EP2924137A1 - Aluminium die casting alloys - Google Patents
Aluminium die casting alloys Download PDFInfo
- Publication number
- EP2924137A1 EP2924137A1 EP14168188.2A EP14168188A EP2924137A1 EP 2924137 A1 EP2924137 A1 EP 2924137A1 EP 14168188 A EP14168188 A EP 14168188A EP 2924137 A1 EP2924137 A1 EP 2924137A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- weight
- alloy
- particles
- aluminum
- optionally
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Images
Classifications
-
- 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
-
- 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
Definitions
- the present invention relates to aluminum alloys that are dispersion-strengthened, age-hardenable, and can be processed by die-casting into shaped objects that have useful mechanical properties at temperatures up to at least 350°C.
- Automotive engines made with aluminum alloys have a high power-to-weight ratio, and therefore they have better fuel efficiency and less negative impact on the environment than cast iron engines.
- 'supercharged' engines are being designed to operate at even higher temperatures than regular engines. Accordingly, cylinder heads and engine blocks in 'supercharged' engines are subjected to thermal cycling over a wider temperature range, and the alloy used in their construction has to withstand the resulting severe thermo-mechanical loading over long periods of time.
- Conventional casting aluminum alloys are not capable of withstanding these temperatures because their precipitation hardening effects disappear at about 200°C.
- the alloys represented in WO 2011/124590 have better mechanical properties at elevated temperatures than traditional aluminum casting alloys.
- the volume fraction of the fine zirconium-vanadium tri-aluminide (Al 3 V 1-x Zr x ) particles in the prior art alloys do not exceed 1 % by volume; they have a limited strengthening effect.
- an option of the prior art invention calls for adding up to 5 % by weight manganese to the alloy.
- manganese, together with aluminum forms metastable manganese aluminide particles (Al 12 Mn) that further increase the strength of the alloy.
- these additional precipitate particles add strength to the alloy at room temperature, their strengthening effect disappears with increased service time at elevated temperatures.
- the present invention relates to a class of aluminum alloys that (i) are dispersion-strengthened, (ii) can be processed by die-casting to produce useful shaped objects, and (iii) can be age-hardened for improved room temperature mechanical properties that are retained at temperatures up to at least 350°C.
- Alloys of the present invention have the general chemical composition: aluminum-nickel-manganese-tungsten/molybdenum-zirconium-vanadium, and their chemical composition is optimized such that their liquidus temperature is less than 725°C. Such low liquidus temperature allows the alloys of the present invention to be processed into useful objects by traditional high-pressure die-casting.
- alloys of the present invention contain a eutectic structure that is stable at temperatures approaching 640°C, and it contains strengthening precipitate particles that are thermally stable at temperatures approaching 350°C.
- the microstructure of the aluminum alloys of the present invention contains nickel trialuminide and aluminum as its eutectic structure, together with other transition metal tri-aluminide particles, namely Al 3 V 1-x Zr x .
- transition metal trialuminide particles have the highly symmetric L1 2 crystal structure, which is analogous to the face centered cubic crystal structure of aluminum. It is this similarity in crystal structure between the aluminum matrix and these strengthening particles that allows for a coherent interface between the two phases; and by doing so, it maximizes the strengthening ability of the particles, impedes their coarsening, and enhances the thermal stability of the alloy.
- alloys of the present invention A feature of the alloys of the present invention that distinguishes them from the prior art aluminum alloys that contain nickel, vanadium, and zirconium together with manganese, but without tungsten is that in the alloys of the present invention, the Al 3 V 1-x Zr x particles are not the only thermally stable strengthening precipitates in the alloy. Alloys of the present invention rely on a relatively large amount of Al 12 Mn 1-x W x precipitate particles for added strength at elevated temperature. Alloys of the present invention also rely on carefully designed tungsten containing manganese-aluminide (Al 12 Mn 1-x W x ) precipitate particles for strength at elevated temperature.
- Al 12 Mn 1-x W x precipitate particles have the body centered cubic crystal structure, which is akin to the face centered cubic crystal structure of the ⁇ -aluminum matrix; and therefore they are semi-coherent with the ⁇ -aluminum matrix. Moreover, Al 12 Mn 1-x W x particles do not readily coarsen when exposed to elevated temperatures and therefore - as shown in figure 1 - unlike the aluminum alloys of the prior art, alloys of the present invention retain a significant fraction of their room temperature mechanical properties at elevated temperatures.
- alloys of the present invention contain tungsten and/ or molybdenum.
- the Al 3 V 1-x Zr x particles are not the only thermally stable strengthening precipitates. Because of their small quantity in the alloy ( ⁇ 1 % by volume), by themself the Al 3 V 1-x Zr x particles can contribute only limited high temperature strength. Alloys of the present invention rely on a relatively large amount of Al 12 Mn 1-x W x precipitate particles for added strength at elevated temperature.
- the precipitation sequence during thermal aging of binary Al-Mn alloys starts with formation of metastable Al 12 Mn particles. These particles are, to a large extent, responsible for the observed strength of thermally aged binary Al-Mn alloys. With extended time at an elevated temperature, these metastable Al 12 Mn particles coarsen and eventually they transform to the stable Al 6 Mn phase. The Al 6 Mn particles have the rhombohedral crystal structure, and therefore they have incoherent interfaces with the surrounding ⁇ -aluminum matrix. Transformation of the metastable, semi-coherent Al 12 Mn particles into stable, incoherent Al 6 Mn particles signals the loss of their strengthening effect.
- the present invention capitalizes on the fact that the lattice of the metastable Al 12 Mn phase is similar to that of the Al 12 W phase (both are body centered cubic), and also on the fact that the lattice parameter of the Al 12 Mn phase (0.754 nm) is close to that of the Al 12 W phase (0.758 nm). For these two reasons, during precipitation from the super saturated solid solution, tungsten can dissolve into the Al 12 Mn phase to form Al 12 Mn 1-x W x co-precipitates. Similar to the Al 12 Mn particles, the Al 12 Mn 1-x W x particles have body centered cubic lattice structure and semi-coherent interfaces with the ⁇ -aluminum matrix.
- thermodynamic calculations show that dissolution of tungsten into Al 12 Mn lowers the Gibbs free energy of the thus-formed Al 12 Mn 1-x W x particles relative to the Gibbs free energy of Al 12 Mn. This makes the Al 12 Mn 1-x W x particles more resistant to coarsening when exposed to elevated temperature, and therefore less prone to transforming into the incoherent Al 6 Mn phase, than the Al 12 Mn particles.
- an aluminum die-casting alloy comprising the following:
- the aluminum die-casting alloy comprises 4 to 6 % by weight nickel.
- the aluminum die-casting alloy further comprises 2 to 4% by weight manganese.
- the aluminum die-casting alloy comprises 0.2 to 0.8 % by weight tungsten.
- the aluminum die-casting alloy comprises 0.2 to 0.8 % by weight molybdenum.
- the aluminum die-casting alloy comprises 0.1 to 0.3 % by weight zirconium.
- the aluminum die-casting alloy comprises 0.3 to 0.4 % by weight vanadium.
- the aluminum die-casting alloy includes substantially uniformly dispersed particles of Al 3 V x Zr 1-x , where x is a fraction of unity that depends on the ratio of Zr : V in the alloy.
- the particles having an equivalent diameter of less than about 50 nm, preferably less than about 30 nm, more preferably less than about 10 nm, particularly less than about 5 nm.
- the aluminum die-casting alloy includes particles of Al 3 Ni having an equivalent diameter of less than about 500 nm, preferably less than about 300 nm, particularly less than about 100 nm.
- the aluminum die-casting alloy includes substantially uniformly dispersed particles of Al 12 Mn 1-x W x , where x is a fraction of unity that depends on the ratio of W : Mn in the alloy, the particles having an equivalent diameter of less than about 500 nm, preferably less than about 300 nm, particularly less than 100 nm.
- the Al 12 Mn 1-x W x particles have a body centered cubic crystal structure.
- the Al 12 Mn 1-x W x particles are semi-coherent with the ⁇ -aluminum matrix.
- the aluminum die-casting alloy includes substantially uniformly dispersed particles of Al 12 Mn 1-x Mo x , where x is a fraction of unity that depends on the ratio of Mo : Mn in the alloy, the particles having an equivalent diameter of less than about 500 nm, preferably less than about 300 nm, particularly less than 100 nm.
- the Al 12 Mn 1-x Mo x particles have a body centered cubic crystal structure.
- the Al 12 Mn 1-x Mo x particles are semi-coherent with the ⁇ -aluminum matrix.
- the die casting alloy includes substantially uniformly dispersed particles of Al 12 Mn 1-x-y W x Mo y , where x and y are fractions of unity that depend on the ratio of W : Mo : Mn in the alloy, the particles having an equivalent diameter of less than about 500 nm, preferably less than about 300 nm, particularly less than 100 nm.
- the Al 12 Mn 1-x-y W x Mo y particles have a body centered cubic crystal structure.
- the Al 12 Mn 1-x-y W x Mo y particles are semi-coherent with the ⁇ -aluminum matrix.
- a high pressure die-cast component is made is made of the alloy according to the invention.
- the aluminum die-casting alloy is solidified in a metal water-cooled mold.
- a cast component is made from an aluminum die-casting alloy according to the invention, wherein the alloy is age-hardened by holding the solidified cast component at a temperature of 350°C to 450°C for 2 to 12 hours.
- the aluminum alloy comprises 5.5 to 6.0 % by weight nickel, 1.75 to 2.0 % by weight manganese, 0.1 to 0.3 % by weight of zirconium, 0.3 to 0.4 % by weight of vanadium and 0.3 to 0.4 % by weight tungsten.
- the aluminum alloy comprises 5.75 to 6.00 % by weight nickel, 3.75 to 4.25 % by weight manganese, 0.3 to 0.4 % by weight of vanadium, 0.1 to 0.2 % by weight zirconium, 0.25 to 0.30 % by weight tungsten, 0.25 to 0.30 by weight molybdenum and Al as remainder.
- the melt was poured into a water-cooled copper mold to produce disk-shaped castings that were then machined into ASTM standard sub-size tensile test specimens.
- the tensile test specimens were aged in an electric box furnace at 450°C for 10 hours and then divided into four groups each group containing six identical specimens.
- the elevated temperature yield strength of each group of specimens was measured by means of an Instron Universal Testing machine. Prior to performing the measurements, the tensile specimens were soaked in an electric box furnace at the following test temperatures for 100 hours; and during the test, each tensile specimen was soaked in the furnace of the Instron Universal Testing machine at the test temperature for an additional 30 minutes in order to allow the specimen to equilibrate at the test temperature.
- Group No. Temperature (oC) 1 25 2 300 3 350 4 400
- Figure 3 shows the change in the measured yield strength of the Al-6Ni-4Mn-0.8W-0.4V-0.1 Zr alloy of the present invention compared to that of 380-F and 356-T6 commercial aluminum-silicon alloys.
- the alloy of the present invention outperforms both commercial alloys at all temperatures above 150°C.
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Crystallography & Structural Chemistry (AREA)
- Continuous Casting (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
Description
- The present invention relates to aluminum alloys that are dispersion-strengthened, age-hardenable, and can be processed by die-casting into shaped objects that have useful mechanical properties at temperatures up to at least 350°C.
- Automotive engines made with aluminum alloys have a high power-to-weight ratio, and therefore they have better fuel efficiency and less negative impact on the environment than cast iron engines. However, with the demand for yet higher fuel efficiencies, 'supercharged' engines are being designed to operate at even higher temperatures than regular engines. Accordingly, cylinder heads and engine blocks in 'supercharged' engines are subjected to thermal cycling over a wider temperature range, and the alloy used in their construction has to withstand the resulting severe thermo-mechanical loading over long periods of time. Conventional casting aluminum alloys are not capable of withstanding these temperatures because their precipitation hardening effects disappear at about 200°C. Consequently, the dimensional stability, strength, and durability of cylinder heads and engine blocks made with these alloys become compromised at the elevated temperatures that are encountered during the operation of 'supercharged' engines. Supercharged engines and cylinder heads are not the only automotive components that could benefit from an aluminum alloy that is specifically designed for service at elevated temperatures. Connecting rods, impellers, brake calipers, and brake rotors could also benefit from such an alloy. Therefore, there is a need for a light, thermally stable alloy that is designed specifically for such applications.
- Several attempts have been made in the past to provide aluminum casting alloys with enhanced thermal stability. Most notable among these attempts are alloys described in
WO 2011/124590 , which is therewith incorporated by reference. - When properly processed, the alloys represented in
WO 2011/124590 have better mechanical properties at elevated temperatures than traditional aluminum casting alloys. However, and because the volume fraction of the fine zirconium-vanadium tri-aluminide (Al3V1-xZrx) particles in the prior art alloys do not exceed 1 % by volume; they have a limited strengthening effect. For this reason, an option of the prior art invention calls for adding up to 5 % by weight manganese to the alloy. Upon aging at a temperature between 350°C and 450°C, manganese, together with aluminum, forms metastable manganese aluminide particles (Al12Mn) that further increase the strength of the alloy. However, although these additional precipitate particles add strength to the alloy at room temperature, their strengthening effect disappears with increased service time at elevated temperatures. - The present invention relates to a class of aluminum alloys that (i) are dispersion-strengthened, (ii) can be processed by die-casting to produce useful shaped objects, and (iii) can be age-hardened for improved room temperature mechanical properties that are retained at temperatures up to at least 350°C.
- It is an objective of the present invention to provide lightweight, wear-resistant, and corrosion-resistant materials that can be cast into useful objects by the conventional die-casting process and that are thermally stable up to at least 350°C.
- Alloys of the present invention have the general chemical composition: aluminum-nickel-manganese-tungsten/molybdenum-zirconium-vanadium, and their chemical composition is optimized such that their liquidus temperature is less than 725°C. Such low liquidus temperature allows the alloys of the present invention to be processed into useful objects by traditional high-pressure die-casting.
- Unlike traditional aluminum-silicon alloys, and similar to alloys of the prior art article, alloys of the present invention contain a eutectic structure that is stable at temperatures approaching 640°C, and it contains strengthening precipitate particles that are thermally stable at temperatures approaching 350°C. Also similar to alloys of the prior art article, the microstructure of the aluminum alloys of the present invention contains nickel trialuminide and aluminum as its eutectic structure, together with other transition metal tri-aluminide particles, namely Al3V1-xZrx. These transition metal trialuminide particles have the highly symmetric L12 crystal structure, which is analogous to the face centered cubic crystal structure of aluminum. It is this similarity in crystal structure between the aluminum matrix and these strengthening particles that allows for a coherent interface between the two phases; and by doing so, it maximizes the strengthening ability of the particles, impedes their coarsening, and enhances the thermal stability of the alloy.
- A feature of the alloys of the present invention that distinguishes them from the prior art aluminum alloys that contain nickel, vanadium, and zirconium together with manganese, but without tungsten is that in the alloys of the present invention, the Al3V1-xZrx particles are not the only thermally stable strengthening precipitates in the alloy. Alloys of the present invention rely on a relatively large amount of Al12Mn1-xWx precipitate particles for added strength at elevated temperature. Alloys of the present invention also rely on carefully designed tungsten containing manganese-aluminide (Al12Mn1-xWx) precipitate particles for strength at elevated temperature. Al12Mn1-xWx precipitate particles have the body centered cubic crystal structure, which is akin to the face centered cubic crystal structure of the α-aluminum matrix; and therefore they are semi-coherent with the α-aluminum matrix. Moreover, Al12Mn1-xWx particles do not readily coarsen when exposed to elevated temperatures and therefore - as shown in
figure 1 - unlike the aluminum alloys of the prior art, alloys of the present invention retain a significant fraction of their room temperature mechanical properties at elevated temperatures. - The main feature of the alloys of the present invention that distinguishes them from those of the prior art is that alloys of the present invention contain tungsten and/ or molybdenum. For this reason, in alloys of the present invention, the Al3V1-xZrx particles are not the only thermally stable strengthening precipitates. Because of their small quantity in the alloy (≤ 1 % by volume), by themself the Al3V1-xZrx particles can contribute only limited high temperature strength. Alloys of the present invention rely on a relatively large amount of Al12Mn1-xWx precipitate particles for added strength at elevated temperature.
- In general, when precipitation-strengthened aluminum alloys are subjected to high temperature during service, the metastable precipitates that were formed by thermal aging coarsen and begin to transform into the stable phase. When this happens, the alloy begins to lose its strength. Therefore, precipitates that have a low coarsening rate have enhanced thermal stability, and alloys that employ such precipitates for strengthening have good tensile properties at high temperature.
Figure 1 shows that the measured yield strength at elevated temperatures of the Al-6Ni-4Mn-0.7W-0.4V-0.1Zr alloy of the present invention is 90 MPa at 300°C, which is significantly higher than that of the Al-6Ni-0.4V-0.1 Zr alloy of the prior art, which is only 60 MPa at 300°C. The reason for this distinguishing feature of the present invention alloy is described in detail in the following paragraphs. - The precipitation sequence during thermal aging of binary Al-Mn alloys starts with formation of metastable Al12Mn particles. These particles are, to a large extent, responsible for the observed strength of thermally aged binary Al-Mn alloys. With extended time at an elevated temperature, these metastable Al12Mn particles coarsen and eventually they transform to the stable Al6Mn phase. The Al6Mn particles have the rhombohedral crystal structure, and therefore they have incoherent interfaces with the surrounding α-aluminum matrix. Transformation of the metastable, semi-coherent Al12Mn particles into stable, incoherent Al6Mn particles signals the loss of their strengthening effect.
- The present invention capitalizes on the fact that the lattice of the metastable Al12Mn phase is similar to that of the Al12W phase (both are body centered cubic), and also on the fact that the lattice parameter of the Al12Mn phase (0.754 nm) is close to that of the Al12W phase (0.758 nm). For these two reasons, during precipitation from the super saturated solid solution, tungsten can dissolve into the Al12Mn phase to form Al12Mn1-xWx co-precipitates. Similar to the Al12Mn particles, the Al12Mn1-xWx particles have body centered cubic lattice structure and semi-coherent interfaces with the α-aluminum matrix. However, thermodynamic calculations show that dissolution of tungsten into Al12Mn lowers the Gibbs free energy of the thus-formed Al12Mn1-xWx particles relative to the Gibbs free energy of Al12Mn. This makes the Al12Mn1-xWx particles more resistant to coarsening when exposed to elevated temperature, and therefore less prone to transforming into the incoherent Al6Mn phase, than the Al12Mn particles.
- A comparable effect on the strength at elevated temperatures can be observed with an addition of molybdenum or a combined addition of tungsten and molybdenum.
- The foregoing objective is achieved according to the present invention by an aluminum die-casting alloy comprising the following:
- 1 to 6 % by weight nickel,
- 1 to 5 % by weight manganese,
- 0.1 to 0.4 % by weight zirconium,
- 0.1 to 0.4 % by weight vanadium,
- 0.1 to 1 % by weight tungsten and/or 0.1 to 1 % by weight molybdenum,
- optionally up to 2 % by weight iron,
- optionally up to 1 % by weight titanium,
- optionally up to 2 % by weight magnesium,
- optionally up to 0.5 % by weight silicon,
- optionally up to 0.5 % by weight copper,
- optionally up to 0,5 % by weight zinc,
- optionally total maximum 5 % by weight transition elements including strontium, scandium, lanthanum, yttrium, hafnium, niobium, tantalum, and/or chromium, and aluminum as the remainder with further elements present as impurities due to production such that the total maximum of impurity elements is 1 % by weight.
- In a preferred embodiment the aluminum die-casting alloy comprises 4 to 6 % by weight nickel.
- In a preferred embodiment the aluminum die-casting alloy further comprises 2 to 4% by weight manganese.
- In a further preferred embodiment the aluminum die-casting alloy comprises 0.2 to 0.8 % by weight tungsten.
- In a further preferred embodiment the aluminum die-casting alloy comprises 0.2 to 0.8 % by weight molybdenum.
- In a further preferred embodiment the aluminum die-casting alloy comprises 0.1 to 0.3 % by weight zirconium.
- In a further preferred embodiment the aluminum die-casting alloy comprises 0.3 to 0.4 % by weight vanadium.
- According to one embodiment the aluminum die-casting alloy includes substantially uniformly dispersed particles of Al3VxZr1-x, where x is a fraction of unity that depends on the ratio of Zr : V in the alloy. The particles having an equivalent diameter of less than about 50 nm, preferably less than about 30 nm, more preferably less than about 10 nm, particularly less than about 5 nm.
- In a further embodiment the aluminum die-casting alloy includes particles of Al3Ni having an equivalent diameter of less than about 500 nm, preferably less than about 300 nm, particularly less than about 100 nm.
- In a further embodiment the aluminum die-casting alloy includes substantially uniformly dispersed particles of Al12Mn1-xWx, where x is a fraction of unity that depends on the ratio of W : Mn in the alloy, the particles having an equivalent diameter of less than about 500 nm, preferably less than about 300 nm, particularly less than 100 nm. The Al12Mn1-xWx particles have a body centered cubic crystal structure. The Al12Mn1-xWx particles are semi-coherent with the α-aluminum matrix.
- In a further embodiment the aluminum die-casting alloy includes substantially uniformly dispersed particles of Al12Mn1-xMox, where x is a fraction of unity that depends on the ratio of Mo : Mn in the alloy, the particles having an equivalent diameter of less than about 500 nm, preferably less than about 300 nm, particularly less than 100 nm. The Al12Mn1-xMox particles have a body centered cubic crystal structure. The Al12Mn1-xMox particles are semi-coherent with the α-aluminum matrix.
- In a further embodiment the die casting alloy includes substantially uniformly dispersed particles of Al12Mn1-x-yWxMoy, where x and y are fractions of unity that depend on the ratio of W : Mo : Mn in the alloy, the particles having an equivalent diameter of less than about 500 nm, preferably less than about 300 nm, particularly less than 100 nm. The Al12Mn1-x-yWxMoy particles have a body centered cubic crystal structure. The Al12Mn1-x-yWxMoy particles are semi-coherent with the α-aluminum matrix.
- In a further embodiment of the invention a high pressure die-cast component is made is made of the alloy according to the invention.
- In a further embodiment of the invention the aluminum die-casting alloy is solidified in a metal water-cooled mold.
- In a method according to the invention a cast component is made from an aluminum die-casting alloy according to the invention, wherein the alloy is age-hardened by holding the solidified cast component at a temperature of 350°C to 450°C for 2 to 12 hours.
- According to one embodiment the aluminum alloy comprises 5.5 to 6.0 % by weight nickel, 1.75 to 2.0 % by weight manganese, 0.1 to 0.3 % by weight of zirconium, 0.3 to 0.4 % by weight of vanadium and 0.3 to 0.4 % by weight tungsten.
- According to a further embodiment the aluminum alloy comprises 5.75 to 6.00 % by weight nickel, 3.75 to 4.25 % by weight manganese, 0.3 to 0.4 % by weight of vanadium, 0.1 to 0.2 % by weight zirconium, 0.25 to 0.30 % by weight tungsten, 0.25 to 0.30 by weight molybdenum and Al as remainder.
- The following example is intended to illustrate the present invention and it is by no means restrictive thereof.
- Measured amounts of aluminum-nickel, aluminum-manganese, aluminum-zirconium, and aluminum-vanadium master alloys, together with pure tungsten powder were added to commercially pure aluminum in order to constitute an alloy of the present invention with the nominal chemical composition: Al-6Ni-4Mn-0.8W-0.4V-0.1Zr. This alloy was melted in an induction furnace at 850ºC for sufficient time to allow dissolution of the master alloys and tungsten powder into the commercially pure aluminum, and homogenization of the resulting melt. The melt temperature was then lowered to 750ºC, and the melt was degassed for 30 minutes with argon utilizing a rotating impeller degasser. After degassing, the melt was poured into a water-cooled copper mold to produce disk-shaped castings that were then machined into ASTM standard sub-size tensile test specimens. The tensile test specimens were aged in an electric box furnace at 450°C for 10 hours and then divided into four groups each group containing six identical specimens. The elevated temperature yield strength of each group of specimens was measured by means of an Instron Universal Testing machine. Prior to performing the measurements, the tensile specimens were soaked in an electric box furnace at the following test temperatures for 100 hours; and during the test, each tensile specimen was soaked in the furnace of the Instron Universal Testing machine at the test temperature for an additional 30 minutes in order to allow the specimen to equilibrate at the test temperature.
Group No. Temperature (ºC) 1 25 2 300 3 350 4 400 -
Figure 3 shows the change in the measured yield strength of the Al-6Ni-4Mn-0.8W-0.4V-0.1 Zr alloy of the present invention compared to that of 380-F and 356-T6 commercial aluminum-silicon alloys. Clearly, the alloy of the present invention outperforms both commercial alloys at all temperatures above 150°C. -
- Figure 1
- is a chart that shows the change in measured yield strength with temperature for the Al-6Ni-0.7W-0.4V-0.1Zr alloy of the present invention and the Al-6Ni-0.4V-0.1Zr alloy of the prior art: At all temperatures, the measured yield strength of the alloy of the present invention is higher than that of the alloy of the prior art.
- Figure 2
- is a chart that shows the change with soak time in measured yield strength for the binary Al-2Mn and ternary Al-2Mn-0.75W alloys. The samples were soaked at 450°C for the various times and their yield strength was measured at room temperature: While the measured yield strength of the binary Al-2Mn alloy decreases rapidly when the alloy is held at 450°C, the measured yield strength of the ternary Al-2Mn-0.75W alloy does not degrade with time up to 250 hours, beyond which time the experiment was terminated.
- Figure 3
- is a chart that shows the change with temperature in measured yield strength of some commercial alloys compared to that of the alloy of the present invention. The tensile test specimens were soaked at the test temperature for 100 hours and tested at the soak temperature. Chart legend: 380-F ≡ standard aluminum-silicon alloy with nominal chemical composition Al-8.5Si-3.5Cu in the as-cast condition, 356-T6 ≡ standard aluminum-silicon-magnesium alloy with nominal chemical composition Al-7Si-0.35Mg-0.2Cu heat-treated according to the T6 schedule, HPDC ≡ high-pressure die-casting, and PM ≡ permanent mold casting. The data source for the 380-F and 356-T alloys is Kaufman, J.G. and Rooy, E.L., Aluminum Alloy Castings: Properties, Processes, and Applications, AFS, Schaumberg, IL(2004).
Claims (21)
- An aluminum die-casting alloy comprising:1 to 6 % by weight nickel,1 to 5 % by weight manganese,0.1 to 0.4 % by weight zirconium,0.1 to 0.4 % by weight vanadium,0.1 to 1 % by weight tungsten and/ or 0.1 to 1 % molybdenum,optionally up to 2 % by weight iron,optionally up to 1 % by weight titanium,optionally up to 2 % by weight magnesium,optionally up to 0.5 % by weight silicon,optionally up to 0.5 % by weight copper,optionally up to 0,5 % by weight zinc,optionally total maximum 5 % by weight transition elements including strontium, scandium, lanthanum, yttrium, hafnium, niobium, tantalum, and/or chromium, and aluminum as the remainder with further elements present as impurities due to production such that the total maximum of impurity elements is 1 % by weight.
- An aluminum die-casting alloy according to claim 1, comprising 4 to 6 % by weight nickel.
- An aluminum die-casting alloy according to any one of the claims 1 to 2, comprising 2 to 4 % by weight manganese.
- An aluminum die-casting alloy according to any one of the claims 1 to 3, comprising 0.2 to 0.8 % by weight tungsten.
- An aluminum die-casting alloy to any one of the claims 1 to 4, comprising 0.2 to 0.8 % by weight molybdenum.
- An aluminum die-casting alloy according to any one of the claims 1 to 5, comprising 0.1 to 0.3 % by weight zirconium.
- An aluminum die-casting alloy according to any one of the claims 1 to 6, comprising 0.3 to 0.4 % by weight vanadium.
- An aluminum die-casting alloy according to any one of claims 1 to 7, including substantially uniformly dispersed particles of Al3VxZr1-x, where x is a fraction of unity that depends on the ratio of Zr : V in the alloy, the particles having an equivalent diameter of less than about 50 nm, preferably less than about 30 nm, more preferably less than about 10 nm, particularly less than about 5 nm.
- An aluminum die-casting alloy according to any one of claims 1 to 7, including particles of Al3Ni having an equivalent diameter of less than about 500 nm, preferably less than about 300 nm, particularly less than about 100 nm.
- An aluminum die casting alloy according to any one of claims 1 to 7, including sub-stantially uniformly dispersed particles of Al12Mn1-xWx, where x is a fraction of unity that depends on the ratio of W : Mn in the alloy, the particles having an equivalent diameter of less than about 500 nm, preferably less than about 300 nm, particularly less than 100 nm.
- The alloy of claim 10 wherein the Al12Mn1-xWx particles have a body centered cubic crystal structure.
- The alloy of claim 10 wherein the Al12Mn1-xWx particles are semi-coherent with the aluminum matrix.
- An aluminum die casting alloy according to any one of claims 1 to 7, including substantially uniformly dispersed particles of Al12Mn1-xMox, where x is a fraction of unity that depends on the ratio of Mo : Mn in the alloy, the particles having an equivalent diameter of less than about 500 nm, preferably less than about 300 nm, particularly less than 100 nm.
- The alloy of claim 13 wherein the Al12Mn1-xMox particles have a body centered cubic crystal structure.
- The alloy of claim 13 wherein the Al12Mn1-xMox particles are semi-coherent with the aluminum matrix.
- An aluminum die casting alloy according to any one of claims 1 to 7, including substantially uniformly dispersed particles of Al12Mn1-x-yWxMoy, where x and y are fractions of unity that depend on the ratio of W : Mo : Mn in the alloy, the particles having an equivalent diameter of less than about 500 nm, preferably less than about 300 nm, particularly less than 100 nm.
- The alloy of claim 16 wherein the Al12Mn1-x-yWxMoy particles have a body centered cubic crystal structure.
- The alloy of claim 16 wherein the Al12Mn1-x-yWxMoy particles are semi-coherent with the -aluminum matrix.
- A high pressure die-cast component made from an aluminum alloy according to any one of claims 1 to 18.
- A cast component made from an aluminum alloy according to any one of claims 1 to 18 where in the alloy is solidified in a metal water-cooled mold.
- A method of producing a cast component made from an aluminum alloy according to any one of claims 1 to 18, wherein the alloy is age-hardened by holding the solidified cast component at a temperature of 350°C to 450°C for 2 to 12 hours.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/EP2015/054180 WO2015144387A1 (en) | 2014-03-26 | 2015-02-27 | Aluminum die-casting alloys |
US15/127,120 US20170101703A1 (en) | 2014-03-26 | 2015-02-27 | Aluminum Die-Casting Alloys |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201461970586P | 2014-03-26 | 2014-03-26 |
Publications (1)
Publication Number | Publication Date |
---|---|
EP2924137A1 true EP2924137A1 (en) | 2015-09-30 |
Family
ID=50693529
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP14168188.2A Withdrawn EP2924137A1 (en) | 2014-03-26 | 2014-05-13 | Aluminium die casting alloys |
Country Status (3)
Country | Link |
---|---|
US (1) | US20170101703A1 (en) |
EP (1) | EP2924137A1 (en) |
WO (1) | WO2015144387A1 (en) |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN105950922A (en) * | 2016-06-07 | 2016-09-21 | 太仓市纯杰金属制品有限公司 | Antioxidant nickel aluminum alloy |
CN105970037A (en) * | 2016-07-15 | 2016-09-28 | 南南铝业股份有限公司 | Aluminum alloy for pedestrian bridges and preparation method thereof |
CN106119637A (en) * | 2016-08-04 | 2016-11-16 | 苏州优浦精密铸造有限公司 | A kind of automobile high-strength aluminum alloy materials |
CN107739857A (en) * | 2017-10-04 | 2018-02-27 | 长沙仲善新能源科技有限公司 | The preparation technology and anticorrosion aluminium material of anticorrosion aluminium material |
CN109778028A (en) * | 2019-01-21 | 2019-05-21 | 宁波市鄞州迪信机械制造有限公司 | A kind of sewing machine aluminium alloy cover board |
WO2020028730A1 (en) * | 2018-08-02 | 2020-02-06 | Tesla, Inc. | Aluminum alloys for die casting |
WO2020165542A1 (en) | 2019-02-15 | 2020-08-20 | C-Tec Constellium Technology Center | Method for manufacturing an aluminum alloy part |
US11421304B2 (en) | 2017-10-26 | 2022-08-23 | Tesla, Inc. | Casting aluminum alloys for high-performance applications |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP7112275B2 (en) * | 2018-07-26 | 2022-08-03 | 三菱重工業株式会社 | Aluminum alloy material, method for producing aluminum alloy material, basket for cask and cask |
US11408061B2 (en) * | 2019-10-01 | 2022-08-09 | Ford Global Technologies, Llc | High temperature, creep-resistant aluminum alloy microalloyed with manganese, molybdenum and tungsten |
CN116240432B (en) * | 2023-02-08 | 2024-05-28 | 上海交通大学 | Die-casting aluminum alloy free of heat treatment, preparation method and application |
CN116287890B (en) * | 2023-03-29 | 2024-01-16 | 深圳市鑫申新材料科技有限公司 | High-strength high-toughness high-welding performance heat-treatment-free high-pressure casting aluminum alloy and performance and preparation method thereof |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS63219543A (en) * | 1987-03-10 | 1988-09-13 | Showa Alum Corp | Aluminum alloy for self-color anodizing |
JPH01132733A (en) * | 1987-11-17 | 1989-05-25 | Kasei Naoetsu:Kk | High damping aluminum alloy |
US20040261916A1 (en) * | 2001-12-21 | 2004-12-30 | Lin Jen C. | Dispersion hardenable Al-Ni-Mn casting alloys for automotive and aerospace structural components |
WO2011124590A1 (en) | 2010-04-07 | 2011-10-13 | Rheinfelden Alloys Gmbh & Co. Kg | Aluminium die casting alloy |
-
2014
- 2014-05-13 EP EP14168188.2A patent/EP2924137A1/en not_active Withdrawn
-
2015
- 2015-02-27 WO PCT/EP2015/054180 patent/WO2015144387A1/en active Application Filing
- 2015-02-27 US US15/127,120 patent/US20170101703A1/en not_active Abandoned
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS63219543A (en) * | 1987-03-10 | 1988-09-13 | Showa Alum Corp | Aluminum alloy for self-color anodizing |
JPH01132733A (en) * | 1987-11-17 | 1989-05-25 | Kasei Naoetsu:Kk | High damping aluminum alloy |
US20040261916A1 (en) * | 2001-12-21 | 2004-12-30 | Lin Jen C. | Dispersion hardenable Al-Ni-Mn casting alloys for automotive and aerospace structural components |
WO2011124590A1 (en) | 2010-04-07 | 2011-10-13 | Rheinfelden Alloys Gmbh & Co. Kg | Aluminium die casting alloy |
EP2653578A1 (en) * | 2010-04-07 | 2013-10-23 | Rheinfelden Alloys GmbH & Co. KG | Aluminum die casting alloy |
Non-Patent Citations (1)
Title |
---|
KAUFMAN, J.G.; ROOY, E.L.: "Aluminum Alloy Castings: Properties, Processes, and Applications", AFS, 2004 |
Cited By (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN105950922A (en) * | 2016-06-07 | 2016-09-21 | 太仓市纯杰金属制品有限公司 | Antioxidant nickel aluminum alloy |
CN105970037A (en) * | 2016-07-15 | 2016-09-28 | 南南铝业股份有限公司 | Aluminum alloy for pedestrian bridges and preparation method thereof |
CN106119637A (en) * | 2016-08-04 | 2016-11-16 | 苏州优浦精密铸造有限公司 | A kind of automobile high-strength aluminum alloy materials |
CN107739857A (en) * | 2017-10-04 | 2018-02-27 | 长沙仲善新能源科技有限公司 | The preparation technology and anticorrosion aluminium material of anticorrosion aluminium material |
US11421304B2 (en) | 2017-10-26 | 2022-08-23 | Tesla, Inc. | Casting aluminum alloys for high-performance applications |
WO2020028730A1 (en) * | 2018-08-02 | 2020-02-06 | Tesla, Inc. | Aluminum alloys for die casting |
CN112567059A (en) * | 2018-08-02 | 2021-03-26 | 特斯拉公司 | Aluminum alloy for die casting |
CN109778028A (en) * | 2019-01-21 | 2019-05-21 | 宁波市鄞州迪信机械制造有限公司 | A kind of sewing machine aluminium alloy cover board |
WO2020165542A1 (en) | 2019-02-15 | 2020-08-20 | C-Tec Constellium Technology Center | Method for manufacturing an aluminum alloy part |
FR3092777A1 (en) | 2019-02-15 | 2020-08-21 | C-Tec Constellium Technology Center | Manufacturing process of an aluminum alloy part |
EP3924124B1 (en) * | 2019-02-15 | 2023-11-15 | C-Tec Constellium Technology Center | Method for manufacturing an aluminum alloy part |
Also Published As
Publication number | Publication date |
---|---|
WO2015144387A1 (en) | 2015-10-01 |
US20170101703A1 (en) | 2017-04-13 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
EP2924137A1 (en) | Aluminium die casting alloys | |
RU2466201C2 (en) | Titanium aluminide alloys | |
EP1897962B1 (en) | Creep resistant magnesium alloy with improved ductility and fracture toughness for gravity casting applications | |
JP5582532B2 (en) | Co-based alloy | |
US20080193322A1 (en) | Hpdc Magnesium Alloy | |
CN109868393B (en) | High temperature cast aluminum alloy for cylinder heads | |
WO2016015488A1 (en) | Aluminum alloy and preparation method therefor and application thereof | |
JP5703881B2 (en) | High strength magnesium alloy and method for producing the same | |
WO2011124590A1 (en) | Aluminium die casting alloy | |
KR20060110292A (en) | Castable magnesium alloys | |
JP6139641B2 (en) | Castable heat resistant aluminum alloy | |
EP1866452A1 (en) | Magnesium alloy | |
WO2014203714A1 (en) | Hot-forged ti-al-based alloy and method for producing same | |
US8858874B2 (en) | Ternary nickel eutectic alloy | |
Panušková et al. | Relation between mechanical properties and microstructure of cast aluminum alloy AlSi9Cu3 | |
US11713500B2 (en) | Advanced cast aluminum alloys for automotive engine application with superior high-temperature properties | |
JP2017503086A (en) | Aluminum casting alloy with improved high temperature performance | |
CN110592445A (en) | 720-doped 740MPa cold extrusion Al-Zn-Mg-Cu-Ti aluminum alloy and preparation method thereof | |
JP4905680B2 (en) | Magnesium casting alloy and compressor impeller using the same | |
EP3505648A1 (en) | High-strength aluminum alloy, internal combustion engine piston comprising said alloy, and method for producing internal combustion engine piston | |
Naumova et al. | Investigation of the structure and properties of eutectic alloys of the Al–Ca–Ni system containing REM | |
WO2017123186A1 (en) | Tial-based alloys having improved creep strength by strengthening of gamma phase | |
JP2020152965A (en) | Aluminum alloy material, method for producing the same, and impeller | |
JP2006161103A (en) | Aluminum alloy member and manufacturing method therefor | |
JP5083965B2 (en) | Casting compressor impeller |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
PUAI | Public reference made under article 153(3) epc to a published international application that has entered the european phase |
Free format text: ORIGINAL CODE: 0009012 |
|
AK | Designated contracting states |
Kind code of ref document: A1 Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR |
|
AX | Request for extension of the european patent |
Extension state: BA ME |
|
17P | Request for examination filed |
Effective date: 20160316 |
|
RBV | Designated contracting states (corrected) |
Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR |
|
GRAP | Despatch of communication of intention to grant a patent |
Free format text: ORIGINAL CODE: EPIDOSNIGR1 |
|
STAA | Information on the status of an ep patent application or granted ep patent |
Free format text: STATUS: GRANT OF PATENT IS INTENDED |
|
INTG | Intention to grant announced |
Effective date: 20180105 |
|
STAA | Information on the status of an ep patent application or granted ep patent |
Free format text: STATUS: THE APPLICATION IS DEEMED TO BE WITHDRAWN |
|
18D | Application deemed to be withdrawn |
Effective date: 20180516 |