EP2771493B9 - High performance aisimgcu casting alloy - Google Patents
High performance aisimgcu casting alloy Download PDFInfo
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- EP2771493B9 EP2771493B9 EP12787267.9A EP12787267A EP2771493B9 EP 2771493 B9 EP2771493 B9 EP 2771493B9 EP 12787267 A EP12787267 A EP 12787267A EP 2771493 B9 EP2771493 B9 EP 2771493B9
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- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 claims 5
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Images
Classifications
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/02—Alloys based on aluminium with silicon as the next major constituent
-
- 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 aluminum alloys, and more particularly, to aluminum alloys used for making cast products.
- Aluminum alloys are widely used, e.g., in the automotive and aerospace industries, due to a high performance-to-weight ratio, favorable corrosion resistance and other factors.
- Various aluminum alloys have been proposed in the past that have characteristic combinations of properties in terms of weight, strength, castability, resistance to corrosion, cost, etc. Improvements in alloys to exhibit an improved combination of properties, e.g., that render them more suitable for one or more applications, remain desirable.
- Lumley R N et al "Rapid Heat Treatment of Aluminm High-Pressure Diecastings", Metallurgical and Materials Transactions A, Springer-Verlag, New York, vol 40, no. 7, 2 May 2009, pages 1716-1726 , concerns the thermal treatment of a series of common high-pressure diecasting aluminum alloys. It discloses an alloy having 9.3 wt.-% Si, 0.73 wt.-% Cu, 0.41 wt.-% Mg, 0.31 wt.-% Zn, 0.79 wt.-% Fe, 0.21 wt.-% Mn, less than 0.2 wt.-% other elements and balance aluminum.
- the disclosed subject matter relates to improved aluminum casting alloys (also known as foundry alloys) and methods for producing same. More specifically, the present application relates to an aluminum casting alloy having a composition as defined in claim 1.
- the aluminum casting alloy includes 1.35 - 2.0 wt. % copper and 0.27 - 0.445 wt. % magnesium.
- the aluminum casting alloy includes 0.5 - 0.75 wt. % copper and 0.395 - 0.53 wt. % magnesium.
- the aluminum casting alloy includes 0.75 - 1.35 wt. % copper and 0.335 - 0.505 wt. % magnesium.
- the aluminum casting alloy includes copper and magnesium such that 5.0 ⁇ (Cu+10Mg) ⁇ 5.5.
- the aluminum casting alloy includes copper and magnesium such that 5.1 ⁇ (Cu+10Mg) ⁇ 5.4.
- the aluminum casting alloy contains ⁇ 0.01 wt. silver.
- the aluminum casting alloy contains 0.05 - 1.0 wt. % silver.
- the casting aluminum casting alloy contains 0.1 - 0.12 wt. % titanium.
- the casting aluminum casting alloy contains 0.12 - 0.14 wt. % vanadium.
- the casting aluminum casting alloy contains 0.08 - 0.19 wt. % zirconium.
- the casting aluminum casting alloy contains 0.14 - 0.3 wt. % manganese.
- the casting aluminum casting alloy contains 0.15 - 0.57 wt. % iron.
- the casting aluminum casting alloy contains 0.1 - 0.12 wt. % vanadium.
- the casting aluminum casting alloy contains 0.11 - 0.13 wt. % zirconium.
- the casting aluminum casting alloy contains 0.27 - 0.3 wt. % nickel.
- the casting aluminum casting alloy contains 0.15 - 0.33 wt. % iron.
- the casting aluminum casting alloy contains 0.03 - 0.15 wt. % manganese.
- the casting aluminum casting alloy contains 0.05 - 0.2 wt. % hafnium.
- the casting aluminum casting alloy contains 0.1 - 0.12 wt. % vanadium.
- the casting aluminum casting alloy contains 0.012 - 0.04 wt. % zirconium.
- Figure 1 shows the three phase equilibria in ternary systems and the four phase equilibria quaternary monovariant lines.
- Points A, B, C, D, E and F are five phase invariant points in the quaternary system.
- Points T1 to T6 are the four-phase invariant points in ternary systems and B1, B2 and B3 are the three phase invariant points in binary systems.
- Q-phase (AlCuMgSi) constituent particles during solidification is almost inevitable for an Al-Si-Mg alloy containing Cu since Q-phase is involved in the eutectic reaction (invariant reaction B). If these Cu-containing Q-phase particles cannot be dissolved during solution heat treatment, the strengthening effect of Cu will be reduced and the ductility of the casting will also suffer.
- thermodynamic computation was used to select alloy composition (mainly Cu and Mg content) and solution heat treatment for avoiding un-dissolved Q-phase particles.
- Figure 2 shows the predicted effect of 1% Cu (all compositions in this report are in weight percent) on the solidification path of Al-9%Si-0.4%Mg-0.1%Fe. More particularly, the solidification temperature range is significantly increased with the addition of 1% Cu due to the formation of Cu-containing phases at lower temperatures.
- Q-AlCuMgSi formed at ⁇ 538°C and ⁇ -Al 2 Cu phase formed at ⁇ 510°C.
- the volume fraction of each constituent phase and their formation temperatures are also influenced by the Cu content.
- Figure 3 shows the predicted effect of Cu content on phase fractions in Al-9%Si-0.4%Mg-0.1%Fe-x%Cu alloys.
- the amount of ⁇ -Al 2 Cu and Q-AlCuMgSi increases while the amount of Mg 2 Si and ⁇ -AlFeMgSi decreases.
- Mg 2 Si phase will not form during solidification.
- the amount of Q- AlCuMgSi is also limited by the Mg content in the alloy if the Cu content is more than 0.7%.
- the Q-AlCuMgSi phase formation temperature (T Q ) in Al-9%Si-Mg-Cu alloys is a function of Cu and Mg content.
- the "formation temperature" of a constituent phase is defined as the temperature at which the constituent phase starts to form from the liquid phase.
- Figure 4 shows the predicted effects of Cu and Mg content on the formation temperature of Q-AlCuMgSi phase.
- the formation temperature of Q-AlCuMgSi phase decreases with increasing Cu content; but increases with increasing Mg content.
- the solution heat treatment temperature (T H ) needs to be controlled above the formation temperature of the Q-AICuMgSi phase, i.e., T H > T Q .
- the upper limit of the solution heat treatment temperature is the equilibrium solidus temperature (T S ) in order to avoid re-melting.
- the solution heat treatment temperature is controlled to be at least 5 to 10°C below the solidus temperature to avoid localized melting and creation of metallurgical flaws known in the art as rosettes.
- T S ⁇ 10 °C > T H > T Q
- the alloy composition mainly the Cu and Mg contents, should be selected so that the formation temperature of Q-AlCuMgSi phase is lower than the solidus temperature.
- Figure 5 shows the predicted effects of Cu and Mg content on the solidus temperature of Al-9%Si-Cu-Mg alloys. As expected, the solidus temperature decreases as the Cu and Mg content increases. It should be noted that Mg content increases the formation temperature of the Q-AlCuMgSi phase but decreases the solidus temperature as indicated in Figure 6 .
- the Q-AlCuMgSi phase formation temperature surface and the (T S -10°C) surface (10°C below the solidus temperature surface) are superimposed in Figure 6 .
- the upper boundary, Cu+10Mg 5.78, was defined by the intersection of the Q-AlCuMgSi phase formation temperature surface and the (T S -5°C) surface (5°C below the solidus temperature surface).
- Q-AlCuMgSi phase particles can be completely dissolved during solution heat treatment when the Cu and Mg contents are controlled within these boundaries.
- the Mg and Cu content to maximize the alloy strength and ductility is shown in Figure 25 .
- Mg and Cu content are defined by:
- the foregoing approach allows the selection of a solutionization temperature by (i) calculating the formation temperature of all dissolvable constituent phases in an aluminum alloy; (ii) calculating the equilibrium solidus temperature of an aluminum alloy; (iii) defining a region in Al-Cu-Mg-Si space where the formation temperature of all dissolvable constituent phases is at least 10°C below the solidus temperature.
- the Al-Cu-Mg-Si space is defined by the relative % composition of each of Al, Cu, Mg and Si and the associated solidus temperatures for the range of relative composition.
- the space may be defined by the solidus temperature associated with relative composition of two elements of interest, e.g., Cu and Mg, which are considered relative to their impact on the significant properties of the alloy, such as tensile properties.
- the solutionizing temperature may be selected to diminish the presence of specific phases, e.g., that have a negative impact on significant properties, such as, tensile properties.
- the alloy e.g., after casting, may be heat treated by heating above the calculated formation temperature of the phase that needs to be completely dissolved after solution heat treatment, e.g., the Q- AlCuMgSi phase, but below the calculated equilibrium solidus temperature.
- the formation temperature of the phase that needs to be completely dissolved after solution heat treatment and solidus temperatures may be determined by computational thermodynamics, e.g., using Pandat TM software and PanAluminum TM Database available from CompuTherm LLC of Madison, WI.
- Alloy Target Composition (wt%) Si Cu Mg Zn Ag Fe Sr* Ti B 1 Al-9Si-0.5Mg 9 0 0.5 0 ⁇ 0.1 0.0125 0.04 0.003 2 Al-9Si-0.35Mg-0.75Cu-4Zn 9 0.75 0.35 4 ⁇ 0.1 0.0125 0.04 0.003 3 Al-9Si-0.45Mg-0.75Cu-4Zn 9 0.75 0.45 4 ⁇ 0.1 0.0125 0.04 0.003 4 Al-9Si-0.45Mg-0.75Cu 9 0.75 0.45 0 ⁇ 0.1 0.0125 0.04 0.003 5 Al-9Si-0.5Mg-0.75Cu 9 0.75 0.5 0 ⁇ 0.1 0.0125 0.04 0.003 6 Al-9Si-0.35Mg-1.25Cu 9 1.25 0.35 0 ⁇ 0.1 0.0125 0.04 0.003 7 Al-9Si-0.45Mg-1.25Cu 9 1.25 0.45 0 ⁇ 0.1 0.0125 0.04 0.003 8 Al-9Si-0.35M
- the hydrogen content (single testing) of the castings is given in Table 5.
- Table 5. Hydrogen Content of the Castings Alloy H Content (ppm) 1 Al-9Si-0.5Mg 0.14 2 Al-9Si-0.35Mg-0.75Cu-4Zn 0.11 3 Al-9Si-0.45Mg-0.75Cu-4Zn 0.19 4 Al-9Si-0.45Mg-0.75Cu 0.11 5 Al-9Si-0.5Mg-0.75Cu 0.14 6 Al-9Si-0.35Mg-1.25Cu 0.15 7 Al-9Si-0.45Mg-1.25Cu 0.13 8 Al-9Si-0.55Mg-1.25Cu 0.16 9 Al-9Si-0.35Mg-1.75Cu 0.13 10 Al-9Si-0.35Mg-1.75Cu-0.5Ag Not measured Note: alloy 3 was degassed with porous lance; all other alloys were degassed using a rotary degasser.
- the solution heat treatment temperature should be higher than the Q-AlCuMgSi phase formation temperature.
- Table 6 lists the calculated final eutectic temperature, Q-phase formation temperature and solidus temperature using the targeted composition of the ten alloys investigated. Table 6.
- T H 533.6 ⁇ 20.98 * Cu + 88.37 * Mg + 33.43 * Cu * Mg ⁇ 0.7763 * Cu * Cu ⁇ 126.267 * Mg * Mg
- T H 579.2 ⁇ 10.48 * Cu ⁇ 71.6 * Mg ⁇ 1.33 * Cu * Mg ⁇ 0.72 * Cu * Cu + 72.95 * Mg * Mg
- FIG. 8 shows the microstructure of the Al-9%Si-0.35%Mg-1.75%Cu alloy (alloy #9) in the T6 temper. Si particles were all well-spheroidized. Some un-dissolved particles were identified as ⁇ -AlFeSi, ⁇ -AlFeMgSi and Al 7 Cu 2 Fe phases. The morphologies of these un-dissolved phases are shown in Figure 9 at higher magnification.
- Tensile properties were evaluated according to the ASTM B557 method. Test bars were cut from the modified ASTM B108 castings and tested on the tensile machine without any further machining. All the tensile results are an average of five specimens. Toughness of selected alloys was evaluated using the un-notched Charpy Impact test, ASTM E23-07a. The specimen size was 10mm X 10mm X 55mm machined from the tensile-bar casting. Two specimens were measured for each alloy.
- Smooth S-N fatigue test was conducted according to the ASTM E606 method. Three stress levels, 100 MPa, 150 MPa, and 200 MPa were evaluated. The R ratio was -1 and the frequency was 30 Hz. Three replicated specimens were tested for each condition. Test was terminated after about 10 7 cycles. Smooth fatigue round specimens were obtained by slightly machining the gauge portion of the tensile bar casting.
- Corrosion resistance type-of-attack of selected conditions was evaluated according to the ASTM G110 method. Corrosion mode and depth-of-attack on both the as-cast surface and machined surface were assessed.
- Table 7 Mechanical properties of various alloys aged at 155°C for different times* Alloy Aged at 155°C for 15hrs Aged at 155°C for 30hrs Aged at 155°C for 60hrs UTS (MPa) TYS (MPa) E (%) Q (MPa) UTS (MPa) TYS (MPa) E (%) Q (MPa) UTS (MPa) TYS (MPa) E (%) Q (MPa) 1. Al-9Si-0.5Mg 405.8 323.3 8.3 543.2 398.5 326.5 6.5 520.4 398.7 340.2 5.3 507.7 2.
- Al-9Si-0.45Mg-1.25Cu 27 12 7 12 9. Al-9Si-0.35Mg-1.75Cu 16 15 8 9 Table 9. S-N fatigue results for some selected alloys aged at 155C for 60 hours ( Smooth, Axial; stress ratio -1) Alloy Stress (MPa) Cycles to Failure 155C/15hrs 155C/60hrs 1.
- Al-9Si-0.45Mg-0.75Cu-4Zn 200 38369 18744 3.
- Al-9Si-0.45Mg-0.75Cu-4Zn 200 39366 11676 4.
- the effect of artificial aging temperature on tensile properties was investigated using the baseline alloy 1-Al-9%Si-0.5%Mg. After a minimum 4 hours of natural aging, the tensile bar castings were aged at 155°C for 15, 30, 60 hours and at 170°C for 8, 16, 24 hours. Three replicate specimens were used for each aging condition.
- Figure 10 shows the tensile properties of the baseline A359 alloy (Al-9%Si-0.5%Mg) at various aging conditions.
- Low aging temperature (155°C) tends to yield higher quality index than the high aging temperature (170°C).
- the low aging temperature at 155°C was selected, even though the aging time is longer to obtain improved properties.
- Figure 11 compares the tensile properties of baseline Al-9%Si-0.5%Mg alloy and Al-9%Si-0.5%Mg-0.75%Cu alloy.
- the addition of 0.75%Cu to Al-9%Si-0.5%Mg alloy increases the yield strength by ⁇ 20 MPa and ultimate tensile strength by ⁇ 40 MPa while maintaining the elongation.
- the average quality index of the Cu-containing alloy is ⁇ 560 MPa, which is much higher than the baseline alloy with an average of ⁇ 520 MPa.
- Figure 12 compares the tensile properties of four cast alloys, 1, 2, 3 and 4.
- Alloy 1 is the baseline alloy.
- Alloy 2-4 all contain 0.75%Cu with various amounts of Mg and/or Zn.
- Alloys 3 and 4 contain 0.45%Mg, while alloy 2 contains 0.35%Mg and alloy 1 contains 0.5%Mg.
- Alloys 2 and 3 also have 4%Zn.
- a preliminary assessment of these four alloys indicates that Mg and Zn increase alloy strength without sacrificing ductility.
- a direct comparison between alloys 3 and 4 indicates that by adding 4%Zn to the Al-9%Si-0.45%Mg-0.75%Cu alloy, both ultimate tensile strength and yield strength are increased while maintaining the elongation.
- the 4%Zn addition also increases the aging kinetics as indicated in Figure 12 .
- yield strength of about 370 MPa can be achieved for the Al-9%Si-0.45%Mg-0.75%Cu-4%Zn alloy, which is about 30MPa higher than that of the alloy without Zn.
- Figure 13 shows the effect of Mg content (0.35-0.55wt%) on the tensile properties of the Al-9%Si-1.25%Cu-Mg alloys (Alloys 6-8).
- the tensile properties of the baseline alloy Al-9%Si-0.5%Mg are also included for comparison.
- Mg content showed significant influence on the tensile properties. With increasing Mg content, both yield strength and tensile strength were increased, but the elongation was decreased. The decrease of elongation with increasing Mg content could be related to higher amount of ⁇ -AlFeMgSi phase particles even if all the Q-AlCuMgSi phase particles were dissolved.
- the impact of Mg content on quality indexes of the Al-9%Si-1.25%Cu-Mg alloys was overall found to be insignificant.
- Figure 14 shows the effect of Ag (0.5wt%) on the tensile properties of Al-9%Si-0.35%Mg-1.75%Cu alloy.
- An addition of 0.5wt% Ag had very limited impact on strength, elongation and quality index of the Al-9%Si-0.35%Mg-1.75%Cu alloy.
- the quality index of the Al-9%Si-0.35%Mg-1.75%Cu (without Ag) alloy is ⁇ 60MPa higher than the baseline alloy, A359 (Alloy 1)
- Figures 15a-15d show the tensile properties of five promising alloys in accordance with the present disclosure along with the baseline alloy Al-9Si-0.5Mg (alloy 1). These five alloys achieve the target tensile properties, i.e., 10-15% increase in tensile and maintaining similar elongation as A356/A357 alloy.
- the alloys are: Al-9%Si-0.45%Mg-0.75%Cu (Alloy 4), Al-9%Si-0.45%Mg-0.75%Cu-4%Zn(Alloy 3), Al-9%Si-0.45%Mg-1.25%Cu (Alloy 7), Al-9%Si-0.35%Mg-1.75%Cu (Alloy 9), and Al-9%Si-0.35%Mg-1.75%Cu-0.5%Ag (Alloy 10).
- Figure 16 shows the results of the individual tests by plotting Charpy impact energy vs. tensile yield strength.
- the filled symbols are for specimens aged at 155°C for 15 hours and open symbols are for specimens aged at 155°C for 60 hours.
- Tensile yield strength increases as the aging time increases, while the Charpy impact energy decreases with increasing aging time.
- the results indicate that most alloys/aging conditions follow the expected strength/toughness relationship. However, the results indeed show a slight degradation of the strength/toughness relationship with higher Cu content such as 1.25 and 1.75wt%.
- Aluminum castings are often used in engineered components subject to cycles of applied stress. Over their commercial lifetime millions of stress cycles can occur, so it is important to characterize their fatigue life. This is especially true for safety critical applications, such as automotive suspension components.
- Increasing aging time tended to decrease the number of cycles to failure. For example, as the aging time increased from 15 hours to 60 hours, the average number of cycles to failure at 150 MPa stress level decreased from ⁇ 323,000 to ⁇ 205,000 for the Al-9%Si-0.45%Mg-0.75%Cu alloy and from ⁇ 155,900 to ⁇ 82,500 for the A359 alloy.
- the result could be a general trend of the strength/fatigue relationship of Al-Si-Mg-(Cu) casting alloys. Again, alloy 3 showed a lower fatigue performance than others.
- Figures 19 to 23 show optical micrographs of the cross-sectional views after 6-hour ASTM G110 tests for five selected alloys of both the as-cast surfaces and machined surfaces.
- the mode of corrosion attack was predominantly interdendritic corrosion.
- the number of corrosion sites was generally higher in the four Cu-containing compositions than in the Cu-free baseline alloy.
- Figs. 19a-d show optical micrographs of cross-sections of Al-9%Si-0.5%Mg after a 6-hour ASTM G110 test: a) of the alloy as cast and aged 15 hours at 155°C; b) of the alloy as cast and aged 60 hours at 155°C; c) of the alloy with a machined surface and aged 15 hours at 155°C; and d) of the alloy with a machined surface and aged 60 hours at 155°C.
- Figs. 20a-d show optical micrographs of cross-sections of Al-9%Si-0.35%Mg-0.75%Cu-4%Zn after a 6-hour ASTM G110 test: a) of the alloy as cast and aged 15 hours at 155°C; b) of the alloy as cast and aged 60 hours at 155°C; c) of the alloy with a machined surface and aged 15 hours at 155°C; and d) of the alloy with a machined surface and aged 60 hours at 155°C.
- Figs. 21a-d show optical micrographs of cross-sections of Al-9%Si-0.45%Mg-0.75%Cu after a 6-hour ASTM G110 test: a) of the alloy as cast and aged 15 hours at 155°C; b) of the alloy as cast and aged 60 hours at 155°C; c) of the alloy with a machined surface and aged 15 hours at 155°C; and d) of the alloy with a machined surface and aged 60 hours at 155°C.
- Figs. 22a-d show optical micrographs of cross-sections of Al-9%Si-0.45%Mg-1.25%Cu after a 6-hour ASTM G110 test: a) of the alloy as cast and aged 15 hours at 155°C; b) of the alloy as cast and aged 60 hours at 155°C; c) of the alloy with a machined surface and aged 15 hours at 155°C; and d) of the alloy with a machined surface and aged 60 hours at 155°C.
- Figs. 23a-d show optical micrographs of cross-sections of Al-9%Si-0.35%Mg-1.75%Cu after a 6-hour ASTM G110 test: a) of the alloy as cast and aged 15 hours at 155°C; b) of the alloy as cast and aged 60 hours at 155°C; c) of the alloy with a machined surface and aged 15 hours at 155°C; and d) of the alloy with a machined surface and aged 60 hours at 155°C.
- Figure 24 shows the depth of attack after the 6-hour ASTM G110 test. There is no clear difference or trend among the alloys. Aging time did not show obvious impact on the depth of attack either, while some differences were found between the as-cast surfaces and the machined surfaces. In general, the corrosion attack was slightly deeper on the machined surface than the as-cast surface of the same sample.
- the present disclosure has described Al-Si-Cu-Mg alloys that can achieve high strength without sacrificing ductility.
- Tensile properties including 450-470MPa ultimate tensile strength, 360-390MPa yield strength, 5-7 % elongation, and 560-590MPa Quality Index were obtained. These properties exceed conventional 3xx alloys and are very similar to that of the A201 (2xx+Ag) Alloy, while the castabilities of the new Al-9Si-MgCu alloys are much better than that of the A201 alloy.
- the new alloys showed better S-N fatigue resistance than A359 (Al-9Si-0.5Mg) alloys. Alloys in accordance with the present disclosure have adequate fracture toughness and general corrosion resistance.
- Figure 26 shows a graph of tensile properties of an alloy in accordance with the present disclosure, namely, Al-9Si-0.35Mg-1.75Cu (previously referred to as alloy 9, e.g., in Figure 15 ) after exposure to various temperatures.
- the exposure time of the alloys was 500 hours at the indicated temperature.
- the samples were also tested at the temperature indicated.
- the yield strength of the alloy diminished significantly at temperatures above 150°C.
- the metal was analyzed to ascertain features associated with the loss in strength due to exposure to increased temperatures.
- Figures 27a and 27b show scanning electron microscope (SEM) micrographs of a cross-section of a sample of alloy 9 prior to exposure to high temperatures, with 27b being an enlarged view of the portion of the micrograph of 31a indicated as "Al". As shown in Figure 27a , the grain boundaries are visible, as well as, Si and AlFeSi particles. The predominately Al portion shown in Figure 27b shows no visible precipitate at 20,000X magnification.
- SEM scanning electron microscope
- Figures 28a-e show a series of scanning electron microscope (SEM) micrographs of a cross-section of alloy C00 (previously referred to as alloy 9, e.g., in Figure 15 ) of the same scale as the micrograph shown in Figure 27b after exposure to increasing temperatures as shown by the correlation of the micrographs to the data points on the tensile property graph G of alloy 9.
- the tensile characteristics of A356 alloy in the given temperature range are also shown in graph G for comparison.
- exposure of alloy 9 to increasing temperatures results in continuously increasing prominence of precipitate particles, which are larger, and which exhibit divergent geometries.
- alloying elements viz., Ti, V, Zr, Mn, Ni, Hf, and Fe could be introduced to the C00 alloy (previously referred to as alloy 9, e.g., in Figure 15 ) of the present disclosure in small amounts to produce an alloy that resists strength degradation at elevated temperatures.
- Table 10 show 18 alloys utilizing additive elements in small quantities to the C00 alloy (previously referred to as alloy 9, e.g., in Figure 15 ) for the purpose of developing improved strength at elevated temperatures.
- Table 10 Alloy Compositions Alloy Actual Composition (wt%) Fe Si Mn Cu Mg Sr Ti B V Zr NI Hf C00 0.08 9.29 0 1.83 0.37 0.0125 0.05 0 0 0 0 C01 0.15 9.3 0.002 1.82 0.002 0.008 0.11 0.0047 0.012 0.002 0 0 C02 0.15 9.35 0.002 1.82 0.39 0.008 0.11 0.0043 0.012 0.002 0 0 C03 0.15 9.05 0.002 1.77 0.37 0.007 0.11 0.0051 0.13 0.002 0 0 C04 0.16 8.95 0.002 1.77 0.36 0.006 0.1 0.0026 0.1 0.091 0 0 C05 0.16 8.86 0.002 1.76 0.36 0.005
- Figure 29 shows a graph of yield strength at room temperature for foregoing alloys.
- A356 is shown for comparison.
- DOE department of energy
- the C00 alloy is comparable in strength at room temperature to alloys C02-C18, all of which substantially exceed the strength of the A356 alloy and the DOE target properties.
- Alloy C01 - without substantial quantities of Mg has a far lower yield strength.
- Figure 30 is a graph of yield strength after exposure to 175 °C for 500 hours for the foregoing alloys.
- the C00, as well as A356 are shown for comparison.
- the C00 alloy substantially exceeds the strength of the A356 alloy.
- Alloys C02-C18 all show marked improvement over both A356 and C00.
- Figure 31 is a graph of yield strength after exposure to 300°C for 500 hours for the foregoing alloys. C00, as well as A356 are shown for comparison.
- Figure 32 shows is a graph of yield strength after exposure to 300°C for various alloys. More particularly, adjacent alloys (going in the direction of the arrows) show the result of an additional element or the increase in quantity of an element. The highest result in the graph of Figure 32 is for C00 + 0.1T +0.16Fe+ 0.13V + 0.15Zr. The addition of more Zr (to 0.18%) to this combination results in decreased performance.
- Figure 33 is a graph of yield strength after exposure to 300 °C for various alloys for 500 hours.
- the graphs show improvements due to the addition of Ti, Fe and Mn to the C00 composition, with the maximum performance noted relative to C00 + 0.11Ti + 0.32Fe + 0.3Mn.
- the addition of V to the foregoing reduces performance and the further addition of 0.12 Zr brings performance almost back to the maximum level.
- Figure 34 is a graph of yield strength after exposure to 300 °C for various alloys, i.e., due to the addition of elements to the C00 composition. The optimal performance is noted relative to C00 + 0.1Ti + 0.28Ni + 0.32 Fe + 0.14Mn + 0.1Hf + 0.11V + 0.04Zr.
Description
- The present invention relates to aluminum alloys, and more particularly, to aluminum alloys used for making cast products.
- Aluminum alloys are widely used, e.g., in the automotive and aerospace industries, due to a high performance-to-weight ratio, favorable corrosion resistance and other factors. Various aluminum alloys have been proposed in the past that have characteristic combinations of properties in terms of weight, strength, castability, resistance to corrosion, cost, etc. Improvements in alloys to exhibit an improved combination of properties, e.g., that render them more suitable for one or more applications, remain desirable.
- Lumley R N et al: "Rapid Heat Treatment of Aluminm High-Pressure Diecastings", Metallurgical and Materials Transactions A, Springer-Verlag, New York, , concerns the thermal treatment of a series of common high-pressure diecasting aluminum alloys. It discloses an alloy having 9.3 wt.-% Si, 0.73 wt.-% Cu, 0.41 wt.-% Mg, 0.31 wt.-% Zn, 0.79 wt.-% Fe, 0.21 wt.-% Mn, less than 0.2 wt.-% other elements and balance aluminum.
- The disclosed subject matter relates to improved aluminum casting alloys (also known as foundry alloys) and methods for producing same. More specifically, the present application relates to an aluminum casting alloy having a composition as defined in
claim 1. - In one approach, the aluminum casting alloy includes 1.35 - 2.0 wt. % copper and 0.27 - 0.445 wt. % magnesium.
- In one approach, the aluminum casting alloy includes 0.5 - 0.75 wt. % copper and 0.395 - 0.53 wt. % magnesium.
- In one approach, the aluminum casting alloy includes 0.75 - 1.35 wt. % copper and 0.335 - 0.505 wt. % magnesium.
- In one approach the aluminum casting alloy includes copper and magnesium such that 5.0 ≤ (Cu+10Mg) ≤ 5.5.
- In one approach, the aluminum casting alloy includes copper and magnesium such that 5.1 ≤ (Cu+10Mg) ≤ 5.4.
- In one approach, the aluminum casting alloy contains ≤ 0.01 wt. silver.
- In one approach, the aluminum casting alloy contains 0.05 - 1.0 wt. % silver.
- In one approach , the aluminum casting alloy is subjected to a solution heat treatment at TH followed by a cold water quench, where TH (°C) = 570 - 10.48*Cu-71.6*Mg-1.3319*Cu*Mg-0.72*Cu*Cu+72.95*Mg*Mg, based on Mg and Cu content in wt%, within the range defined by a lower limit for TH : TQ = 533.6-20.98*Cu+88.037*Mg+33.43*Cu*Mg-0.7763*Cu*Cu-126.267*Mg*Mg and an upper limit for TH : TS = 579.2-10.48*Cu-71.6*Mg-1.3319*Cu*Mg-0.72*Cu*Cu+72.95*Mg*Mg.
- In one approach, the casting aluminum casting alloy contains 0.1 - 0.12 wt. % titanium.
- In one approach, the casting aluminum casting alloy contains 0.12 - 0.14 wt. % vanadium.
- In one approach, the casting aluminum casting alloy contains 0.08 - 0.19 wt. % zirconium.
- In one approach, the casting aluminum casting alloy contains 0.14 - 0.3 wt. % manganese.
- In one approach, the casting aluminum casting alloy contains 0.15 - 0.57 wt. % iron.
- In one approach, the casting aluminum casting alloy contains 0.1 - 0.12 wt. % vanadium.
- In one approach, the casting aluminum casting alloy contains 0.11 - 0.13 wt. % zirconium.
- In one approach, the casting aluminum casting alloy contains 0.27 - 0.3 wt. % nickel.
- In one approach, the casting aluminum casting alloy contains 0.15 - 0.33 wt. % iron.
- In one approach, the casting aluminum casting alloy contains 0.03 - 0.15 wt. % manganese.
- In one approach, the casting aluminum casting alloy contains 0.05 - 0.2 wt. % hafnium.
- In one approach, the casting aluminum casting alloy contains 0.1 - 0.12 wt. % vanadium.
- In one approach, the casting aluminum casting alloy contains 0.012 - 0.04 wt. % zirconium.
-
-
Figure 1 is a graph of phase equilibria involving (Al) and liquid in an Al-Cu-Mg-Si system. -
Figure 2 is a graph of the effect of Cu additions on the solidification path of Al-9%Si-0.4%Mg-0.1%Fe alloy. -
Figure 3 is a graph of the effect of Cu content on phase fractions in Al-9%-0.4%Mg-0.1%Fe-x%Cu alloys. -
Figure 4 is a graph of the effect of Cu and Mg content on the Q-phase formation temperature of Al-9%Si-Mg-Cu alloys. -
Figure 5 is a graph of the effect of Mg and Cu content on the equilibrium solidus temperature of Al-9%Si-Mg-Cu alloys. -
Figure 6 is a graph of the effect of Mg and Cu content on the equilibrium solidus temperature (TS) and Q-phase formation temperature (TQ) of Al-9%Si-Mg-Cu alloys. -
Figure 7 is a graph of the effect of zinc and silicon on the fluidity of Al-x%Si-0.5%Mg-y%Zn alloys -
Figure 8 is an SEM (scanning electron micrograph) @200X magnification, showing spherical Si particles and un-dissolved Fe-containing particles. -
Figures 9a-b are photographs of undissolved Fe-containing particles in the investigated alloys. -
Figures 10a-d are graphs of the effect of aging condition on tensile properties of the Al-9Si-0.5Mg alloy. -
Figures 11a-d are graphs of the effect of Cu on tensile properties of the Al-9%Si-0.5%Mg alloy. -
Figures 12a-d are graphs of the effect of Cu and Zn on tensile properties of the Al-9%Si-0.5%Mg alloy. -
Figures 13a-d are graphs of the effect of Mg content on tensile properties of the Al-9%Si-1.25%Cu-Mg alloy. -
Figures 14a-d are graphs of the effect of Ag on tensile properties of the Al-9%Si-0.35%Mg-1.75%Cu alloy. -
Figures 15a-d are graphs of tensile properties for six alloys aged for different times at an elevated temperature, as described in the disclosure. -
Figure 16 is a graph of Charpy impact energy (CIE) vs. yield strength for five alloys aged for different times at an elevated temperature. -
Figure 17 is a graph of S-N fatigue curves of selected alloys aged at 155°C for 15 hours. Smooth, Axial; stress ratio = -1. -
Figure 18 is a graph of S-N fatigue curves of selected alloys aged at 155°C for 60 hours. Smooth, Axial; stress ratio = -1. -
Figure 19a-d - 23a-d are optical micrographs of cross-sections of samples of five alloys as cast and machined and aged for two different time periods at an elevated temperature after 6-hour ASTM G110. -
Figure 24 is a graph of depth of attack of selected alloys aged for different time periods on the as-cast and machined surfaces after a 6-hour G110 test. -
Figure 25 is a graph of Mg and Cu content correlated to strength and ductility for Al-9Si-Mg-Cu alloys. -
Figure 26 is a graph of tensile properties of a specific alloy (alloy 9) after exposure to high temperatures. -
Figures 27a and 27b are scanning electron micrographs of a cross-section of a sample ofalloy 9 prior to exposure to high temperatures. -
Figures 28a-e are a series of scanning electron micrographs of a cross-section ofalloy 9 after exposure to increasing temperatures correlated to a tensile property graph ofalloy 9 and A356 alloy. -
Figure 29 is a graph of yield strength at room temperature for various alloys. -
Figure 30 is a graph of yield strength after exposure to 175 °C for various alloys. -
Figure 31 is a graph of yield strength after exposure to 300 °C for various alloys. -
Figure 32 is a graph of yield strength after exposure to 300 °C for various alloys. -
Figure 33 is a graph of yield strength after exposure to 300 °C for various alloys. -
Figure 34 is a graph of yield strength after exposure to 300 °C for various alloys. - To improve the performances of Al-Si-Mg-Cu cast alloys, a novel alloy design method was used and is described as follows:
In Al-Si-Mg-Cu casting alloys, increasing Cu content can increase the strength due to higher amount of θ'-Al2Cu and Q' precipitates but reduce ductility, particularly if the amount of un-dissolved constituent Q-phase increases.Figure 1 shows the calculated phase diagram of the Al-Cu-Mg-Si quaternary system, as shown in X. Yan, Thermodynamic and solidification modeling coupled with experimental investigation of the multicomponent aluminum alloys. University of Wisconsin -Madison, 2001, which is incorporated in its entirety by reference herein.Figure 1 shows the three phase equilibria in ternary systems and the four phase equilibria quaternary monovariant lines. Points A, B, C, D, E and F are five phase invariant points in the quaternary system. Points T1 to T6 are the four-phase invariant points in ternary systems and B1, B2 and B3 are the three phase invariant points in binary systems. The formation of Q-phase (AlCuMgSi) constituent particles during solidification is almost inevitable for an Al-Si-Mg alloy containing Cu since Q-phase is involved in the eutectic reaction (invariant reaction B). If these Cu-containing Q-phase particles cannot be dissolved during solution heat treatment, the strengthening effect of Cu will be reduced and the ductility of the casting will also suffer. - In order to minimize/eliminate un-dissolved Q-phase (AlCuMgSi) and maximize solid solution/precipitation strengthening, the alloy composition, solution heat treatment and aging practice should be optimized. In accordance with the present disclosure, a thermodynamic computation was used to select alloy composition (mainly Cu and Mg content) and solution heat treatment for avoiding un-dissolved Q-phase particles. Pandat thermodynamic simulation software and the PanAluminum database LLC, Computherm, Pandat Software and PanAluminum Database. http://www.computherm.com were used to calculate these thermodynamic data.
- The inventors of the present disclosure recognize that adding Cu to Al-Si-Mg cast alloys will change the solidification sequence.
Figure 2 shows the predicted effect of 1% Cu (all compositions in this report are in weight percent) on the solidification path of Al-9%Si-0.4%Mg-0.1%Fe. More particularly, the solidification temperature range is significantly increased with the addition of 1% Cu due to the formation of Cu-containing phases at lower temperatures. For the Al-9%Si-0.4%Mg-0.1%Fe-1%Cu alloy, Q-AlCuMgSi formed at ~538°C and θ-Al2Cu phase formed at ~510°C. The volume fraction of each constituent phase and their formation temperatures are also influenced by the Cu content. -
Figure 3 shows the predicted effect of Cu content on phase fractions in Al-9%Si-0.4%Mg-0.1%Fe-x%Cu alloys. As the Cu content increases, the amount of θ-Al2Cu and Q-AlCuMgSi increases while the amount of Mg2Si and π-AlFeMgSi decreases. In alloys with more than 0.7% Cu, Mg2Si phase will not form during solidification. The amount of Q- AlCuMgSi is also limited by the Mg content in the alloy if the Cu content is more than 0.7%. - The Q-AlCuMgSi phase formation temperature (TQ) in Al-9%Si-Mg-Cu alloys is a function of Cu and Mg content. The "formation temperature" of a constituent phase is defined as the temperature at which the constituent phase starts to form from the liquid phase.
Figure 4 shows the predicted effects of Cu and Mg content on the formation temperature of Q-AlCuMgSi phase. The formation temperature of Q-AlCuMgSi phase decreases with increasing Cu content; but increases with increasing Mg content. - In accordance with the present disclosure, in order to completely dissolve all the as-cast Q-AlCuMgSi phase particles, the solution heat treatment temperature (TH) needs to be controlled above the formation temperature of the Q-AICuMgSi phase, i.e., TH > TQ. The upper limit of the solution heat treatment temperature is the equilibrium solidus temperature (TS) in order to avoid re-melting. As a practical measure, the solution heat treatment temperature is controlled to be at least 5 to 10°C below the solidus temperature to avoid localized melting and creation of metallurgical flaws known in the art as rosettes. Hence, in practice, the following relationship is established:
- In accordance with the present disclosure, to achieve this criterion, the alloy composition, mainly the Cu and Mg contents, should be selected so that the formation temperature of Q-AlCuMgSi phase is lower than the solidus temperature.
Figure 5 shows the predicted effects of Cu and Mg content on the solidus temperature of Al-9%Si-Cu-Mg alloys. As expected, the solidus temperature decreases as the Cu and Mg content increases. It should be noted that Mg content increases the formation temperature of the Q-AlCuMgSi phase but decreases the solidus temperature as indicated inFigure 6 . The Q-AlCuMgSi phase formation temperature surface and the (TS-10°C) surface (10°C below the solidus temperature surface) are superimposed inFigure 6 . These two surfaces intersect along the curve A-B-C. The area that meets the criterion of Equation (1) is on the right hand side of curve A-B-C, i.e., TQ < TS - 10 °C . Projection of the curve A-B-C to the Cu-Mg composition plane yields the center line Cu+10Mg=5.25 of the preferred composition boundary, as shown inFigure 25 . The lower boundary, Cu+10Mg=4.73, was defined by the intersection of the Q-AlCuMgSi phase formation temperature surface and the (TS-15°C) surface (15°C below the solidus temperature surface). The upper boundary, Cu+10Mg=5.78, was defined by the intersection of the Q-AlCuMgSi phase formation temperature surface and the (TS-5°C) surface (5°C below the solidus temperature surface). For Al-9%Si-0.1%Fe-x%Cu-y%Mg alloys, Q-AlCuMgSi phase particles can be completely dissolved during solution heat treatment when the Cu and Mg contents are controlled within these boundaries. - In accordance with the present disclosure, the Mg and Cu content to maximize the alloy strength and ductility is shown in
Figure 25 . - The preferred relationship of Mg and Cu content is defined by:
- Cu+10Mg=5.25 with 0.5<Cu<2.0.
- The upper bound is Cu+10Mg=5.8 and the lower bound is Cu+10Mg=4.7.
- The foregoing approach allows the selection of a solutionization temperature by (i) calculating the formation temperature of all dissolvable constituent phases in an aluminum alloy; (ii) calculating the equilibrium solidus temperature of an aluminum alloy; (iii) defining a region in Al-Cu-Mg-Si space where the formation temperature of all dissolvable constituent phases is at least 10°C below the solidus temperature. The Al-Cu-Mg-Si space is defined by the relative % composition of each of Al, Cu, Mg and Si and the associated solidus temperatures for the range of relative composition. For a given class of alloy, e.g., Al-Cu-Mg-Si, the space may be defined by the solidus temperature associated with relative composition of two elements of interest, e.g., Cu and Mg, which are considered relative to their impact on the significant properties of the alloy, such as tensile properties. In addition, the solutionizing temperature may be selected to diminish the presence of specific phases, e.g., that have a negative impact on significant properties, such as, tensile properties. The alloy, e.g., after casting, may be heat treated by heating above the calculated formation temperature of the phase that needs to be completely dissolved after solution heat treatment, e.g., the Q- AlCuMgSi phase, but below the calculated equilibrium solidus temperature. The formation temperature of the phase that needs to be completely dissolved after solution heat treatment and solidus temperatures may be determined by computational thermodynamics, e.g., using Pandat™ software and PanAluminum™ Database available from CompuTherm LLC of Madison, WI.
- Based on the foregoing analysis, several Mg and Cu content combinations were selected as given in Table 3. Additionally, studies by the present inventors have indicated that an addition of zinc with a concentration greater than 3wt% to Al-Si-Mg-(Cu) alloys can increase both ductility and strength of the alloy. As shown in
Figure 7 , zinc can also increase the fluidity of Al-Si-Mg alloys. Thus, an addition of zinc (4wt%) was also evaluated. It has also been reported L. A. Angers, Development of Advanced I/M 2xxx Alloys for High Speed Civil Transport Applications, Alloy Technology Division Report No. AK92, 1990-04-16 that an addition of Ag can accelerate age-hardening of high Cu-containing (>∼1.5wt%) aluminum alloys, and increase the tensile strength at room temperature and elevated temperature. An addition of Ag (0.5wt%) was also included in alloys with higher Cu content such as 1.75wt% Cu. Hence, ten alloy compositions were selected for evaluation. The target compositions of these alloys are given in Table 3. It should be noted thatalloy 1 in Table 3 is the baseline alloy, A359.Table 3. Target Compositions Alloy Target Composition (wt%) Si Cu Mg Zn Ag Fe Sr* Ti B 1 Al-9Si-0.5 Mg 9 0 0.5 0 <0.1 0.0125 0.04 0.003 2 Al-9Si-0.35Mg-0.75Cu- 4Zn 9 0.75 0.35 4 <0.1 0.0125 0.04 0.003 3 Al-9Si-0.45Mg-0.75Cu- 4Zn 9 0.75 0.45 4 <0.1 0.0125 0.04 0.003 4 Al-9Si-0.45Mg-0.75 Cu 9 0.75 0.45 0 <0.1 0.0125 0.04 0.003 5 Al-9Si-0.5Mg-0.75 Cu 9 0.75 0.5 0 <0.1 0.0125 0.04 0.003 6 Al-9Si-0.35Mg-1.25 Cu 9 1.25 0.35 0 <0.1 0.0125 0.04 0.003 7 Al-9Si-0.45Mg-1.25 Cu 9 1.25 0.45 0 <0.1 0.0125 0.04 0.003 8 Al-9Si-0.55Mg-1.25 Cu 9 1.25 0.55 0 <0.1 0.0125 0.04 0.003 9 Al-9Si-0.35Mg-1.75 Cu 9 1.75 0.35 0 <0.1 0.0125 0.04 0.003 10 Al-9Si-0.35Mg-1.75Cu-0.5 Ag 9 1.75 0.35 0 0.5 <0.1 0.0125 0.04 0.003 - A modified ASTM tensile-bar mold was used for the casting. A lubricating mold spray was used on the gauge section, while an insulating mold spray was used on the remaining portion of the cavity. Thirty castings were made for each alloy. The average cycle time was about two minutes. The actual compositions investigated are listed in Table 4, below.
Table 4. Actual Compositions Alloy Actual Composition (wt%) Si Cu Mg Zn Ag Fe Sr* Ti B 1 Al-9Si-0.5Mg 8.87 0.021 0.48 0 0.079 0.0125 0.05 0.003 2 Al-9Si-0.35Mg-0.75Cu-4Zn 9.01 0.75 0.37 4.03 0.077 0.0125 0.031 0.003 3 Al-9Si-0.45Mg-0.75Cu-4Zn 9.09 0.75 0.46 4.02 0.081 0.0125 0.04 0.003 4 Al-9Si-0.45Mg-0.75Cu 9.18 0.76 0.45 0.083 0.0125 0.042 0.003 5 Al-9Si-0.5Mg-0.75Cu 9.02 0.77 0.49 0.081 0.0125 0.013 0.003 6 Al-9Si-0.35Mg-1.25Cu 9.02 1.25 0.34 0.088 0.0125 0.03 0.003 7 Al-9Si-0.45Mg-1.25Cu 9.11 1.28 0.44 0.082 0.0125 0.04 0.003 8 Al-9Si-0.55Mg-1.25Cu 8.99 1.27 0.53 0.1 0.0125 0.04 0.003 9 Al-9Si-0.35Mg-1.75Cu 9.29 1.83 0.37 0.08 0.0125 0.048 0.003 10 Al-9Si-0.35Mg-1.75Cu-0.5Ag 8.88 1.78 0.35 0.5 0.081 0.0125 0.044 0.003 Table 5. Hydrogen Content of the Castings Alloy H Content (ppm) 1 Al-9Si-0.5Mg 0.14 2 Al-9Si-0.35Mg-0.75Cu-4Zn 0.11 3 Al-9Si-0.45Mg-0.75Cu-4Zn 0.19 4 Al-9Si-0.45Mg-0.75Cu 0.11 5 Al-9Si-0.5Mg-0.75Cu 0.14 6 Al-9Si-0.35Mg-1.25Cu 0.15 7 Al-9Si-0.45Mg-1.25Cu 0.13 8 Al-9Si-0.55Mg-1.25Cu 0.16 9 Al-9Si-0.35Mg-1.75Cu 0.13 10 Al-9Si-0.35Mg-1.75Cu-0.5Ag Not measured Note: alloy 3 was degassed with porous lance; all other alloys were degassed using a rotary degasser. - To dissolve all the Q-AlCuMgSi phase particles, the solution heat treatment temperature should be higher than the Q-AlCuMgSi phase formation temperature. Table 6 lists the calculated final eutectic temperature, Q-phase formation temperature and solidus temperature using the targeted composition of the ten alloys investigated.
Table 6. Calculated Final Eutectic Temperature, Q-phase Formation Temperature and Solidus Temperature for Ten Investigated Casting Alloys Alloy Final eutectic temperature, C Q-phase forming temperature, C Solidus temperature, C 1 Al-9Si-0.5Mg 560 - 563 2 Al-9Si-0.35Mg-0.75Cu-4Zn 470 518 540 3 Al-9Si-0.45Mg-0.75Cu-4Zn 470 518 543 4 Al-9Si-0.45Mg-0.75 Cu 510 541 554 5 Al-9Si-0.5Mg-0.75 Cu 510 541 553 6 Al-9Si-0.35Mg-1.25 Cu 510 533 552 7 Al-9Si-0.45Mg-1.25 Cu 510 536 548 8 Al-9Si-0.55Mg-1.25 Cu 510 538 545 9 Al-9Si-0.35Mg-1.75 Cu 510 528 543 10 Al-9Si-0.35Mg-1.75Cu-0.5 Ag 510 526 543 Alloys - The practice I for
alloys - 1.5 hour log heat-up to 471°C
- 2 hour soak at 471°C
- 0.5 hour ramp up to 504°C
- 4 hour soak at 504°C
- 0.5 hour ramp up to TH
- 6 hour soak at TH
- CWQ (Cold Water Quench)
- 1.5 hour log heat-up to 491°C
- 2 hour soak at 491°C
- 0.25 hour ramp up to 504°C
- 4 hour soak at 504°C
- 0.5 hour ramp up to TH
- 6 hour soak at TH
- CWQ (Cold Water Quench)
-
-
-
- The microstructure of the solution heat treated specimens was characterized using optical and SEM microscopy. There were no un-dissolved Q-phase particles detected in all the Cu-containing alloys investigated.
Figure 8 shows the microstructure of the Al-9%Si-0.35%Mg-1.75%Cu alloy (alloy #9) in the T6 temper. Si particles were all well-spheroidized. Some un-dissolved particles were identified as β-AlFeSi, π-AlFeMgSi and Al7Cu2Fe phases. The morphologies of these un-dissolved phases are shown inFigure 9 at higher magnification. - Tensile properties were evaluated according to the ASTM B557 method. Test bars were cut from the modified ASTM B108 castings and tested on the tensile machine without any further machining. All the tensile results are an average of five specimens. Toughness of selected alloys was evaluated using the un-notched Charpy Impact test, ASTM E23-07a. The specimen size was 10mm X 10mm X 55mm machined from the tensile-bar casting. Two specimens were measured for each alloy.
- Smooth S-N fatigue test was conducted according to the ASTM E606 method. Three stress levels, 100 MPa, 150 MPa, and 200 MPa were evaluated. The R ratio was -1 and the frequency was 30 Hz. Three replicated specimens were tested for each condition. Test was terminated after about 107 cycles. Smooth fatigue round specimens were obtained by slightly machining the gauge portion of the tensile bar casting.
- Corrosion resistance (type-of-attack) of selected conditions was evaluated according to the ASTM G110 method. Corrosion mode and depth-of-attack on both the as-cast surface and machined surface were assessed.
- All the raw test data including tensile, Charpy impact and S-N fatigue are given in Tables 7 to 9. A summary of the findings is given in the following sections.
Table 7. Mechanical properties of various alloys aged at 155°C for different times* Alloy Aged at 155°C for 15hrs Aged at 155°C for 30hrs Aged at 155°C for 60hrs UTS (MPa) TYS (MPa) E (%) Q (MPa) UTS (MPa) TYS (MPa) E (%) Q (MPa) UTS (MPa) TYS (MPa) E (%) Q (MPa) 1. Al-9Si-0.5Mg 405.8 323.3 8.3 543.2 398.5 326.5 6.5 520.4 398.7 340.2 5.3 507.7 2. Al-9Si-0.35Mg-0.75Cu-4Zn 431.5 342.0 5.5 542.6 433.5 358.0 4.5 531.5 446.8 366.0 6.5 568.7 3. Al-9Si-0.45Mg-0.75Cu-4Zn 460.5 370.5 5.5 571.6 469.0 378.5 7.0 595.8 465.3 390.7 5.0 570.2 4. Al-9Si-0.45Mg-0.75Cu 451.5 339.0 6.5 573.4 450.5 354.8 5.0 555.3 464.0 373.5 6.5 585.9 5. Al-9Si-0.5Mg-0.75Cu 426.0 317.3 8.0 561.5 442.8 348.2 6.7 566.4 442.5 364.5 6.0 559.2 6. Al-9Si-0.35Mg-1.25Cu 411.2 299.2 7.3 540.2 436.3 326.3 7.0 563.1 446.5 342.8 6.5 568.4 7. Al-9Si-0.45Mg-1.25Cu 424.3 328.0 4.8 525.8 453.8 353.0 5.8 567.7 455.3 375.8 4.0 545.6 8. Al-9Si-0.55Mg-1.25Cu 444.8 336.5 6.0 561.6 460.3 365.3 4.8 561.8 475.8 385.0 4.8 577.3 9. Al-9Si-0.35Mg-1.75Cu 465.7 325.0 9.0 608.8 459.5 355.3 5.5 570.6 478.8 386.3 5.0 583.6 10. Al-9Si-0.35Mg-1.75Cu-0.5Ag 463.3 343.0 7.5 594.5 471.7 364.5 6.3 591.9 471.0 389.3 4.5 569.0 * Averaged value from five tensile specimens.
The Quality Index, Q = UTS +150 log(E).Table 8. Charpy impact test results for some selected alloys Alloy Energy (ft-lbs) 155°C/15hrs 155°C/ 60hrs specimen 1 Specimen 3Specimen 7Specimen 91. Al-9Si-0.5 Mg 6 27 23 27 3. Al-9Si-0.45Mg-0.75Cu- 4Zn 17 18 10 12 4. Al-9Si-0.45Mg-0.75Cu 32 15 28 13 7. Al-9Si-0.45Mg-1.25Cu 27 12 7 12 9. Al-9Si-0.35Mg-1.75 Cu 16 15 8 9 Table 9. S-N fatigue results for some selected alloys aged at 155C for 60 hours ( Smooth, Axial; stress ratio = -1) Alloy Stress (MPa) Cycles to Failure 155C/ 15hrs 155C/ 60hrs 1. Al-9Si-0.5 Mg 100 1680725 1231620 1. Al-9Si-0.5 Mg 100 1302419 272832 1. Al-9Si-0.5 Mg 100 4321029 1077933 1. Al-9Si-0.5 Mg 150 71926 148254 1. Al-9Si-0.5 Mg 150 242833 42791 1. Al-9Si-0.5 Mg 150 153073 56603 1. Al-9Si-0.5 Mg 200 16003 54623 1. Al-9Si-0.5 Mg 200 8654 30708 1. Al-9Si-0.5 Mg 200 36597 39376 3. Al-9Si-0.45Mg-0.75Cu- 4Zn 100 160572 248032 3. Al-9Si-0.45Mg-0.75Cu- 4Zn 100 298962 131397 3. Al-9Si-0.45Mg-0.75Cu- 4Zn 100 120309 394167 3. Al-9Si-0.45Mg-0.75Cu- 4Zn 150 120212 12183 3. Al-9Si-0.45Mg-0.75Cu- 4Zn 150 70152 42074 3. Al-9Si-0.45Mg-0.75Cu- 4Zn 150 190200 31334 3. Al-9Si-0.45Mg-0.75Cu- 4Zn 200 38369 18744 3. Al-9Si-0.45Mg-0.75Cu- 4Zn 200 29686 14822 3. Al-9Si-0.45Mg-0.75Cu- 4Zn 200 39366 11676 4. Al-9Si-0.45Mg-0.75 Cu 100 485035 575446 4. Al-9Si-0.45Mn-0.75 Cu 100 4521553 233110 4. Al-9Si-0.45Mg-0.75 Cu 100 3287495 940229 4. Al-9Si-0.45Mg-0.75 Cu 150 170004 141654 4. Al-9Si-0.45Mg-0.75 Cu 150 110500 234640 4. Al-9Si-0.45Mg-0.75 Cu 150 688783 238478 4. Al-9Si-0.45Mg-0.75 Cu 200 108488 22686 4. Al-9Si-0.45Mg-0.75 Cu 200 40007 36390 4. Al-9Si-0.45Mg-0.75 Cu 200 51678 20726 7. Al-9Si-0.45Mg-1.25 Cu 100 1115772 1650686 7. Al-9Si-0.45Mg-1.25 Cu 100 318949 1744140 7. Al-9Si-0.45Mg-1.25 Cu 100 468848 484262 7. Al-9Si-0.45Mg-1.25 Cu 150 102341 232171 7. Al-9Si-0.45Mg-1.25 Cu 150 145766 106741 7. Al-9Si-0.45Mg-1.25 Cu 150 63720 226188 7. Al-9Si-0.45Mg-1.25 Cu 200 41686 21873 7. Al-9Si-0.45Mg-1.25 Cu 200 20709 58819 7. Al-9Si-0.45Mg-1.25 Cu 200 52709 4367 9. Al-9Si-0.35Mg-1.75 Cu 100 2159782 2288145 9. Al-9Si-0.35Mg-1.75 Cu 100 354677 1011473 9. Al-9Si-0.35Mg-1.75 Cu 100 4258369 783758 9. Al-9Si-0.35Mg-1.75 Cu 150 281867 164554 9. Al-9Si-0.35Mg-1.75 Cu 150 135810 188389 9. Al-9Si-0.35Mg-1.75 Cu 150 100053 146740 9. Al-9Si-0.35Mg-1.75 Cu 200 24014 48506 9. Al-9Si-0.35Mg-1.75 Cu 200 30695 8161 9. Al-9Si-0.35Mg-1.75 Cu 200 62211 31032 - The effect of artificial aging temperature on tensile properties was investigated using the baseline alloy 1-Al-9%Si-0.5%Mg. After a
minimum 4 hours of natural aging, the tensile bar castings were aged at 155°C for 15, 30, 60 hours and at 170°C for 8, 16, 24 hours. Three replicate specimens were used for each aging condition. -
Figure 10 shows the tensile properties of the baseline A359 alloy (Al-9%Si-0.5%Mg) at various aging conditions. Low aging temperature (155°C) tends to yield higher quality index than the high aging temperature (170°C). Thus, the low aging temperature at 155°C was selected, even though the aging time is longer to obtain improved properties. -
Figure 11 compares the tensile properties of baseline Al-9%Si-0.5%Mg alloy and Al-9%Si-0.5%Mg-0.75%Cu alloy. The addition of 0.75%Cu to Al-9%Si-0.5%Mg alloy increases the yield strength by ∼20 MPa and ultimate tensile strength by ∼40 MPa while maintaining the elongation. The average quality index of the Cu-containing alloy is ∼560 MPa, which is much higher than the baseline alloy with an average of ∼520 MPa. -
Figure 12 compares the tensile properties of four cast alloys, 1, 2, 3 and 4.Alloy 1 is the baseline alloy. Alloy 2-4 all contain 0.75%Cu with various amounts of Mg and/or Zn.Alloys alloy 2 contains 0.35%Mg andalloy 1 contains 0.5%Mg.Alloys alloys Figure 12 . When aged at 155°C for 15 hours, yield strength of about 370 MPa can be achieved for the Al-9%Si-0.45%Mg-0.75%Cu-4%Zn alloy, which is about 30MPa higher than that of the alloy without Zn. -
Figure 13 shows the effect of Mg content (0.35-0.55wt%) on the tensile properties of the Al-9%Si-1.25%Cu-Mg alloys (Alloys 6-8). The tensile properties of the baseline alloy Al-9%Si-0.5%Mg are also included for comparison. Mg content showed significant influence on the tensile properties. With increasing Mg content, both yield strength and tensile strength were increased, but the elongation was decreased. The decrease of elongation with increasing Mg content could be related to higher amount of π-AlFeMgSi phase particles even if all the Q-AlCuMgSi phase particles were dissolved. The impact of Mg content on quality indexes of the Al-9%Si-1.25%Cu-Mg alloys was overall found to be insignificant. -
Figure 14 shows the effect of Ag (0.5wt%) on the tensile properties of Al-9%Si-0.35%Mg-1.75%Cu alloy. An addition of 0.5wt% Ag had very limited impact on strength, elongation and quality index of the Al-9%Si-0.35%Mg-1.75%Cu alloy. It should be noted that the quality index of the Al-9%Si-0.35%Mg-1.75%Cu (without Ag) alloy is ∼60MPa higher than the baseline alloy, A359 (Alloy 1) -
Figures 15a-15d show the tensile properties of five promising alloys in accordance with the present disclosure along with the baseline alloy Al-9Si-0.5Mg (alloy 1). These five alloys achieve the target tensile properties, i.e., 10-15% increase in tensile and maintaining similar elongation as A356/A357 alloy. The alloys are: Al-9%Si-0.45%Mg-0.75%Cu (Alloy 4), Al-9%Si-0.45%Mg-0.75%Cu-4%Zn(Alloy 3), Al-9%Si-0.45%Mg-1.25%Cu (Alloy 7), Al-9%Si-0.35%Mg-1.75%Cu (Alloy 9), and Al-9%Si-0.35%Mg-1.75%Cu-0.5%Ag (Alloy 10). - Based on the data, it is believed that the following tensile properties can be obtained with alloys aged at 155°C for time ranged from 15 to 60 hrs.
Ultimate tensile strength: 450-470MPa Tensile yield strength: 360-390MPa Elongation: 5-7% Quality index: 560-590MPa - These properties are much higher than A359 (Alloy 1) and are very similar to A201 (A14.6Cu0.35Mg0.7Ag) cast alloy (UTS 450MPa, TYS 380MPa,
Elongation 8%, and Q 585 MPa)ASM Handbook Volume 15, Casting, ASM International, December 2008 - Based on the tensile property results, four alloys without Ag (
Alloys -
Figure 16 shows the results of the individual tests by plotting Charpy impact energy vs. tensile yield strength. The filled symbols are for specimens aged at 155°C for 15 hours and open symbols are for specimens aged at 155°C for 60 hours. Tensile yield strength increases as the aging time increases, while the Charpy impact energy decreases with increasing aging time. The results indicate that most alloys/aging conditions follow the expected strength/toughness relationship. However, the results indeed show a slight degradation of the strength/toughness relationship with higher Cu content such as 1.25 and 1.75wt%. - Aluminum castings are often used in engineered components subject to cycles of applied stress. Over their commercial lifetime millions of stress cycles can occur, so it is important to characterize their fatigue life. This is especially true for safety critical applications, such as automotive suspension components.
-
Figures 17 and18 show the S-N fatigue test results of five selected alloys aged at 155°C for 15 and 60 hours, respectively. During these tests a constant amplitude stress (R= -1) was applied to the test specimens. Three different stress levels, 100MPa, 150MPa and 200MPa were applied. The total number of cycles to failure was recorded. - When aged at 155°C for 15 hours, all the Cu-containing alloys showed better fatigue performance (higher number of cycles to failure) than the baseline A359 alloy at higher stress levels (>150MPa). At lower stress levels (<125MPa), the fatigue lives of the Al-9Si-0.45Mg-0.75Cu and Al-9Si-0.35Mg-1.75Cu alloys are very similar to the A359 alloy, while the fatigue life of the Al-9Si-0.45Cu-0.75Cu-4Zn alloy (alloy 3) was lower than the A359 alloy. The lower fatigue life of this alloy could result from the higher hydrogen content of the casting, as stated previously.
- Increasing aging time (higher tensile strength) tended to decrease the number of cycles to failure. For example, as the aging time increased from 15 hours to 60 hours, the average number of cycles to failure at 150 MPa stress level decreased from ∼323,000 to ∼205,000 for the Al-9%Si-0.45%Mg-0.75%Cu alloy and from ∼155,900 to ∼82,500 for the A359 alloy. The result could be a general trend of the strength/fatigue relationship of Al-Si-Mg-(Cu) casting alloys. Again,
alloy 3 showed a lower fatigue performance than others. -
Figures 19 to 23 show optical micrographs of the cross-sectional views after 6-hour ASTM G110 tests for five selected alloys of both the as-cast surfaces and machined surfaces. The mode of corrosion attack was predominantly interdendritic corrosion. The number of corrosion sites was generally higher in the four Cu-containing compositions than in the Cu-free baseline alloy. - More particularly,
Figs. 19a-d show optical micrographs of cross-sections of Al-9%Si-0.5%Mg after a 6-hour ASTM G110 test: a) of the alloy as cast and aged 15 hours at 155°C; b) of the alloy as cast and aged 60 hours at 155°C; c) of the alloy with a machined surface and aged 15 hours at 155°C; and d) of the alloy with a machined surface and aged 60 hours at 155°C. -
Figs. 20a-d show optical micrographs of cross-sections of Al-9%Si-0.35%Mg-0.75%Cu-4%Zn after a 6-hour ASTM G110 test: a) of the alloy as cast and aged 15 hours at 155°C; b) of the alloy as cast and aged 60 hours at 155°C; c) of the alloy with a machined surface and aged 15 hours at 155°C; and d) of the alloy with a machined surface and aged 60 hours at 155°C. -
Figs. 21a-d show optical micrographs of cross-sections of Al-9%Si-0.45%Mg-0.75%Cu after a 6-hour ASTM G110 test: a) of the alloy as cast and aged 15 hours at 155°C; b) of the alloy as cast and aged 60 hours at 155°C; c) of the alloy with a machined surface and aged 15 hours at 155°C; and d) of the alloy with a machined surface and aged 60 hours at 155°C. -
Figs. 22a-d show optical micrographs of cross-sections of Al-9%Si-0.45%Mg-1.25%Cu after a 6-hour ASTM G110 test: a) of the alloy as cast and aged 15 hours at 155°C; b) of the alloy as cast and aged 60 hours at 155°C; c) of the alloy with a machined surface and aged 15 hours at 155°C; and d) of the alloy with a machined surface and aged 60 hours at 155°C. -
Figs. 23a-d show optical micrographs of cross-sections of Al-9%Si-0.35%Mg-1.75%Cu after a 6-hour ASTM G110 test: a) of the alloy as cast and aged 15 hours at 155°C; b) of the alloy as cast and aged 60 hours at 155°C; c) of the alloy with a machined surface and aged 15 hours at 155°C; and d) of the alloy with a machined surface and aged 60 hours at 155°C. -
Figure 24 shows the depth of attack after the 6-hour ASTM G110 test. There is no clear difference or trend among the alloys. Aging time did not show obvious impact on the depth of attack either, while some differences were found between the as-cast surfaces and the machined surfaces. In general, the corrosion attack was slightly deeper on the machined surface than the as-cast surface of the same sample. - Overall, the additions of Cu or Cu+Zn do not change the corrosion mode nor increase the depth-of -attack of the alloys. It is believed that all the alloys evaluated have similar corrosion resistance as the baseline alloy, A359.
- The present disclosure has described Al-Si-Cu-Mg alloys that can achieve high strength without sacrificing ductility. Tensile properties including 450-470MPa ultimate tensile strength, 360-390MPa yield strength, 5-7 % elongation, and 560-590MPa Quality Index were obtained. These properties exceed conventional 3xx alloys and are very similar to that of the A201 (2xx+Ag) Alloy, while the castabilities of the new Al-9Si-MgCu alloys are much better than that of the A201 alloy. The new alloys showed better S-N fatigue resistance than A359 (Al-9Si-0.5Mg) alloys. Alloys in accordance with the present disclosure have adequate fracture toughness and general corrosion resistance.
- Because alloys such as those described in the present disclosure may be utilized in applications wherein they are exposed to high temperatures, such as in engines in the form of engine blocks, cylinder heads, pistons, etc., it is of interest to assess how such alloys behave when exposed to high temperatures.
Figure 26 shows a graph of tensile properties of an alloy in accordance with the present disclosure, namely, Al-9Si-0.35Mg-1.75Cu (previously referred to asalloy 9, e.g., inFigure 15 ) after exposure to various temperatures. As noted, for each test generating data in the graph, the exposure time of the alloys was 500 hours at the indicated temperature. The samples were also tested at the temperature indicated. As shown in the graph, the yield strength of the alloy diminished significantly at temperatures above 150°C. In accordance with the present disclosure, the metal was analyzed to ascertain features associated with the loss in strength due to exposure to increased temperatures. -
Figures 27a and 27b show scanning electron microscope (SEM) micrographs of a cross-section of a sample ofalloy 9 prior to exposure to high temperatures, with 27b being an enlarged view of the portion of the micrograph of 31a indicated as "Al". As shown inFigure 27a , the grain boundaries are visible, as well as, Si and AlFeSi particles. The predominately Al portion shown inFigure 27b shows no visible precipitate at 20,000X magnification. -
Figures 28a-e show a series of scanning electron microscope (SEM) micrographs of a cross-section of alloy C00 (previously referred to asalloy 9, e.g., inFigure 15 ) of the same scale as the micrograph shown inFigure 27b after exposure to increasing temperatures as shown by the correlation of the micrographs to the data points on the tensile property graph G ofalloy 9. The tensile characteristics of A356 alloy in the given temperature range are also shown in graph G for comparison. As can be appreciated from the sequence of micrographs, exposure ofalloy 9 to increasing temperatures results in continuously increasing prominence of precipitate particles, which are larger, and which exhibit divergent geometries. - The inventors of the present disclosure recognized that certain alloying elements, viz., Ti, V, Zr, Mn, Ni, Hf, and Fe could be introduced to the C00 alloy (previously referred to as
alloy 9, e.g., inFigure 15 ) of the present disclosure in small amounts to produce an alloy that resists strength degradation at elevated temperatures. - The following table (Table 10) show 18 alloys utilizing additive elements in small quantities to the C00 alloy (previously referred to as
alloy 9, e.g., inFigure 15 ) for the purpose of developing improved strength at elevated temperatures.Table 10. Alloy Compositions Alloy Actual Composition (wt%) Fe Si Mn Cu Mg Sr Ti B V Zr NI Hf C00 0.08 9.29 0 1.83 0.37 0.0125 0.05 0 0 0 0 C01 0.15 9.3 0.002 1.82 0.002 0.008 0.11 0.0047 0.012 0.002 0 0 C02 0.15 9.35 0.002 1.82 0.39 0.008 0.11 0.0043 0.012 0.002 0 0 C03 0.15 9.05 0.002 1.77 0.37 0.007 0.11 0.0051 0.13 0.002 0 0 C04 0.16 8.95 0.002 1.77 0.36 0.006 0.1 0.0026 0.1 0.091 0 0 C05 0.16 8.86 0.002 1.76 0.36 0.005 0.1 0.0016 0.13 0.15 0 0 C06 0.16 8.54 0.002 1.72 0.35 0.004 0.1 0.005 0.13 0.18 0 0 C07 0.16 9.31 0.15 1.8 0.34 0.004 0.11 0.0044 0.025 0.016 0 0 C08 0.16 9.32 0.16 1.84 0.34 0.004 0.11 0.0051 0.025 0.017 0 0 C09 0.17 9.1 0.28 1.8 0.33 0.003 0.11 0.005 0.025 0.016 0 0 C10 0.32 9.26 0.3 1.83 0.34 0.003 0.11 0.0045 0.024 0.017 0 0 C11 0.49 8.96 0.3 1.78 0.32 0.003 0.12 0.0055 0.11 0.016 0 0 C12 0.56 8.97 0.3 1.79 0.32 0.002 0.1 0.0039 0.11 0.12 0 0 C13 0.15 9.28 0.003 1.82 0.33 0.0125 0.1 0.005 0.0012 0.002 0.28 0 C14 0.2 9.28 0.004 1.81 0.33 0.004 0.1 0.0026 0.012 0.002 0.28 0 C15 0.31 9.27 0.03 1.82 0.33 0.004 0.1 0.0032 0.012 0.002 0.28 0 C16 0.32 9.14 0.1 1.79 0.32 0.003 0.1 0.0032 0.012 0.003 0.27 0.1 C17 0.32 8.88 0.12 1.75 0.3 0.003 0.1 0.0031 0.11 0.013 0.26 0.1 C18 0.32 8.89 0.14 1.76 0.3 0.003 0.1 0.003 0.11 0.036 0.27 0.1 -
Figure 29 shows a graph of yield strength at room temperature for foregoing alloys. A356 is shown for comparison. In addition, a department of energy (DOE) published target for strength improvement is shown for comparison [Predictive Modeling for Automotive Light weighting Applications and Advanced Alloy Development for Automotive and Heavy-Duty Engines, Issue by Department of Energy on 03/22/2012]. As can be appreciated, the C00 alloy is comparable in strength at room temperature to alloys C02-C18, all of which substantially exceed the strength of the A356 alloy and the DOE target properties. Alloy C01 - without substantial quantities of Mg, has a far lower yield strength. -
Figure 30 is a graph of yield strength after exposure to 175 °C for 500 hours for the foregoing alloys. The C00, as well as A356 are shown for comparison. As can be appreciated, the C00 alloy substantially exceeds the strength of the A356 alloy. Alloys C02-C18), all show marked improvement over both A356 and C00. -
Figure 31 is a graph of yield strength after exposure to 300°C for 500 hours for the foregoing alloys. C00, as well as A356 are shown for comparison.Figure 32 shows is a graph of yield strength after exposure to 300°C for various alloys. More particularly, adjacent alloys (going in the direction of the arrows) show the result of an additional element or the increase in quantity of an element. The highest result in the graph ofFigure 32 is for C00 + 0.1T +0.16Fe+ 0.13V + 0.15Zr. The addition of more Zr (to 0.18%) to this combination results in decreased performance. -
Figure 33 is a graph of yield strength after exposure to 300 °C for various alloys for 500 hours. The graphs show improvements due to the addition of Ti, Fe and Mn to the C00 composition, with the maximum performance noted relative to C00 + 0.11Ti + 0.32Fe + 0.3Mn. The addition of V to the foregoing reduces performance and the further addition of 0.12 Zr brings performance almost back to the maximum level. -
Figure 34 is a graph of yield strength after exposure to 300 °C for various alloys, i.e., due to the addition of elements to the C00 composition. The optimal performance is noted relative to C00 + 0.1Ti + 0.28Ni + 0.32 Fe + 0.14Mn + 0.1Hf + 0.11V + 0.04Zr.
Claims (11)
- An aluminum casting alloy consisting of:8.5 - 9.5 wt. % silicon;0.5 - 2.0 wt. % copper (Cu);wherein the alloy includesi. 1.35 - 2.0 wt. % copper and 0.27 - 0.445 wt. % magnesium, orii. 0.5 - 0.75 wt. % copper and 0.395 - 0.53 wt. % magnesium, oriii. 0.75 - 1.35 wt. % copper and 0.335 - 0.505 wt. % magnesium;0.27 - 0.53 wt. % magnesium (Mg);wherein the aluminum casting alloy includes copper and magnesium such that 4.7 ≤ (Cu+10Mg) ≤ 5.8;up to 0.25 wt. % zinc;up to 1.0 wt. % silver;up to 1.0 wt. % nickelup to 1.0 wt. % hafniumup to 1.0 wt. % manganeseup to 1.0 wt. % iron;up to 0.30 wt. % titanium;up to 0.30 wt. % zirconium;up to 0.30 wt. % vanadium;up to 0.10 wt. % of one or more of strontium, sodium and antimony;other elements being ≤ 0.04 wt. % each and ≤ 0.12 wt. % in total;the balance being aluminum.
- The aluminum casting alloy of Claim 1, wherein the aluminum casting alloy includes copper and magnesium such that 5.0 ≤ (Cu+10Mg) ≤ 5.5,
- The aluminum casting alloy of Claim 1, wherein the aluminum casting alloy includes copper and magnesium such that 5.1 ≤ (Cu+10Mg) ≤ 5.4.
- The aluminum casting alloy of Claim 1, wherein the alloy contains ≤ 0.01 wt. silver
- The aluminum casting alloy of Claim 1, wherein the alloy contains 0.05 - 1.0 wt. % silver.
- The casting alloy of Claim 1, wherein the alloy includes 0.1 - 0.12 wt. % titanium.
- The casting alloy of Claim 6, wherein the alloy includes 0.12 - 0.14 wt. % vanadium
- The casting alloy of Claim 7, wherein the alloy includes 0.08 - 0.19 wt. % zirconium.
- The casting alloy of Claim 6, wherein the alloy includes 0.14 - 0.3 wt. % manganese, or wherein the alloy includes 0.14 - 0.3 wt. % manganese and 0.15 - 0.57 wt. % iron, or wherein the alloy includes 0.14 - 0.3 wt. % manganese, 0.15 - 0.57 wt. % iron and 0.1 - 0.12 wt. % vanadium, or wherein the alloy includes 0.14 - 0.3 wt. % manganese, 0.15 - 0.57 wt. % iron, 0.1 - 0.12 wt. % vanadium and 0.11 - 0.13 wt. % zirconium.
- The casting alloy of Claim 6, wherein the alloy includes 0.27 - 0.3 wt. % nickel, or wherein the alloy includes 0.27 - 0.3 wt. % nickel and 0.15 - 0.33 wt. % iron, or wherein the alloy includes 0.27 - 0.3 wt. % nickel, 0.15 - 0.33 wt. % iron and 0.03 - 0.15 wt. % manganese, or wherein the alloy includes 0.27 - 0.3 wt. % nickel, 0.15 - 0.33 wt. % iron, 0.03 - 0.15 wt. % manganese and 0.05 - 0.2 wt. % hafnium, or wherein the alloy includes 0.27 - 0.3 wt. % nickel, 0.15 - 0.33 wt. % iron, 0.03 - 0.15 wt. % manganese and 0.1 - 0.12 wt. % vanadium, or wherein the alloy includes 0.27 - 0.3 wt. % nickel, 0.15 - 0.33 wt. % iron, 0.03 - 0.15 wt. % manganese, 0.1 - 0.12 wt. % vanadium and 0.012 - 0.04 wt. % zirconium.
- The aluminum casting alloy of any one of Claims 1 to 10, wherein the alloy is subjected to solution heat treat at TH followed by a cold water quench, where the preferred TH (°C) = 570 - 10.48*Cu-71.6*Mg-1.3319*Cu*Mg-0.72*Cu*Cu+72.95*Mg*Mg, based on Mg and Cu content in wt%, within the range defined bar a lower limit for TH : TQ = 533.6-20.98*Cu+88.037*Mg+33.43*Cu*Mg-0.7763*Cu*Cu-126.267*Mg*Mg and an upper limit for TH : TS = 579.2-10.48*Cu-71.6*Mg-1.3319*Cu*Mg-0.72*Cu*Cu+72.95*Mg*Mg.
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PCT/US2012/062250 WO2013063488A2 (en) | 2011-10-28 | 2012-10-26 | High performance aisimgcu casting alloy |
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EP (1) | EP2771493B9 (en) |
CN (2) | CN107245612B (en) |
BR (1) | BR112014010030B1 (en) |
CA (1) | CA2853728C (en) |
ES (1) | ES2607728T3 (en) |
MX (1) | MX347730B (en) |
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EP2865773B1 (en) * | 2013-10-23 | 2016-04-13 | Befesa Aluminio, S.L. | Aluminium casting alloy |
EP2865772B1 (en) * | 2013-10-23 | 2016-04-13 | Befesa Aluminio, S.L. | Aluminium casting alloy |
CN103740987B (en) * | 2014-01-27 | 2016-07-06 | 烟台三和新能源科技有限公司 | High-strength aluminum alloy and production technology thereof |
CN104357714B (en) * | 2014-11-07 | 2016-04-20 | 辽宁工程技术大学 | A kind of aluminum silicon alloy and preparation method thereof |
CN104532036B (en) * | 2015-01-29 | 2016-06-29 | 吉泽升 | A kind of preparation method adopting automobile waste aluminum component regeneration extrusion casint dedicated aluminium alloy |
CN105063437B (en) * | 2015-08-01 | 2017-09-19 | 徐大海 | The housing of Internet of Things information collecting device |
CN106119624A (en) * | 2016-08-25 | 2016-11-16 | 马鸿斌 | A kind of high heat conduction aluminum alloy and preparation method thereof |
CN106702225A (en) * | 2016-11-15 | 2017-05-24 | 马鸿斌 | High-thermal-conductivity aluminum alloy and preparation method thereof |
ES2753164T3 (en) | 2016-12-28 | 2020-04-07 | Befesa Aluminio S L | Aluminum alloy for casting |
ES2753167T3 (en) | 2016-12-28 | 2020-04-07 | Befesa Aluminio S L | Aluminum alloy for casting |
ES2753168T3 (en) | 2016-12-28 | 2020-04-07 | Befesa Aluminio S L | Aluminum alloy for casting |
JP6267408B1 (en) * | 2017-06-23 | 2018-01-24 | 株式会社大紀アルミニウム工業所 | Aluminum alloy and aluminum alloy castings |
CN108265204A (en) * | 2018-01-24 | 2018-07-10 | 安徽浩丰实业有限公司 | A kind of piston material containing cobalt and preparation method thereof |
EP3550036B1 (en) * | 2018-04-06 | 2022-01-05 | GF Casting Solutions AG | Direct aging |
CN109972003B (en) * | 2019-04-03 | 2020-05-22 | 上海交通大学 | High-elongation heat-resistant aluminum alloy suitable for gravity casting and preparation method thereof |
CN114672704A (en) * | 2022-04-13 | 2022-06-28 | 佛山市南海创利有色金属制品有限公司 | Al-Si series aluminum alloy ingot and preparation method thereof |
CN115233049B (en) * | 2022-07-29 | 2023-07-21 | 湖南江滨机器(集团)有限责任公司 | Heat treatment-free aluminum alloy and preparation method thereof |
CN115679162A (en) * | 2022-11-18 | 2023-02-03 | 江西万泰铝业有限公司 | New energy automobile heat treatment-free aluminum alloy material and low-carbon preparation method |
CN116288085B (en) * | 2023-02-08 | 2024-01-05 | 常州工学院 | Heat treatment method for improving high-temperature strength of Al-Cu-Mn-Zr aluminum alloy |
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DE19524564A1 (en) * | 1995-06-28 | 1997-01-02 | Vaw Alucast Gmbh | Aluminium@ alloy for casting cylinder heads |
KR101223546B1 (en) * | 2004-07-28 | 2013-01-18 | 알코아 인코포레이티드 | An al-si-mg-zn-cu alloy for aerospace and automotive castings |
JPWO2008016169A1 (en) * | 2006-08-01 | 2009-12-24 | 昭和電工株式会社 | Aluminum alloy molded product manufacturing method, aluminum alloy molded product and production system |
JP5344527B2 (en) * | 2007-03-30 | 2013-11-20 | 株式会社豊田中央研究所 | Aluminum alloy for casting, aluminum alloy casting and method for producing the same |
EP1997924B1 (en) * | 2007-05-24 | 2009-12-23 | ALUMINIUM RHEINFELDEN GmbH | High-temperature aluminium alloy |
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WO2013063488A3 (en) | 2013-10-31 |
PL2771493T3 (en) | 2017-08-31 |
CA2853728C (en) | 2021-05-25 |
CN107245612A (en) | 2017-10-13 |
CN104093867A (en) | 2014-10-08 |
EP2771493B8 (en) | 2017-08-09 |
CN107245612B (en) | 2019-04-16 |
BR112014010030A2 (en) | 2017-04-25 |
ES2607728T3 (en) | 2017-04-03 |
BR112014010030B1 (en) | 2018-11-06 |
BR112014010030A8 (en) | 2018-01-02 |
WO2013063488A2 (en) | 2013-05-02 |
MX2014005099A (en) | 2015-02-12 |
CA2853728A1 (en) | 2013-05-02 |
EP2771493B1 (en) | 2016-09-14 |
CN104093867B (en) | 2017-05-03 |
EP2771493A2 (en) | 2014-09-03 |
MX347730B (en) | 2017-05-11 |
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