EP2811042A1 - Geschmiedetes aluminiumlegierungsmaterial und herstellungsverfahren dafür - Google Patents

Geschmiedetes aluminiumlegierungsmaterial und herstellungsverfahren dafür Download PDF

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Publication number
EP2811042A1
EP2811042A1 EP13744215.8A EP13744215A EP2811042A1 EP 2811042 A1 EP2811042 A1 EP 2811042A1 EP 13744215 A EP13744215 A EP 13744215A EP 2811042 A1 EP2811042 A1 EP 2811042A1
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Prior art keywords
forged material
aluminum alloy
mass
forging
proof stress
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French (fr)
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EP2811042B1 (de
EP2811042A4 (de
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Yoshiya Inagaki
Masayuki Hori
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Kobe Steel Ltd
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Kobe Steel Ltd
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    • 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
    • C22F1/05—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 of the Al-Si-Mg type, i.e. containing silicon and magnesium in approximately equal proportions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/02—Casting exceedingly oxidisable non-ferrous metals, e.g. in inert atmosphere
    • B22D21/04—Casting aluminium or magnesium
    • 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
    • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
    • C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
    • 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
    • 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 an aluminum alloy forged material suitably used for strength members for transportation machines or the like, particularly chassis members of an automobile, and a method for manufacturing the same.
  • aluminum alloys composed of 6000 series (Al-Mg-Si series) aluminum alloys according to the JIS standard or the AA standard, and the like, are used for structural materials or structural parts of transportation machines such as vehicles, ships, aircrafts, motorcycles, and automobiles.
  • the 6000 series aluminum alloys have relatively excellent resistance to corrosion.
  • the 6000 series aluminum alloys are also excellent in terms of their easy reusability of scraps as 6000 series aluminum alloy molten raw materials.
  • aluminum alloy cast materials and aluminum alloy forged materials are used for structural materials or structural parts of transportation machines.
  • the aluminum alloy forged materials are used for structural members of automobiles, particularly for underbody parts such as upper arms and lower arms as they require mechanical properties including higher strength and toughness.
  • Each of such aluminum alloy materials is produced by performing hot forging (die forging) such as mechanical forging or hydraulic forging after a homogenizing heat treatment of an aluminum alloy cast material, and then performing a tempering treatment including a solution-quenching treatment and an artificial aging treatment (sometime referred simply to aging treatment hereinafter).
  • a raw material for forging besides the cast material mentioned above, an extruded material obtained by extruding a cast material after a homogenizing heat treatment may also be used.
  • an aluminum alloy forged material described in Japanese Patent No. 3766357 Disclosed in the patent literature is an aluminum alloy forged material including Mg: 0.6 - 1.8 mass%, Si: 0.8 - 1.8 mass%, Cu: 0.2 - 1.0 mass%, mass ratio of Si/Mg is 1 or more, further including one or more of Mn: 0.1 - 0.6 mass%, Cr: 0.1 - 0.2 mass% and Zr: 0.1 - 0.2 mass%, and the remainder being A1 and inevitable impurities.
  • the aluminum alloy forged material of the composition has a thickness of the thinnest portion of 30 mm or less, electrical conductivity measured at the surface of 41.0 - 42.5 % IACS after artificial aging treatment, and 0.2 % proof stress of 350 MPa or more.
  • dispersions in various conditions of homogenizing heat treatment and hot forging can be usually accommodated to a certain extent.
  • the dispersions in manufacturing conditions, which are usually accommodated affect the 0.2 % proof stress of an aluminum forged material if the mechanical strength of the forged material is enhanced so that the 0.2 % proof stress is 360 MPa or more by containing an excess amount of Si as well as Cu and Mn which are added in an increased amount to enhance the mechanical strength of the thinned forged material.
  • forged material of high mechanical strength and high toughness cannot be secured as the 0.2 % proof stress of the products excessively varies even if the manufacturing conditions are within the specified range.
  • An object of the present invention is to stably provide an aluminum alloy forged material which exhibits increased mechanical strength and high toughness even if the forged aluminum alloy material is reduced in thickness, by containing an excess amount of Si and a high amount of a strength-increasing element such as Cu and Mn, and a method for manufacturing the same.
  • the present invention to solve the above-mentioned problem is characterized in that the aluminum alloy forged material comprising: 0.60 - 1.80 mass% of Mg; 0.80 - 1.80 mass% of Si; 0.20 - 1.00 mass% of Cu; 0.05 - 0.40 mass% of Fe; 0.001 - 0.15 mass% of Ti; 1 - 500 ppm of B; further comprising one or more selected from 0.10 - 0.60 mass% of Mn, 0.10 - 0.40 mass% of Cr, and 0.10 - 0.20 mass% of Zr; and the remainder being A1 and inevitable impurities, and the electrical conductivity measured at the surface of the aluminum alloy forged material at 20 °C is greater than 42.5 % IACS but not more than 46.0 % IACS, the 0.2 % proof stress is 360 MPa or more, and the Charpy impact value is 6 J/cm 2 or more.
  • mechanical strength and toughness of the aluminum alloy forged material are improved by containing the specific amounts of Mg, Si, Cu, Fe, Ti, and B, and further containing the specific amount of a strength-increasing element such as Mn, and by controlling the 0.2 % proof stress and the Charpy impact value to the specific value or larger.
  • the mechanical strength and toughness of the forged material are also improved by controlling the electrical conductivity measured at the surface of the aluminium alloy forged material to the specific range because the ratio of sub-grain structure is increased while maintaining the corrosion resistance.
  • Mass ratio of Si/Mg is preferably 1 or more in the aluminum alloy of the present invention. If the Si/Mg mass ratio is 1 or more, the 0.2 % proof stress of the aluminum alloy forged material further increases.
  • Content of hydrogen gas is preferably 0.25 ml/100 g-Al or less in the aluminum alloy forged material.
  • the method for manufacturing the aluminum alloy forged material according to the present invention is comprising: a melting step of melting the aluminum alloy into a molten metal, a casting step of casting the molten metal at a cooling rate of 10 °C/sec or more to form an ingot, a homogenizing heat treatment step of subjecting the ingot to heating at a rate of 5 °C/min or less, and to a homogenizing heat treatment at 450 - 550 °C, a forging step of subjecting the ingot having been subjected to the homogenizing heat treatment to forging at 460 - 540 °C of the forging start temperature, and after the forging step, a solution heat treatment step of subjecting the forged material to a solution heat treatment at 520 - 570 °C, and an artificial aging treatment step of subjecting the forged material to an artificial aging treatment at 170 - 200 °C for 4 - 9 hours.
  • the present inventors have conceived and found that by containing an excess amount of Si and an increased amount of Cu and Mn or the like, electrical conductivity measured at the surface of the aluminum alloy (sometimes referred to as surface electrical conductivity hereinafter) is more closely correlated with the 0.2 % proof stress of the forged material in an aluminum alloy forged material which exhibits high mechanical strength of 0.2 % proof stress of 360 MPa or more, even if the forged material is reduced in thickness.
  • the surface electrical conductivity reflecting the structure of an aluminum alloy, is closely correlated with the 0.2 % proof stress of the aluminum alloy. It is not necessarily limited to 6000 series aluminum alloy forged material. However, in ordinary 6000 series aluminum alloy forged materials, the relation between electrical conductivity on the surface of aluminum alloy forged material and 0.2 % proof stress is moderately linear. Unless the surface electrical conductivity drastically changes, 0.2 % proof stress is not significantly influenced by the electrical conductivity in the ordinary 6000 series aluminum alloy forged materials.
  • the 0.2 % proof stress tends to be maximized if the surface electrical conductivity is more than 42.5 % IACS but not more than 46.0 % IACS. Moreover, the 0.2 % proof stress shows peculiar characteristics of sharp decrease if the surface electrical conductivity is out of the range.
  • the dispersions in electrical conductivity on the surface of the aluminum alloy forged material due to dispersions in manufacturing conditions more sensitively affect the 0.2 % proof stress of the forged material.
  • a forged material with 0.2 % proof stress of 360 MPa or more is not stably produced due to the dispersion of the manufacturing conditions that are usually accommodated as described above.
  • 0.2 % proof stress of 360 MPa or more in an A1 alloy forged material can be secured and such material can be stably produced by controlling the surface electrical conductivity to more than 42.5 % IACS but not greater than 46.0 % IACS.
  • a forged material with 0.2 % proof stress of 360 MPa or more can be stably produced.
  • an aluminum alloy forged material comprising an excess amount of Si and a large quantity of a strength-increasing element such as Cu or Mn, and by which high strength and high toughness can be stably obtained while maintaining the corrosion resistance even if the forged material is thinned, and also provided is a method for producing the same.
  • the present invention therefore has considerable industrial significance as it expands the use of aluminum alloy forged material for transportation machines.
  • the aluminum alloy forged material (referred to A1 alloy forged material hereinafter) according to the present invention is explained.
  • A1 alloy forged material electrical conductivity measured at 20 °C at the surface of the material after an artificial aging treatment which is described later is controlled to a range of greater than 42.5 % IACS but not more than 46.0 % IACS in order to secure and stably obtain 0.2 % proof stress of 360 MPa or more.
  • 0.2 % proof stress of 360 MPa or more can not be attained if the electrical conductivity at 20 °C measured at the surface is either 42.5 % IACS or less, or more than 46.0 % IACS.
  • the electrical conductivity of the A1 alloy forged material shows a similar behavior not only at the surface but also within the bulk including the center portion. Because of convenience in measurement, the electrical conductivity at the surface of the A1 alloy forged material is selected in the present invention.
  • test specimen of A1 alloy forged material for measurement of electrical conductivity is prepared from an A1 alloy forged material after an artificial aging treatment by mechanical grinding the surface about 0.05 to 0.1 mm or by etching the surface about a few micrometers.
  • the electrical conductivity at the surface is measured by using, for example, an Eddy current type electrical conductivity meter (AutoSigma 3000DL, manufactured by GE Inspection Technologies Japan).
  • Eddy current type electrical conductivity meter AutoSigma 3000DL, manufactured by GE Inspection Technologies Japan.
  • the electrical conductivity on the surface of A1 alloy forged material comprehensively reflects the contents of each of alloy elements as well as structure of the material including their dispersion and degree of crystallization. Further, in addition to these material factors, the electrical conductivity also reflects total metallurgical state of the material including factors in manufacturing conditions.
  • the surface electrical conductivity is not necessarily the same even if the content of each alloying element or the process conditions such as temperature of homogenizing heat treatment and starting temperature of hot forging are roughly in accord with each other.
  • Influencing factors of manufacturing condition, which affect surface electrical conductivity of the A1 alloy forged material after the artificial aging treatment include; in addition to the above-described temperature conditions, details of the cooling rate in the casting step, the heating rate, the holding temperature, and the cooling rate of ingot in the homogenizing heat treatment step, type of hot forging apparatus such as mechanical forging and hydraulic forging, number of times of the forging, working ratio in each of the forging steps, the condition of forging finish temperature, the temperature and time conditions of the solution heat treatment, the quenching treatment, and the artificial aging treatment.
  • 0.2 % proof stress is controlled to 360 MPa or more and Charpy impact value is controlled to 6 J/cm 2 or more in the A1 alloy forged material.
  • the A1 alloy forged material By controlling the 0.2 % proof stress to 360 MPa or more and the Charpy impact value to 6 J/cm 2 or more in the A1 alloy forged material to possess high enough mechanical strength and toughness, it becomes possible to use the A1 alloy forged material for structural material or parts for transportation machines such as an automobile and a ship.
  • the A1 alloy forged material of the present invention comprises Al-Mg-Si series (6000 series) A1 alloy, and the chemical components are specified to secure high mechanical strength, high toughness, and high durability such as stress corrosion cracking resistance for the material to be used for structural material or structural parts for transportation machines such as an automobile and a ship.
  • the chemical components in the Al alloy forged material of the present invention are ones of main factors to govern the electrical conductivity on the surface of the forged material.
  • the chemical composition of the aluminum alloy forged material of the present invention includes Mg: 0.60 - 1.80 mass%, Si: 0.80 - 1.80 mass%, Cu: 0.20 - 1.00 mass%, Fe: 0.05 - 0.40 mass%, Ti: 0.001 - 0.15 mass%, B: 1 - 500 ppm; further comprising one or more element selected from Mn: 0.10 - 0.60 mass%, Cr: 0.10 - 0.40 mass% and Zr: 0.10 - 0.20 mass%; and the remainder being Al and inevitable impurities, accordingly.
  • the chemical composition of the aluminum alloy forged material of the present invention may not necessarily be in accord with a standard component of 6000 series A1 alloy of the JIS standard or the like.
  • other kinds of element are allowed to be contained appropriately within a range which does not inhibit the characteristics of the present invention.
  • inevitable impurities which are inevitably mixed from molten raw material scraps are also allowed within a range which does not inhibit the qualities of the forged material of the present invention.
  • Mg is precipitated as Mg 2 Si (6' phase) in crystal grains together with Si by artificial aging treatment, and is an essential element for imparting the high 0.2 % proof stress to the aluminum alloy forged material.
  • the content of Mg is less than 0.60 mass%, the amount of age hardening during the artificial aging treatment is decreased, resulting in deterioration of Charpy impact value (referred to as an index of toughness hereinbelow) and corrosion resistance which are essential properties for an Al alloy forged material as for the high 0.2 % proof stress.
  • the content of Mg exceeds 1.80 mass%, the 0.2 % proof stress is excessively increased to inhibit forging properties.
  • Mg 2 Si is liable to precipitate in the middle of a quenching step after a solution heat treatment as explained below. It hinders decrease of average grain size of the Mg 2 Si and Al-Fe-Si-(Mn,Cr,Zr)-based crystallized and precipitated products residing on grain boundaries, which are formed by selective chemical bonding of Al, Si, Mn, Cr, Zr, and Fe, and suppresses average distance between the crystallized and precipitated products. As a result, the corrosion resistance of the A1 alloy forged material is deteriorated.
  • the content of Mg exceeds the specified range, it becomes difficult to control the electrical conductivity of the surface of the Al alloy forged materials to the range of greater than 42.5 % IACS but not more than 46.0 % IACS by adjusting the manufacturing conditions. Accordingly, the content of Mg is adjusted to the range from 0.60 to 1.80 mass%.
  • Mg 2 Si is combined with Mg to form Mg 2 Si ( ⁇ ' phase) which precipitates during the artificial aging treatment.
  • the precipitation of Mg 2 Si crystals contributes to increasing 0.2 % proof stress of the aluminum alloy forged material.
  • the Si content is less than 0.80 mass%, the amount of temper hardening decreases, and 0.2 % proof stress and corrosion resistance of the A1 alloy forged material are deteriorated.
  • the Si content exceeds 1.80 mass%, coarse single body Si particles are crystallized and precipitated in casting and in the middle of quenching after the solution heat treatment.
  • too much amount of the excessive Si prevents average grain size of the Al-Fe-Si-(Mn,Cr,Zr)-based crystallized and precipitated products residing on grain boundaries from decreasing, and suppresses average distance between the crystallized and precipitated products, resulting in deterioration of corrosion resistance and toughness of the A1 alloy forged material, as for Mg. Furthermore, the excessive Si deteriorates the workability of the A1 alloy forged material by lowering its elongation. Moreover, when the content of Si exceeds the specified range, it becomes difficult to control the electrical conductivity of the surface of the Al alloy forged materials to the range of greater than 42.5 % IACS but not more than 46.0 % IACS by adjusting the manufacturing conditions. The content of Si is to be 0.80 - 1.80 mass%, accordingly.
  • Cu contributes to enhancement of 0.2 % proof stress for the material by solid solution strengthening. Furthermore, Cu has an effect to significantly promote age hardening of A1 alloy forged material in the step of the artificial aging treatment.
  • the content of Cu is preferably controlled to 0.30 mass% or more.
  • the content of Cu exceeds 1.00 mass%, it extremely increases the sensitivity of stress corrosion cracking and intergranular corrosion of the structure of the aluminum alloy forged material, and deteriorates the corrosion resistance of the aluminum alloy forged material.
  • the content of Cu exceeds the specified range, it becomes difficult to control the electrical conductivity of the surface of the Al alloy forged materials to the range of more than 42.5 % IACS and 46.0 % IACS or less by adjusting the manufacturing conditions. Therefore, the content of Cu is to be in the range of 0.20 - 1.00 mass%, and preferably 0.30 - 1.00 mass%.
  • Fe is added to improve the toughness of the A1 alloy forged material.
  • Fe forms Al 7 Cu 2 Fe, Al 12 (Fe,Mn) 3 Cu 2 , (Fe,Mn)Al 6 , and coarse Al-Fe-Si-(Mn,Cr,Zr)-based crystallized and precipitated products which is a problem to be solved by the present invention. These crystallized and precipitated products provide the start point of fracture and deteriorate the fracture toughness, fatigue properties and the like.
  • the content of Fe is more than 0.40 mass%, more strictly 0.35 mass%, then the Al-Fe-Si-(Mn,Cr,Zr)-based crystallized and precipitated products residing on grain boundaries become coarse, and average distance between the crystallized and precipitated products decreases, resulting in decrease of the toughness. If the content of Fe is less than 0.05 mass%, on the other hand, cracking during the casting step and abnormal material structure are induced.
  • the content of Fe is to be in a range of 0.05 - 0.40 mass%, accordingly.
  • the content of Fe is preferably to be in a range of 0.05 - 0.35 mass%.
  • Ti is added to the aluminum alloy to make crystal grains in the ingot finer to improve the workability of the material in the extrusion, rolling, and forging steps. If a content of Ti is less than 0.001 mass%, the effect of improved workability is not obtained. On the other hand, if the content of Ti is higher than 0.15 mass%, coarse precipitated crystalline particles are formed and the workability is deteriorated. The content of Ti is to be in a range of 0.001 - 0.15 mass%, accordingly.
  • B is added to the aluminum alloy to make crystal grains in the ingot finer to improve the workability of the material in the extrusion, rolling, and forging steps. If a content of B is less than 1 ppm, the effect is not obtained. On the other hand, if the content of B is higher than 500 ppm, coarse precipitated crystalline particles are formed and the workability is deteriorated. The content of B is to be in a range of 1 - 500 ppm, accordingly.
  • dispersed particles collectively known as (Fe,Mn,Cr,Zr) 3 SiAl 12 system of Al-Mn, Al-Cr, and Al-Zr intermetallic compounds which precipitate by selective chemical bonding of Fe, Mn, Cr, Zr, Si, and A1 or others according to their contents during the homogenizing heat treatment step and subsequent the hot forging step.
  • the aluminum alloy according to the present invention contains one or more elements selected from Mn, Cr and Zr, within the range of the contents. If the content of Mn, Cr and Zr is too low, the effect cannot be expected. On the other hand, if an excessive amount of these elements is contained, coarse Al-Fe-Si-(Mn,Cr,Zr)-based intermetallic compounds or crystallized and precipitated products are liable to be formed in the middle of melting and casting steps. They behave as fracture starting points and are factors to deteriorate at least one of electrical conductivity, 0.2 % proof stress, toughness, and corrosion resistance of the Al alloy forged material. Accordingly, the content of each of the elements is adjusted to the range of Mn: 0.10 - 0.60 mass%, Cr: 0.10 - 0.40 mass% and Zr: 0.10 - 0.20 mass%, and one or more kinds of them are to be contained.
  • Elements such as Zn, Be, and V may be assumed inevitably contained in the aluminum alloy. Each of these elements may be contained as long as the amount is low enough not to affect the feature of the present invention. Specifically, an amount of each of these elements is to be 0.05 mass% or less and a total amount of these elements is to be 0.15 mass%.
  • Mass ratio of Si/Mg is preferably 1 or more in the aluminum alloy of the present invention. By controlling the Si/Mg mass ratio to 1 or more within the content of the elements the 0.2 % proof stress further increases. If the Si/Mg mass ratio is less than 1, such enhancement of the 0.2 % proof stress cannot be realized.
  • the content of hydrogen in the A1 alloy forged material of the present invention is preferably to be regulated to a range shown below.
  • hydrogen H 2
  • the content of hydrogen is to be regulated to 0.25 ml/100 g-Al or less, and preferably as low as possible.
  • the manufacturing method in relation with the present invention includes a melting step, a casting step, a homogenizing heat treatment step, a forging step, and a tempering step.
  • the Al alloy forged material of the present invention may be manufactured in a usual manner, other than controlling the surface electrical conductivity to the range of more than 42.5 % IACS but not more than 46.0 % IACS, the 0.2 % proof stress, and the toughness of the A1 alloy forged material.
  • Explained hereinafter are conditions of each of the steps to improve the characteristics of the A1 alloy forged material such as controlling the electrical conductivity within the specified range.
  • the melting step is a step to dissolve an aluminum alloy having the above-described composition into a molten metal.
  • the casting step is a step to cast the molten metal having the above-described composition into an ingot.
  • Ordinal melting and casting method such as continuous casting and rolling method, semi-continuous casting method (direct chill casting process), hot-top casting method, or the like is suitably selected and the ingot is casted.
  • Shape of ingot is not particularly limited. It may be a round bar or a slab shape.
  • the molten alloy is cast to an ingot at a cooling rate of 10 °C/sec or more for the purpose of refinement of crystal grains in the ingot, decreasing the mean crystal grain size of the Al-Fe-Si-(Mn,Cr,Zr)-based crystallized and precipitated products residing on grain boundaries, and increasing the average distance between the crystallized and precipitated products. If the cooling rate is low, the mean crystal grain size of the Al-Fe-Si-(Mn,Cr,Zr)-based crystallized and precipitated products residing on grain boundaries increases, and the average distance between the crystallized and precipitated products decreases, resulting in decrease of the 0.2 % proof stress of the A1 alloy forged material after an artificial aging treatment. It is noted that the cooling rate of the molten alloy is defined as a mean cooling rate from the liquidus temperature to the solidus temperature.
  • the homogenizing heat treatment step is a step of subjecting the ingot to homogenizing heat treatment.
  • the treatment is conducted at a heating rate of 5 °C/min or less and at a holding temperature ranging from 450 to 550 °C.
  • the (Fe,Mn,Cr,Zr) 3 SiAl 12 dispersed particles become coarse and the density decreases, failing to disperse relatively high density of fine dispersed crystals among the crystal grains and to obtaining fine crystal grains.
  • the 0.2 % proof stress of the A1 alloy forged material is decreased after the homogenizing heat treatment.
  • the holding temperature is too low, i.e., less than 450 °C, the number of the (Fe,Mn,Cr,Zr) 3 SiAl 12 dispersed precipitates decreases, causing a shortage of density of the dispersed grains. Further, sufficient solid solution of the Al-Fe-Si-(Mn,Cr,Zr)-based crystallized and precipitated products cannot be realized. It becomes difficult to decrease the mean grain size of Mg 2 Si and Al-Fe-Si-(Mn,Cr,Zr)-based crystallized and precipitated products residing on grain boundaries in the A1 alloy forged material after a tempering step explained later, and to increase the average distance between the crystallized and precipitated products.
  • the heating rate to the holding temperature is suppressed low as to 5 °C/min. or less in order to maintain the 0.2 % proof stress of the Al alloy forged material after the artificial aging treatment.
  • Holding duration at the holding temperature is preferably 2 hours or more.
  • the air furnace, the induction heating furnace, a niter furnace, or the like is used appropriately.
  • the heating rate of an ingot is defined as a mean heating rate from room temperature to the holding temperature.
  • the forging step is a step of using the above-mentioned ingot subjected to the homogenizing heat treatment as a forging raw material, and performing predetermined hot forging by forging using a mechanical press or by forging using a hydraulic press.
  • starting temperature of the forging raw material is adjusted to 460 - 540 °C. If the starting temperature is less than 460 °C, precipitation of Mg 2 Si is suppressed because a ratio of sub- grain and the density of grain boundaries in the forged structure are decreased. As a result, the 0.2 % proof stress is deteriorated as the electrical conductivity on the surface of the A1 alloy forged material after the artificial aging treatment cannot be controlled within the range of the present invention.
  • the starting temperature is more than 540 °C, there are cases in which a portion of the material melts because of heat generated during the forging step. As a result, the 0.2 % proof stress and the corrosion resistance are deteriorated as the electrical conductivity cannot be controlled within the range of the present invention.
  • the finishing temperature of the forging raw material in the hot forging step is preferably to be 350 - 540 °C from a point of view to control the electrical conductivity to the range of the present invention.
  • an ingot which has been extruded and/or rolled after a homogenizing heat treatment may also be used as a forging raw material.
  • the shape of the A1 alloy forged material is not particularly limited, and may be near net shape which is close to that of a final product.
  • a heat treatment step is a step of performing a solution treatment and an artificial aging treatment after the forging step, in order to obtain 0.2 % proof stress, corrosion resistance, and toughness necessary for an A1 alloy forged material.
  • the heat treatment step includes T6 (an artificial aging treatment for obtaining the maximum strength after the solution treatment at 520 - 570 °C), T7 (excessive artificial aging treatment (over-aging treatment) surpassing the conditions of the artificial aging treatment for obtaining the maximum strength after the solution treatment), T8 (an artificial aging treatment for obtaining the maximum strength, in addition to a cold forging after the solution treatment) or the like.
  • the solution heat treatment is conducted at a temperature range of 520 - 570 °C. If the treatment temperature is excessively low, insufficient solutionizing prevents the solid solution of Mg 2 Si, controlling the electrical conductivity to the specified range of the present invention, which results in decrease of 0.2 % proof stress. If the treatment temperature is excessively high, localized melting and coarsening of crystal grains are induced, resulting in decrease of 0.2 % proof stress.
  • the holding duration and heating rate of the solution heat treatment are preferably 20 minutes to 20 hours and 100 °C/hr or more, respectively, in order to secure the 0.2 % proof stress.
  • the heating rate of the A1 alloy forged material is defined as a mean heating rate from the temperature of the material immersed in the solution to the holding temperature in the present invention.
  • a quenching step may be conducted after the solution heat treatment.
  • the quenching treatment may be conducted by cooling in either cold or hot water.
  • the cooling rate is preferably 40 °C/sec or more in order to prevent degradation of toughness and fatigue property of the forged material.
  • An air furnace, an induction heating furnace, a niter furnace, or the like is used appropriately.
  • Temperature and duration of the artificial aging step significantly affect the electrical conductivity on the surface of the Al alloy forged material after the artificial aging step. It is thus necessary to select appropriate conditions in the step by considering the process hysteresis of the material in order to secure the 0.2 % proof stress by controlling the electrical conductivity within the range of the present invention as well as to secure the essential toughness and corrosion resistance. Depending on the amount of alloy elements and process hysteresis (manufacturing conditions) before the artificial aging treatment step, it is necessary to confirm in each of the processing step and manufacturing apparatus.
  • processing condition of the artificial aging treatment is selected from a range of temperature of 170 to 200 °C and a duration of 4 to 9 hours, considering the conditions aiming for the material having the maximum strength by the tempering treatments of T6, T7, and T8 steps.
  • the air furnace, the induction heating furnace, an oil bath, or the like is used appropriately.
  • the manufacturing method according to the present invention preferably includes a degassing step between the melting step and the casting step.
  • the degassing step is a step of removing a hydrogen gas (degassing treatment) from the above-mentioned molten metal of the aluminum alloy melted in the melting step, and controlling a hydrogen gas concentration in 100 g of the aluminum alloy to 0.25 ml or less.
  • the removal of the hydrogen gas is performed in a holding furnace for adjusting the components of the molten metal, and removing inclusions by fluxing, chlorine refining, or in-line refining of the molten metal.
  • the hydrogen gas is removed by blowing an inert gas of argon or the like into the molten metal using SNIF (Spinning Nozzle Inert Floatation) or porous plugs (Japanese Unexamined Patent Application Publication No. 2002-146447 ) in an apparatus for removing the hydrogen gas.
  • the determination of the hydrogen gas concentration is performed by measuring a hydrogen gas concentration in an ingot produced in the casting step described later or in a forging produced in the forging step, which is described later.
  • the hydrogen gas concentration in the ingot can be obtained by, e.g., cutting a sample out of the ingot prior to the homogenizing heat treatment, subjecting the sample to ultrasonic cleaning using alcohol and acetone, and measuring the hydrogen gas concentration in the sample by, e g., the inert gas flow fusion-thermal conductivity method (LIS A06-1993).
  • the hydrogen gas concentration in the forged material can be obtained by, e.g., cutting a sample out of the forging, immersing the sample in a NaOH solution, removing an oxide coating on the surface thereof with a nitric acid, subjecting the sample to ultrasonic cleaning using alcohol and acetone, and measuring the hydrogen gas concentration in the sample by the vacuum heating extraction volumetric method (LIS A06-1993).
  • a pre-forming step by forging roll or the like may be included prior to the forging step.
  • A1 alloy ingots of compositions shown in Table 1 were casted at a cooling rate of 20 °C/sec by a hot-top casting method into a round bar of 68 mm in diameter and 580 mm in length. The ingots were then subjected to a homogenizing heat treatment at a heating rate of 5 °C/min and a holding temperature of 550 °C for 4 hours.
  • a hot forging was performed three times so that the total forging working ratio reaches 75 % by a mechanical forging method using an upper and a lower dies at the forging start temperature and forging finish temperature shown in Table 2.
  • Manufactured was an A1 alloy forged material in a shape of chassis members of an automobile. The thinnest part of the forged material was 6 mm in thickness.
  • the A1 alloy forged material was subjected to a solution heat treatment at 550 °C for 1 hour in an air furnace, followed by a water cooling (water quenching) step.
  • the forged material was subsequently subjected to an artificial aging treatment at 190 °C for 5 hours in an air furnace.
  • tensile properties such as tensile strength, 0.2 % proof stress, elongation, which are measures of mechanical strength, and Charpy impact value (mechanical property) which is a measure of toughness.
  • Charpy impact value mechanical property
  • the measurement of Charpy impact value was performed using test specimens S2 collected from each of the Al alloy forged material as shown in FIG. 2 and by a test method according to the provisions of JIS-Z-2242.
  • the test pieces having 0.2 % proof stress of 360 MPa or more and Charpy impact values of 6 J/cm 2 or more were each evaluated as excellent.
  • Test pieces S3 of a C-ring shape illustrated in FIG. 3 were also collected from each of the A1 alloy forged material, and subjected to a stress corrosion cracking resistance test.
  • the stress corrosion cracking resistance test was performed using the test pieces S3 in the C-ring shape and the alternate immersion test method according to the provisions of ASTMG47. Under added stress of 75 % of the yield stress in LT direction of the test pieces S3, the C-ring shape test pieces were repeatedly subjected to a cycle of immersion and pulling into and out of a salt water during a test period of 90 days. Then presence/absence of stress corrosion cracking in each of the test pieces was examined.
  • test pieces which did not undergo cracking nor grain boundary corrosion including whole-surface corrosion on the surface were each provided with "good” representing excellent stress corrosion cracking resistance, and evaluated as having excellent corrosion resistance.
  • the test pieces without stress corrosion cracking but with grain boundary corrosion which could potentially leads to stress corrosion cracking were each provided with "not very good” representing not very good stress corrosion cracking resistance, and evaluated as having not very good corrosion resistance.
  • the test pieces which underwent cracking were each provided with "poor” representing poor stress corrosion cracking resistance, and evaluated as having poor corrosion resistance.
  • the results are shown in Table 2. [Table 1] Alloy No. Al alloy composition (In mass%. Contents of B and H 2 are in ppm and ml/100g-Al, respectively.
  • A1 alloy forged material examples Nos. 1 - 10, 10A - 10H were excellent in terms of 0.2 % proof stress, Charpy impact value, and stress corrosion cracking resistance, satisfying the scope of claims of the present invention.
  • A1 alloy forged material comparative examples Nos. 11-34 did not satisfy the scope of claims of the present invention, and are inferior in terms of either 0.2 % proof stress, Charpy impact value, or stress corrosion cracking resistance.
  • comparative example No. 11 was inferior in terms of the Charpy impact value and the stress corrosion crack resistance because the content of Mg was less than the lower limit.
  • Comparative example No. 12 was inferior in terms of the stress corrosion crack resistance and the electrical conductivity was less than the lower limit because the content of Mg was more than the upper limit.
  • Comparative example No. 13 was inferior in terms of the 0.2 % proof stress and the stress corrosion crack resistance because the content of Si was less than the lower limit.
  • Comparative example No. 14 was inferior in terms of the Charpy impact value and the stress corrosion crack resistance and the electrical conductivity was less than the lower limit because the content of Si was more than the upper limit.
  • Comparative example No. 15 was inferior in terms of the 0.2 % proof stress because the content of Cu was less than the lower limit.
  • Comparative example No. 16 was inferior in terms of the stress corrosion crack resistance and the electrical conductivity was less than the lower limit because the content of Cu was more than the upper limit.
  • Comparative example No. 17 was inferior in terms of the Charpy impact value and the stress corrosion crack resistance and the electrical conductivity was less than the lower limit because the contents of Mg, Si, and Cu were more than each of the upper limit.
  • Comparative example No. 18 was inferior in terms of the 0.2 % proof stress because it did not contain either Mn or Cr or Zr. Comparative example No. 19 was inferior in terms of the 0.2 % proof stress and the electrical conductivity was less than the lower limit because the content of Mn was more than the upper limit. Comparative example No. 20 was inferior in terms of the 0.2 % proof stress and the stress corrosion crack resistance because the content of Cr was more than the upper limit. Comparative example No. 21 was inferior in terms of the 0.2 % proof stress and the stress corrosion crack resistance because the content of Zr was more than the upper limit. Comparative example No. 22 was inferior in terms of the 0.2 % proof stress and the electrical conductivity was less than the lower limit because the contents of Mn, Cr, and Zr were more than each of the upper limit.
  • comparative example No. 23 was inferior in terms of the 0.2 % proof stress because the cooling rate was less than the lower limit.
  • comparative example No. 24 was inferior in terms of the 0.2 % proof stress because the heating rate was more than the upper limit.
  • comparative example No. 25 was inferior in terms of the 0.2 % proof stress because the duration in the homogenizing heat treatment step was more than the upper limit.
  • comparative example No. 26 which is the A1 alloy forged material according to the invention of Japanese Patent No.
  • comparative example No. 27 was inferior in terms of the 0.2 % proof stress and the resistance to stress corrosion cracking because the forging start temperature was more than the upper limit and hence the electrical conductivity became more than the upper limit.
  • comparative example No. 28 was inferior in terms of the 0.2 % proof stress because the temperature of the solution heat treatment was less than the lower limit and hence the electrical conductivity became more than the upper limit.
  • comparative example No. 29 was inferior in terms of the 0.2 % proof stress because the temperature of the artificial aging treatment was more than the upper limit and hence the electrical conductivity became more than the upper limit.
  • Comparative example No. 30 was inferior in terms of the Charpy impact value because the content of Fe was more than the upper limit. Cracking occurred and comparative example No. 31 could not be forged because the content of Fe was less than the lower limit. Comparative example No. 32 was inferior in terms of the Charpy impact value because the content of Ti was more than the upper limit. Comparative example No. 33 was inferior in terms of the Charpy impact value because the content of B was more than the upper limit. Comparative example No. 34 cracked during the forging step because the cast structure became coarse as it did not contain Ti and B.

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  • Chemical & Material Sciences (AREA)
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  • Metallurgy (AREA)
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  • Physics & Mathematics (AREA)
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EP3214191A1 (de) 2016-03-04 2017-09-06 Impol 2000, d. d. Hochfeste al-mg-si-aluminiumlegierung und deren herstellungsverfahren
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EP2921567A4 (de) * 2012-11-19 2016-06-29 Kobe Steel Ltd Aluminiumlegierung für hochdruckwasserstoff-gasbehälter und verfahren zur herstellung davon
EP3214191A1 (de) 2016-03-04 2017-09-06 Impol 2000, d. d. Hochfeste al-mg-si-aluminiumlegierung und deren herstellungsverfahren
EP3464659B1 (de) 2016-06-01 2020-03-11 Aleris Aluminum Duffel BVBA 6xxx-serien-aluminiumlegierungsschmiederohmaterial und verfahren zur herstellung davon
EP3464659B2 (de) † 2016-06-01 2023-07-12 Aleris Aluminum Duffel BVBA 6xxx-serien-aluminiumlegierungsschmiederohmaterial und verfahren zur herstellung davon

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JP2013177672A (ja) 2013-09-09
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CN103975085B (zh) 2017-02-22
JP5863626B2 (ja) 2016-02-16
EP2811042B1 (de) 2017-06-21
EP2811042A4 (de) 2016-06-08
US20140367001A1 (en) 2014-12-18

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