EP2865774B1 - Aluminium casting alloy - Google Patents

Aluminium casting alloy Download PDF

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Publication number
EP2865774B1
EP2865774B1 EP13382424.3A EP13382424A EP2865774B1 EP 2865774 B1 EP2865774 B1 EP 2865774B1 EP 13382424 A EP13382424 A EP 13382424A EP 2865774 B1 EP2865774 B1 EP 2865774B1
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Prior art keywords
weight
alloy
aluminium casting
aluminium
casting alloy
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EP13382424.3A
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German (de)
French (fr)
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EP2865774A1 (en
Inventor
Francisco Sáenz de Tejada Picornell
Iñigo Anza Ortiz de Apodaca
Iban Vicario Gómez
Ignacio Crespo Camino
Alberto Abuin Ariceta
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Befesa Aluminio SL
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Befesa Aluminio SL
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Priority to EP13382424.3A priority Critical patent/EP2865774B1/en
Priority to ES13382424.3T priority patent/ES2582530T3/en
Publication of EP2865774A1 publication Critical patent/EP2865774A1/en
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    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • C22C21/02Alloys based on aluminium with silicon as the next major constituent

Definitions

  • the field of the invention is related to aluminium casting alloys.
  • the present invention relates to a hypoeutectic secondary aluminum-silicon alloy, useful to produce, by high pressure die casting, components which have to fulfill premium abrasion resistance requirements in as-cast condition at room temperature.
  • Aluminum casting alloys have not been traditionally well suited for abrasion applications in which, among others, high hardness properties must be present.
  • abrasion requirements are, among other, piston cylinders, brake discs or steering boxes.
  • Brake discs and piston cylinders must support not only abrasion but also thermal fatigue resistance, and if aluminium is employed instead of steel, hypereutectic alloys have been traditionally applied to produce automotive components by gravity die casting (GC).
  • GC gravity die casting
  • Hypereutectic alloys present primary silicon grains that are normally refined with phosporous and T5 thermal treatment to resist abrasion.
  • Nickel is the most important alloying element, with also Copper and dissoluted Zinc, to keep mechanical properties at high temperatures.
  • hypereutectic alloys are not so well suited. They do not fulfill the required hardness (above 115-120HB), Nickel is superfluous and Phosphorous is so volatile that requires skilled technicians to melt the alloy, which must be hold at temperatures above 750°C. Only high hardness and high strength are the objective properties, which opens the door to components produced by high pressure die casting (HPDC) with hypoeutectic aluminum.
  • HPDC high pressure die casting
  • HPDC process has been widely employed to new applications in the last twenty years, due to its low cost for big series, a high component reproducibility and reliability and it is hence mostly preferred when compared with GC.
  • Alloys of primary quality with a Fe/Mn ratio of 1 ⁇ 2 has been disclosed in the prior art, and decrease die soldering and reduce as much as possible the negative effect of Al 5 FeSi intermetallics on the elongation values.
  • WO2006/066314 discloses an aluminium-based high pressure die casting comprising (in wt.%): 4 to 4.9% Cu; 0.09-0.7% Mg; 0.19-0.21% Mn; 0.1-0.12% Ni; 8.3-9.2% Si ; 0.98-1% Fe; 0.5-0.56 Zn; ⁇ 0.1% Sn; ⁇ 0.1% Pb; ⁇ 0.1% Ti, ⁇ 0.1 % Cr, and the remainder consisting of aluminium and incidental impurities.
  • elongation and mechanical properties elongation (A) equal to or more than 1%, yield strength (Rp0.2) equal to or more than 200 MPa, ultimate tensile strength (Rm) equal to or more than 300 MPa and Brinell Hardness (HB) equal to or more than 120 HB.
  • elongation and mechanical properties are required for components designed to support simultaneously high abrasion and high static bending/torsion loads, maintaining a minimal ductility and other processing properties as alloy fluidity, low die soldering, easy welding or high machinability, among others.
  • a preferred embodiment of the present invention is an aluminium casting alloy, wherein said alloy consists of:
  • Silicon content has been set into a wide range between 7-11% by weight to guarantee high fluidity, especially for thin wall castings.
  • Copper content has been set at values above 4% as it is required to get hardness above 125 HB and high strength.
  • Magnesium content is also a key element to maximize the hardness and mechanical properties, whose content must be coupled with the copper content, showing best performance when both set above 0.5% by weight and 4% by weight, respectively.
  • Iron content plays a key role into the mechanical properties and hence it has been limited to 0.6-1% by weight to guarantee both low mold soldering and small volume fraction of Al 5 FeSi intermetallics, which are minimized by the manganese content, implying an elongation above 1%.
  • the manganese content helps to transform the Al 5 FeSi intermetallics into Al 12 (Mn,Fe)Si 2 and to reduce as much as possible the negative effect of those intermetallics. Values of manganese above 0.3% by weight were not found to be useful in terms of Al 5 FeSi intermetallics transformation.
  • a further embodiment of the invention is the aluminium casting alloy of the invention, wherein said alloy comprises 8-9% by weight of silicon.
  • a further embodiment of the invention is the aluminium casting alloy of the invention, wherein said alloy comprises 0.8-1 % by weight of iron.
  • a further embodiment of the invention is the aluminium casting alloy of the invention, wherein said alloy comprises 4-4.5% by weight of copper.
  • a further embodiment of the invention is the aluminium casting alloy of the invention, wherein said alloy comprises 0.05-0.3% by weight of manganese.
  • a further embodiment of the invention is the aluminium casting alloy of the invention, wherein said alloy comprises 0.6-0.7% by weight of magnesium.
  • Example 1 Aluminium casting alloys (prepararation, composition and mechanical properties)
  • Aluminium compositions have been prepared by melting a standard EN-AC 46500 alloy in a holding furnace at 690°C and later poured into the injection vessel, being injected into the mold cavity of a 950 tonnes closing force HPDC machine at 685°C. No vacuum conditions were applied.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Cell Electrode Carriers And Collectors (AREA)
  • Conductive Materials (AREA)
  • Fuel Cell (AREA)
  • Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Description

    FIELD OF THE INVENTION
  • The field of the invention is related to aluminium casting alloys. Specifically, the present invention relates to a hypoeutectic secondary aluminum-silicon alloy, useful to produce, by high pressure die casting, components which have to fulfill premium abrasion resistance requirements in as-cast condition at room temperature.
  • BACKGROUND OF THE INVENTION
  • Aluminum casting alloys have not been traditionally well suited for abrasion applications in which, among others, high hardness properties must be present.
  • Regarding the automotive sector, in which most of the aluminum castings are consumed, some well-known parts that must fulfill abrasion requirements are, among other, piston cylinders, brake discs or steering boxes. Brake discs and piston cylinders must support not only abrasion but also thermal fatigue resistance, and if aluminium is employed instead of steel, hypereutectic alloys have been traditionally applied to produce automotive components by gravity die casting (GC). Hypereutectic alloys present primary silicon grains that are normally refined with phosporous and T5 thermal treatment to resist abrasion. Nickel is the most important alloying element, with also Copper and dissoluted Zinc, to keep mechanical properties at high temperatures.
  • For room temperature applications (i.e. steering boxes) hypereutectic alloys are not so well suited. They do not fulfill the required hardness (above 115-120HB), Nickel is superfluous and Phosphorous is so volatile that requires skilled technicians to melt the alloy, which must be hold at temperatures above 750°C. Only high hardness and high strength are the objective properties, which opens the door to components produced by high pressure die casting (HPDC) with hypoeutectic aluminum.
  • HPDC process has been widely employed to new applications in the last twenty years, due to its low cost for big series, a high component reproducibility and reliability and it is hence mostly preferred when compared with GC.
  • Unfortunately, typical hardnesses of hypoeutectic alloys lie on values around 80-100 HB, what is still below the required 120HB. Therefore, when producing steering boxes, a steel sleeve is placed in the internal surface of the box to accommodate the steering shaft. Both shaft and box are typically AlSi9Cu3 as cast components produced by HPDC, and even the addition of a new step (sleeve placement) is worth when compared with expensive GC production with hypereutectic alloy with a T5 thermal treatment.
  • Some other new alloys have been later developed to eliminate the thermal treatments, as those belonging to the AlZn families, which after 1 week of natural aging reach hardness values close to 120 HB. Unfortunately, the main disadvantage of these alloys is that quality requirements are only achievable by primary alloys. Primary alloys means mainly Iron content below 0.15% by weight, Copper content below 0.03% by weight and Zinc content below 0.1% by weight, being those contents only achievable if Aluminium is produced by electrolysis smelting from raw alumina. All refined aluminium alloys produced from scraps, drosses and swarfs coming from post-processing operations and end of life products is hence limited to low mechanical secondary alloy applications, what is a large limitation for industry sustainability and for the aluminum recycling sector.
  • Alloys of primary quality with a Fe/Mn ratio of ½ has been disclosed in the prior art, and decrease die soldering and reduce as much as possible the negative effect of Al5FeSi intermetallics on the elongation values.
  • WO2006/066314 discloses an aluminium-based high pressure die casting comprising (in wt.%): 4 to 4.9% Cu; 0.09-0.7% Mg; 0.19-0.21% Mn; 0.1-0.12% Ni; 8.3-9.2% Si ; 0.98-1% Fe; 0.5-0.56 Zn; <0.1% Sn; <0.1% Pb; <0.1% Ti, <0.1 % Cr, and the remainder consisting of aluminium and incidental impurities.
  • The problem to be solved is the provision of a novel alloy of secondary quality produced for HPDC which can be used in as-cast condition and that presents the following values of elongation and mechanical properties: elongation (A) equal to or more than 1%, yield strength (Rp0.2) equal to or more than 200 MPa, ultimate tensile strength (Rm) equal to or more than 300 MPa and Brinell Hardness (HB) equal to or more than 120 HB. Said values of elongation and mechanical properties are required for components designed to support simultaneously high abrasion and high static bending/torsion loads, maintaining a minimal ductility and other processing properties as alloy fluidity, low die soldering, easy welding or high machinability, among others.
  • DESCRIPTION OF THE INVENTION
  • A preferred embodiment of the present invention is an aluminium casting alloy, wherein said alloy consists of:
    • 7-11% by weight of silicon,
    • 0.6-1% by weight of iron,
    • 4-5% by weight of copper,
    • 0.05-0.5% by weight of manganese,
    • 0.05-1.2% by weight of zinc,
    • 0.56-0.9% by weight of magnesium,
    • 0.01-0.15% by weight of titanium,
    • 0.01-0.1% by weight of chrome,
    • 0.01-0.1% by weight of nickel,
    • 0.01-0.1 % by weight of lead and
    • 0.01-0.1% by weight of tin,
    • herewith aluminium casting alloy of the invention.
  • Silicon content has been set into a wide range between 7-11% by weight to guarantee high fluidity, especially for thin wall castings.
  • Copper content has been set at values above 4% as it is required to get hardness above 125 HB and high strength.
  • Magnesium content is also a key element to maximize the hardness and mechanical properties, whose content must be coupled with the copper content, showing best performance when both set above 0.5% by weight and 4% by weight, respectively.
  • Iron content plays a key role into the mechanical properties and hence it has been limited to 0.6-1% by weight to guarantee both low mold soldering and small volume fraction of Al5FeSi intermetallics, which are minimized by the manganese content, implying an elongation above 1%.
  • The manganese content helps to transform the Al5FeSi intermetallics into Al12(Mn,Fe)Si2 and to reduce as much as possible the negative effect of those intermetallics. Values of manganese above 0.3% by weight were not found to be useful in terms of Al5FeSi intermetallics transformation.
  • A further embodiment of the invention is the aluminium casting alloy of the invention, wherein said alloy comprises 8-9% by weight of silicon.
  • A further embodiment of the invention is the aluminium casting alloy of the invention, wherein said alloy comprises 0.8-1 % by weight of iron.
  • A further embodiment of the invention is the aluminium casting alloy of the invention, wherein said alloy comprises 4-4.5% by weight of copper.
  • A further embodiment of the invention is the aluminium casting alloy of the invention, wherein said alloy comprises 0.05-0.3% by weight of manganese.
  • A further embodiment of the invention is the aluminium casting alloy of the invention, wherein said alloy comprises 0.6-0.7% by weight of magnesium.
  • EXAMPLES OF THE INVENTION Example 1. Aluminium casting alloys (prepararation, composition and mechanical properties)
  • Aluminium compositions have been prepared by melting a standard EN-AC 46500 alloy in a holding furnace at 690°C and later poured into the injection vessel, being injected into the mold cavity of a 950 tonnes closing force HPDC machine at 685°C. No vacuum conditions were applied.
  • A serial of 30 specimens were produced, for each composition. Casted specimens were cooled down in air. Specimens dimensions and later mechanical characterization were set and carried out following, respectively, UNE-EN ISO 6892-1 B:2010 standards. For the hardness determination, plate specimens with 5 mm thickness have been casted and tested.
  • Several compositions were tested, the content of the content if specified in Table 1. The obtained results are also specified in Table 1. Table 1
    Alloy 1 (comparative composition, not according to the invention) Alloy 2 (comparative composition, not according to the invention) Alloy 3 Alloy 4
    Si (% by weight) 8.68 9.08 8.9 10.41
    Fe (% by weight) 0.95 1.07 1.32 1.32
    Cu (% by weight) 1.78 3.1 4.33 3.97
    Mn (% by weight) 0.33 0.272 0.272 0.54
    Mg (% by weight) 0.046 0.62 0.56 0.54
    Zn (% by weight) 1.74 1.23 1.19 1.14
    Ti (% by weight) 0.023 0.188 0.225 0.272
    Cr (% by weight) 0.018 0.195 0.198 0.189
    Ni (% by weight) 0.062 0.099 0.106 0.102
    Pb (% by weight) 0.051 0.091 0.092 0.087
    Sn (% by weight) 0.018 0.034 0.036 0.035
    Rp0.2 (MPa) 150 208 227 218
    Rm (MPa) 290 300 305 290
    A (%) 4.5 1.75 1.2 1.1
    Brinell Hardness (HB) - 116 125 122
  • The values obtained after one month of natural aging is shown in Table 2. Table 2
    Alloy 2 (comparative composition, not according to the invention) Alloy 3 Alloy 4
    Rp0.2 (MPa) 220 241.5 230
    Rm (MPa) 317 324 300
    A (%) 2.2 2.4 2
    Brinell Hardness (HB) 120 135 130

Claims (6)

  1. Aluminium casting alloy, characterized in that said alloy is consisting of:
    7-11% by weight of silicon,
    0.6-1 % by weight of iron,
    4-5% by weight of copper,
    0.05-0.5% by weight of manganese,
    0.05-1.2% by weight of zinc,
    0.56-0.9% by weight of magnesium,
    0.01-0.15% by weight of titanium,
    0.01-0.1 % by weight of chrome,
    0.01-0.1% by weight of nickel,
    0.01-0.1% by weight of lead,
    0.01-0.1 % by weight of tin,
    and aluminium as the remainder.
  2. Aluminium casting alloy according to claim 1, characterized in that said alloy is consisting of 8-9% by weight of silicon.
  3. Aluminium casting alloy according to claim 1 or claim 2, characterized in that said alloy is consisting of 0.8-1% by weight of iron.
  4. Aluminium casting alloy according to any one of claims 1 to 3, characterized in that said alloy is consisting of 4-4.5% by weight of copper.
  5. Aluminium casting alloy according to any one of claims 1 to 4, characterized in that said alloy is consisting of 0.05-0.3% by weight of manganese.
  6. Aluminium casting alloy according to any one of claims 1 to 5, characterized in that said alloy is consisting of 0.6-0.7% by weight of magnesium.
EP13382424.3A 2013-10-23 2013-10-23 Aluminium casting alloy Active EP2865774B1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP13382424.3A EP2865774B1 (en) 2013-10-23 2013-10-23 Aluminium casting alloy
ES13382424.3T ES2582530T3 (en) 2013-10-23 2013-10-23 Cast aluminum alloy

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP13382424.3A EP2865774B1 (en) 2013-10-23 2013-10-23 Aluminium casting alloy

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EP2865774B1 true EP2865774B1 (en) 2016-04-13

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2024194350A1 (en) 2023-03-20 2024-09-26 Federal-Mogul Nürnberg GmbH Method for producing a brake disk or a brake drum, brake disk or brake drum, use of an aluminum alloy to produce a brake disk or a brake drum, and disk brake or drum brake

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105671353B (en) * 2016-01-26 2017-09-26 山东正诺集团有限公司 A kind of enhanced aluminium base of inorganic particulate is braked the preparation method of disk material
CN106591640B (en) * 2016-11-18 2019-04-16 广州致远新材料科技有限公司 A kind of wear-resistant aluminum alloy
EP3342888B1 (en) * 2016-12-28 2019-05-29 Befesa Aluminio, S.L. Aluminium casting alloy
KR101955993B1 (en) * 2017-02-17 2019-03-08 주식회사 지.에이.엠 High strength aluminium alloy and high strength aluminium alloy casting
CN108411166A (en) * 2018-02-28 2018-08-17 山东河山机械股份有限公司 A kind of pack alloy and preparation method thereof

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0111082A1 (en) * 1982-10-16 1984-06-20 Cosworth Research And Development Limited Aluminium alloy for casting
GB2332449B (en) * 1997-12-20 2002-05-22 Ae Goetze Automotive Ltd Aluminium alloy
US6908590B2 (en) * 2002-03-19 2005-06-21 Spx Corporation Aluminum alloy
JP5236948B2 (en) * 2004-12-23 2013-07-17 コモンウェルス サイエンティフィック アンドインダストリアル リサーチ オーガナイゼーション Heat treatment of aluminum alloy high pressure die castings.

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2024194350A1 (en) 2023-03-20 2024-09-26 Federal-Mogul Nürnberg GmbH Method for producing a brake disk or a brake drum, brake disk or brake drum, use of an aluminum alloy to produce a brake disk or a brake drum, and disk brake or drum brake
DE102023106915A1 (en) 2023-03-20 2024-09-26 Federal-Mogul Nürnberg GmbH Method for producing a brake disc, brake disc and use of an aluminium alloy for producing a brake disc

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EP2865774A1 (en) 2015-04-29
ES2582530T3 (en) 2016-09-13

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