EP3143173B1 - Method for producing an engine component, engine component, and use of an aluminum alloy - Google Patents
Method for producing an engine component, engine component, and use of an aluminum alloy Download PDFInfo
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- EP3143173B1 EP3143173B1 EP15720740.8A EP15720740A EP3143173B1 EP 3143173 B1 EP3143173 B1 EP 3143173B1 EP 15720740 A EP15720740 A EP 15720740A EP 3143173 B1 EP3143173 B1 EP 3143173B1
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
- F02F3/00—Pistons
- F02F3/0084—Pistons the pistons being constructed from specific materials
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- 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
- B22D21/002—Castings of light metals
- B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D25/00—Special casting characterised by the nature of the product
- B22D25/02—Special casting characterised by the nature of the product by its peculiarity of shape; of works of art
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/02—Alloys based on aluminium with silicon as the next major constituent
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/02—Alloys based on aluminium with silicon as the next major constituent
- C22C21/04—Modified aluminium-silicon alloys
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/12—Alloys based on aluminium with copper as the next major constituent
- C22C21/14—Alloys based on aluminium with copper as the next major constituent with silicon
-
- 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
- C22C21/12—Alloys based on aluminium with copper as the next major constituent
- C22C21/16—Alloys based on aluminium with copper as the next major constituent with magnesium
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
- F02F2200/00—Manufacturing
- F02F2200/06—Casting
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Combustion & Propulsion (AREA)
- General Engineering & Computer Science (AREA)
- Pistons, Piston Rings, And Cylinders (AREA)
Description
Die vorliegende Erfindung betrifft ein Verfahren zur Herstellung und Verwendung eines Motorbauteils, insbesondere eines Kolbens für einen Verbrennungsmotor, bei dem eine Aluminiumlegierung im Schwerkraftkokillengussverfahren abgegossen wird, ein Motorbauteil, das zumindest teilweise aus einer Aluminiumlegierung besteht, und die Verwendung einer Aluminiumlegierung zur Herstellung eines solchen Motorbauteils.The present invention relates to a method for producing and using an engine component, in particular a piston for an internal combustion engine, in which an aluminum alloy is gravity-cast, an engine component at least partially made of an aluminum alloy, and the use of an aluminum alloy for producing such an engine component ,
In den letzten Jahren wurden zunehmend Forderungen nach besonders ökonomischen und damit ökologischen Transportmitteln laut, die hohen Verbrauchs- und Emissionsanforderungen gerecht werden müssen. Zudem besteht jeher das Bedürfnis, Motoren möglichst leistungsfähig und verbrauchsarm zu gestalten. Ein entscheidender Faktor bei der Entwicklung von leistungsfähigen und emissionsarmen Verbrennungsmotoren sind Kolben, die bei immer höheren Verbrennungstemperaturen und Verbrennungsdrücken eingesetzt werden können, was im Wesentlichen durch immer leistungsfähigere Kolbenwerkstoffe ermöglicht wird.In recent years there has been an increasing demand for particularly economical and thus ecological means of transport, which have to meet high consumption and emission requirements. In addition, there is always the need to make engines as powerful and low-consumption. A key factor in the development of high-performance and low-emission internal combustion engines are pistons, which can be used at ever higher combustion temperatures and combustion pressures, which is essentially made possible by more efficient piston materials.
Grundsätzlich muss ein Kolben für einen Verbrennungsmotor eine hohe Warmfestigkeit aufweisen und dabei gleichzeitig möglichst leicht und fest sein. Dabei ist es von besonderer Bedeutung, wie die mikrostrukturelle Verteilung, Morphologie, Zusammensetzung und thermische Stabilität höchstwarmfester Phasen ausgebildet sind. Eine diesbezügliche Optimierung berücksichtigt üblicherweise einen minimalen Gehalt an Poren und oxidischen Einschlüssen.Basically, a piston for a combustion engine must have a high heat resistance and at the same time be as light and strong as possible. It is of particular importance how the microstructural distribution, morphology, composition and thermal stability of highly heat-resistant phases are formed. An optimization in this regard usually takes into account a minimum content of pores and oxide inclusions.
Der gesuchte Werkstoff muss sowohl hinsichtlich isothermer Schwingfestigkeit (HCF) als auch hinsichtlich thermomechanischer Ermüdungsfestigkeit (TMF) optimiert werden. Um die TMF optimal auszugestalten ist stets eine möglichst feine Mikrostruktur des Werkstoffs anzustreben. Eine feine Mikrostruktur reduziert die Gefahr des Entstehens von Mikroplastizität bzw. von Mikrorissen an relativ großen primären Phasen (insbesondere an primären Siliziumausscheidungen) und damit auch die Gefahr von Rissinitiierung und - ausbreitung.The material sought must be optimized for both isothermal fatigue strength (HCF) and thermo-mechanical fatigue strength (TMF). In order to optimally design the TMF, it is always desirable to have the finest possible microstructure of the material. A fine microstructure reduces the risk of microplasticity or microcracks on relatively large primary phases (in particular of primary silicon precipitates) and thus also the risk of crack initiation and propagation.
Unter TMF-Beanspruchung treten an relativ großen primären Phasen, insbesondere an primären Siliziumausscheidungen, aufgrund unterschiedlicher Ausdehnungskoeffizienten der einzelnen Bestandteile der Legierung, nämlich der Matrix und der primären Phasen, Mikroplastizitäten bzw. Mikrorisse auf, welche die Lebensdauer des Kolbenwerkstoffs erheblich senken können. Zur Erhöhung der Lebensdauer ist bekannt, die primären Phasen möglichst klein zu halten.Under TMF stress occur on relatively large primary phases, in particular on primary silicon precipitates, due to different expansion coefficients of the individual components the alloy, namely the matrix and the primary phases, microplasticities or microcracks, which can significantly reduce the life of the piston material. To increase the life is known to keep the primary phases as small as possible.
Beim verwendeten Schwerkraftkokillenguss gibt es eine Konzentrationsobergrenze, bis zu der Legierungselemente eingebracht werden sollten und bei deren Überschreiten die Gießbarkeit der Legierung verringert oder Gießen unmöglich wird. Darüber hinaus kommt es bei zu hohen Konzentrationen von festigkeitssteigernden Elementen zur Bildung großer plattenförmiger intermetallischer Phasen, welche die Ermüdungsfestigkeit drastisch absenken.In the gravity die casting used, there is an upper limit of the concentration up to which alloying elements should be introduced and, if exceeded, the castability of the alloy is reduced or casting becomes impossible. In addition, too high concentrations of strength-enhancing elements lead to the formation of large plate-shaped intermetallic phases, which drastically reduce the fatigue strength.
Die
Die
Die
Die
Die
Weiter wird beschrieben, dass die Größe von einem nicht-metallischen Einschluss, der innerhalb des Kolbens vorhanden ist, geringer als 100 µm ist.It is further described that the size of a non-metallic inclusion present within the bulb is less than 100 μm.
Die
Die
Die Anmeldung
Abschließend soll die
Eine Aufgabe der vorliegenden Erfindung liegt darin, ein Verfahren zur Herstellung eines Motorbauteils, insbesondere eines Kolbens für einen Verbrennungsmotor bereitzustellen, bei dem eine Aluminiumlegierung im Schwerkraftkokillengussverfahren abgegossen wird, so dass ein höchstwarmfestes Motorbauteil im Schwerkraftkokillengussverfahren hergestellt werden kann.An object of the present invention is to provide a method for producing an engine component, in particular a piston for an internal combustion engine, wherein an aluminum alloy is poured by gravity die casting, so that a highly heat resistant engine component can be produced by gravity die casting.
Die Lösung dieser Aufgabe wird durch das Verfahren nach Anspruch 1 gegeben. Weitere bevorzugte Ausführungsformen der Erfindung ergeben sich aus den diesbezüglichen Unteransprüchen.The solution to this problem is given by the method according to claim 1. Further preferred embodiments of the invention will become apparent from the relevant subclaims.
Eine weitere Aufgabe der Erfindung liegt darin, ein Motorbauteil, insbesondere einen Kolben für einen Verbrennungsmotor, bereitzustellen, das/der höchstwarmfest ist und dabei zumindest teilweise aus einer Aluminiumlegierung besteht.A further object of the invention is to provide an engine component, in particular a piston for an internal combustion engine, which is highly heat-resistant and at least partially consists of an aluminum alloy.
Diese Aufgabe wird durch den Gegenstand des Anspruchs 10 gelöst und weitere bevorzugte Ausführungsformen ergeben sich aus den diesbezüglichen Unteransprüchen.This object is achieved by the subject matter of claim 10 and further preferred embodiments will become apparent from the relevant subclaims.
Bei einem erfindungsgemäßen Verfahren weist die Aluminiumlegierung die folgenden Legierungselemente:
- Silizium (Si) von etwa 7, bevorzugt von etwa 9 Gew.-% bis zu < etwa 14,5, bevorzugt bis zu < etwa 12, weiter bevorzugt bis zu < etwa 10,5 und noch weiter bevorzugt bis zu < etwa 10 Gew.-%;
- Nickel (Ni) von > etwa 1,2, bevorzugt von > etwa 2 Gew.-% t bis zu < etwa 3,5 und weiter bevorzugt bis zu < etwa 2 Gew.-%;
- Kupfer (Cu) von > etwa 3,7, bevorzugt von > etwa 5,2 und weiter bevorzugt von > 5,5 Gew.-% bis zu < etwa 10, bevorzugt bis zu < etwa 8, weiter bevorzugt bis zu ≤ etwa 5,5 und noch weiter bevorzugt bis zu etwa 5,2 Gew.-%;
- Kobalt (Co) bis zu < etwa 1 Gew.-%, bevorzugt von > etwa 0,2 Gew.-% bis < etwa 1 Gew.-%;
- Magnesium (Mg) von etwa 0,1, bevorzugt von etwa 0,5, weiter bevorzugt von etwa 0,6, noch weiter bevorzugt von > etwa 0,65 und insbesondere bevorzugt ≥ etwa 1,2 bis zu etwa 1,5, bevorzugt bis zu etwa 1,2 Gew.-% und noch weiter bevorzugt bis zu ≤ etwa 0,8 Gew.-%;
- Eisen (Fe) von etwa 0,1, bevorzugt von etwa 0,4 Gew.-% bis zu ≤ etwa 0,7, bevorzugt bis zu etwa 0,6 Gew.-%;
- Mangan (Mn) von etwa 0,1 Gew.-% bis zu ≤ etwa 0,7 und bevorzugt bis zu etwa 0,4 Gew.-%;
- Zirkonium (Zr) von > etwa 0,1, bevorzugt von etwa > 0,2 Gew.-% bis zu < etwa 0,5, bevorzugt bis zu ≤ etwa 0,4 und weiter bevorzugt bis zu < etwa 0,2 Gew.-%;
- Vanadium (V) von ≥ etwa 0,1 Gew.-% bis zu ≤ etwa 0,3, bevorzugt bis zu < etwa 0,2 Gew.-%;
- Titan (Ti) von etwa 0,05, bevorzugt von etwa 0,1 Gew.-% bis zu etwa 0,5, bevorzugt bis zu ≤ etwa 0,2 Gew.-%;
- Phosphor (P) von etwa 0,004 Gew.-% bis zu etwa ≤ 0,05, bevorzugt bis zu etwa 0,008 Gew.-%
- Silicon (Si) of about 7, preferably from about 9 wt .-% to <about 14.5, preferably up to <about 12, more preferably up to <about 10.5 and even more preferably up to <about 10 wt .-%;
- Nickel (Ni) of> about 1.2, preferably from> about 2 wt% t to <about 3.5 and more preferably to <about 2 wt%;
- Copper (Cu) of> about 3.7, preferably of> about 5.2 and more preferably of> 5.5 wt .-% to <about 10, preferably up to <about 8, more preferably up to ≤ about 5 , 5 and even more preferably up to about 5.2% by weight;
- Cobalt (Co) up to <about 1 wt%, preferably from> about 0.2 wt% to <about 1 wt%;
- Magnesium (Mg) of about 0.1, preferably about 0.5, more preferably about 0.6, even more preferably> about 0.65, and most preferably ≥ about 1.2 up to about 1.5, preferably up to about 1.2% by weight, and more preferably up to about 0.8% by weight;
- Iron (Fe) of about 0.1, preferably from about 0.4% to about ≦ about 0.7, preferably up to about 0.6% by weight;
- Manganese (Mn) from about 0.1% to about ≦ about 0.7 and preferably up to about 0.4% by weight;
- Zirconium (Zr) of> about 0.1, preferably from about> 0.2% by weight to <about 0.5, preferably up to ≦ about 0.4, and more preferably up to <about 0.2% by weight. -%;
- Vanadium (V) of ≥ about 0.1 wt .-% to ≤ about 0.3, preferably up to <about 0.2 wt .-%;
- Titanium (Ti) of about 0.05, preferably from about 0.1% to about 0.5, preferably up to about 0.2% by weight;
- Phosphorus (P) from about 0.004% by weight to about ≦ 0.05, preferably up to about 0.008% by weight
Durch die gewählte Aluminiumlegierung ist es möglich, im Schwerkraftkokillengussverfahren ein Motorbauteil herzustellen, das einen hohen Anteil fein verteilter, hochwarmfester, thermisch stabiler Phasen und eine feine Mikrostruktur aufweist. Die Anfälligkeit gegenüber Rissinitiierung und Rissausbreitung z.B. an Oxiden oder primären Phasen wird durch die Wahl der erfindungsgemäßen Legierung gegenüber den bisher bekannten Herstellungsverfahren von Kolben und ähnlichen Motorbauteilen reduziert und die TMF-HCF-Lebensdauer erhöht.By the selected aluminum alloy, it is possible to produce a motor component in the gravity die casting process, which has a high proportion of finely divided, highly heat-resistant, thermally stable phases and a fine microstructure. Susceptibility to crack initiation and crack propagation e.g. On oxides or primary phases is reduced by the choice of the alloy according to the invention over the previously known manufacturing processes of pistons and similar engine components and increases the TMF-HCF life.
Die erfindungsgemäße Legierung, insbesondere der vergleichsweise geringe Siliziumgehalt, führt auch dazu, dass zumindest bei einem erfindungsgemäß hergestellten Kolben in dessen thermisch hochbelastetem Muldenrandbereich vergleichsweise weniger und feineres primäres Silizium vorliegt, sodass die Legierung zu besonders guten Eigenschaften eines erfindungsgemäß hergestellten Kolbens führt. Somit kann ein höchstwarmfestes Motorbauteil im Schwerkraftkokillengussverfahren hergestellt werden. Die erfindungsgemäßen Anteile an Kupfer, Zirkonium, Vanadium und Titan, insbesondere der vergleichsweise hohe Gehalt an Zirkonium, Vanadium und Titan bewirken einen vorteilhaften Anteil festigkeitssteigernder Ausscheidungen, ohne dabei jedoch große plattenförmige intermetallische Phasen zu verursachen. Beispielsweise können die Legierungseigenschaften durch eine gezielte Auswahl des Cu-Gehalts in dem erfindungsgemäßen Bereich anwendungsspezifisch optimiert werden. Höhere Cu-Gehalte verbessern insbesondere die Warmfestigkeit der Legierung. Geringere Gehalte erlauben hingegen die Erhöhung der Wärmeleitfähigkeit und Verringerung der Dichte der Legierung. Ferner sind die erfindungsgemäßen Anteile an Kobalt und Phosphor vorteilhaft darin, dass Kobalt die Härte und (Warm-)Festigkeit der Legierung erhöht und Phosphor als Keimbildner für primäre Siliziumausscheidungen dazu beiträgt, dass diese besonders fein und gleichmäßig verteilt ausgeschieden werden. Zirkonium und Kobalt tragen zudem, insbesondere im Muldenrandbereich, zu Festigkeitssteigerungen bei erhöhten Temperaturen bei.The alloy according to the invention, in particular the comparatively low silicon content, also results in comparatively less and finer primary silicon being present in its thermally highly loaded bowl edge region, at least in the case of a piston produced according to the invention, so that the alloy leads to particularly good properties of a piston produced according to the invention. Thus, a highly heat resistant engine component can be produced by the gravity die casting method. The proportions of copper, zirconium, vanadium and titanium according to the invention, in particular the comparatively high content of zirconium, vanadium and titanium, produce an advantageous proportion of strength-increasing precipitates, without, however, causing large plate-shaped intermetallic phases. For example, the alloy properties can be optimized in an application-specific manner by a targeted selection of the Cu content in the range according to the invention. In particular, higher Cu contents improve the heat resistance of the alloy. By contrast, lower contents allow the increase of the thermal conductivity and reduction of the density of the alloy. Furthermore, the proportions of cobalt and phosphorus according to the invention are advantageous in that cobalt increases the hardness and (warm) strength of the alloy and phosphorus as a nucleating agent for primary silicon precipitates contributes to their being precipitated particularly finely and evenly distributed. In addition, zirconium and cobalt contribute to increases in strength at elevated temperatures, in particular in the edge area of the bowl.
Mit Vorteil weisen die genannten Aluminiumlegierungen bevorzugt 0,6 Gew.-% bis 0,8 Gew.-% Magnesium auf, das in dem bevorzugten Konzentrationsbereich insbesondere zur wirkungsvollen Ausbildung sekundärer, festigkeitssteigernder Phasen beiträgt, ohne dass eine übermäßige Oxidbildung auftritt. Ferner weist die Legierung alternativ oder zusätzlich bevorzugt 0,4 Gew.-% bis 0,6 Gew.-% Eisen auf, das die Klebeneigung der Legierung in der Gießkokille vorteilhaft vermindert, wobei in dem genannten Konzentrationsbereich die Bildung plattenförmiger Phasen begrenzt bleibt.Advantageously, the said aluminum alloys preferably comprise 0.6% by weight to 0.8% by weight of magnesium, which in the preferred concentration range contributes, in particular, to the effective formation of secondary, strength-increasing phases without excessive oxide formation occurring. Furthermore, the alloy alternatively or additionally preferably has from 0.4% by weight to 0.6% by weight of iron, which advantageously reduces the tendency of the alloy to stick in the casting mold, wherein the formation of plate-shaped phases remains limited in said concentration range.
Die oben beschriebenen Aluminiumlegierungen können zudem von etwa 0,0005, bevorzugt von > etwa 0,006 und weiter bevorzugt von etwa 0,01 Gew.-% bis zu etwa 0,5, bevorzugt bis zu etwa < etwa 0,1 Gew.-% Beryllium (Be) enthalten, wobei der Gehalt an Kalzium auf ≤ etwa 0,0005 Gew.-% begrenzt ist. Aus der Zugabe von Beryllium resultiert eine besonders gute Gießbarkeit der Legierung. Dessen Zugabe in die Schmelze bewirkt eine dichte Oxidhaut auf der Schmelze, welche als Diffusionsbarriere fungiert und die Oxidation und Wasserstoffaufnahme der Schmelze reduziert. Auch kann die Diffusion von Aluminium und Magnesium nach außer verhindert werden. Obige Effekte sind insbesondere beim Einsatz von Warmhalteöfen relevant. Zusätzlich kommt es zur Bildung einer feinen/dünnen Oxidschicht an der Erstarrungsfront beim Gießen, zum Beispiel in einer Kokille, welche das Fließvermögen verbessert. Insgesamt können somit dünne Wände und feine Formstrukturen besser und ohne zusätzliche Hilfsmaßnahmen gefüllt werden. Zusätzlich dazu verbessert die Zugabe von Beryllium die Festigkeitskennwerte der Legierung insgesamt. Während der Alterung ist eine höhere Dichte an festigkeitssteigernden Ausscheidungen erzielbar. Die Zugabe von Beryllium ergänzt die vorteilhaften Effekte der vorliegenden Aluminiumlegierungen um eine Reduzierung der Oxidation der Schmelze, trägt zur besseren Gießbarkeit, insbesondere im Schwerkraftkokillenguss, bei und verbessert die Festigkeit der Legierung. Gleichzeitig ist es bevorzugt, den Kalziumgehalt auf das obige niedrige Niveau zu begrenzen. Die gleichzeitige Anwesenheit von darüber hinausgehenden Gehalten an Kalzium kann den vorteilhaften Effekten des Berylliums entgegenwirken und die Oxidation verstärken. Diesbezüglich ist ein möglichst geringer Kalziumgehalt vorteilhaft.The aluminum alloys described above may also be from about 0.0005, preferably from> about 0.006 and more preferably from about 0.01% to about 0.5, preferably to about <about 0.1% by weight beryllium (Be), wherein the content of calcium is limited to ≤ about 0.0005% by weight. The addition of beryllium results in a particularly good castability of the alloy. Its addition to the melt causes a dense oxide skin on the melt, which acts as a diffusion barrier and reduces the oxidation and hydrogen uptake of the melt. The diffusion of aluminum and magnesium can also be prevented. The above effects are particularly relevant when using holding furnaces. In addition, a fine / thin oxide layer is formed on the solidification front during casting, for example, in a mold, which improves flowability. Overall, thus thin walls and fine mold structures can be filled better and without additional assistance. In addition, the addition of beryllium improves the strength characteristics of the alloy as a whole. During aging, a higher density of strength enhancing precipitates is achievable. The addition of beryllium adds to the beneficial effects of the present aluminum alloys by reducing the oxidation of the melt, contributes to better castability, particularly in gravity die casting, and improves the strength of the alloy. At the same time, it is preferable to limit the calcium content to the above low level. The simultaneous presence of excess levels of calcium can counteract the beneficial effects of beryllium and enhance oxidation. In this regard, the lowest possible calcium content is advantageous.
Besonders bevorzugte Aluminiumlegierungen A, B und C der vorliegenden Erfindung ergeben sich aus nachfolgender Tabelle (Angaben in Gew.-%):
Die Legierungen A, B und C realisieren die oben gennannten technischen Vorteile. Darüber hinaus erweist sich bei Legierung A der vergleichsweise hohe Cu- und Zr-Gehalt als vorteilhaft, welcher eine Anhebung festigkeitssteigernder Ausscheidungen bewirkt. Gleiches gilt für die bevorzugte Legierung B, wobei diese einen verringerten Nickelgehalt aufweist, der ferner zur Senkung der Legierungskosten beiträgt. Der in Legierung C vergleichsweise erhöhte Gehalt an Zr, V und Ti trägt ebenfalls zusätzlich zur Anhebung festigkeitssteigernder Ausscheidungen bei. Generell bewirkt ein erhöhter Zr-Gehalt eine weitere Verbesserung der Festigkeit. Legierung C weist besonders bevorzugt einen Si- Gehalt < 10,5 Gew.-% auf. Legierung D, nicht Gegenstand dieser Erfindung, ist vorteilhaft darin, dass die Zugabe von Beryllium, wie oben beschrieben, das Oxidations- und Fließverhalten der Schmelze sowie die Festigkeit der Legierung verbessert. Dieser Effekt wird noch durch den vergleichsweise geringen Mg-Gehalt und den auf ein niedriges Niveau begrenzten Ca-Gehalt weiter gesteigert. Legierung D kann zudem noch die Legierungselemente in folgenden bevorzugten Konzentrationsbereichen aufweisen: Nickel (Ni) von etwa 2 bis < etwa 3,5 Gew.-%, Kupfer (Cu) von > etwa 3,7 bis etwa 5,2 Gew.-%, Magnesium (Mg) von > etwa 0,65 bis < etwa 0,8 Gew.-%, Eisen (Fe) von etwa 0,4 bis etwa 0,6 Gew.-%, Mangan (Mn) von etwa 0,1 bis etwa 0,4 Gew.-% und für Beryllium, die oben genannten bevorzugten Konzentrationsgrenzen. Optional ist die Anwesenheit/Zugabe von Beryllium zur Verbesserung der Oxidations-, Fließ- und Festigkeitseigenschaften auch in/zu den Legierungen A, B und C möglich. Dabei sollte ebenfalls der Kalziumgehalt auf das angegebene niedrige Niveau begrenzt werden, um den vorteilhaften Effekten des Berylliums nicht entgegenzuwirken. Insgesamt besteht zwischen den Legierungen A, B und C eine gewisse Kombinierbarkeit, sodass deren vorteilhafte technische Effekte auch zusammen in einer einzelnen Legierung realisiert werden können.The alloys A, B and C realize the above-mentioned technical advantages. In addition, in Alloy A, the comparatively high Cu and Zr content proves to be advantageous, which causes an increase in strength-increasing precipitations. The same applies to the preferred alloy B, which has a reduced nickel content, which further contributes to the reduction of alloying costs. The relatively high content of Zr, V and Ti in Alloy C also adds to the increase in strength increasing precipitations. In general, an increased Zr content causes a further improvement in strength. Alloy C particularly preferably has an Si content <10.5% by weight. Alloy D, not part of this invention, is advantageous in that the addition of beryllium, as described above, improves the oxidation and flow behavior of the melt as well as the strength of the alloy. This effect is further increased by the comparatively low Mg content and the limited to a low level Ca content. Alloy D may also have the alloying elements in the following preferred concentration ranges: nickel (Ni) from about 2 to about 3.5 wt%, copper (Cu) from about 3.7 to about 5.2 wt%. , Magnesium (Mg) of> about 0.65 to <about 0.8 wt%, iron (Fe) of about 0.4 to about 0.6 wt%, manganese (Mn) of about 0.1 to about 0.4% by weight, and for beryllium, the preferred concentration limits mentioned above. Optionally, the presence / addition of beryllium to improve the oxidation, flow and strength properties is also possible in / to the alloys A, B and C. The calcium content should also be limited to the specified low level in order not to counteract the beneficial effects of beryllium. Overall, there is a certain combinability between the alloys A, B and C, so that their advantageous technical effects can also be realized together in a single alloy.
Mit Vorteil beträgt das Gewichtsverhältnis von Eisen zu Mangan in den genannten Aluminiumlegierungen höchstens etwa 5:1 bevorzugt etwa 2,5:1. In dieser Ausführungsform enthält die Aluminiumlegierung also höchstens fünf Teile Eisen gegenüber einem Teil Mangan, bevorzugt etwa 2,5 Teile Eisen gegenüber einem Teil Mangan. Durch dieses Verhältnis werden besonders vorteilhafte Festigkeitseigenschaften des Motorbauteils erzielt.Advantageously, the weight ratio of iron to manganese in said aluminum alloys is at most about 5: 1, preferably about 2.5: 1. Thus, in this embodiment, the aluminum alloy contains at most five parts iron versus one part manganese, preferably about 2.5 parts iron versus one part manganese. By this ratio particularly advantageous strength properties of the engine component can be achieved.
Die Nickelkonzentration beträgt < 3,5 Gew.-%, da sich ansonsten zu große, plattenförmige (primäre, nickelreiche) Phasen im Gefüge ausbilden können, die aufgrund ihrer Kerbwirkung die Festigkeit und/oder Lebensdauer herabsetzen können. Bei den bevorzugten Nickelkonzentrationen größer > 1,2 Gew.-% wird ein thermisch stabiles Primärphasennetzwerk mit Konnektivität und Kontiguität erzeugt.The nickel concentration is <3.5 wt .-%, since otherwise can form too large, plate-shaped (primary, nickel-rich) phases in the structure, which can reduce their strength and / or life due to their notch effect. At the preferred nickel concentrations greater than 1.2 wt%, a thermally stable primary phase network is produced with connectivity and contiguity.
Ferner ist es bevorzugt, dass die Summe aus Nickel und Kobalt in den genannten Aluminiumlegierungen > 2,0 Gew.-% und < 3,8 Gew.-% beträgt. Die untere Grenze stellt dabei eine vorteilhafte Festigkeit der Legierung sicher und die obere Grenze gewährleistet mit Vorteil eine feine Mikrostruktur und vermeidet die Bildung grober, plattenförmiger Phasen, welche die Festigkeit verringern würden.Further, it is preferable that the sum of nickel and cobalt in said aluminum alloys is> 2.0 wt% and <3.8 wt%. The lower limit ensures an advantageous strength of the alloy and the upper limit advantageously ensures a fine microstructure and avoids the formation of coarse, plate-shaped phases which would reduce the strength.
Mit Vorteil weisen die Aluminiumlegierungen eine feine Mikrostruktur mit einem geringen Gehalt von Poren und Einschlüssen und/oder wenig und kleines primäres Silizium, insbesondere im hochbelasteten Muldenrandbereich, auf. Dabei ist unter einem geringen Gehalt von Poren vorzugsweise eine Porosität von < 0,01 % und unter wenig primärem Silizium < 1 % zu verstehen. Ferner ist die feine Mikrostruktur vorteilhaft dadurch beschrieben, dass die mittlere Länge des primären Silizium ca. < 5 µm und dessen maximale Länge ca. < 10 µm beträgt und die intermetallischen Phasen und/oder primären Ausscheidungen Längen von im Mittel ca. < 30 µm und maximal < 50 µm aufweisen. Die feine Mikrostruktur trägt insbesondere zur Verbesserung der thermomechanischen Ermüdungsfestigkeit bei. Eine Begrenzung der Größe der Primärphasen kann die Anfälligkeit gegen Rissinitiierung und Rissausbreitung verringern und so die TMF-HCF-Lebensdauer signifikant erhöhen. Ferner ist es auf Grund der Kerbwirkung von Poren und Einschlüssen besonders vorteilhaft deren Gehalt gering zu halten.Advantageously, the aluminum alloys have a fine microstructure with a low content of pores and inclusions and / or little and small primary silicon, especially in the highly loaded bowl rim area. In this case, a low content of pores is preferably to be understood as meaning a porosity of <0.01% and less than a few primary silicon <1%. Furthermore, the fine microstructure is advantageously described by the fact that the average length of the primary silicon about <5 microns and its maximum length is about <10 microns and the intermetallic phases and / or primary precipitates lengths of on average about <30 microns and have a maximum <50 microns. The fine microstructure contributes in particular to the improvement of the thermomechanical fatigue strength. Limiting the size of the primary phases can reduce the susceptibility to crack initiation and crack propagation, thus significantly increasing the TMF-HCF lifetime. Furthermore, it is particularly advantageous due to the notch effect of pores and inclusions to keep their content low.
Ein erfindungsgemäßes Motorbauteil besteht zumindest teilweise aus einer der oben genannten Aluminiumlegierungen. Ein weiterer unabhängiger Aspekt der Erfindung liegt in der Verwendung der oben ausgeführten Aluminiumlegierungen für die Herstellung eines Motorbauteils, insbesondere eines Kolbens eines Verbrennungsmotors, nach Anspruch 19 und dem diesbezüglichen Unteranspruch. Insbesondere werden die aufgefundenen Aluminiumlegierungen dabei im Schwerkraftkokillengussverfahren verarbeitet.An engine component according to the invention consists at least partially of one of the abovementioned aluminum alloys. Another independent aspect of the invention is the use of the above-mentioned aluminum alloys for the manufacture of an engine component, in particular a piston of an internal combustion engine, according to claim 19 and the related subclaim. In particular, the aluminum alloys found are processed by gravity die casting.
Claims (20)
- Method for producing an engine component, in particular a piston for an internal combustion engine, in which an aluminium alloy is cast using the gravity die casting process,
wherein the aluminium alloy has the following alloy elements:silicon: 7 wt.% to < 14.5 wt.%, nickel: > 1.2 wt.% to < 3.5 wt.%, copper: > 3.7 wt.% to < 10 wt.%, cobalt: to < 1 wt.%, magnesium: 0.1 wt.% to 1.5 wt.%, iron: 0.1 wt.% to ≤ 0.7 wt.%, manganese: 0.1 wt.% to ≤ 0.7 wt.%, zirconium: > 0.1 wt.% to < 0.5 wt.%, vanadium: ≥ 0.1 wt.% to ≤ 0.3 wt.%, titanium: 0.05 wt.% to 0.5 wt.%, phosphorus: 0.004 wt.% to ≤ 0.05 wt.%, optionally beryllium: 0.0005 wt.% to 0.5 wt.% and optionally calcium: to ≤ 0.0005 wt.% - Method according to claim 1, wherein the aluminium alloy further has:
beryllium: 0.0005 wt.% to 0.5 wt.% and calcium: to ≤ 0.0005 wt.% - Method according to claim 1 or 2, wherein the aluminium alloy has:
silicon: 9 wt.% to < 10.5 wt.%, nickel: > 2 wt.% to < 3.5 wt.%, copper: > 5.2 wt.% to < 10 wt.%, cobalt: to < 1 wt.%, magnesium: 0.5 wt.% to 1.5 wt.%, iron: 0.1 wt.% to 0.7 wt.%, manganese: 0.1 wt.% to 0.4 wt.%, zirconium: 0.2 wt.% to < 0.4 wt.%, vanadium: > 0.1 wt.% to < 0.2 wt.%, titanium: 0.05 wt.% to < 0.2 wt.%, phosphorus: 0.004 wt.% to 0.008 wt.%, - Method according to claim 1 or 2, wherein the aluminium alloy has:
silicon: 9 wt.% to < 10.5 wt.%, nickel: > 1.2 wt.% to < 2.0 wt.%, copper: > 5.2 wt.% to < 10 wt.%, cobalt: to < 1 wt.%, magnesium: 0.5 wt.% to 1.5 wt.%, iron: 0.1 wt.% to 0.7 wt.%, manganese: 0.1 wt.% to 0.4 wt.%, zirconium: 0.2 wt.% to < 0.4 wt.%, vanadium: > 0.1 wt.% to < 0.2 wt.%, titanium: 0.05 wt.% to < 0.2 wt.%, phosphorus: 0.004 wt.% to 0.008 wt.%, - Method according to claim 1 or 2, wherein the aluminium alloy has:
silicon: 9 wt.% to < 12 wt.%, nickel: 2 wt.% to < 3.5 wt.%, copper: > 3.7 wt.% to 5.2 wt.%, cobalt: to < 1 wt.%, magnesium: 0.5 wt.% to 1.5 wt.%, iron: 0.1 wt.% to 0.7 wt.%, manganese: 0.1 wt.% to 0.4 wt.%, zirconium: 0.2 wt.% to 0.4 wt.%, vanadium: 0.1 wt.% to 0.3 wt.%, titanium: 0.1 wt.% to 0.5 wt.%, phosphorus: 0.004 wt.% to 0.008 wt.%, - Method according to claim 1, wherein the aluminium alloy has:
silicon: 7 wt.% to < 14.5 wt.%, nickel: > 1.2 wt.% to < 3.5 wt.%, copper: > 3.7 wt.% to ≤ 5.5 wt.%, cobalt: to < 1 wt.%, magnesium: 0.1 wt.% to 1.2 wt.%, iron: 0.1 wt.% to ≤ 0.7 wt.%, manganese: 0.1 wt.% to ≤ 0.7 wt.%, zirconium: > 0.1 wt.% to < 0.5 wt.%, vanadium: ≥ 0.1 wt.% to ≤ 0.3 wt.%, titanium: 0.05 wt.% to ≤ 0.2 wt.%, phosphorus: 0.004 wt.% to ≤ 0.05 wt.%, beryllium: 0.0005 wt.% to 0.5 wt.%, calcium: to ≤ 0.0005 wt.% - Method according to any of the preceding claims 1 to 6, wherein in the aluminium alloy a weight ratio of iron to manganese is at most approximately 5:1, preferably the weight ratio of iron to manganese is approximately 2.5:1.
- Method according to any of the preceding claims 1 to 7, wherein a sum of nickel and cobalt is preferably > 2.0 wt.% and < 3.8 wt.%.
- Method according to any of the preceding claims 1 to 8, wherein the aluminium alloy has a fine microstructure with a low content of pores and inclusions and/or few and small primary silicon, in particular in a trough rim area of the engine component, wherein the porosity is < 0.01 % and/or the content of primary silicon is < 1 %, wherein the primary silicon has mean lengths of < 5 µm and/or maximum lengths of < 10 µm, and the intermetallic phases and/or primary precipitations have mean lengths of < 30 µm and/or maximum lengths of < 50 µm.
- Engine component, in particular piston for an internal combustion engine, which consists at least partially of an aluminium alloy, wherein the aluminium alloy has the following alloy elements:
silicon: 7 wt.% to < 14.5 wt.%, nickel: > 1.2 wt.% to < 3.5 wt.%, copper: > 3.7 wt.% to < 10 wt.%, cobalt: to < 1 wt.%, magnesium: 0.1 wt.% to 1.5 wt.%, iron: 0.1 wt.% to ≤ 0.7 wt.%, manganese: 0.1 wt.% to ≤ 0.7 wt.%, zirconium: > 0.1 wt.% to < 0.5 wt.%, vanadium: ≥ 0.1 wt.% to ≤ 0.3 wt.%, titanium: 0.05 wt.% to 0.5 wt.%, phosphorus: 0.004 wt.% to ≤ 0.05 wt.%, optionally beryllium: 0.0005 wt.% to 0.5 wt.% and optionally calcium: to ≤ 0.0005 wt.% - Engine component according to claim 10, wherein the aluminium alloy further has:
beryllium: 0.0005 wt.% to 0.5 wt.% and calcium: to ≤ 0.0005 wt.%. - Engine component according to claim 10 or 11, wherein the aluminium alloy has:
silicon: 9 wt.% to < 10.5 wt.%, nickel: > 2 wt.% to < 3.5 wt.%, copper: > 5.2 wt.% to < 10 wt.%, cobalt: to < 1 wt.%, magnesium: 0.5 wt.% to 1.5 wt.%, iron: 0.1 wt.% to 0.7 wt.%, manganese: 0.1 wt.% to 0.4 wt.%, zirconium: 0.2 wt.% to < 0.4 wt.%, vanadium: > 0.1 wt.% to < 0.2 wt.%, titanium: 0.05 wt.% to < 0.2 wt.%, phosphorus: 0.004 wt.% to 0.008 wt.%, - Engine component according to claim 10 or 11, wherein the aluminium alloy has:
silicon: 9 wt.% to < 10.5 wt.%, nickel: > 1.2 wt.% to < 2.0 wt.%, copper: > 5.2 wt.% to < 10 wt.%, cobalt: to < 1 wt.%, magnesium: 0.5 wt.% to 1.5 wt.%, iron: 0.1 wt.% to 0.7 wt.%, manganese: 0.1 wt.% to 0.4 wt.%, zirconium: 0.2 wt.% to < 0.4 wt.%, vanadium: > 0.1 wt.% to < 0.2 wt.%, titanium: 0.05 wt.% to < 0.2 wt.%, phosphorus: 0.004 wt.% to 0.008 wt.%, - Engine component according to claim 10 or 11, wherein the aluminium alloy has:
silicon: 9 wt.% to < 12 wt.%, nickel: 2 wt.% to < 3.5 wt.%, copper: > 3.7 wt.% to 5.2 wt.%, cobalt: to < 1 wt.%, magnesium: 0.5 wt.% to 1.5 wt.%, iron: 0.1 wt.% to 0.7 wt.%, manganese: 0.1 wt.% to 0.4 wt.%, zirconium: 0.2 wt.% to 0.4 wt.%, vanadium: 0.1 wt.% to 0.3 wt.%, titanium: 0.1 wt.% to 0.5 wt.%, phosphorus: 0.004 wt.% to 0.008 wt.%, - Engine component according to claim 10, wherein the aluminium alloy has:
silicon: 7 wt.% to < 14.5 wt.%, nickel: > 1.2 wt.% to < 3.5 wt.%, copper: > 3.7 wt.% to ≤ 5.5 wt.%, cobalt: to < 1 wt.%, magnesium: 0.1 wt.% to 1.2 wt.%, iron: 0.1 wt.% to ≤ 0.7 wt.%, manganese: 0.1 wt.% to ≤ 0.7 wt.%, zirconium: > 0.1 wt.% to < 0.5 wt.%, vanadium: ≥ 0.1 wt.% to ≤ 0.3 wt.%, titanium: 0.05 wt.% to ≤ 0.2 wt.%, phosphorus: 0.004 wt.% to ≤ 0.05 wt.%, beryllium: 0.0005 wt.% to 0.5 wt.%, calcium: to ≤ 0.0005 wt.% - Engine component according to any of the preceding claims 10 to 15, wherein in the aluminium alloy a weight ratio of iron to manganese is at most approximately 5:1, preferably the weight ratio of iron manganese is approximately 2.5:1.
- Method according to any of the preceding claims 10 to 16, wherein a sum of nickel and cobalt is preferably > 2.0 wt.% and < 3.8 wt.%.
- Method according to any of the preceding claims 10 to 17, wherein the aluminium alloy has a fine microstructure with a low content of pores and inclusions and/or few and small primary silicon, in particular in a trough rim area of the engine component, wherein the porosity is < 0.01 % and/or the content of primary silicon is < 1 %, wherein the primary silicon has mean lengths of < 5 µm and/or maximum lengths of < 10 µm, and the intermetallic phases and/or primary precipitations have mean lengths of < 30 µm and/or maximum lengths of < 50 µm.
- Use of an aluminium alloy for producing an engine component, in particular a piston of an internal combustion engine,
wherein the aluminium alloy has the following alloy elements:silicon: 7 wt.% to < 14.5 wt.%, nickel: > 1.2 wt.% to < 3.5 wt.%, copper: > 3.7 wt.% to < 10 wt.%, cobalt: to < 1 wt.%, magnesium: 0.1 wt.% to 1.5 wt.%, iron: 0.1 wt.% to ≤ 0.7 wt.%, manganese: 0.1 wt.% to ≤ 0.7 wt.%, zirconium: > 0.1 wt.% to < 0.5 wt.%, vanadium: ≥ 0.1 wt.% to ≤ 0.3 wt.%, titanium: 0.05 wt.% to 0.5 wt.%, phosphorus: 0.004 wt.% to ≤ 0.05 wt.%, optionally beryllium 0.0005wt.% to 0.5 wt.% and optionally calcium: to ≤ 0.0005 wt.% and aluminium and unavoidable impurities as the remainder. - Use according to claim 19, wherein the aluminium alloy further has:
beryllium: 0.0005 wt.% to 0.5 wt.% and calcium: to ≤ 0.0005 wt.%.
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CN107937767B (en) * | 2017-12-28 | 2019-07-26 | 苏州仓松金属制品有限公司 | A kind of novel high-performance aluminum alloy materials and preparation method thereof |
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DE102020205193A1 (en) | 2019-05-16 | 2020-11-19 | Mahle International Gmbh | Process for producing an engine component, engine component and the use of an aluminum alloy |
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CN113444927B (en) * | 2021-06-18 | 2022-11-25 | 中铝材料应用研究院有限公司 | Aluminum alloy piston material and preparation method thereof |
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Also Published As
Publication number | Publication date |
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EP3143173B2 (en) | 2022-08-10 |
DE102014209102A1 (en) | 2015-11-19 |
CN106795591B (en) | 2018-10-26 |
CN106795591A (en) | 2017-05-31 |
JP2017519105A (en) | 2017-07-13 |
US20170226957A1 (en) | 2017-08-10 |
WO2015173172A1 (en) | 2015-11-19 |
KR20170007404A (en) | 2017-01-18 |
EP3143173A1 (en) | 2017-03-22 |
MX2016014860A (en) | 2017-06-27 |
BR112016026554A2 (en) | 2017-08-15 |
US11280292B2 (en) | 2022-03-22 |
KR102379579B1 (en) | 2022-03-29 |
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