EP2471967B1 - Method for obtaining improved mechanical properties in recycled aluminium castings free of platelet-shaped beta-phases - Google Patents

Method for obtaining improved mechanical properties in recycled aluminium castings free of platelet-shaped beta-phases Download PDF

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Publication number
EP2471967B1
EP2471967B1 EP20100382360 EP10382360A EP2471967B1 EP 2471967 B1 EP2471967 B1 EP 2471967B1 EP 20100382360 EP20100382360 EP 20100382360 EP 10382360 A EP10382360 A EP 10382360A EP 2471967 B1 EP2471967 B1 EP 2471967B1
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Prior art keywords
aluminium alloy
casting
iron
aluminium
alloy
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German (de)
English (en)
French (fr)
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EP2471967A1 (en
Inventor
Ana Isabel Fernández Calvo
Andrea Niklas
Ignacio Alfaro Abreu
Iñigo Anza Ortiz de Apodaca
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Befesa Aluminio SL
Casa Maristas Azterlan
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Befesa Aluminio SL
Casa Maristas Azterlan
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Application filed by Befesa Aluminio SL, Casa Maristas Azterlan filed Critical Befesa Aluminio SL
Priority to EP20100382360 priority Critical patent/EP2471967B1/en
Priority to ES10382360.5T priority patent/ES2507865T3/es
Priority to PCT/ES2011/070911 priority patent/WO2012089886A2/es
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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
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/02—Making non-ferrous alloys by melting
    • C22C1/026—Alloys based on aluminium
    • 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
    • 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, more particularly, it relates to aluminium alloy castings suitable as components for instance for vehicles, machines and electric applications which are required to have high strength and high elongation values among other properties.
  • the present invention also relates to a process for its preparation from recycled aluminium alloys in order to obtain recycled aluminium casting free of platelet-shaped beta-phases.
  • Aluminium alloys are widely used in diverse applications for instance as components in the automotive, aerospace, industrial machines, electric applications etc., because of their excellent mechanical properties as well as other technological properties such as corrosion resistance and reduced hot cracking tendency.
  • the primary production which is of minerals rich in aluminium (bauxite)
  • aluminium recycling secondary alloy whose raw material is dross and other residues rich in aluminium.
  • the primary alloy production consists basically in reducing the oxide present in bauxite enhancing the purity of aluminium by electrolysis.
  • the most important drawback of this method is the high quantity of energy (from 14 to 15 Kwh/kg) which is necessary to produce aluminium whereas in the aluminium recycling method the costs are about 0,5-0,75 Kwh/kg, that is lower than 5% of the primary production.
  • AlSiMg alloys are nowadays one of the most common aluminium castings alloys for high safety parts, such as automotive or aerospace components, which require high mechanical properties. This alloy presents also high ductility due to the low content in impurities and to the addition of elements such as Ti or Sr which refine and modify the microstructure, respectively. AlSiMg alloys are broadly used for castings produced in sand, permanent and investment moulds.
  • the high content in impurities, especially the high iron content, in secondary alloys (recycled aluminium) is considered as the main disadvantage.
  • the iron content increases in recycled aluminium after each subsequent melting; its elimination or reduction is technically very complex and rather expensive, not being economically feasible.
  • the microstructure of AlSiMg alloys presents alpha aluminium dendrites and Al-Si eutectic and other intermetallic phases among which the iron-rich ones can be highlighted.
  • Iron is well known for being the most common and detrimental impurity in aluminium alloys for mechanical properties, promoting the appearance of hard and brittle intermetallic iron-rich phases during solidification.
  • the platelet-shaped beta phase (Al 5 FeSi) is the most prejudicial since it is well known that ductility and toughness are significantly decreased. Therefore, there has been recently an increasing interest in developing methods for producing improved recycled aluminium alloys in which the formation of the beta phase is reduced and the mechanical properties are thus improved.
  • the strategy was based on the inhibition of the platelet morphology by promoting the precipitation of the Al 15 Fe 3 Si 2 -type phase with the addition of a neutralizing element (Mn, Cr, Co and Be) and in some case controlling the condition of crystallization.
  • a neutralizing element Mn, Cr, Co and Be
  • the patent WO 97/13882 discloses a method for producing iron-containing AlSi-alloys in particular Al-Si-Mn-Fe- alloys.
  • the mechanical properties of aforementioned Al-alloys with iron contents between 0,4 and 2.0 wt.% can be improved by controlling the morphology of the iron containing intermetallic precipitates.
  • the precipitation of platelet-shaped beta phase ( ⁇ -Al 5 FeSi) has been found to be suppressed by a primary precipitation of the hexagonal Al 8 Fe 2 Si-type phase which is in turn less harmful one.
  • the method comprises further controlling the condition of the crystallization by the addition of one or more elements such as Ti, Zr, Sr, Na and Ba.
  • the present invention which is given in the claims refers to an iron containing aluminium alloy, hereinafter referred to as the alloy of the invention, which is free from primary platelet-shaped beta-phase of the Al 5 FeSi-type in the solidified structure presenting the following compositions (amounts expressed in weight percentage, wt.% in respect to the total weight of the alloy): Si 6.00 - 9.50 Fe 0.15 - 0.60 Mn 0.04 - 0.60 Mg 0.20 - 0.70 Cr 0.01 - 0.60 Ti 0.05 - 0.30 Sr and/or Na 0.001 - 0.25 V 0.00 - 0.60 Cu 0.01 - 0.25 Ni 0.01 - 0.1 Zn 0.01 - 0.1
  • the iron-containing aluminium alloy of the invention presents a composition characterized in that the amount of Mn plus Cr in weight percentage is equal or larger than 50 % of Fe amount.
  • the iron-containing aluminium alloy of the invention presents a composition characterized in that the amount of Mn plus Cr plus V in weight percentage is equal or larger than 50 % of Fe amount.
  • the iron-containing aluminium alloy of the invention presents a Fe content between 0.15 - 0.40% in weight percentage and an amount of Mn plus Cr plus V comprised between 0.15 - 0.40 wt.%.
  • the present invention refers to a process for the preparation of the aluminium alloy of the invention comprising the following steps:
  • the process of the invention comprises the degassing process according to already known methods such as treating the molten alloy with dry nitrogen or dry argon until the hydrogen content dissolved in the melt is low enough.
  • the process comprises the addition of alloying elements added as pure elements or as master alloys.
  • the present invention resides in the addition of alloying elements: Mn+Cr or Mn+Cr+V, to the base composition of a secondary AlSi7Mg ingot of second fusion (or recycled aluminium).
  • the process comprises the addition of grain refiner and eutectic modification agents by means of master alloys additions.
  • the modifier agent Na or Sr are the most common ones and are added to achieve the modification of the eutectic Al-Si structure, which precipitates during solidification, showing a rounded morphology instead of needle structure, typical when such a modifying agent is not added. It is well known that the presence of such needle structures reduces the mechanical properties (ductility, strength) of the alloys, promoting the appearance of cracks.
  • TiB master alloys are used to obtain a microstructures which shows a fine grain size and thus improving the final mechanical properties and also, reducing the porosity tendency.
  • the platelet-shaped beta phases (Al 5 FeSi), so detrimental for the final mechanical properties, disappear and are substituted by globular-shaped alpha-phases (Al 8 Fe 2 Si) obtaining a substantial improvement in mechanical properties (Tensile strength, yield stress and elongation).
  • the properties of the recycled alloys obtained according to the process of the present invention show mechanical properties comparable to those obtained in primary alloys.
  • step e the degassed molten alloy is poured into a sand and permanent mould. After filling the mould the cast alloy solidifies and an aluminium casting is obtained.
  • a T6 treatment comprises a first step of solution heat treatment, heating the castings at a temperature between 500 to 600oC for 2 to 6 hours, followed by quenching.
  • the second step will consist in an artificial aging at a temperature between 150 to 180oC for 2 to 8 hours.
  • an aluminium alloy casting obtainable by the above defined process presenting a tensile strength between 250-300 MPa, a yield strength between 190-230 MPa and elongation values between 4,5-9%.
  • the aluminium alloy casting of the invention can be used as a component for transport components such as wheels, suspension parts, brake parts, and energetic industry components.
  • a further aspect of the invention relates to a component made from recycled aluminium alloy castings such as steering knuckle, master cylinder and brake calliper.
  • tensile test specimen are poured in sand mould and permanent moulds from the aluminium alloy of the invention with additions of Mn, Cr and V.
  • the mechanical properties were determined with tensile test specimen according to norm (UNE UNE-EN_1706), (see fig 2 ).
  • the aluminium alloys present a tensile strength of at least 250 MPa, a yield strength of at least 190 MPa and an elongation of at least 4.5 %.
  • the test pieces according to the invention were submitted to microstructural analysis. The inventors found that the addition of controlled amounts of Mn, Cr and V according to the present invention eliminates the platelet-shape beta-phases (Al 5 FeSi).
  • the aluminium alloys have been produced by using secondary AlSi7Mg ingots, obtained from scrap, recycled aluminium dross and other metal residues rich in aluminium.
  • the following table shows the chemical compositions of recycled ingots used in the examples, with iron contents between 0.28 and 0.34 wt.%.
  • Three recycled ingots (ref. I, II and III) have been used in the experimental tests (Base Composition) are shown, the rest being Al: Ingot Secondary AlSi7 Mg alloy Chemical Composition (wt.%) Si Fe Cu Mn Mg Cr Ni Zn Ti Sr V Ref. I 7.11 0.34 0.06 0.09 0.27 0.017 0.01 0.07 0.07 0.005 ⁇ 0.01 Ref. II 6.94 0.28 0.04 0.04 0.28 0.004 0.00 0.04 0.14 ⁇ 0.003 ⁇ 0.01 Ref. III 6.92 0.28 0.04 0.04 0.25 ⁇ 0.01 0.01 0.04 0.16 ⁇ 0.003 ⁇ 0.01 Aluminium in balance
  • the recycled ingots were melted in an electric furnace (capacity of 50 kg of molten aluminium) at 710-750oC. The melt was then alloyed and liquid treated according to the predetermined following schedule:
  • the melt was held for 10 minutes between consecutive additions for chemical homogenization.
  • medals were cast and analysed thereafter by means of spark emission spectrometry.
  • the melt was subjected to degassing by using N 2 during approximately 20 minutes.
  • the effectiveness of degassing was checked by means of Reduced Pressure or Straube-Pfeiffer Test where samples for alloy density evaluation were taken after degassing. In all cases, a minimum density of 2.65 gr/cm 3 was obtained in samples solidified in vacuum.
  • the metal liquid was poured into chemically bonded sand moulds, at temperatures between 710 y 740 oC, in order to obtain tensile test specimens (norm UNE-EN-ISO 6892-1).
  • the tensile test specimens ( Figure 2 ) were subjected to a T6 heat treatment in a laboratory furnace with a temperature control of ⁇ 2 oC.
  • the sequences of this thermal process were the following:
  • microstructures of the cast alloys were examined using optical and scanning electron microscopy: grain size, modification rate, iron rich phases and porosity have been evaluated in the tensile casting, see example in Figure 3 .
  • the Figure 4 shows different morphologies of iron phases observed in recycled aluminium alloys by using optical microscopy. Iron is known to be the most common and at the same time most detrimental impurity in aluminium alloys since it causes hard and brittle iron-rich intermetallic phases to precipitate during solidification. The most detrimental phase in the microstructure is the beta-phase of the Al 5 FeSi- type because of its platelet-shape, see Figure 4a ). This figure shows a typical ⁇ -A 5 FeSi phase with a monoclinic crystal structure and plate like morphology. Such platelets may have an extension of several millimetres and appear as needles in micrographic sections.
  • aluminium alloys with Mn, Cr and V additions do not present interactions with TiB master alloys (grain refiner agent) and Sr additions (modification of Si eutectic phases), obtaining good levels of grain refinement, Si modification and hydrogen degassing.
  • the Figure 5 shows micrographs which correspond to aluminium alloys: a) without alloying additions (Mn, Cr, V) and b) with the additions of Mn + Cr and c) with the addition of Mn, Cr and V. From results it can be seen that in b) and c) no platelet-shape phases (beta-phases) were found when performing the aforementioned additions in the conditions previously described in opposition to a) where these platelet-shape phases can be clearly observed (see arrows pointing thereto).
  • beta phase morphology (platelet-shape) is modified with the additions of Mn plus Cr or Mn plus Cr plus V, obtaining phases with a globular/chinese script morphology less harmful to mechanical 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)
  • Manufacture And Refinement Of Metals (AREA)
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EP20100382360 2010-12-28 2010-12-28 Method for obtaining improved mechanical properties in recycled aluminium castings free of platelet-shaped beta-phases Active EP2471967B1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
EP20100382360 EP2471967B1 (en) 2010-12-28 2010-12-28 Method for obtaining improved mechanical properties in recycled aluminium castings free of platelet-shaped beta-phases
ES10382360.5T ES2507865T3 (es) 2010-12-28 2010-12-28 Método para obtener propiedades mecánicas mejoradas en moldeos de aluminio reciclado libres de fases beta con forma de plaqueta
PCT/ES2011/070911 WO2012089886A2 (es) 2010-12-28 2011-12-28 Procedimiento para obtener propiedades mecánicas mejoradas en coladas de aluminio reciclado libres de fases beta con forma de laminilla

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP20100382360 EP2471967B1 (en) 2010-12-28 2010-12-28 Method for obtaining improved mechanical properties in recycled aluminium castings free of platelet-shaped beta-phases

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EP2471967A1 EP2471967A1 (en) 2012-07-04
EP2471967B1 true EP2471967B1 (en) 2014-07-09

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ES (1) ES2507865T3 (es)
WO (1) WO2012089886A2 (es)

Families Citing this family (19)

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CN103290277A (zh) * 2013-05-23 2013-09-11 宁国市锦泰高科铝业有限责任公司 一种船舶冷却系统用高纯高强铝合金及其制备方法
EP3121302B1 (en) * 2015-04-15 2018-09-19 Daiki Aluminium Industry Co., Ltd. Aluminum alloy for die casting, and die-cast aluminum alloy using same
CZ2015521A3 (cs) * 2015-07-28 2016-12-14 Univerzita J. E. Purkyně V Ústí Nad Labem Hliníková slitina, zejména pro výrobu odlitků segmentů forem pro lisování pneumatik, a způsob tepelného zpracování odlitků segmentů forem
CN105063392B (zh) * 2015-08-13 2017-03-08 安徽优合铝业科技有限公司 一种轮毂浇铸成型工艺
WO2017170240A1 (ja) 2016-03-29 2017-10-05 東ソー株式会社 電解二酸化マンガン及びその製造方法並びにその用途
US11198925B2 (en) 2016-03-31 2021-12-14 Rio Tinto Alcan International Limited Aluminum alloys having improved tensile properties
CZ2019402A3 (cs) * 2016-12-22 2019-08-14 Ksm Castings Group Gmbh Slévárenská slitina Al
KR20200140917A (ko) * 2018-05-07 2020-12-16 알코아 유에스에이 코포레이션 Al-Mg-Si-Mn-Fe 주조 합금
DE102019205267B3 (de) * 2019-04-11 2020-09-03 Audi Ag Aluminium-Druckgusslegierung
CN110923487B (zh) * 2019-12-11 2021-09-10 苏州大学 铝合金废料中Fe元素的分离方法
CN111719068B (zh) * 2020-05-30 2022-08-23 苏州慧金新材料科技有限公司 一种手机中板用合金材料及其制备方法和应用
JP2022150384A (ja) * 2021-03-26 2022-10-07 本田技研工業株式会社 アルミニウム合金、積層造形物の製造方法および積層造形物
CN113215455B (zh) * 2021-05-11 2022-10-04 苏州菲姆卡金属科技有限公司 一种高质量再生铝及其制备方法
CN115927925A (zh) * 2021-09-24 2023-04-07 通用汽车环球科技运作有限责任公司 低碳足迹铸铝组件
DE102021129329A1 (de) 2021-11-11 2023-05-11 Bayerische Motoren Werke Aktiengesellschaft Verfahren zum Herstellen einer Aluminium-Legierung sowie Bauteil
CN115612898B (zh) * 2022-05-05 2024-06-07 蔚来汽车科技(安徽)有限公司 铝合金以及采用其制备的零部件
CN117305664A (zh) * 2022-06-21 2023-12-29 通用汽车环球科技运作有限责任公司 铝-硅合金中富铁相的痕量元素改性以适应高铁含量
CN115323208B (zh) * 2022-08-16 2023-06-02 沈阳西蒙科技有限公司 一种低氢、低夹渣含量的铸造结构件及其铸造生产方法
CN116403755A (zh) * 2023-04-12 2023-07-07 北京理工大学 一种高强高导电率再生铝合金导线及其制备方法

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SE505823C2 (sv) 1995-10-10 1997-10-13 Opticast Ab Förfarande för framställning av järninnehållande aluminiumlegeringar fria från flakformad fas av Al5FeSi-typ
JPH1112705A (ja) * 1997-06-20 1999-01-19 Sumitomo Light Metal Ind Ltd 切削性に優れた高強度アルミニウム合金鍛造品の製造方法
EP0992601A1 (de) * 1998-10-05 2000-04-12 Alusuisse Technology & Management AG Verfahren zur Herstellung eines Bauteiles aus einer Aluminiumlegierung durch Druckgiessen
US20050167012A1 (en) * 2004-01-09 2005-08-04 Lin Jen C. Al-Si-Mn-Mg alloy for forming automotive structural parts by casting and T5 heat treatment
DE102006032699B4 (de) * 2006-07-14 2010-09-09 Bdw Technologies Gmbh & Co. Kg Aluminiumlegierung und deren Verwendung für ein Gussbauteil insbesondere eines Kraftwagens

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Publication number Publication date
ES2507865T3 (es) 2014-10-15
EP2471967A1 (en) 2012-07-04
WO2012089886A2 (es) 2012-07-05
WO2012089886A3 (es) 2012-12-13

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