EP3235917A1 - Alloy for pressure die casting - Google Patents

Alloy for pressure die casting Download PDF

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Publication number
EP3235917A1
EP3235917A1 EP16165969.3A EP16165969A EP3235917A1 EP 3235917 A1 EP3235917 A1 EP 3235917A1 EP 16165969 A EP16165969 A EP 16165969A EP 3235917 A1 EP3235917 A1 EP 3235917A1
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EP
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Prior art keywords
weight
alloy
alloy according
ppm
die casting
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Granted
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EP16165969.3A
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German (de)
French (fr)
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EP3235917B1 (en
Inventor
Stuart Wiesner
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Aluminium Rheinfelden Alloys GmbH
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Rheinfelden Alloys GmbH and Co KG
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Application filed by Rheinfelden Alloys GmbH and Co KG filed Critical Rheinfelden Alloys GmbH and Co KG
Priority to EP16165969.3A priority Critical patent/EP3235917B1/en
Priority to PCT/EP2016/059723 priority patent/WO2017182102A1/en
Priority to MX2018012786A priority patent/MX2018012786A/en
Priority to CN201680084625.8A priority patent/CN109072353A/en
Priority to CA3021397A priority patent/CA3021397C/en
Priority to KR1020187032871A priority patent/KR102609410B1/en
Priority to US16/094,324 priority patent/US20190119791A1/en
Publication of EP3235917A1 publication Critical patent/EP3235917A1/en
Publication of EP3235917B1 publication Critical patent/EP3235917B1/en
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Classifications

    • 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
    • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/043—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with silicon as the next major constituent
    • 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

Definitions

  • the invention relates to a diecasting alloy based on aluminum and silicon, in particular for use in light vehicle structural parts.
  • the alloy according to the invention takes account of the ever increasing demands for lightweight construction in the automotive industry.
  • the use of a material with higher strength allows the designer to realize thinner-walled and thus lighter structures. In this way, a further step towards low fuel consumption in the automobile can be realized.
  • AlSi10Mg or AlSi7Mg alloys are among the most widely used casting alloys in the industry.
  • the EP 1612286 B1 discloses an AlSi alloy which has high elongation values already in the cast state without further heat treatment. With this alloy it is possible to obtain good values for the yield strength and the tensile strength of castings as cast, so that the alloy is particularly suitable for the production of safety components in the automotive industry. In this known from the prior art alloy has been shown that by the addition of molybdenum or a combined addition of molybdenum and zirconium, the desired values for the tensile strength and the yield strength can be achieved.
  • the EP0687742B1 also discloses an aluminum-silicon based die-casting alloy, which is used in particular in automotive safety components. Unlike the alloy from the EP 1612286 B1 , the produced die castings are subjected to a heat treatment. In the case of this alloy, it has been found that the achieved increased strength values depend to a large extent on the magnesium content and this content therefore has to be tolerated very closely in the production.
  • the object of the invention is to develop a high-strength die-cast aluminum alloy which exhibits improved mechanical properties in terms of tensile strength, yield strength and elongation at break.
  • the alloy according to the invention is said to have good castability, no increased tendency to adhere, no increased risk of heat cracking, and no restriction as regards mold filling capability.
  • the aluminum base may contain at least 50% secondary metal (recycled material).
  • the alloy according to the invention contains 0.15-0.5% by weight of iron.
  • the alloy according to the invention contains 0.05 to 0.20% by weight of molybdenum.
  • the alloy according to the invention contains from 0.05 to 0.20% by weight of zirconium.
  • the alloy according to the invention contains 60-120 ppm gallium.
  • the alloy according to the invention contains 0.3 to 0.5% by weight of manganese.
  • the alloy according to the invention contains 0.2 to 0.4% by weight of zinc.
  • the alloy according to the invention contains 0.15 to 0.25% by weight of copper.
  • the alloy according to the invention contains 8.5 to 10.0% by weight of silicon.
  • the alloy according to the invention contains from 0.3 to 0.4% by weight of magnesium.
  • the diecasting alloy according to the invention is preferably used for pressure casting of crash-relevant or strength-relevant structural parts in the automotive industry.
  • the appropriate strength of an aluminum die casting alloy is achieved in addition to the choice of combination of alloying elements by a targeted heat treatment.
  • the alloy according to the invention is subjected to a T6 heat treatment comprising solution heat treatment, air quenching or water quenching and heat aging. It could be determined that compared with the alloy EP 0687742B1 high yield strengths of just over 200 N / mm 2 can be achieved.
  • the alloy according to the invention is time-stable after T6 heat treatment, i. there is no self-curing.
  • the alloy according to the invention may be subjected to a T7 heat treatment.
  • alloy composition according to the invention it is possible to achieve improved values for tensile strength, the yield strength and the elongation at break in die cast parts in the material state T6 or T7.
  • the slightly increased iron content is taken into account by reducing the manganese content, otherwise there is a risk of sludge formation in the holding furnace at the casting machine.
  • the tendency of the alloy to adhere decreases, since both iron and manganese have a positive effect and the reduction of Mn is more than compensated for by the Fe content.
  • the MnFe ratio prevents the formation of so-called beta phases, ie plate-shaped AlMnFeSi precipitates, which significantly reduces the ductility of the material.
  • Such excretions are known under the microscope as so-called. Iron needles.
  • the alpha-AlMnFeSi precipitates are formed very finely in the inventive alloy by the addition of the elements Mo, Zr and Ga, so that their harmful effect on Dehnhong and corrosion tendency can be minimized.
  • strontium or sodium leads to a finely crystalline precipitation of the silicon, which results in the formation of a refined eutectic, and also has a positive influence on the strength and elongation of the alloy according to the invention.
  • Grain refining is preferably carried out in the case of the alloy according to the invention.
  • the alloy may preferably be supplied with 1 to 30 ppm of phosphorus.
  • the alloy may also contain titanium and boron for grain refining, the addition of titanium and boron via a master alloy with 1 to 2% by weight of Ti and 1 to 2% by weight of B, residual aluminum.
  • the aluminum master alloy contains 1.3 to 1.8% by weight of Ti and 1.3 to 1.8% by weight of B, and has a Ti / B weight ratio of about 0.8 to 1.2.
  • the Content of the master alloy in the alloy according to the invention is preferably adjusted to 0.05 to 0.5 wt .-%.
  • the weldability could be checked in TIG welding tests.
  • punch rivet tests the alloy according to the invention was rivet free of cracks despite its high strength.
  • compositions of an exemplary alloy of the EP0687742B1 (Alloy 1) and two embodiments (alloys A, B) of the inventive alloy compared.
  • the statements are in wt .-%.
  • the mechanical characteristics (R m , R p0.2 and A 5 ) were measured on 3 mm die-cast plates.
  • the same T6 heat treatment with air quenching and applied with water quenching The mean value of approx. 30 train tests is shown in each case.

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  • 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)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)
  • Extrusion Of Metal (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

Die Erfindung betrifft eine Druckgusslegierung auf Aluminium-Silizium Basis mit einer Zusammensetzung bestehend aus: 8,5 bis 11,5 Gew.-% Silizium; 0,1 bis 0,5 Gew.-% Magnesium; 0,3 bis 0,8 Gew.-% Mangan; 0,02 - 0,5 Gew.-% Eisen; 0,005 - 0,5 Gew.-% Zink; 0,02 bis 0,3 Gew.-% Molybdän; 0,1 bis 0,5 Gew.-% Kupfer; 0,02 bis 0,15 Gew.-% Titan; 0,02 bis 0.3 Gew-.% Zirkon, 5 bis 250 ppm Phosphor, 10 bis 200 ppm Gallium und der Rest Aluminium und unvermeidbare Verunreinigungen. Die Legierung ist mit einem Recyclinganteil von 50 % herstellbar.The invention relates to an aluminum-silicon based die casting alloy having a composition consisting of: 8.5 to 11.5 wt.% Silicon; 0.1 to 0.5% by weight of magnesium; 0.3 to 0.8% by weight of manganese; 0.02-0.5% by weight of iron; 0.005-0.5% by weight of zinc; 0.02 to 0.3% by weight of molybdenum; 0.1 to 0.5% by weight of copper; 0.02 to 0.15% by weight of titanium; 0.02 to 0.3% by weight of zirconium, 5 to 250 ppm of phosphorus, 10 to 200 ppm of gallium and the remainder aluminum and unavoidable impurities. The alloy can be produced with a recycling percentage of 50%.

Description

Die Erfindung betrifft eine Druckgusslegierung auf der Basis von Aluminium und Silizium, insbesondere für den Einsatz in leichten Fahrzeug-Strukturteilen.The invention relates to a diecasting alloy based on aluminum and silicon, in particular for use in light vehicle structural parts.

Mit der erfindungsgemässen Legierung wird den immer höheren Anforderungen nach Leichtbau in der Automobilindustrie Rechnung getragen. Die Anwendung eines Werkstoffes mit höherer Festigkeit ermöglicht es dem Konstrukteur, dünnwandigere und somit leichtere Strukturen zu realisieren. Auf diese Weise ist ein weiterer Schritt hin zu geringem Kraftstoffverbrauch im Automobil realisierbar.The alloy according to the invention takes account of the ever increasing demands for lightweight construction in the automotive industry. The use of a material with higher strength allows the designer to realize thinner-walled and thus lighter structures. In this way, a further step towards low fuel consumption in the automobile can be realized.

Legierungen vom Typ AlSi10Mg oder AlSi7Mg zählen zu den am weitesteten in der Industrie verbreiteten Gusslegierungen.AlSi10Mg or AlSi7Mg alloys are among the most widely used casting alloys in the industry.

An dieser Stelle seien zwei aus dem Stand der Technik bekannte und im Automobilbau eingesetzte Druckgusslegierungen genannt, welche von der Anmelderin selbst entwickelt wurden.At this point, two known from the prior art and used in automotive die-casting alloys are called, which were developed by the applicant itself.

Die EP 1612286 B1 offenbart eine AlSi-Legierung, welche bereits im Gusszustand ohne eine weitere Wärmebehandlung hohe Dehnwerte aufweist. Mit dieser Legierung lassen sich bei Druckgussteilen im Gusszustand gute Werte für die Dehngrenze und die Zugfestigkeit erzielen, sodass die Legierung insbesondere zur Herstellung von Sicherheitsbauteilen im Automobilbau geeignet ist. Bei dieser aus dem Stand der Technik bekannten Legierung hat sich gezeigt, dass durch die Zugabe von Molybdän oder einer kombinierten Zugabe von Molybdän und Zirkon die gewünschten Werte für die Zugfestigkeit und die Dehngrenze erzielt werden.The EP 1612286 B1 discloses an AlSi alloy which has high elongation values already in the cast state without further heat treatment. With this alloy it is possible to obtain good values for the yield strength and the tensile strength of castings as cast, so that the alloy is particularly suitable for the production of safety components in the automotive industry. In this known from the prior art alloy has been shown that by the addition of molybdenum or a combined addition of molybdenum and zirconium, the desired values for the tensile strength and the yield strength can be achieved.

Die EP0687742B1 offenbart ebenfalls eine Druckgusslegierung auf Aluminium-Silizium Basis, welche insbesondere bei Sicherheitsbauteilen im Automobilbau zum Einsatz kommt. Anders als bei der Legierung aus der EP 1612286 B1 , werden die hergestellten Druckgussstücke einer Wärmebehandlung unterzogen. Bei dieser Legierung wurde festgestellt, dass die erreichten gesteigerten Festigkeitswerte in starkem Mass vom Magnesiumgehalt abhängig sind und dieser Gehalt daher in der Fertigung sehr eng zu tolerieren ist.The EP0687742B1 also discloses an aluminum-silicon based die-casting alloy, which is used in particular in automotive safety components. Unlike the alloy from the EP 1612286 B1 , the produced die castings are subjected to a heat treatment. In the case of this alloy, it has been found that the achieved increased strength values depend to a large extent on the magnesium content and this content therefore has to be tolerated very closely in the production.

Weitere aus dem Stand der Technik bekannte AlSi-Legierungen sind in der EP 2 653 579 B1 und in der EP 2 735 621 A1 angeführt. Beide Legierungen begrenzen den Eisenanteil auf max. 0.2 Gew. %.Other known from the prior art AlSi alloys are in the EP 2 653 579 B1 and in the EP 2 735 621 A1 cited. Both alloys limit the iron content to max. 0.2% by weight.

Ausgehend von der in der EP 0687742B1 beschriebenen Legierung besteht die Aufgabe darin, eine hochfeste Aluminium-Druckgusslegierung zu entwickeln, welche verbesserte mechanische Kennwerte hinsichtlich der Zugfestigkeit, der Dehngrenze und der Bruchdehnung zeigt. Darüber hinaus soll die erfindungsgemässe Legierung eine gute Giessbarkeit, keine erhöhte Klebeneigung, kein erhöhtes Risiko zur Warmrissneigung sowie keine Einschränkung hinsichtlich der Formfüllfähigkeit aufweisen.Starting from the in the EP 0687742B1 The object of the invention is to develop a high-strength die-cast aluminum alloy which exhibits improved mechanical properties in terms of tensile strength, yield strength and elongation at break. In addition, the alloy according to the invention is said to have good castability, no increased tendency to adhere, no increased risk of heat cracking, and no restriction as regards mold filling capability.

Es ist eine weitere Aufgabe eine hochfeste Aluminium-Druckgusslegierung mit den vorgängig genannten Eigenschaften zu entwickeln, wobei die Aluminiumbasis der Legierung einen Anteil von mindestens 50% Sekundärmetall (Recylingmaterial) enthalten darf.It is another object to develop a high strength die-cast aluminum alloy having the aforementioned properties, the aluminum base the alloy may contain at least 50% secondary metal (recycled material).

Erfindungsgemäss wird diese Aufgabe gelöst durch eine Druckgusslegierung auf Basis von Aluminium-Silizium, bestehend aus:

  • 8,5 bis 11,5 Gew.-% Silizium
  • 0,1 bis 0,5 Gew.-% Magnesium
  • 0,3 bis 0,8 Gew.-% Mangan
  • 0,02 - 0,5 Gew.-% Eisen
  • 0,005 - 0,5 Gew.-% Zink
  • 0,1 bis 0,5 Gew.-% Kupfer
  • 0,02 bis 0,3 Gew.-% Molybdän
  • 0,02 bis 0,3 Gew.-% Zirkon
  • 0,02 bis 0,25 Gew.-% Titan
  • 3 bis 50 ppm Bor
  • 10 bis 200 ppm Gallium
According to the invention, this object is achieved by a diecasting alloy based on aluminum-silicon, consisting of:
  • 8.5 to 11.5 wt .-% silicon
  • 0.1 to 0.5 wt .-% magnesium
  • 0.3 to 0.8% by weight of manganese
  • 0.02-0.5% by weight of iron
  • 0.005-0.5% by weight of zinc
  • 0.1 to 0.5% by weight of copper
  • 0.02 to 0.3 wt .-% molybdenum
  • 0.02 to 0.3 wt .-% zirconium
  • 0.02 to 0.25% by weight of titanium
  • 3 to 50 ppm boron
  • 10 to 200 ppm gallium

Wahlweise 30 bis 300 ppm Strontium oder 5 bis 30 ppm Natrium oder 1 bis 30 ppm Calcium zur Dauerveredelung und 5 bis 250 ppm Phosphor und/oder 0,02 bis 0,25 Gew.-% Titan und 3 bis 50 ppm Bor zur Kornfeinung und der Rest Aluminium und unvermeidbare Verunreinigungen.Optionally, 30 to 300 ppm strontium or 5 to 30 ppm sodium or 1 to 30 ppm calcium for permanent refining and 5 to 250 ppm phosphorus and / or 0.02 to 0.25 wt% titanium and 3 to 50 ppm boron for grain refining and the rest aluminum and unavoidable impurities.

Weitere Ausführungsformen sind in den abhängigen Patentansprüchen wiedergegeben.Further embodiments are given in the dependent claims.

In einer Ausführungsform enthält die erfindungsgemässe Legierung 0,15-0,5 Gew. % Eisen.In one embodiment, the alloy according to the invention contains 0.15-0.5% by weight of iron.

In einer weiteren Ausführungsform enthält die erfindungsgemässe Legierung 0,05 bis 0,20 Gew.-% Molybdän.In a further embodiment, the alloy according to the invention contains 0.05 to 0.20% by weight of molybdenum.

In einer weiteren Ausführungsform enthält die erfindungsgemässe Legierung durch 0,05 bis 0,20 Gew.-% Zirkon.In a further embodiment, the alloy according to the invention contains from 0.05 to 0.20% by weight of zirconium.

In einer weiteren Ausführungsform enthält die erfindungsgemässe Legierung 60 - 120 ppm Gallium.In a further embodiment, the alloy according to the invention contains 60-120 ppm gallium.

In einer weiteren Ausführungsform enthält die erfindungsgemässe Legierung 0.3 bis 0.5 Gew. % Mangan.In a further embodiment, the alloy according to the invention contains 0.3 to 0.5% by weight of manganese.

In einer weiteren Ausführungsform enthält die erfindungsgemässe Legierung 0,2 bis 0,4 Gew.-% Zink.In a further embodiment, the alloy according to the invention contains 0.2 to 0.4% by weight of zinc.

In einer weiteren Ausführungsform enthält die erfindungsgemässe Legierung 0,15 bis 0,25 Gew.-% Kupfer.In a further embodiment, the alloy according to the invention contains 0.15 to 0.25% by weight of copper.

In einer weiteren Ausführungsform enthält die erfindungsgemässe Legierung 8,5 bis 10,0 Gew.-% Silizium.In a further embodiment, the alloy according to the invention contains 8.5 to 10.0% by weight of silicon.

In einer weiteren Ausführungsform enthält die erfindungsgemässe Legierung 0,3 bis 0,4 Gew.-% Magnesium.In a further embodiment, the alloy according to the invention contains from 0.3 to 0.4% by weight of magnesium.

Bevorzugt wird die erfindungsgemässe Druckgusslegierung zum Druckgiessen crashrelevanter oder festigkeitsrelevanter Strukturteilen im Automobilbau eingesetzt.The diecasting alloy according to the invention is preferably used for pressure casting of crash-relevant or strength-relevant structural parts in the automotive industry.

Die geeignete Festigkeit einer Aluminium-Druckgusslegierung wird neben der Wahl der Kombination an Legierungselementen auch durch eine gezielte Wärmebehandlung erreicht. Die erfindungsgemässe Legierung wird einer T6-Wärmebehandlung umfassend Lösungsglühen, Luftabschreckung oder Wasserabschreckung und Warmauslagerung unterzogen. Dabei konnte festgestellt werden, dass verglichen mit der Legierung aus EP 0687742B1 hohe Dehngrenzen von knapp über 200 N/mm2 erreicht werden können.The appropriate strength of an aluminum die casting alloy is achieved in addition to the choice of combination of alloying elements by a targeted heat treatment. The alloy according to the invention is subjected to a T6 heat treatment comprising solution heat treatment, air quenching or water quenching and heat aging. It could be determined that compared with the alloy EP 0687742B1 high yield strengths of just over 200 N / mm 2 can be achieved.

Die erfindungsgemässe Legierung ist nach der T6-Wärmebehandlung zeitfest, d.h. es tritt keine Selbstaushärtung ein.The alloy according to the invention is time-stable after T6 heat treatment, i. there is no self-curing.

Ferner ist es möglich, durch eine T6-Wärmebehandlung bei Anwendung hoher Glühtemperaturen von 530°C Dehngrenzen von bis zu 280 N/mm2 zu erreichen, in dem anschliessend eine Wasserabschreckung erfolgt.Furthermore, it is possible to achieve by a T6 heat treatment with application of high annealing temperatures of 530 ° C Dehngrenzen of up to 280 N / mm 2 , in which then a water quenching takes place.

Ferner kann die erfindungsgemässe Legierung einer T7-Wärmebehandlung unterzogen sein.Furthermore, the alloy according to the invention may be subjected to a T7 heat treatment.

Mit der erfindungsgemässen Legierungszusammensetzung lassen sich bei Druckgussteilen im Werkstoffzustand T6 bzw. T7 verbesserte Werte für Zugfestigkeit, die Dehngrenze und die Bruchdehnung erzielen.With the alloy composition according to the invention, it is possible to achieve improved values for tensile strength, the yield strength and the elongation at break in die cast parts in the material state T6 or T7.

Verglichen mit der Legierung aus EP 0687742B1 konnte festgestellt werden, dass die Wahl des Gehalts an Kupfer von 0,1 bis 0,5 Gew.-%, vorzugsweise 0,15 bis 0,25 Gew.-%, für die Verbesserung der mechanischen Kennwerte der Legierung verantwortlich ist. Gemäss EP 0687742 B1 sind das Einbringen von Kupfer beim Einschmelzen zu vermeiden, da Kupfer einen nachteiligen Einfluss auf die Korrosionsbeständigkeit hat. Die Zusammensetzung der erfindungsgemässen Legierung wurde so gewählt, dass die Entstehung von korrosionsfördernden Phasen wie z.B. Al2Cu vermieden wird. Ein Salzsprühnebel-Wechseltest (ISO 9227) und ein interkristalliner Korrosionstest (ASTM G110-92) dienten zur Überprüfung der Korrosionsneigung. Es konnte eine vergleichbare Korrosionsbeständigkeit wie die der bereits im Automobilbau eingesetzten Legierung aus EP1612286 B1 , welche den Kupfergehalt jedoch ausdrücklich auf max. 0.1 Gew. % Kupfer beschränkt, festgestellt werden. Weitere Elemente, die die mechanischen Kennwerte, insbesondere die Dehnung, verbessern, sind die Wahl des Molybdän-Gehalts und die Zugabe von Zirkon. Die Zugabe von mind. 0,08 % Zirkon bewirkt eine Steigerung der Dehnwerte ohne einen Abfall der Festigkeit des Werkstoffs. Diese Wirkung wird durch eine hochschmelzende Phase erreicht. In diesem Zusammenhang spielt der Zeitfaktor eine besondere Rolle. Größe und Ausprägung hochschmelzender Phasen sind stets abhängig von den Erstarrungsbedingungen. Im Druckguss beginnt die Erstarrung in der Regel bereits in der Giesskammer, setzt sich während der Formfüllung fort und endet in dickwandigen Bereichen oftmals erst nach der Bauteilentnahme. Die erfindungsgemäße Legierung ist für diese Abläufe entwickelt worden. Nur im Druckgießprozess haben die Ausscheidungen die richtige Größe und Ausprägung, um nach einer T6-Wärmebehandlung optimale Werkstoffkennwerte zu zeigen.Compared with the alloy out EP 0687742B1 It was found that the choice of the content of copper from 0.1 to 0.5 wt .-%, preferably 0.15 to 0.25 wt .-%, is responsible for improving the mechanical properties of the alloy. According to EP 0687742 B1 the introduction of copper during smelting should be avoided as copper has a negative influence on the corrosion resistance. The composition of the alloy according to the invention was chosen so that the formation of corrosion-promoting phases such as Al 2 Cu is avoided. A salt spray change test (ISO 9227) and an intercrystalline corrosion test (ASTM G110-92) were used to verify the corrosion tendency. It could have a corrosion resistance comparable to that of the alloy already used in the automotive industry EP1612286 B1 , which expressly limits the copper content to max. 0.1% by weight copper limited. Other elements that improve the mechanical properties, in particular the elongation, are the choice of molybdenum content and the addition of zirconium. The addition of at least 0.08% zirconium causes an increase in the expansion values without a decrease in the strength of the material. This effect is achieved by a high-melting phase. In this context, the time factor plays a special role. The size and characteristics of high-melting phases are always dependent on the solidification conditions. In die casting, the solidification usually begins in the casting chamber, continues during the mold filling and often ends in thick-walled areas only after the component removal. The alloy according to the invention has been developed for these processes. Only in the die casting process, the precipitates have the right size and characteristics to show optimal material properties after a T6 heat treatment.

Wird gleichzeitig Molybdän zugegeben, wirken diese beiden Elemente zusammen und es wird zusätzlich eine Steigerung der Festigkeit erreicht. Eine Erhöhung dieser Elemente über 0,2 % hinaus hat keine positive Wirkung auf die Kennwerte des Werkstoffs.If molybdenum is added at the same time, these two elements act together and, in addition, an increase in strength is achieved. Increasing these elements beyond 0.2% has no positive effect on the characteristics of the material.

Eine ähnliche Wirkung zeigte die Zugabe von Gallium auf die erfindungsgemäße Legierung. Mit der Zugabe von Gallium, neben Zirkon und Molybdän, konnte ein feineres Gefüge erreicht werden, insbesondere bei leicht erhöhtem Eisengehalt.A similar effect was shown by the addition of gallium to the alloy according to the invention. With the addition of gallium, in addition to zirconium and molybdenum, a finer structure could be achieved, especially with slightly increased iron content.

Die Zugabe von Mo, Zr und Ga spielt eine besondere Rolle, wenn Recyclingmaterial, sprich Sekundäraluminium zur Herstellung der Legierung, verwendet wird. Bei einem Eisengehalt von 0,2 % ist es möglich, die schädliche Wirkung des Eisens auf die Bruchdehnung zu minimieren. Es entsteht ein deutlich feineres Gefüge, in dem AlMgFeSi-Phasen kleiner und gleichmäßiger verteilt sind.The addition of Mo, Zr and Ga plays a special role when recycling material, that is secondary aluminum, is used to produce the alloy. With an iron content of 0.2%, it is possible to minimize the harmful effect of iron on the elongation at break. This results in a much finer microstructure in which AlMgFeSi phases are smaller and more evenly distributed.

Dem leicht erhöhten Eisengehalt wird durch eine Senkung des Mangananteils Rechnung getragen, ansonsten besteht die Gefahr von Schlammbildung im Warmhalteofen an der Gießmaschine. Die Klebeneigung der Legierung sinkt dennoch, da hierbei Eisen ebenso wie Mangan positiv wirkt und die Reduktion von Mn durch den Fe-Gehalt überkompensiert wird.The slightly increased iron content is taken into account by reducing the manganese content, otherwise there is a risk of sludge formation in the holding furnace at the casting machine. However, the tendency of the alloy to adhere decreases, since both iron and manganese have a positive effect and the reduction of Mn is more than compensated for by the Fe content.

Zudem wird durch das MnFe-Verhältnis die Entstehung von sog. Betaphasen vermieden, also plattenförmingen AlMnFeSi-Ausscheidungen, wodurch die Duktilität des Werkstoffs entscheidend reduziert wird. Solche Ausscheidungen sind unter dem Mikroskop als sog. Eisennadeln bekannt.In addition, the MnFe ratio prevents the formation of so-called beta phases, ie plate-shaped AlMnFeSi precipitates, which significantly reduces the ductility of the material. Such excretions are known under the microscope as so-called. Iron needles.

Die Alpha-AlMnFeSi-Ausscheidungen werden bei der erfindungsgemässen Legierung durch die Zugabe der Elemente Mo, Zr und Ga sehr fein ausgebildet, sodass ihre schädliche Wirkung auf Dehnwerte und Korrosionsneigung minimiert werden kann.The alpha-AlMnFeSi precipitates are formed very finely in the inventive alloy by the addition of the elements Mo, Zr and Ga, so that their harmful effect on Dehnwerte and corrosion tendency can be minimized.

Durch den gewählten, geringen Anteil an Zink in Verbindung mit den anderen, erfindungsgemässen Elementen wurden eine Verbesserung der Gießbarkeit und eine Erhöhung der Bruchdehnung erreicht. Im Allgemeinen zeigt ein Zinkgehalt von bis zu 0.5 Gew. % noch keine Wirkung auf Werkstoffkennwerte. Die gegenüber Patent EP 0687742B1 verbesserte Gießbarkeit der Legierung wirkt sich aber auf die Oberflächenqualität der Bauteile und somit auf die Werkstoffkennwerte aus.By the selected, low proportion of zinc in conjunction with the other elements according to the invention, an improvement in the castability and an increase in the elongation at break were achieved. In general, a zinc content of up to 0.5 wt.% Has no effect on material properties. The opposite Patent EP 0687742B1 Improved castability of the alloy, however, has an effect on the surface quality of the components and thus on the material characteristics.

Die Zugabe von Strontium oder Natrium führt zu einer feinkristallinen Ausscheidung des Siliziums, was die Ausbildung eines veredelten Eutektikums zur Folge, und ebenfalls einen positiven Einfluss auf die Festigkeit und Dehnung der erfindungsgemässen Legierung hat.The addition of strontium or sodium leads to a finely crystalline precipitation of the silicon, which results in the formation of a refined eutectic, and also has a positive influence on the strength and elongation of the alloy according to the invention.

Bevorzugt wird bei der erfindungsgemässen Legierung eine Kornfeinung durchgeführt. Hierzu kann der Legierung vorzugsweise 1 bis 30 ppm Phosphor zugeführt werden. Alternativ oder zusätzlich kann die Legierung zur Kornfeinung auch Titan und Bor enthalten, wobei die Zugabe von Titan und Bor über eine Vorlegierung mit 1 bis 2 Gew.-% Ti und 1 bis 2 Gew.-% B, Restaluminium, erfolgt. Bevorzugt enthält die Aluminium-Vorlegierung 1,3 bis 1,8 Gew.-% Ti und 1,3 bis 1,8 Gew.-% B und weist ein Ti/B Gewichtsverhältnis von etwa 0,8 bis 1,2 auf. Der Gehalt der Vorlegierung in der erfindungsgemässen Legierung wird bevorzugt auf 0,05 bis 0,5 Gew.-% eingestellt.Grain refining is preferably carried out in the case of the alloy according to the invention. For this, the alloy may preferably be supplied with 1 to 30 ppm of phosphorus. Alternatively or additionally, the alloy may also contain titanium and boron for grain refining, the addition of titanium and boron via a master alloy with 1 to 2% by weight of Ti and 1 to 2% by weight of B, residual aluminum. Preferably, the aluminum master alloy contains 1.3 to 1.8% by weight of Ti and 1.3 to 1.8% by weight of B, and has a Ti / B weight ratio of about 0.8 to 1.2. The Content of the master alloy in the alloy according to the invention is preferably adjusted to 0.05 to 0.5 wt .-%.

Im Rahmen der Untersuchungen war es möglich, die erfindungsgemässe Legierung mit einem Recyclinganteil von 50-70 % herzustellen.Within the framework of the investigations it was possible to produce the alloy according to the invention with a recycling proportion of 50-70%.

Notwendig hierfür ist hochwertiges Recyclingmaterial, wie beispielsweise Schrotte von Rädern, Strangpressprofilen, Blechen und auch Spänen sowie die Verwendung eines bewährten Kipp-Trommelofens zum Schmelzen der Legierung. Bis zu einem Eisengehalt von 0,25 % konnten die Anforderungen an crashrelevante Strukturbauteile erfüllt werden, bis zu einem Eisengehalt von 0,40 % war ein Einsatz in festigkeitsrelevanten Strukturbauteilen möglich.Necessary for this is high-quality recycling material, such as scrap of wheels, extruded profiles, sheets and chips as well as the use of a proven tilting drum furnace for melting the alloy. Up to an iron content of 0.25%, the requirements for crash-relevant structural components could be fulfilled; up to an iron content of 0.40%, it was possible to use them in structural components relevant to structural strength.

Die Schweisseignung konnte in WIG-Schweißtests überprüft werden. In Stanznietversuchen war die erfindungsgemäße Legierung trotz ihrer hohen Festigkeit rissfrei nietbar.The weldability could be checked in TIG welding tests. In punch rivet tests, the alloy according to the invention was rivet free of cracks despite its high strength.

VergleichsbeispielComparative example

Im Folgenden sind die Zusammensetzungen einer beispielhaften Legierung aus der EP0687742B1 (Legierung 1) und zwei Ausführungsbeispiele (Legierungen A, B) der erfindungsgemässen Legierung gegenübergestellt. Die Angaben verstehen sich in Gew.-%. Anhand dieser zwei Legierungen wurden die mechanischen Kennwerte (Rm, Rp0.2 und A5) an druckgegossenen 3 mm-Platten gemessen. Bei allen Versuchen wurde dieselbe T6-Wärmebehandlung mit Luftabschreckung und mit Wasserabschreckung angewendet. Dargestellt ist jeweils der Mittelwert aus ca. 30 Zugprüfungen.

Figure imgb0001
The following are the compositions of an exemplary alloy of the EP0687742B1 (Alloy 1) and two embodiments (alloys A, B) of the inventive alloy compared. The statements are in wt .-%. Using these two alloys, the mechanical characteristics (R m , R p0.2 and A 5 ) were measured on 3 mm die-cast plates. In all experiments, the same T6 heat treatment with air quenching and applied with water quenching. The mean value of approx. 30 train tests is shown in each case.
Figure imgb0001

Erzielte ResultateAchieved results

T6-Wärmebehandlung, Abschreckung an LuftT6 heat treatment, quenching in air Rm [N/mm2]Rm [N / mm 2 ] Rp0,2 [N/mm2]Rp 0.2 [N / mm 2 ] A5 [%]A 5 [%] Legierung 1Alloy 1 236236 167167 7,97.9 Legierung AAlloy A 288288 209209 11,011.0 Legierung BAlloy B 280280 189189 9,69.6 T6-Wärmebehandlung, Abschreckung in WasserT6 heat treatment, quenching in water Rm [N/mm2]Rm [N / mm 2 ] Rp0,2 [N/mm2]Rp 0.2 [N / mm 2 ] A5 [%]A 5 [%] Legierung 1Alloy 1 326326 241241 7,97.9 Legierung AAlloy A 332332 257257 10,010.0 Legierung BAlloy B 348348 264264 8,28.2

Claims (11)

Druckgusslegierung auf Basis Aluminium-Silizium, bestehend aus: 8,5 bis 11,5 Gew.-% Silizium 0,1 bis 0,5 Gew.-% Magnesium 0,3 bis 0,8 Gew.-% Mangan 0,02 - 0,5 Gew.-% Eisen 0,005 - 0,5 Gew.-% Zink 0,1 bis 0,5 Gew.-% Kupfer 0,02 bis 0,3 Gew.-% Molybdän 0,02 bis 0.3 Gew.-% Zirkon 10 bis 200 ppm Gallium wahlweise 30 bis 300 ppm Strontium oder 5 bis 30 ppm Natrium oder 1 bis 30 ppm Calcium zur Dauerveredelung und 5 bis 250 ppm Phosphor und/oder 0,02 bis 0,25 Gew.-% Titan und 3 bis 50 ppm Bor zur Kornfeinung und der Rest Aluminium und unvermeidbare Verunreinigungen.Diecasting alloy based on aluminum-silicon, consisting of: 8.5 to 11.5 wt .-% silicon 0.1 to 0.5 wt .-% magnesium 0.3 to 0.8% by weight of manganese 0.02-0.5% by weight of iron 0.005-0.5% by weight of zinc 0.1 to 0.5% by weight of copper 0.02 to 0.3 wt .-% molybdenum 0.02 to 0.3 wt .-% zirconium 10 to 200 ppm gallium optionally 30 to 300 ppm of strontium or 5 to 30 ppm of sodium or 1 to 30 ppm of calcium for permanent processing and 5 to 250 ppm of phosphorus and / or 0.02 to 0.25% by weight of titanium and 3 to 50 ppm boron for grain refining and the rest aluminum and unavoidable impurities. Druckgusslegierung nach Anspruch 1, gekennzeichnet durch 0,15-0,5 Gew. % Eisen.Diecasting alloy according to claim 1, characterized by 0.15-0.5% by weight of iron. Druckgusslegierung nach einem der vorangegangenen Ansprüche, gekennzeichnet durch 0,05 bis 0,20 Gew.-% Molybdän.Die casting alloy according to one of the preceding claims, characterized by 0.05 to 0.20 wt .-% molybdenum. Druckgusslegierung nach einem der vorangegangenen Ansprüche, gekennzeichnet durch 0,05 bis 0,20 Gew.-% Zirkon.Die casting alloy according to one of the preceding claims, characterized by 0.05 to 0.20 wt .-% zirconium. Druckgusslegierung nach einem der vorangegangenen Ansprüche, gekennzeichnet durch 60 - 120 ppm GalliumDie casting alloy according to one of the preceding claims, characterized by 60-120 ppm gallium Druckgusslegierung nach einem der vorangegangenen Ansprüche, gekennzeichnet durch 0.3 bis 0.5 Gew. % Mangan.Die-cast alloy according to one of the preceding claims, characterized by 0.3 to 0.5 wt.% Manganese. Druckgusslegierung nach einem der vorangegangenen Ansprüche, gekennzeichnet durch 0,2 bis 0,4 Gew.-% Zink.Die casting alloy according to one of the preceding claims, characterized by 0.2 to 0.4 wt .-% zinc. Druckgusslegierung nach einem der vorangegangenen Ansprüche, gekennzeichnet durch 0,15 bis 0,25 Gew.-% Kupfer.Die casting alloy according to one of the preceding claims, characterized by 0.15 to 0.25 wt .-% copper. Druckgusslegierung nach einem der vorangegangenen Ansprüche, gekennzeichnet durch 8,5 bis 10,0 Gew.-% Silizium.Die casting alloy according to one of the preceding claims, characterized by 8.5 to 10.0 wt .-% silicon. Druckgusslegierung nach einem der vorangegangenen Ansprüche, gekennzeichnet durch 0,3 bis 0,4 Gew.-% Magnesium.Die casting alloy according to one of the preceding claims, characterized by 0.3 to 0.4 wt .-% magnesium. Verwendung einer Druckgusslegierung nach einem der vorangegangenen Ansprüche zum Druckgiessen von crashrelevanten oder festigkeitsrelevanten Strukturteilen im Automobilbau.Use of a diecasting alloy according to one of the preceding claims for die casting of crash-relevant or strength-relevant structural parts in the automotive industry.
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