EP3339465B1 - Method for solution heat treating with pressure - Google Patents

Method for solution heat treating with pressure Download PDF

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Publication number
EP3339465B1
EP3339465B1 EP17206338.0A EP17206338A EP3339465B1 EP 3339465 B1 EP3339465 B1 EP 3339465B1 EP 17206338 A EP17206338 A EP 17206338A EP 3339465 B1 EP3339465 B1 EP 3339465B1
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EP
European Patent Office
Prior art keywords
solution heat
high pressure
die cast
ksi
bar
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EP17206338.0A
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German (de)
English (en)
French (fr)
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EP3339465A1 (en
Inventor
Kevin R. Morasch
Kevin R. Anderson
Raymond J. Donahue
Christopher J. Misorski
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Brunswick Corp
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Brunswick Corp
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Priority claimed from US15/389,989 external-priority patent/US11047032B2/en
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • 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
    • C22F1/002—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working by rapid cooling or quenching; cooling agents used therefor

Definitions

  • the present application relates to heat treatment of high pressure die cast objects, and more particularly to the solution heat treatment of high pressure die cast objects with pressure.
  • the present invention relates to a method of heat treating a high pressure die cast aluminum alloy object with the features of the introductory part of claim 1.
  • High pressure die casting is a low cost, dimensionally accurate casting process for high volume production of many cast objects, including, but not limited to marine propellers, marine and automotive engine components, vehicle chassis, vehicle closures, vehicle structural bodies, and advanced vehicle bodies. Approximately 70% of all cast aluminum is cast using the high pressure die casting process, primarily using aluminum alloys. In high volume, the high pressure die casting process delivers castings on a cost per pound basis that are lower cost at higher dimensional accuracy than alternative methods such as permanent mold casting or sand casting.
  • the disadvantage of the high pressure die casting process is that it results in cast objects having comparatively lower strength than permanent mold or sand casting.
  • This lower strength is due to the fact that the high pressure die casting process moves metal in a violent, turbulent fashion, entrapping air in the molten metal during the casting process.
  • This entrapped air becomes problematic because, in order to increase the strength of a high pressure aluminum die cast object, it is preferable to heat treat the cast object after casting.
  • a typical heat treatment to strengthen aluminum alloys is solution heat treatment and artificial aging to achieve the T6 treatment condition.
  • the cast object In traditional solution heat treatment, the cast object is placed in an air furnace, fused salt bath, or fluidized sand bed and manipulated with heat to develop a wide range of mechanical properties and achieve a combination of properties unattainable by other means.
  • the high pressure die cast object is heated to a specific temperature to create a super-saturated solution of alloy elements, and the object is then soaked at that temperature for a given time. Subsequently, the die cast object is rapidly quenched and artificially aged at a lower temperature for a given period of time.
  • cast objects may be subjected to temperatures up to 538 °C (1000°F) for up to 12 hours.
  • a permanent mold or sand cast aluminum alloy cast object will dissolve any magnesium present into solid solution for the given alloy, and will thermally modify the eutectic silicon providing mechanical advantages.
  • any entrained gas in the casting will volumetrically expand at the increased temperature, increasing the pressure within the pore or defect. This increase in pressure and the result of low mechanical properties of the metal at that elevated temperature creates a situation where the metal plastically deforms leaving a blister defect either internally or at the surface that creates aesthetic and mechanical problems.
  • blister defects were prevented by heat treating high pressure die cast objects at very short solution times (e.g. 15 minutes). This short solution time fails to allow for sufficient modification of the eutectic and does not create the mechanical advantages that a longer (e.g. 2-12 hour) treatment creates.
  • HIP hot isostatic pressing
  • the HIP process involves healing of shrinkage porosity and subsequent improvements in tensile and fatigue properties for sand cast or permanent mold cast aluminum castings.
  • Internal shrinkage porosity results from solidification shrinkage of the alloy and processing variables such as the geometric effects of the mold, or the effects of casting parameters including metal temperature, mold temperature, cooling rate, and pour rate.
  • the HIP procedure involves the use of uniform gas pressure applied at elevated temperatures and subsequent slow cooling to room temperature. The parts are commonly solution heat treated after cooling to room temperature. In the case of aluminum alloys, pressures above 1034 bar (15 KSI) and temperatures around 527°C (980°F) can be used.
  • the hot isostatic pressing process requires high pressures, above 1034 bar (15 KSI), and large, expensive pressure vessels to attain that pressure. More significantly, the hot isostatic pressing process is incapable of fixing blistering defects resulting from the high pressure die casting process. In other words, the extensive amount of entrapped air in high pressure die cast aluminum alloy castings cannot be fixed by the hot isostatic pressing process.
  • This well-known lack of effectiveness of HIP processing on high pressure die castings was verified by the inventors in an experiment where a high pressure die cast propeller was subjected to 1034 bar (15 KSI) pressure at 538°C (1000°F) for 4 hours of hot isostatic pressing and allowed to cool to room temperature.
  • US3732128 discloses a heat treatment of die castings of Al, Mg or their alloys consisting of heating to 300°C to 600°C in a closed chamber at 100-10000 psi for 1-72 h are rapidly cooled while still under pressure, and are then reheated to 100°C to 250°C for 1 to 72 h under atmospheric pressure. Mechanical properties are improved without the formation of blisters.
  • the present application discloses an application of external pressure during solution heat treatment of a high pressure die cast object to inhibit the problematic blistering defects that occur during a traditional heat treatment of a high pressure die cast object.
  • the present application discloses a method of heat treating a high pressure die cast object.
  • the method includes obtaining a high pressure die cast object, and solution heat treating the high pressure die cast object above 371°C (700°F) for 0.5 to 12 hours at a pressure between 35 bar (0.5 KSI) and 2413 bar (35 KSI). Subsequently, the cast object may be quenched and artificially aged to create a high pressure die cast object without blistering defects.
  • the pressure applied during the solution heat treatment step is between 172 bar (2.5 KSI) and 690 bar (10 KSI) or at any pressure or range of pressures therebetween. In an embodiment the pressure applied is between 172 bar (2.5 KSI) and 345 bar (5 KSI) or at any pressure or range of pressures therebetween.
  • the step of solution heat treating comprises a T6 heat treatment with the application of pressure between 172 bar (2.5 KSI) to 690 bar (10 KSI), or at any pressure or range of pressures between 172 bar (2.5 KSI) and 690 bar (10 KSI).
  • the solution heat treatment temperature is between 371°C (700°F) and 649°C (1200°F), or at any temperature or range of temperatures therebetween.
  • the temperature is between 427°C (800°F) and 538°C (1000°F), or at any temperature or range of temperatures therebetween.
  • the solution heat treatment temperature is at 538°C (1000°F).
  • the solution heat treatment step is 2 to 8 hours, while in yet another embodiment, the solution heat treatment time with pressure is 4 to 6 hours. It will be recognized that such ranges are exemplary, and the range of time may be at any time within the ranges noted.
  • the method of heat treating may further include the step of quenching the cast object.
  • the method of heat treating may also include a step of artificially aging the cast object.
  • the step of quenching will typically occur immediately after the cast object is removed from the solution heat treatment pressure vessel. Allowing the cast object to slowly cool to room temperature without cooling is not desirable since the beneficial effects to the microstructure from solution heat treatment may be lost.
  • the step of obtaining a high pressure die cast aluminum alloy object includes the steps of casting the object with high pressure in a die casting equipment and removing the object thereafter from the high pressure die casting equipment.
  • the yield strength of cast objects may increase by 50% to 100%. This translates into a 15-30% weight reduction on average for structural components. This weight reduction has substantial economic and societal value in terms of energy and CO2 footprint reduction in automotive and other transportation applications where increasing fuel economy is paramount.
  • the present application relates to a method of reducing and/or eliminating blistering defects in high pressure die cast metal objects that typically occur during the solution heat treatment of high pressure die cast objects.
  • the present application contemplates that application of pressure between 172 bar (2.5 KSI) and 690 bar (10 KSI), or at any pressure or range of pressures therebetween, will eliminate blistering defects.
  • the application pressure is lower than the pressure applied during hot isostatic pressing.
  • the application of pressure creates a balance with any air that may be entrained or entrapped in the high pressure die cast object due to the turbulent nature of the high pressure die casting process. By the application of pressure, any air entrained or entrapped in the casting cannot expand, and therefore blisters are reduced and/or eliminated.
  • the increasing internal pressure of entrained air during solution heat treatment is offset as the casting is heated to elevated temperatures with external pressure. If the external pressure and the inherent strength of the material at elevated temperatures is greater than the internal pressure of the entrapped air, blistering will not occur.
  • the present application contemplates a method of heat treating a high pressure die cast object.
  • the high pressure die cast object is an aluminum alloy high pressure die cast object, however, the present application may be used for heat treating any high pressured die cast metal object wherein air becomes entrained during the turbulent high pressure die casting process.
  • the method contemplates first obtaining a high pressure die cast object 2.
  • the high pressure die cast object 2 is a marine propeller, however the present application is applicable for any high pressure die cast object that may be formed using the high pressure die casting method, including but not limited to, vehicle chassis, vehicle closures, structural bodies, and advanced vehicle bodies.
  • a pressure vessel 4 having an end closure 6, heating means such as heating elements 8 and workload support 10 may be used for the step of solution heat treating with pressure.
  • the pressure vessel 4 may be any certified pressure vessel capable of applying pressure up to 2413 bar (35 KSI) and heat up to 649°C (1200°F).
  • a certified pressure vessel capable of applying pressure up to 1034 bar (15 KSI) is acceptable, while in other embodiments, certified vessels that have a maximum pressure of 690 bar (10 KSI) or 345 bar (5 KSI) are acceptable.
  • Acceptable pressure vessels for solution heat treatment with pressure in accordance with the present application may be obtained from American Isostatic Presses, Inc. of Columbus, Ohio.
  • the pressure vessel 4 may further include insulation 12 to efficiently solution heat treat the high pressure die cast object 2 at the requisite temperatures and pressures. Additionally, a thermocouple feed through 14 and power feed through 16 may be present to provide for the measurement of heat and pressure.
  • the pressure vessel 4 is connected to a compressor (not shown) to create the necessary pressure during the solution heat treatment process.
  • the high pressure die cast object 2 is placed within the pressure vessel 4, and the pressure vessel 4 is sealed with end closure 6.
  • the cast object is then solution heat treated to above 371°C (700°F) at a pressure between 172 bar to 390 bar (2.5 KSI to 10 KSI) for 2 to 8 houers.
  • the temperature is between 371°C (700°F) and 649°C (1200°F) or at any temperature or range of temperatures therebetween.
  • the temperature is between 427°C (800°F) and 538°C (1000°F), in yet another embodiment, the temperature is at 538°C (1000°F).
  • the pressure may vary, with one embodiment applying pressure between 172 bar (2.5 KSI) and 690 bar (10 KSI), another embodiment applying pressure between 172 bar (2.5 KSI) and 345 bar (5 KSI), and an embodiment where pressure is applied at 345 bar (5 KSI).
  • the time and temperature comprises a T6 heat treatment.
  • the high pressure die cast object is solution heat treated at 538°C (1000°F) for 4 hours at 345 bar (5 KSI) to achieve a high pressure die cast object devoid of blistering defects.
  • the gas used to apply pressure through the compressor may be atmospheric gas, an inert gas, or any other gas sufficient to apply the required pressures during solution heat treatment without combusting.
  • the gas is an inert gas.
  • the gas used is argon.
  • the solution heat treatment with pressure provides for the ability to increase the yield strength of high pressure die cast objects.
  • the typical mechanical properties of high pressure die cast alloy A360.0 in the as cast condition for temperatures up to 371°C (700°F) are demonstrated in Table 1, below.
  • Table 1 Typical tensile properties for separately cast test bars of alloys 360.0-F and A360.0-F at elevated temperature Temperature Tensile strength Yield strength(s) Elongation(b) °C F° MPa ksi MPa ksi % 360.0 aluminum 24 75 325 47 170 25 3 100 212 305 44 170 25 2 150 300 240 35 165 24 4 205 400 150 22 95 14 8 250 500 85 12 50 7.5 20 315 600 50 7 30 4.5 35 370 700 30 4.5 20 3 40 A360.0 aluminum 24 75 315 46 165 24 5 100 212 295 43 165 24 3 150 300 235 34 160 23 5 205 400 145 21 90 13 14 250 500 75 11 45 6.5 30 315 600 45 6.5 28 4 45 370 700 30 4 15 2.5 45 (a) 0.2% offset, (b) In 50 mm or 2 in.
  • FIG. 2 demonstrates a high pressure die cast aluminum alloy marine propeller treated at the T6 heat treatment of 538°C (1000°F) for 4 hours with 0 bar (0 KSI) pressure applied. Numerous blistering defects 20 are demonstrated.
  • high pressure die cast aluminum alloy marine propellers were subjected to solution heat treatment with pressure.
  • Eighteen (18) high pressure die cast aluminum alloy propellers were solution heat treated with an externally applied gas pressure of 1034 bar (15 KSI), 690 bar (10 KSI) and 345 bar (5 KSI), respectfully (i.e. six (6) samples at each pressure).
  • Each solution heat treatment was at 538°C (1000°F) for 4 hours.
  • the externally applied gas pressure was accomplished through placing the high pressure die cast aluminum alloy marine propellers in a pressure vessel 4, and the pressure was applied using argon. The results are shown in Figs. 6 , 7 and 8 , wherein an elimination of blister defects 20 was observed.
  • High pressure die cast aluminum alloy marine propellers were subjected to solution heat treatment with pressure.
  • Three (3) high pressure die cast aluminum alloy marine propellers were each solution heat treated at 240 bar (3.5 KSI), 138 bar (2.0 KSI), and 35 bar (0.5 KSI) at 538°C (1000°F) for 4 hours.
  • the three propellers solution heat treated at 240 bar (3.5 KSI) demonstrated an elimination of blistering defects as shown in Fig. 5 .
  • the three high pressure die cast aluminum alloy marine propellers solution heat treated at 35 bar (0.5 KSI) demonstrated a reduction of blistering defects as shown in Fig. 3 .
  • the three high pressure die cast aluminum alloy marine propellers solution heat treated at 138 bar (2.0 KSI) demonstrated a significant reduction of blistering, with one small blister on only 1 of 3 propeller blades, as shown in Fig. 4 .
  • the propeller was subjected to a drop weight impact test to ascertain whether the blister reduced the mechanical ductility of the propeller blade. As shown in Figure 2 , the propeller processed at 159 bar (2.3 KSI) after a drop weight impact test showing the very small blister did not substantially reduce ductility or result in fracture of the blade. However, because one (1) very small blister was detected on one (1) blade at 159 bar (2.3 KSI), the lower pressure limit where the invention can be expected to be reliably practiced without any blistering is 172 bar (2.5 KSI).
  • the highest pressure limit where both blistering will not occur and the invention has utility is not defined by the blistering mechanism itself. Pressures equal to 172 bar (2.5 KSI) and up to 2413 bar (35 KSI) have been demonstrated to eliminate blistering. Instead, the upper limit of pressure where the invention has practical utility is defined by the increasing equipment cost of the pressure vessel and increasing process cycle time that adds to the final product cost. As pressure increases, both the capital cost of the pressure vessel itself increases and the process cycle time and associated cost increases on a non-linear basis. When these capital and process cycle time costs become excessive, it is not financially advantageous to use high pressure diecast articles and the inventive processing method. Instead, other metalworking or casting processes, such as but not limited to forging a wrought blank and machining or ablation casting become more financially preferred.
  • the upper pressure limit of 1034 bar (15 KSI) is defined by the capital equipment and process costs of today's modern pressure vessel technology.

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  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
EP17206338.0A 2016-12-23 2017-12-11 Method for solution heat treating with pressure Active EP3339465B1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US15/389,989 US11047032B2 (en) 2013-03-05 2016-12-23 Method for solution heat treating with pressure

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EP3339465A1 EP3339465A1 (en) 2018-06-27
EP3339465B1 true EP3339465B1 (en) 2020-01-15

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JP (1) JP7054621B2 (zh)
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Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3732128A (en) * 1971-07-16 1973-05-08 Nl Industries Inc Heat treatments of die castings under pressure
US6773666B2 (en) * 2002-02-28 2004-08-10 Alcoa Inc. Al-Si-Mg-Mn casting alloy and method
JP2004052087A (ja) * 2002-07-24 2004-02-19 Kobe Steel Ltd Ａｌ基金属鋳造品の熱間等方圧プレス処理法
US20050173032A1 (en) * 2004-02-11 2005-08-11 Hubert Koch Casting of an aluminium alloy
JP5236948B2 (ja) * 2004-12-23 2013-07-17 コモンウェルス サイエンティフィック アンドインダストリアル リサーチ オーガナイゼーション アルミニウム合金高圧ダイカスト鋳物の熱処理
KR101360040B1 (ko) * 2011-12-06 2014-02-07 현대자동차주식회사 고압 주조 실린더 블록의 열처리 방법
US11072044B2 (en) * 2014-04-14 2021-07-27 Siemens Energy, Inc. Superalloy component braze repair with isostatic solution treatment

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
None *

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CN108239731A (zh) 2018-07-03
JP2018103264A (ja) 2018-07-05
EP3339465A1 (en) 2018-06-27
JP7054621B2 (ja) 2022-04-14

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