaction, disappear.
  • FIG. 2 is a flowchart illustrating dissociation of calcium oxide used to be added into a molten magnesium according to the present invention.
  • casting is performed by putting the molten magnesium into a mold at room temperature or in a pre-heating state.
  • the mold may include any one selected from a metallic mold, a ceramic mold, a graphite mold, and equivalents thereof.
  • the casting method may include gravity casting, continuous casting, and equivalent methods thereof.
  • Step S7 the mold is cooled down to room temperature, and thereafter, the magnesium alloy (e.g., magnesium alloy ingot) is taken out from the mold.
  • the magnesium alloy e.g., magnesium alloy ingot
  • the magnesium-based alloy formed by the above-described manufacturing method may have hardness (HRF) of 40 to 80.
  • HRF hardness
  • the hardness value may change widely depending on processing methods and heat treatment or the like, and thus the magnesium-based alloy according to the present invention is not limited to thereto.
  • magnesium in the molten magnesium reacts with alkaline earth metal to thereby form a magnesium (alkaline earth metal) compound.
  • the alkaline earth metal oxide is CaO
  • Mg 2 Ca is formed.
  • Oxygen constituting CaO is discharged out of the molten magnesium in the form of oxygen gas (O 2 ), or combines with Mg to be MgO and is then discharged in the form of dross (see Reaction Formula 1 below).
  • Reaction Formula 1 Pure Mg + CaO -> Mg (Matrix) + Mg 2 Ca ... [O 2 produced + MgO dross produced]
  • magnesium in the molten magnesium alloy reacts with alkaline earth metal to thereby form a magnesium (alkaline earth metal) compound or an aluminum (alkaline earth metal) compound.
  • an alloying element reacts with alkaline earth metal to form a compound together with magnesium or aluminum.
  • the alkaline earth metal oxide is CaO
  • Mg 2 Ca, Al 2 Ca, or (Mg, Al, other alloying element) 2 Ca is formed.
  • Oxygen constituting CaO is discharged out of the molten magnesium in the form of oxygen gas (O 2 ) as in the pure Mg case, or combines with Mg to be MgO, which is discharged in the form of dross (see Reaction Formula 2 below).
  • the present invention makes it possible to manufacture a magnesium alloy economically when compared to related art methods of manufacturing a magnesium alloy.
  • An alkaline earth metal (e.g., Ca) is a relatively high-priced alloying element as compared to an alkaline earth metal oxide (e.g., CaO), and thus it acts as a main factor of increasing the price of magnesium alloys. Also, alloying is relatively easy by adding alkaline earth metal oxide into magnesium or magnesium alloy instead of adding alkaline earth metal. On the other hand, alloying effects equal to or greater than the case of directly adding alkaline earth metal (e.g., Ca) can be achieved by adding the chemically stable alkaline earth metal oxide (e.g., CaO). That is, Ca, which is produced by the reduction reaction of the CaO added into the molten Mg, acts as an alloying element of Mg or the Mg alloy.
  • CaO chemically stable alkaline earth metal oxide
  • dissolution of the alkaline earth metal in the magnesium alloy occurs in a certain amount when the alkaline earth metal is directly input into magnesium or the magnesium alloy.
  • dissolution is absent or extremely small during the addition of the alkaline earth metal oxide (CaO) when comparing the degree of the dissolution with the case of directly adding the alkaline earth metal. It was confirmed that an intermetallic compound including an Al 2 Ca phase forms much easier when Ca is indirectly added through CaO as compared to the case of directly adding Ca.
  • FIG. 4a is a micrograph of a commercially available MRI153 magnesium alloy
  • FIG. 4b is a micrograph of an Eco-MRI 153 alloy manufactured according to the present invention.
  • the Eco-MRI 153 alloy denotes a magnesium alloy in which CaO is added instead of Ca for obtaining the Ca content equivalent to the commercially available MRI153 magnesium alloy and the corresponding Ca content is alloyed into the magnesium alloy using the reduction reaction.
  • the meaning of 'CaO addition' in the present invention implies that the reduction reaction process is undergone after the addition of the CaO.
  • the final Ca content was formed to 0.98 wt% using the reduction reaction by adding the CaO into the molten magnesium or the magnesium alloy. Then, an alloy having an equivalent composition to the commercially available MRI153 magnesium alloy was manufactured by adjusting other alloying compositions including 7.95 wt% of aluminum (Al), 0.20 wt% of manganese (Mn), 0.27 wt% of strontium (Sr), less than 0.01 wt% of zinc (Zn),and less than 0.01 wt% of tin (Sn).
  • the composition of the commercially available MRI153 magnesium alloy includes 7.95 wt% of Al, 0.98 wt% of Ca, 0.20 wt% of Mn, 0.27 wt% of Sr, less than 0.01 wt% of Zn, and less than 0.01 wt% of Sn.
  • a comparative example was manufactured to have the MRI153 alloy composition by directly adding Ca.
  • the MRI153 magnesium alloy (Eco-MRI153) manufactured by the CaO addition has a finer microstructure than the commercially available MRI153 magnesium alloy manufactured through the direct addition of Ca and also, casting defects almost do not exist.
  • the final Ca content is formed to 2.25 wt% using the reduction reaction by adding the CaO into the molten magnesium or the magnesium alloy.
  • An alloy (Eco-MRI230) having an equivalent composition to the commercially available MRI230 magnesium alloy was manufactured by adjusting other alloying compositions including 6.45 wt% of Al, 0.27 wt% of Mn, 0.25 wt% of Sr, less than 0.01 wt% of Zn, and less than 0.84 wt% of Sn.
  • the composition of the commercially available MRI230 magnesium alloy includes 6.45 wt% of Al, 2.25 wt% of Ca, 0.27 wt% of Mn, 0.25 wt% of Sr, less than 0.01 wt% of Zn, less than 0.84 wt% of Sn, and a balance being Mg.
  • a comparative example was manufactured to have the MRI230 alloy composition by directly adding Ca.
  • the Eco-MRI230 has a finer microstructure than the commercially available MRI230 magnesium alloy and casting defects almost do not exist like in the above embodiment.
  • the final composition of the Mg alloy in the present invention may be adjusted within the range including upper and lower limits of the respective alloying elements of the commercially available MRI153 and MRI230 magnesium alloys.
  • the range of 6.0 to 8.0 wt% including the lower and upper limits of 6.45 wt% and 7.95 wt%, respectively.
  • an embodiment is possible in the ranges including 6.0 to 8.0 wt% of Al, 0.8 to 2.4 wt% of Ca, 0.1 to 0.3 wt% of Mn, 0.2 to 0.3 wt% of Sr, less than 0.04 wt% of Zn, and less than 0.9 wt% of Sn.
  • an added amount of CaO in the present invention is adjusted such that the reduced Ca may be included in the ranges of 0.8 wt% to 2.4 wt% of the final Mg alloy. That is, the added amount of CaO may be adjusted to 1.12 to 3.36 wt% which is 1.4 times of the amount of Ca.
  • the total amount of CaO will be added 1.4 times the weight of a final Ca target composition under the assumption that all CaO are reduced into Ca.
  • the added amount of CaO in the molten magnesium alloy is 1.4 times to 1.7 times the weight of the final Ca target composition.
  • the amount of CaO may be added 1.4 times to 1.7 times the weight of the final Ca target composition.
  • FIGS. 5a to 5d show compositional analysis of transmission electron microscope (TEM) micrographs of the magnesium alloy manufactured by adding 1.8 wt% of CaO into a AZ61 magnesium alloy by the manufacturing method of the magnesium alloy according to the present invention.
  • FIGS. 5a , 5b and 5c show that magnesium, aluminum and calcium components are detected, respectively.
  • TEM transmission electron microscope
  • Table 2 presents quantitative data on the composition of the above phase.
  • the compound was formed with Al and Ca, and from a quantitative compositional analysis of the phase, it can be understood that an Al 2 Ca phase was formed.
  • High-temperature properties of the magnesium alloy are improved by grain boundary strengthening due to the formation of the Al 2 Ca phase and suppressing formation of a thermally unstable ⁇ -Mg 17 Al 12 phase.
  • the reason is considered due to the Al 2 Ca phases, which are uniformly distributed and formed due to the CaO addition, or other formed phases (e.g., Mg2Ca and (Mg, Al, other alloying element) 2 Ca).
  • Table 2 wt% at% Al 68.73 76.55 Ca 31.27 23.45 Total 100 100
  • FIG. 6 is a graph showing yield strength (TYS) when adding calcium oxide in a magnesium alloy.
  • TLS yield strength
  • the experiments were performed by adding 0.5 wt% to 3.8 wt% of CaO into an AM60B magnesium alloy.
  • Ca was added into the alloy by inducing the reduction reaction caused by additionally adding the CaO into the commercial AM60B alloy.
  • the yield strength was in the range of 140 MPa to 145 MPa when 0.9 wt% of the calcium oxide was added into the magnesium alloy, and the yield strength was 150 MPa when 1.4 wt% of the calcium oxide was added into the magnesium alloy. When 3.5 wt% of calcium oxide was added into the magnesium alloy, the yield strength was also 150 MPa.
  • the yield strength according to the added amount (wt%) of CaO is presented in Table 3 below.
  • Table 3 Alloy Added amount of CaO Yield strength [MPa]
  • Magnesium alloy (AM60B) 0.5 to 0.9 wt% 141 to 143 1.0 to 1.4 wt% 146 to 151 1.5 to 1.9 wt% 147 to 152 2.0 to 2.5 wt% 150 to 155 2.6 to 3.2 wt% 150 3.3 to 3.8 wt% 150 to 152
  • the yield strength which is capable of being used at a high temperature of 90 °C, is obtained at 0.5 to 0.9 wt% of the CaO, and a high-temperature characteristic, which is appropriate for a temperature of 150 °C or more, is obtained at more than the above content of the CaO. That is, it can be understood that the yield strength is relatively better at high temperature when 1.0 to 3.5 wt% of the calcium oxide is added into the magnesium alloy.
  • FIG. 7 is a graph showing tensile strength (UTS) when adding the calcium oxide in the magnesium alloy.
  • UTS tensile strength
  • the experiments were performed by adding the CaO in the range of 0.5 wt% to 3.8 wt% into an AM60B magnesium alloy.
  • Ca was added into the alloy by inducing the reduction reaction caused by additionally adding the CaO into the commercial AM60B alloy.
  • the tensile strength was 225 MPa when 0.9 wt% of the calcium oxide was added into the magnesium alloy, and the tensile strength was 239 MPa when 1.4 wt% of the calcium oxide was added into the magnesium alloy. When 3.5 wt% of the calcium oxide was added into the magnesium alloy, the tensile strength was 232 MPa.
  • the tensile strength according to the added amount (wt%) of CaO is presented in Table 4 below.
  • Table 4 Alloy Added amount of CaO
  • the tensile strength which is capable of being used at a high temperature of 90 °C, is obtained at 0.5 to 0.9 wt% of the CaO, and a high-temperature characteristic, which is appropriate for a temperature of 150 °C or more, is obtained at more than the above content of the CaO. That is, it can be understood that the tensile strengths are relatively better at high temperature when 1.0 to 3.5 wt% of the calcium oxide is added into the magnesium alloy.
  • FIG. 8 is a graph showing elongation when adding the calcium oxide in the magnesium alloy. In the experimental conditions at this time, tensile tests were performed on tensile specimens at a rate of 1 mm/min after holding for 30 minutes at 150 °C.
  • the experiments were performed by adding the CaO in the range of 0.5 wt% to 3.8 wt% into an AM60B magnesium alloy.
  • Ca was added into the alloy by inducing the reduction reaction caused by additionally adding the CaO into the commercial AM60B alloy.
  • the elongation obtained was in the range of 13 % to 14 % when 0.9 wt% of the calcium oxide was added into the magnesium alloy, and the elongation obtained was in the range of 14 % to 15 % when 1.4 wt% of the calcium oxide was added into the magnesium alloy.
  • the elongation was 14 %.
  • FIG. 9 is a graph comparing room-temperature mechanical properties between Mg alloys having compositions of the Eco-MRI153 and the Eco-MRI230 manufactured using CaO and Mg alloys having compositions of the MRI153 and the MRI230 manufactured using Ca.
  • the magnesium-based alloy for high temperature (the Eco-MRI153 and the Eco-MRI230) according to the present invention exhibit superior yield strength (YS), tensile strength (UTS) and elongation to the MRI153 and the MRI230 even at room temperature. That is, the Eco-MRI153 and the Eco-MRI230 have better room-temperature mechanical properties than the MRI153 and the MRI230 manufactured using Ca.
  • FIG. 10 is a graph comparing high-temperature mechanical properties of Mg alloys between the MRI153 alloy manufactured using CaO and the MRI153 alloy using Ca.
  • the magnesium-based alloy (the Eco-MRI153) according to the present invention exhibit superior yield strength and tensile strength to the MRI153 even at high temperature (150 °C).
  • the Eco-MRI153 of the present invention was smaller than the MRI153. It can be understood that changes in the elongation are small at high temperature so that the magnesium-based alloy according to the present invention has stable mechanical properties even for temperature changes. That is, the magnesium-based alloy manufactured using the CaO according to the present invention has good elongation as well as good yield strength and tensile strength even at high temperature.
  • FIG. 11 is a graph comparing yield strength at room and high temperature between an Eco-MRI153 magnesium alloy in which a Ca composition is indirectly adjusted by adding CaO and an MRI153 magnesium alloy in which a composition is adjusted by directly adding Ca. It can be understood that in the case of the Eco-MRI153, high-temperature yield strength is increased 8 % as compared to the MRI153.
  • FIG. 12 is a graph comparing tensile strength at room and high temperature between an Eco-MRI153 magnesium alloy in which a Ca composition is indirectly adjusted by adding CaO and an MRI153 magnesium alloy in which a composition is adjusted by adding Ca.
  • the Eco-MRI153 manufactured by adding the CaO has higher yield and tensile strengths at room and high temperature (150 °C) than the MRI153 having the same composition manufactured by directly adding the Ca.
  • high-temperature tensile strength is increased 8 % as compared to the MRI153.
  • the high-temperature tensile strength in FIG. 11 a remarkable improvement may be confirmed in the Eco-MRI153 adjusting the composition with the CaO according to the present invention.
  • FIG. 13 is a graph comparing elongation at room and high temperature between an Eco-MRI153 magnesium alloy in which a Ca composition is indirectly adjusted by adding CaO and an MRI153 magnesium alloy in which a composition is adjusted by adding Ca.
  • the high-temperature elongation at 150 °C was remarkably low in the Eco-MRI153 adjusting the composition by adding the CaO. That is, changes in the elongation depending on the temperature were smaller in the Eco-MRI153 manufactured by adding the CaO than the MRI153 manufactured by directly adding the Ca.
  • FIG. 14 is a graph comparing creep strain (200 hr, 50 MPa and 150 °C) between an Eco-MRI153 magnesium alloy in which a composition is indirectly adjusted by adding CaO according to the present invention, and an MRI153 magnesium alloy in which a composition is adjusted by adding Ca according to a comparative example.
  • Creep resistance was better in the Eco-MRI153 alloy manufactured by adding the CaO than the commercial MRI153 alloy manufactured by adding the Ca. That is, creep strain (elongation) was smaller in the Eco-MR153 alloy.
  • FIG. 15 is a graph comparing creep strain (200 hr, 70 MPa and 175 °C) between an MRI153 (Eco-MRI153) alloy in which a composition is adjusted by adding CaO according to the present invention, and an MRI153 magnesium alloy in which a composition is adjusted by adding Ca according to a comparative example.
  • Creep resistance at the high temperature was better in the Eco-MRI230 alloy manufactured by adding the CaO than the commercial MRI230 alloy manufactured by adding the Ca. That is, creep strain was smaller in the Eco-MR230 alloy.

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PL2374905T3 (pl) 2019-05-31

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