EP3257957A1 - Aluminum alloy forging and method of producing the same - Google Patents

Aluminum alloy forging and method of producing the same Download PDF

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Publication number
EP3257957A1
EP3257957A1 EP17168677.7A EP17168677A EP3257957A1 EP 3257957 A1 EP3257957 A1 EP 3257957A1 EP 17168677 A EP17168677 A EP 17168677A EP 3257957 A1 EP3257957 A1 EP 3257957A1
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EP
European Patent Office
Prior art keywords
mass
forging
aluminum alloy
phase
equivalent diameter
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.)
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Application number
EP17168677.7A
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German (de)
English (en)
French (fr)
Inventor
Takumi Maruyama
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Resonac Holdings Corp
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Showa Denko KK
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Publication of EP3257957A1 publication Critical patent/EP3257957A1/en
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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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0408—Light metal alloys
    • C22C1/0416—Aluminium-based 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
    • C22C21/04—Modified aluminium-silicon alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/008—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of engine cylinder parts or of piston parts other than piston rings
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/047—Making non-ferrous alloys by powder metallurgy comprising intermetallic compounds

Definitions

  • the present invention relates to an aluminum alloy forging excellent in strength at high temperature and a method of producing the aluminum alloy forging. More particularly, it relates to an aluminum alloy forging suitably used as a sliding member, such as, e.g., an engine piston of an internal combustion engine, which is required to have a large heat load, abrasion resistance, and seizure resistance, and a method of producing the aluminum alloy forging.
  • a sliding member such as, e.g., an engine piston of an internal combustion engine, which is required to have a large heat load, abrasion resistance, and seizure resistance
  • an engine piston for an internal combustion engine is a member that slides at high temperature, it is required to have excellent abrasion resistance and sufficient high temperature strength, and further required to have excellent seizure resistance.
  • eutectic or hypereutectic Al-Si alloys contain about 10 mass% or more of Si. This eutectic or hypereutectic Al-Si alloy is small in coefficient of thermal expansion and excellent in abrasion resistance, so it is used as a material for a sliding member, such as, e.g., an automobile engine piston.
  • an aluminum alloy powder material capable of being used even in high-temperature atmosphere.
  • an aluminum alloy powder an aluminum alloy powder containing one or two heavy metals selected from the group consisting of Si: 15.0 to 25.0% by weight, Fe: 5.9 to 15.0% by weight, and Mn: 7.1 to 15.0% by weight, and the balance being Al and inevitable impurities, and having a size of a Si crystal grain of 15 ⁇ m or less is known (see Patent Document 1: Japanese Unexamined Laid-open Patent Publication No. S63-266005 ).
  • the present invention was made in view of such a technical background, and aims to provide an aluminum alloy forging excellent in forgeability, such as easy to forging deformation and no occurrence of cracking, and also high in high temperature strength, and also to provide a method of producing such an aluminum alloy forging.
  • the present invention provides the following means.
  • an aluminum alloy forging excellent in forgeability such as easy to forging deformation and no occurrence of cracking, and high in temperature strength is provided. Therefore, this forging is suitable as, for example, a sliding member for an automobile engine piston, etc.
  • an aluminum alloy forging higher in high temperature strength is provided.
  • the obtained forging is suitable as, for example, a sliding member for an automobile engine piston.
  • an aluminum alloy forging higher in high temperature strength can be manufactured.
  • an aluminum alloy forging further increased in high temperature strength can be manufactured.
  • An aluminum alloy forging is a forging of an aluminum alloy atomized powder containing: Si: 10.0 mass% to 19.0 mass%, Mn: 3.0 mass% to 10.0 mass%, Cu: 0.5 mass% to 10.0 mass%, Mg: 0.2 mass% to 3.0 mass%, and the balance being Al (aluminum) and inevitable impurities.
  • a cross-sectional structure of the forging is configured so as to include a ⁇ -phase of CuAl 2 , and an average circle equivalent diameter of the ⁇ -phase is 0.66 ⁇ m to 1.66 ⁇ m.
  • the forging having the aforementioned configuration is an aluminum alloy atomized powder forging. Since an atomized powder is used, the aforementioned forging is fine and uniform in structure. Compared to an alloy obtained by the aforementioned casting method, characteristics, such as, e.g., abrasion resistance and low coefficient of thermal expansion, can be improved. Furthermore, in the forging having the aforementioned configuration, its cross-sectional structure includes a ⁇ -phase of CuAl 2 and the average circle equivalent diameter of the ⁇ -phase is in the range of 0.66 ⁇ m to 1.66 ⁇ m. For this reason, a forging excellent in forgeability, such as easy to forge deformation and no occurrence of cracking, and large in high temperature strength can be obtained.
  • the average circle equivalent diameter of the ⁇ -phase is smaller than 0.66 ⁇ m, larger high temperature strength cannot be obtained. Also, when the average circle equivalent diameter of the ⁇ -phase is larger than 1.66 ⁇ m, the dispersion hardening ability decreases, which results in, for example, insufficient strength (high temperature strength) in the operating temperature range of a sliding member.
  • the average circle equivalent diameter of the ⁇ -phase is preferably 0.86 ⁇ m to 1.46 ⁇ m.
  • the aluminum alloy forging is preferably configured such that it has an Al-Mn-Si based intermetallic compound and the average circle equivalent diameter of the Al-Mn-Si based intermetallic compound is in the range of 0.04 ⁇ m to 0.24 ⁇ m in the cross-sectional structure of the forging.
  • the average circle equivalent diameter is less than 0.04 ⁇ m, large high temperature strength cannot be obtained.
  • the average circle equivalent diameter of the ⁇ -phase is larger than 0.24 ⁇ m, the dispersion hardening ability decreases, which results in, for example, insufficient strength (high temperature strength) in the operating temperature range of a sliding member.
  • the circle equivalent diameter of the ⁇ -phase is a value obtained by converting as a diameter of a circle having the same area as the area of the ⁇ -phase (CuAl 2 ) in the SEM photograph (image), and the circle equivalent diameter of the Al-Mn-Si based intermetallic compound is a value converted as a diameter of a circle having the same area as the area of the Al-Mn-Si based intermetallic compound in the SEM photograph (image).
  • An aluminum molten metal containing Si: 10.0 mass% to 19.0 mass%, Mn: 3.0 mass% to 10.0 mass%, Cu: 0.5 mass% to 10.0 mass%, Mg: 0.2 mass% to 3.0 mass%, and the balance being Al and inevitable impurities is rapidly solidified by an atomizing method into a powder to obtain an aluminum alloy powder (Powdering Step).
  • the molten aluminum alloy having the aforementioned specific composition is prepared by a normal dissolution method.
  • the obtained molten aluminum alloy is powdered by an atomizing method.
  • the atomizing method is a method in which fine droplets of the molten aluminum alloy are misted and sprayed by a flow of gas, such as a nitrogen gas, from a spray nozzle to rapidly solidify the fine droplets to obtain a fine aluminum alloy powder.
  • the cooling rate is preferably from 10 3 to 10 5 °C/sec. It is preferable to obtain an aluminum alloy powder of 30 ⁇ m to 70 ⁇ m. It is preferable to classify the obtained aluminum alloy powder using a sieve. Among other things, it is more preferable to obtain an aluminum alloy powder of 150 ⁇ m or less.
  • the aluminum alloy powder obtained in the powdering step is compression molded to obtain a green compact (Compression Molding Step).
  • the aluminum alloy powder heated to 250°C to 300°C is filled in a metal mold heated to 230°C to 270°C and compression molded into a predetermined shape to obtain a green compact.
  • the pressure of the compression molding is not particularly limited, it is usually preferable that the pressure be set at 0.5 ton/cm 2 to 3.0 ton/cm 2 . Further, it is preferable to prepare a green compact having a relative density of 60% to 90%.
  • the shape of the green compact is not particularly limited, it is preferable to form into a cylindrical shape or a disc-shape, considering the extrusion step which will be described below.
  • the green compact obtained in the Compression Molding Step is hot extruded to obtain an extruded material (Extrusion Step).
  • the green compact is subjected to mechanical processing such as facing as necessary, and then subjected to a degassing treatment, heating, and an extrusion step.
  • the heating temperature of the green compact before extrusion is preferably set to 300°C to 450°C.
  • the green compact is inserted into an extrusion container, pressurized by an extrusion ram, and extruded from an extrusion die into, for example, a round bar shape. At this time, it is preferable that the extrusion container be previously heated to 300°C to 400°C.
  • the extrusion pressure is preferably set to 10 MPa to 25 MPa.
  • the hot forging is performed.
  • the hot forging it is preferable to adopt hermetically forging or semi-closed type forging so that the forged material (forging) is formed into a shape close to a product shape (for example, an engine piston shape).
  • the hot forging may be free forging.
  • the temperature of the hot forging is preferably set to 300°C to 450°C.
  • the forged material may be subjected to cutting, surface polishing, etc., to obtain a product (forging) such as a sliding member for an automobile engine piston, etc., but the following heat treatment may be performed.
  • the forged material is subjected to a solution treatment.
  • This solution treatment is a treatment to dissolve Cu, Mg, etc., in a supersaturated state, and the heating temperature of the solution treatment is preferably 480°C to 500°C.
  • a quenching treatment is performed by water quenching, etc., to obtain a supersaturated solid solution in which Cu, Mg, etc., are solid-dissolved so as to exceed the solid solubility limit at room temperature.
  • the quenching temperature is preferably 0°C to 50°C.
  • an aging treatment is performed.
  • intermetallic compounds containing Cu, Mg, etc. can be finely precipitated, which can improve the strength and abrasion resistance of the forging.
  • the aging treatment is preferably performed at a temperature of 180°C to 280°C for 1 hour to 4 hours.
  • a product (forging) such as a sliding member exemplified by an engine piston for an automobile, can be obtained.
  • the aluminum alloy is an aluminum alloy containing Si: 10.0 mass% to 19.0 mass%, Mn: 3.0 mass% to 10.0 mass%, Cu: 0.5 mass% to 10.0 mass%, Mg: 0.2 mass% to 3.0 mass%, the balance being Al and inevitable impurities.
  • the Si content in the aluminum alloy is set so as to fall within the range of 10.0 mass% to 19.0 mass%.
  • the Si content rate is less than 10.0 mass%, the amount of Si crystallized material decreases, resulting in decrease in abrasion resistance and strength.
  • the Si content rate exceeds 19.0 mass%, coarse primary crystal Si crystallizes to cause decrease in strength, causing embrittlement of the material, which results in deteriorated forgeability.
  • the Si content rate in the aluminum alloy is preferably 12 mass% to 16 mass%, which can assuredly achieve both high temperature strength and excellent forgeability.
  • the Mn content in the aluminum alloy is set so as to fall within the range of 3.0 mass% to 10.0 mass%.
  • the Mn content in the aluminum alloy is preferably in the range of 6.0 mass% to 8.0 mass%.
  • the Cu content in the aluminum alloy is set so as to fall within the range of 0.5 mass% to 10.0 mass%.
  • Cu is an essential element for improving room temperature strength and high temperature strength.
  • the Cu content rate is less than 0.5 mass%, the solid solution amount decreases and the effect of improving the strength decreases, and the strength improvement effect due to the dispersion strengthening by the crystallized CuAl 2 phase is small.
  • the Cu content rate exceeds 10.0 mass%, the extrusion processability decreases and the ⁇ -phase (CuAl 2 ) coarsely precipitates or crystallizes at the grain boundary, possibly reducing the elongation at break.
  • the Mg content in the aluminum alloy is set so as to fall within the range of 0.2 mass% to 3.0 mass%.
  • Mg is an essential element for improving room temperature strength and high temperature strength.
  • the Mg content rate is less than 0.2 mass%, the effect of improving the strength is less. Further, when the Mg content rate exceeds 3.0 mass%, the extrusion processability deteriorates.
  • the aluminum alloy may be configured to contain 0.01 mass% to 5.0 mass% of each of one or more elements selected from the group consisting of Ti, Zr, V, W, Cr, Co, Mo, Ta, Hf, and Nb. In this case, an aluminum alloy forging further increased in high temperature strength is obtained.
  • the molten aluminum alloy was atomized with gas and rapidly solidified into a powder, classified with a 100 mesh sieve. Thus, an aluminum alloy powder passed through a 100 mesh sieve was obtained.
  • the obtained aluminum alloy powder was preheated to a temperature of 280°C, the preheated aluminum alloy powder was filled in a mold heated at the same temperature of 280°C, and compression molded at a pressure of 1.5 ton/cm 2 .
  • a columnar green compact (compact) having a diameter of 210 mm and a length of 250 mm was obtained.
  • the green compact obtained was faced by a lathe to a diameter of 203 mm to obtain a green compact billet.
  • the obtained billet was heated to 350°C, and this heated billet was inserted into an extrusion container maintained at 350°C and having an inner diameter of 210 mm, and extruded at an extrusion rate of 7.8 by an indirect extrusion method with a die having an inner diameter of 75 mm.
  • an extruded material 10 was obtained.
  • Fig. 1 shows an extruded material 10 before forging
  • Fig. 2 shows a forging 20 after forging.
  • an aluminum alloy for forming a molten aluminum alloy using an aluminum alloy containing Si: 15.6 mass%, Mn: 6.72 mass%, Cu: 3.09 mass%, Mg: 1.06 mass%, and the balance being Al and inevitable impurities, an aluminum alloy forging was obtained in the same manner as in Example 1 except that the temperature of molten aluminum alloy was 900°C and a sieve of 170 mesh was used as a sieve.
  • an aluminum alloy for forming a molten aluminum alloy using an aluminum alloy containing Si: 15.6 mass%, Mn: 6.78 mass%, Cu: 3.12 mass%, Mg: 1.11 mass%, and the balance being Al and inevitable impurities, an aluminum alloy forging was obtained in the same manner as in Example 1 except that the temperature of molten aluminum alloy was 1,100°C.
  • an aluminum alloy for forming a molten aluminum alloy using an aluminum alloy containing Si: 15.6 mass%, Mn: 6.78 mass%, Cu: 3.12 mass%, Mg: 1.11 mass%, and the balance being Al and inevitable impurities, an aluminum alloy forging was obtained in the same manner as in Example 1 except that the temperature of molten aluminum alloy was 1,100°C and a sieve of 50 mesh was used as a sieve.
  • the obtained forging was heated to 490°C and held for 3 hours and then quenched in water at 20°C. Thereafter, as an aging treatment, it was heated at 220°C for 1 hour to obtain a T7 treated product.
  • the T7 treated product was processed into a tensile test piece having a gauge distance of 20 mm and a parallel portion diameter of 4 mm, and the high temperature tensile strength (tensile strength at 300°C) was measured by performing a high temperature tensile test of the tensile test piece. In the high-temperature tensile test, the high temperature tensile test piece was held at 300°C for 100 hours and then tested at 300°C. The evaluation was made based on the following criteria. In Example 1, the tensile strength at 300°C was 160 MPa, and it was evaluated as ⁇ (large high temperature tensile strength was obtained).
  • the obtained forging was heated to 490°C and held for 3 hours and then quenched in water at 20°C. Thereafter, as an aging treatment, it was heated at 220°C for 1 hour to obtain a T7 treated product.
  • a structure observation sample having a size of 10 mm ⁇ 10 mm ⁇ 10 mm was cut out from the T7 treated product.
  • the obtained structure observation sample was filled with resin, then subjected to mirror polishing by physical polishing and observed with a FE-SEM (Field Emission Scanning Electron Microscope; JEOL JSM-7000F) on the cross-section perpendicular to the upset direction (reflected electron image was observed).
  • the image analysis of the obtained reflected electron image ( ⁇ 10k) was performed.
  • the object of the image analysis is a ⁇ -phase (CuAl 2 phase) and an Al-Mn-Si based intermetallic compound.
  • the circle equivalent diameters of arbitrary three fields of view (three places) in the electron microscope image were respectively calculated, and the average value was calculated to obtain an "average circle equivalent diameter". That is, the average circle equivalent diameter of the ⁇ -phase (CuAl 2 phase) and the average circle equivalent diameter of Al-Mn-Si based intermetallic compound were obtained (see Table 1).
  • Example 1 As is apparent from Table 1, the aluminum alloy forging of Example 1 according to the present invention was high in high temperature tensile strength (tensile strength at 300°C).
  • the aluminum alloy forging according to the present invention and the aluminum alloy forging produced by the production method of the present invention are excellent in forgeability and excellent in strength at high temperature. Therefore, it is suitable as a sliding member for an automobile engine piston, etc., but it is not particularly limited to such use.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Powder Metallurgy (AREA)
  • Manufacture Of Metal Powder And Suspensions Thereof (AREA)
  • Forging (AREA)
EP17168677.7A 2016-06-13 2017-04-28 Aluminum alloy forging and method of producing the same Withdrawn EP3257957A1 (en)

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JP2016117232A JP6738212B2 (ja) 2016-06-13 2016-06-13 アルミニウム合金鍛造品及びその製造方法

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JP2019190366A (ja) * 2018-04-25 2019-10-31 昭和電工株式会社 インペラ用鍛造品
JP2019190364A (ja) * 2018-04-25 2019-10-31 昭和電工株式会社 インペラ用鍛造品
JP2019190365A (ja) * 2018-04-25 2019-10-31 昭和電工株式会社 インペラ用鍛造品
JP2020100863A (ja) * 2018-12-21 2020-07-02 昭和電工株式会社 コンプレッサー摺動部品用アルミニウム合金、コンプレッサー摺動部品鍛造品およびその製造方法

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5913041A (ja) * 1982-07-12 1984-01-23 Showa Denko Kk 耐熱耐摩耗性高力アルミニウム合金粉末成形体およびその製造方法
JPS63266005A (ja) 1987-11-10 1988-11-02 Showa Denko Kk 耐熱耐摩耗性高力アルミニウム合金粉末
EP3170594A1 (en) * 2015-10-21 2017-05-24 Showa Denko K.K. Aluminum alloy powder for hot forging of sliding component, method of producing the same, aluminum alloy forged product for sliding component, and method of producing the same

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JPS61295301A (ja) * 1985-06-25 1986-12-26 Honda Motor Co Ltd 耐熱性高カアルミニウム合金粉末およびその成形体
JPS6210237A (ja) * 1985-07-09 1987-01-19 Showa Denko Kk 熱間鍛造用アルミニウム合金
JPS63230842A (ja) * 1987-03-18 1988-09-27 Showa Denko Kk 熱間鍛造性に優れたアルミニウム合金
JPS62247044A (ja) * 1987-04-03 1987-10-28 Sumitomo Electric Ind Ltd 高強度耐摩耗性アルミニウム合金
JPS6439341A (en) * 1987-08-06 1989-02-09 Sumitomo Electric Industries Al-si-mn sintered alloy for forging
CN105522156B (zh) * 2014-10-23 2018-01-09 东睦新材料集团股份有限公司 一种粉末冶金高硅铝合金压缩机活塞的制造方法

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5913041A (ja) * 1982-07-12 1984-01-23 Showa Denko Kk 耐熱耐摩耗性高力アルミニウム合金粉末成形体およびその製造方法
JPS63266005A (ja) 1987-11-10 1988-11-02 Showa Denko Kk 耐熱耐摩耗性高力アルミニウム合金粉末
EP3170594A1 (en) * 2015-10-21 2017-05-24 Showa Denko K.K. Aluminum alloy powder for hot forging of sliding component, method of producing the same, aluminum alloy forged product for sliding component, and method of producing the same

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