EP3486340B1 - Aluminum alloy plastic working material and production method therefor - Google Patents
Aluminum alloy plastic working material and production method therefor Download PDFInfo
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- EP3486340B1 EP3486340B1 EP17827456.9A EP17827456A EP3486340B1 EP 3486340 B1 EP3486340 B1 EP 3486340B1 EP 17827456 A EP17827456 A EP 17827456A EP 3486340 B1 EP3486340 B1 EP 3486340B1
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- aluminum alloy
- plastic working
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- alloy plastic
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- 229910000838 Al alloy Inorganic materials 0.000 title claims description 128
- 239000004033 plastic Substances 0.000 title claims description 108
- 239000008207 working material Substances 0.000 title claims description 92
- 238000004519 manufacturing process Methods 0.000 title claims description 14
- 239000013078 crystal Substances 0.000 claims description 22
- 238000010438 heat treatment Methods 0.000 claims description 20
- RKTYLMNFRDHKIL-UHFFFAOYSA-N copper;5,10,15,20-tetraphenylporphyrin-22,24-diide Chemical compound [Cu+2].C1=CC(C(=C2C=CC([N-]2)=C(C=2C=CC=CC=2)C=2C=CC(N=2)=C(C=2C=CC=CC=2)C2=CC=C3[N-]2)C=2C=CC=CC=2)=NC1=C3C1=CC=CC=C1 RKTYLMNFRDHKIL-UHFFFAOYSA-N 0.000 claims description 18
- 238000002441 X-ray diffraction Methods 0.000 claims description 10
- 229910052782 aluminium Inorganic materials 0.000 claims description 9
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 9
- 239000012535 impurity Substances 0.000 claims description 4
- 238000012545 processing Methods 0.000 claims description 4
- 230000000052 comparative effect Effects 0.000 description 29
- 238000005266 casting Methods 0.000 description 27
- 230000000694 effects Effects 0.000 description 18
- 238000000034 method Methods 0.000 description 18
- 238000011282 treatment Methods 0.000 description 17
- 238000000265 homogenisation Methods 0.000 description 13
- 230000007423 decrease Effects 0.000 description 7
- 239000000463 material Substances 0.000 description 7
- 239000004848 polyfunctional curative Substances 0.000 description 7
- 239000000956 alloy Substances 0.000 description 6
- 230000005496 eutectics Effects 0.000 description 6
- 238000007670 refining Methods 0.000 description 6
- 238000005096 rolling process Methods 0.000 description 6
- 239000000203 mixture Substances 0.000 description 5
- 238000009864 tensile test Methods 0.000 description 5
- 238000001125 extrusion Methods 0.000 description 4
- 238000004663 powder metallurgy Methods 0.000 description 4
- 229910000521 B alloy Inorganic materials 0.000 description 3
- 238000009749 continuous casting Methods 0.000 description 3
- 229910000765 intermetallic Inorganic materials 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 238000001953 recrystallisation Methods 0.000 description 3
- 238000007711 solidification Methods 0.000 description 3
- 230000008023 solidification Effects 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 238000005097 cold rolling Methods 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 238000005242 forging Methods 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 239000002344 surface layer Substances 0.000 description 2
- 229910002483 Cu Ka Inorganic materials 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000007872 degassing Methods 0.000 description 1
- 238000006477 desulfuration reaction Methods 0.000 description 1
- 230000023556 desulfurization Effects 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 238000010191 image analysis Methods 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000005482 strain hardening Methods 0.000 description 1
Images
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
-
- 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
Definitions
- the present invention relates to an aluminum alloy plastic working material which has a low Young's modulus, but has an excellent proof stress, and relates to a method for producing the working material.
- aluminum Since aluminum has many excellent characteristics such as corrosion resistance, electric conductivity, thermal conductivity, light weight, brightness and machinability, aluminum is used for various purposes. In addition, since plastic deformation resistance is small, various shapes can be imparted, and aluminum is also widely used for members subjected to plastic working such as bending processing.
- JP 2011-105982 A proposes an aluminum alloy containing an Al phase and an Al 4 Ca phase, wherein the Al 4 Ca phase contains an Al 4 Ca crystallized product, and an average value of the longer side of the Al 4 Ca crystallized product is 50 ⁇ m or less.
- EP A 2189548 proposes an aluminum alloy including 0.1 to 12 et% of Ca.
- an object of the present invention is to provide an aluminum alloy plastic working material which has a low Young's modulus, but has an excellent proof stress, and relates to a method for efficiently producing the working material.
- a first aspect of the present invention provides an aluminum alloy plastic working material according to claim 1.
- the crystal structure of the Al 4 Ca phase which is used as the dispersed phase is basically a tetragonal crystal
- the present inventors have intensively studied and found that when the crystal structure of the Al 4 Ca phase contains a monoclinic crystal, the proof stress do not decrease so much, but the Young's modulus is greatly decreased.
- the intensity ratio (I 1 /I 2 ) of the highest diffraction peak (I 1 ) attributed to the tetragonal system to the highest diffraction peak (I 2 ) attributed to the monoclinic system, which are obtained by an X-ray diffraction measurement is 1 or less, the Young's modulus can be greatly lowered while maintaining the proof stress.
- the aluminum alloy plastically working material of the present invention further contains at least one or more of Fe: 0.05 to 1.0 wt% and Ti: 0.005 to 0.05 wt%.
- the casting property can be improved by broadening the solidification temperature range (solid-liquid coexisting region), and thus the casting surface of the ingot can also be improved. Further there is an effect that the dispersed crystallized product of Fe makes the eutectic structure uniform. The effect becomes remarkable when the Fe content is 0.05 wt% or more. To the contrary, when contained in excess of 1.0 wt%, the eutectic structure becomes coarse and there is a risk to lower the proof stress.
- Ti acts as a refining material of the casted structure and exhibits an action to improve casting property, extrudability, and rolling property. The effect is remarkable when the Ti content is 0.005 wt% or more. To the contrary, even when added in excess of 0.05 wt%, it cannot be expected to increase the effect of refining the casted structure, and on the contrary, there is a risk that a coarse intermetallic compound which is to be the starting point of fracture may be generated. It is preferable that Ti is added by a rod hardener (Al-Ti-B alloy) during the casting. B added at this time together with Ti as the rod hardener is acceptable.
- a rod hardener Al-Ti-B alloy
- an average crystal grain size of the Al 4 Ca phase is 1.5 ⁇ m or less.
- the average grain size of the Al 4 Ca phase becomes too large, the proof stress of the aluminum alloy decreases, but when the average grain size is 1.5 ⁇ m or less, it is possible to suppress the decrease of the proof stress.
- a second aspect of the present invention provides a method for producing an aluminum alloy plastic working material according to claim 2.
- the first step for obtaining a plastic workpiece of an aluminum alloy by subjecting an aluminum alloy ingot which contains 5.0 to 10.0 wt% of Ca with the remainder aluminum and inevitable impurities, and has a volume ratio of an Al 4 Ca phase which is a dispersed phase of 25% or more to a plastic processing by conducting the step for subjecting to a heat treatment in a temperature range of 100 to 300 °C (Second step), a part of the tetragonal Al 4 Ca phase can be changed into monoclinic crystal.
- the holding temperature in the second step is less than 100 °C, a change from a tetragonal to a monoclinic crystal is difficult to occur, and when the holding temperature is 300 °C or more, recrystallization of the aluminum base material occurs and there is a risk that the proof stress will be lowered.
- the more preferable temperature range of the heat treatment is 160 to 240 °C. Though the appropriate time for the heat treatment varies depending on the size and shape of the aluminum alloy material, it is preferable that the temperature of the aluminum alloy material itself is kept at least at the holding temperature for 1 hour or more.
- the aluminum alloy ingot contains at least one or more of Fe: 0.05 to 1.0 wt% and Ti: 0.005 to 0.05 wt%.
- the casting property can be improved by broadening the solidification temperature range (solid-liquid coexisting region), and thus the casting surface of the ingot can also be improved. Further there is an effect that the dispersed crystallized product of Fe makes the eutectic structure uniform. The effect becomes remarkable when the Fe content is 0.05 wt% or more. To the contrary, when contained in excess of 1.0 wt%, the eutectic structure becomes coarse and there is a risk to lower the proof stress.
- Ti acts as a refining material of the casted structure and exhibits an action to improve casting property, extrudability, and rolling property. The effect is remarkable when the Ti content is 0.005 wt% or more. To the contrary, even when added in excess of 0.05 wt%, it cannot be expected to increase the effect of refining the casted structure, and on the contrary, there is a risk that a coarse intermetallic compound which is to be the starting point of fracture may be generated. It is preferable that Ti is added by a rod hardener (Al-Ti-B alloy) during the casting. B added at this time together with Ti as the rod hardener is acceptable.
- a rod hardener Al-Ti-B alloy
- the aluminum alloy ingot is not subjected to a heat treatment where the ingot is maintained at a temperature of 400 °C or more.
- a homogenization treatment is carried out where the ingot is held at a temperature of 400 to 600 °C, but when this homogenization treatment is performed, the Al 4 Ca phase contained in the aluminum alloy tends to be large, and the average grain size becomes larger than 1.5 ⁇ m. Since the proof stress reduces due to the increase in the average grain size, it is preferable that the homogenization treatment at a holding temperature of 400 °C or higher would not be performed.
- an aluminum alloy plastic working material which has both an excellent proof stress and a low Young's modulus, and a method for efficiently producing the working material.
- the aluminum alloy plastic working material includes 5.0 to 10.0 wt% of Ca, and the remainder aluminum and unavoidable impurities.
- Ca forms a compound of Al 4 Ca and has the activity to lower the Young's modulus of the aluminum alloy.
- the effect becomes remarkable when the content of Ca is 5.0% or more.
- the casting property decreases, and since particularly casting by continuous casting such as DC casting becomes difficult, it is necessary to produce by a method with a high production cost such as powder metallurgy method.
- powder metallurgy method there is a risk that oxides formed on the surface of the alloy powder may get mixed in the product, which may lower the proof stress.
- the casting property can be improved by broadening the solidification temperature range (solid-liquid coexisting region), and thus the casting surface of the ingot can also be improved. Further there is an effect that the dispersed crystallized product of Fe makes the eutectic structure uniform. The effect becomes remarkable when being 0.05 wt% or more, and to the contrary, when contained in excess of 1.0 wt%, the eutectic structure becomes coarse and there is a risk to lower the proof stress.
- Ti acts as a refining material of the casted structure and exhibits an action to improve casting property, extrudability, and rolling property.
- the effect is remarkable when being 0.005 wt% or more, and to the contrary, even when added in excess of 0.05 wt%, it cannot be expected to increase the effect of refining the casted structure, and on the contrary, there is a risk that a coarse intermetallic compound which is to be the starting point of fracture may be generated.
- Ti is added by a rod hardener (Al-Ti-B alloy) during the casting. B added at this time together with Ti as the rod hardener is acceptable.
- the aluminum alloy plastic working material has a volume ratio of an Al 4 Ca phase, which is a dispersed phase, is 25% or more, the Al 4 Ca phase comprises a tetragonal Al 4 Ca phase and a monoclinic Al 4 Ca phase, and an intensity ratio (I 1 /I 2 ) of the highest diffraction peak (I 1 ) attributed to the tetragonal system to the highest diffraction peak (I 2 ) attributed to the monoclinic system, which are obtained by an X-ray diffraction measurement, is 1 or less.
- the tetragonal Al 4 Ca phase and the monoclinic Al 4 Ca phase exist in the Al 4 Ca phase, which is a dispersed phase, and the volume ratio of the combined Al 4 Ca phase is 25% or more.
- the volume ratio of the Al 4 Ca phase is 25% or more, it is possible to impart an excellent proof stress to the aluminum alloy plastic working material.
- an average crystal grain size of the Al 4 Ca phase is 1.5 ⁇ m or less.
- the average grain size of the Al 4 Ca phase exceeds 1.5 ⁇ m, there is a risk that the proof stress of the aluminum alloy plastic working material decreases.
- the crystal structure of the Al 4 Ca phase is generally a tetragonal crystal
- the present inventors have intensively studied and found that when the monoclinic crystal structure exists in the Al 4 Ca phase, the proof stress do not almost decrease, but the Young's modulus is greatly decreased. It is not necessary that all crystal structure of the Al 4 Ca phases is monoclinic, and it may be in the state of being mixed with the tetragonal crystal.
- the existence of the Al 4 Ca phase which has the monoclinic crystal structure can be identified, for example, by measuring the diffraction peak with X ray diffraction method.
- the intensity ratio (I 1 /I 2 ) of the highest diffraction peak (I 1 ) attributed to the tetragonal system to the highest diffraction peak (I 2 ) attributed to the monoclinic system can generally be obtained by a X-ray diffraction measurement.
- FIG. 1 shows a process chart of the aluminum alloy plastic working material of the present invention.
- the method for producing the aluminum alloy plastic working material of the present invention includes a first step (S01) of subjecting an aluminum alloy ingot to plastic working, and a second step (S02) of applying a heat treatment. Each step and the like will be explained herein below.
- the molten metal After subjecting the aluminum alloy molten metal having the composition of the above-mentioned aluminum alloy plastic working material of the present invention to conventionally known molten metal cleaning treatments such as desulfurization treatment, degassing treatment, and filtration treatment, the molten metal is casted into an ingot having a desired shape.
- the casting method there is no particular restriction on the casting method, and various conventionally known casting methods can be used. For example, it is preferable, by using a continuous casting method such as DC casting, to cast into a shape that the plastic working (extrusion, rolling, forging, etc.) in the first step (S01) is easy to be performed.
- a rod hardener Al-Ti-B
- Al-Ti-B may be added to improve casting property.
- a homogenization treatment is carried out where the ingot is held at a temperature of 400 to 600 °C, but when this homogenization treatment is performed, the Al 4 Ca phase tends to be large (average grain size of 1.5 ⁇ m or larger), and since the proof stress of the aluminum alloy reduces, it is preferable that the homogenization treatment would not be performed in the method for producing aluminum alloy plastic working material according to the present invention.
- the first step (S01) is a step of subjecting the aluminum alloy ingot obtained in (1) to the plastic working to obtain a desired shape.
- either hot working or cold working may be used, or a plurality of them may be combined.
- the aluminum alloy becomes a processed structure, and the proof stress is improved.
- most Al 4 Ca phases contained in the aluminum alloy have the tetragonal crystal structure.
- the second step (S02) is a step for applying the heat treatment to the aluminum alloy plastic working material obtained in the first step (S01).
- the holding temperature of the heat treatment is preferably 100 to 300 °C, more preferably 160 to 240 °C.
- the temperature of at least the aluminum alloy plastic working material is kept at the above holding temperature for 1 hour or more.
- An aluminum alloy having the composition shown Table 1 was cast into an ingot (billet) of ⁇ 8 inches by a DC casting method without any homogenization treatment, and then, plastic-working at an extrusion temperature of 500 °C to obtain a plate having a width of 180 mm ⁇ a thickness of 8 mm. Then, after cold rolling to a thickness of 5 mm, a heat treatment was carried out to hold at 200 °C for 4 hours to obtain the present aluminum alloy working plastic material.
- [Table 1] (unit: wt%) Ca Fe Ti Al Present aluminum alloy plastic working material 1 5.2 0.001 0.002 Bal. Comparative aluminum alloy plastic working material 1 Present aluminum alloy plastic working material 2 6.2 0.05 0.002 Bal.
- Comparative aluminum alloy plastic working material 2 Present aluminum alloy plastic working material 3 7.3 0.05 0.01 Bal. Comparative aluminum alloy plastic working material 3 Present aluminum alloy plastic working material 4 8.1 0.001 0.01 Bal. Comparative aluminum alloy plastic working material 4 Present aluminum alloy plastic working material 5 9.5 0.05 0.05 Bal. Comparative aluminum alloy plastic working material 5
- the obtained present aluminum alloy plastic working material 3 was subjected to the X-ray diffraction measurement to measure the position pf the peak of the Al 4 Ca phase.
- a specimen of 20 mm ⁇ 20 mm was cut out from the plate-like aluminum alloy plastic working material, the surface layer portion was removed by about 500 ⁇ m, and then a ⁇ -2 ⁇ measurement was carried out with respect to the region from a Cu-Ka beam source. The results are shown in FIG. 2 .
- the intensity ratio (I 1 /I 2 ) of the highest diffraction peak (I 1 ) attributed to the tetragonal system to the highest diffraction peak (I 2 ) attributed to the monoclinic system was 0.956.
- the present aluminum alloy plastic working materials 6 to 9 were obtained in the same manner as in the case of the present aluminum alloy plastic working material 3 except that the heat treatment temperature was any one of 100 °C, 160 °C, 240 °C and 300 °C.
- the Young's modulus and proof stress were measured by a tensile test. The obtained results are shown in Table 3.
- An aluminum alloy having the composition shown Table 1 was cast into an ingot (billet) of ⁇ 8 inches by a DC casting method without any homogenization treatment, and then, plastic-working at an extrusion temperature of 500 °C to obtain a plate having a width of 180 mm ⁇ a thickness of 8 mm. Thereafter, the cold rolling to a thickness of 5 mm was carried out to obtain the comparative aluminum alloy plastic working materials 1 to 5.
- the obtained comparative aluminum alloy plastic working material 3 was subjected to the X-ray diffraction measurement to measure the position pf the peak of the Al 4 Ca phase.
- a specimen of 20 mm ⁇ 20 mm was cut out from the plate-like aluminum alloy plastic working material, the surface layer portion was removed by about 500 ⁇ m, and then a ⁇ -2 ⁇ measurement was carried out with respect to the region from a Cu-K ⁇ beam source.
- the results are shown in FIG. 2 .
- the intensity ratio (I 1 /I 2 ) of the highest diffraction peak (I 1 ) attributed to the tetragonal system to the highest diffraction peak (I 2 ) attributed to the monoclinic system was 1.375.
- the comparative aluminum alloy plastic working materials 6 and 7 were obtained in the same manner as in the case of the present aluminum alloy plastic working material 3 except that the heat treatment temperature was 90 °C and 310 °C.
- the Young's modulus and proof stress were measured by a tensile test. The obtained results are shown in Table 3.
- the comparative aluminum alloy plastic working material 8 was obtained in the same manner as in the case of the present aluminum alloy plastic working material 3 except that, after casting in an ingot (billet), the homogenization treatment was carried out while holding at 550 °C.
- JIS-14B specimen was cut out from the comparative aluminum alloy plastic working material 8, and the Young's modulus and proof stress were measured by a tensile test. The obtained results are shown in Table 4.
- the Young's modulus and the proof stress of the present aluminum alloy plastic working material 3 which is different only in the presence or absence of homogenization treatment are also shown as comparison data.
- the Young's modulus of the aluminum alloy plastic working materials of the present invention (the present aluminum alloy plastic working materials 1 to 5) are greatly lower than the Young's modulus of the comparative aluminum alloy plastic working materials 1 to 5 which were not subjected to the heat treatment.
- the proof stress and tensile strength of the present aluminum alloy plastic working materials 1 to 5 are not greatly reduced as compared with the comparative aluminum alloy plastic working materials 1 to 5. It is clear that the volume ratios of the dispersed phase (Al 4 Ca phase) in the aluminum alloy plastic working materials of the present invention are 25% or more.
- FIG. 3 and FIG. 4 The structural photographs of the present aluminum alloy plastic working material 3 and the comparative aluminum alloy plastic working material 8 by an optical microscope are shown in FIG. 3 and FIG. 4 , respectively.
- the black region is the Al 4 Ca phase
- the average crystal grain size of the Al 4 Ca phase is measured by image analysis.
- Table 4 Homogenization treatment Average crystal grain size of Al 4 Ca phase Young's modulus Proof stress Tensile strength ( ⁇ m) (GPa) (MPa) (MPa) Comparative aluminum alloy plastic working material 8 Did 1.56 53 158 229 Present aluminum alloy plastic working material 3 Non 1.15 53 169 254
Description
- The present invention relates to an aluminum alloy plastic working material which has a low Young's modulus, but has an excellent proof stress, and relates to a method for producing the working material.
- Since aluminum has many excellent characteristics such as corrosion resistance, electric conductivity, thermal conductivity, light weight, brightness and machinability, aluminum is used for various purposes. In addition, since plastic deformation resistance is small, various shapes can be imparted, and aluminum is also widely used for members subjected to plastic working such as bending processing.
- Here, when the rigidity of the aluminum alloy is high, there is a problem that the spring back amount increases when the plastic working such as bending processing is performed, and thus it is difficult to obtain dimensional accuracy. Under such circumstances, an aluminum alloy material having a low Young's modulus is desired, and a method for lowering the Young's modulus of the aluminum alloy material has been studied.
- For example,
JP 2011-105982 A - In the aluminum alloy disclosed in
JP 2011-105982 A -
JP 2011-105982 A EP A 2189548 proposes an aluminum alloy including 0.1 to 12 et% of Ca. - However, as represented by, for example, terminals of electrical equipment, the requirement for the dimensional accuracy of the product where aluminum alloys are used has been strict year by year, so that aluminum alloys with lower rigidity are required while maintaining proof stress. Under such technical background, the current situation is that the aluminum alloy of Patent Literature 1 cannot sufficiently satisfy the above requirements.
- Considering the above problems in the prior arts, an object of the present invention is to provide an aluminum alloy plastic working material which has a low Young's modulus, but has an excellent proof stress, and relates to a method for efficiently producing the working material.
- As a result of extensive study with respect to the aluminum alloy plastic working material and production method therefor in order to achieve the above object, the present inventors have found that it is extremely effective that an Al4Ca phase is used as the dispersed phase and the crystal structure of the Al4Ca phase is appropriately controlled, and have reached the present invention.
- Namely, a first aspect of the present invention provides an aluminum alloy plastic working material according to claim 1.
- By addition of Ca, a compound of Al4Ca is prepared, which has an activity to lower the Young's modulus of the aluminum alloy. The effect becomes remarkable when the content of Ca is 5.0% or more. To the contrary, when added in excess of 10.0%, the casting property decreases, and since particularly casting by continuous casting such as DC casting becomes difficult, it is necessary to produce by a method with a high production cost such as powder metallurgy method. In the case of producing by the powder metallurgy method, there is a risk that oxides formed on the surface of the alloy powder may get mixed in the product, which may lower the proof stress.
- In the aluminum alloy plastic working product of the present invention, though the crystal structure of the Al4Ca phase which is used as the dispersed phase is basically a tetragonal crystal, the present inventors have intensively studied and found that when the crystal structure of the Al4Ca phase contains a monoclinic crystal, the proof stress do not decrease so much, but the Young's modulus is greatly decreased. Here, when the intensity ratio (I1/I2) of the highest diffraction peak (I1) attributed to the tetragonal system to the highest diffraction peak (I2) attributed to the monoclinic system, which are obtained by an X-ray diffraction measurement, is 1 or less, the Young's modulus can be greatly lowered while maintaining the proof stress.
- Further, it is preferable that the aluminum alloy plastically working material of the present invention further contains at least one or more of Fe: 0.05 to 1.0 wt% and Ti: 0.005 to 0.05 wt%.
- When Fe is contained in the aluminum alloy, the casting property can be improved by broadening the solidification temperature range (solid-liquid coexisting region), and thus the casting surface of the ingot can also be improved. Further there is an effect that the dispersed crystallized product of Fe makes the eutectic structure uniform. The effect becomes remarkable when the Fe content is 0.05 wt% or more. To the contrary, when contained in excess of 1.0 wt%, the eutectic structure becomes coarse and there is a risk to lower the proof stress.
- Ti acts as a refining material of the casted structure and exhibits an action to improve casting property, extrudability, and rolling property. The effect is remarkable when the Ti content is 0.005 wt% or more. To the contrary, even when added in excess of 0.05 wt%, it cannot be expected to increase the effect of refining the casted structure, and on the contrary, there is a risk that a coarse intermetallic compound which is to be the starting point of fracture may be generated. It is preferable that Ti is added by a rod hardener (Al-Ti-B alloy) during the casting. B added at this time together with Ti as the rod hardener is acceptable.
- Further, in the aluminum alloy plastic working product of the present invention, an average crystal grain size of the Al4Ca phase is 1.5 µm or less. When the average grain size of the Al4Ca phase becomes too large, the proof stress of the aluminum alloy decreases, but when the average grain size is 1.5 µm or less, it is possible to suppress the decrease of the proof stress.
- Further, a second aspect of the present invention provides a method for producing an aluminum alloy plastic working material according to claim 2.
- After the first step for obtaining a plastic workpiece of an aluminum alloy by subjecting an aluminum alloy ingot which contains 5.0 to 10.0 wt% of Ca with the remainder aluminum and inevitable impurities, and has a volume ratio of an Al4Ca phase which is a dispersed phase of 25% or more to a plastic processing, by conducting the step for subjecting to a heat treatment in a temperature range of 100 to 300 °C (Second step), a part of the tetragonal Al4Ca phase can be changed into monoclinic crystal.
- When the holding temperature in the second step is less than 100 °C, a change from a tetragonal to a monoclinic crystal is difficult to occur, and when the holding temperature is 300 °C or more, recrystallization of the aluminum base material occurs and there is a risk that the proof stress will be lowered. The more preferable temperature range of the heat treatment is 160 to 240 °C. Though the appropriate time for the heat treatment varies depending on the size and shape of the aluminum alloy material, it is preferable that the temperature of the aluminum alloy material itself is kept at least at the holding temperature for 1 hour or more.
- In the method for producing the aluminum alloy plastic working material of the present invention, it is preferable that the aluminum alloy ingot contains at least one or more of Fe: 0.05 to 1.0 wt% and Ti: 0.005 to 0.05 wt%.
- When Fe is contained in the aluminum alloy, the casting property can be improved by broadening the solidification temperature range (solid-liquid coexisting region), and thus the casting surface of the ingot can also be improved. Further there is an effect that the dispersed crystallized product of Fe makes the eutectic structure uniform. The effect becomes remarkable when the Fe content is 0.05 wt% or more. To the contrary, when contained in excess of 1.0 wt%, the eutectic structure becomes coarse and there is a risk to lower the proof stress.
- Ti acts as a refining material of the casted structure and exhibits an action to improve casting property, extrudability, and rolling property. The effect is remarkable when the Ti content is 0.005 wt% or more. To the contrary, even when added in excess of 0.05 wt%, it cannot be expected to increase the effect of refining the casted structure, and on the contrary, there is a risk that a coarse intermetallic compound which is to be the starting point of fracture may be generated. It is preferable that Ti is added by a rod hardener (Al-Ti-B alloy) during the casting. B added at this time together with Ti as the rod hardener is acceptable.
- Furthermore, in the method for producing an aluminum alloy plastic working material according to the present invention, it is preferable that, before the first step, the aluminum alloy ingot is not subjected to a heat treatment where the ingot is maintained at a temperature of 400 °C or more.
- Generally, in the case of preparing an aluminum alloy, before the ingot is subjected to plastic working, a homogenization treatment is carried out where the ingot is held at a temperature of 400 to 600 °C, but when this homogenization treatment is performed, the Al4Ca phase contained in the aluminum alloy tends to be large, and the average grain size becomes larger than 1.5 µm. Since the proof stress reduces due to the increase in the average grain size, it is preferable that the homogenization treatment at a holding temperature of 400 °C or higher would not be performed.
- According to the present invention, it is possible to provide an aluminum alloy plastic working material which has both an excellent proof stress and a low Young's modulus, and a method for efficiently producing the working material.
-
-
FIG. 1 is a process chart relating to the method of producing the aluminum alloy plastic working material of the present invention. -
FIG. 2 is an X-ray diffraction pattern of the aluminum alloy plastic working material. -
FIG. 3 is a photograph of the structure of the present aluminum alloyplastic working material 3. -
FIG. 4 is a photograph of the structure of the comparative aluminum alloy plastic workingmaterial 3. - Hereinafter, the aluminum alloy plastic working material and the method for producing therefor of the present invention will be described in detail with reference to the drawings, but the present inventions are not limited to only those.
- The aluminum alloy plastic working material includes 5.0 to 10.0 wt% of Ca, and the remainder aluminum and unavoidable impurities. In addition, it is preferable to further contain at least one or more of Fe: 0.05 to 1.0 wt% and Ti: 0.005 to 0.05 wt%.
- Each component element will be explained below.
- Ca forms a compound of Al4Ca and has the activity to lower the Young's modulus of the aluminum alloy. The effect becomes remarkable when the content of Ca is 5.0% or more. To the contrary, when added in excess of 10.0%, the casting property decreases, and since particularly casting by continuous casting such as DC casting becomes difficult, it is necessary to produce by a method with a high production cost such as powder metallurgy method. In the case of producing by the powder metallurgy method, there is a risk that oxides formed on the surface of the alloy powder may get mixed in the product, which may lower the proof stress.
- When Fe is contained, the casting property can be improved by broadening the solidification temperature range (solid-liquid coexisting region), and thus the casting surface of the ingot can also be improved. Further there is an effect that the dispersed crystallized product of Fe makes the eutectic structure uniform. The effect becomes remarkable when being 0.05 wt% or more, and to the contrary, when contained in excess of 1.0 wt%, the eutectic structure becomes coarse and there is a risk to lower the proof stress.
- Ti acts as a refining material of the casted structure and exhibits an action to improve casting property, extrudability, and rolling property. The effect is remarkable when being 0.005 wt% or more, and to the contrary, even when added in excess of 0.05 wt%, it cannot be expected to increase the effect of refining the casted structure, and on the contrary, there is a risk that a coarse intermetallic compound which is to be the starting point of fracture may be generated. It is preferable that Ti is added by a rod hardener (Al-Ti-B alloy) during the casting. B added at this time together with Ti as the rod hardener is acceptable.
- As long as the effects of the present invention are not impaired, it is permissible to contain other elements.
- The aluminum alloy plastic working material has a volume ratio of an Al4Ca phase, which is a dispersed phase, is 25% or more, the Al4Ca phase comprises a tetragonal Al4Ca phase and a monoclinic Al4Ca phase, and an intensity ratio (I1/I2) of the highest diffraction peak (I1) attributed to the tetragonal system to the highest diffraction peak (I2) attributed to the monoclinic system, which are obtained by an X-ray diffraction measurement, is 1 or less.
- The tetragonal Al4Ca phase and the monoclinic Al4Ca phase exist in the Al4Ca phase, which is a dispersed phase, and the volume ratio of the combined Al4Ca phase is 25% or more. By making the volume ratio of the Al4Ca phase to 25% or more, it is possible to impart an excellent proof stress to the aluminum alloy plastic working material.
- Further, an average crystal grain size of the Al4Ca phase is 1.5 µm or less. When the average grain size of the Al4Ca phase exceeds 1.5 µm, there is a risk that the proof stress of the aluminum alloy plastic working material decreases.
- Though the crystal structure of the Al4Ca phase is generally a tetragonal crystal, the present inventors have intensively studied and found that when the monoclinic crystal structure exists in the Al4Ca phase, the proof stress do not almost decrease, but the Young's modulus is greatly decreased. It is not necessary that all crystal structure of the Al4Ca phases is monoclinic, and it may be in the state of being mixed with the tetragonal crystal. The existence of the Al4Ca phase which has the monoclinic crystal structure can be identified, for example, by measuring the diffraction peak with X ray diffraction method.
- Regarding the Al4Ca phases, the intensity ratio (I1/I2) of the highest diffraction peak (I1) attributed to the tetragonal system to the highest diffraction peak (I2) attributed to the monoclinic system, can generally be obtained by a X-ray diffraction measurement. The lattice constants of the tetragonal Al4Ca are a = 0.4354 and c = 1.118, and the lattice constants of the orthorhombic Al4Ca are a = 0.6158, b = 0.6175, c = 1.118, β = 88.9 °.
-
FIG. 1 shows a process chart of the aluminum alloy plastic working material of the present invention. The method for producing the aluminum alloy plastic working material of the present invention includes a first step (S01) of subjecting an aluminum alloy ingot to plastic working, and a second step (S02) of applying a heat treatment. Each step and the like will be explained herein below. - After subjecting the aluminum alloy molten metal having the composition of the above-mentioned aluminum alloy plastic working material of the present invention to conventionally known molten metal cleaning treatments such as desulfurization treatment, degassing treatment, and filtration treatment, the molten metal is casted into an ingot having a desired shape.
- There is no particular restriction on the casting method, and various conventionally known casting methods can be used. For example, it is preferable, by using a continuous casting method such as DC casting, to cast into a shape that the plastic working (extrusion, rolling, forging, etc.) in the first step (S01) is easy to be performed. In the casting, a rod hardener (Al-Ti-B) may be added to improve casting property.
- Generally, in the case of preparing an aluminum alloy, before the ingot is subjected to plastic working, a homogenization treatment is carried out where the ingot is held at a temperature of 400 to 600 °C, but when this homogenization treatment is performed, the Al4Ca phase tends to be large (average grain size of 1.5 µm or larger), and since the proof stress of the aluminum alloy reduces, it is preferable that the homogenization treatment would not be performed in the method for producing aluminum alloy plastic working material according to the present invention.
- The first step (S01) is a step of subjecting the aluminum alloy ingot obtained in (1) to the plastic working to obtain a desired shape.
- For the plastic working such as extrusion, rolling, or forging, either hot working or cold working may be used, or a plurality of them may be combined. By performing the plastic working, the aluminum alloy becomes a processed structure, and the proof stress is improved. In the stage of the plastic working, most Al4Ca phases contained in the aluminum alloy have the tetragonal crystal structure.
- The second step (S02) is a step for applying the heat treatment to the aluminum alloy plastic working material obtained in the first step (S01).
- By subjecting the aluminum alloy plastic working material subjected to plastic working in the first step (S01) to the heat treatment at 100 to 300 °C, a part of the tetragonal Al4Ca phase can be converted into the monoclinic crystal. The change from the tetragonal to the monoclinic is difficult to occur when the holding temperature is less than 100 °C. On the other hand, since, when the holding temperature is 300 °C or higher, recrystallization of the aluminum base material may occur and there is a risk that the proof stress may be reduced, the holding temperature of the heat treatment is preferably 100 to 300 °C, more preferably 160 to 240 °C.
- Though the optimum period of time for the heat treatment varies depending on the size and shape of the aluminum alloy plastic working material to be treated, it is preferable that the temperature of at least the aluminum alloy plastic working material is kept at the above holding temperature for 1 hour or more.
- The representative embodiments of the present invention have been described above, but the present invention is not limited only to these embodiments, and various design changes are possible, and all such design changes are included in the technical scope of the present invention.
- An aluminum alloy having the composition shown Table 1 was cast into an ingot (billet) of ϕ8 inches by a DC casting method without any homogenization treatment, and then, plastic-working at an extrusion temperature of 500 °C to obtain a plate having a width of 180 mm × a thickness of 8 mm. Then, after cold rolling to a thickness of 5 mm, a heat treatment was carried out to hold at 200 °C for 4 hours to obtain the present aluminum alloy working plastic material.
[Table 1] (unit: wt%) Ca Fe Ti Al Present aluminum alloy plastic working material 1 5.2 0.001 0.002 Bal. Comparative aluminum alloy plastic working material 1 Present aluminum alloy plastic working material 2 6.2 0.05 0.002 Bal. Comparative aluminum alloy plastic working material 2 Present aluminum alloy plastic working material 37.3 0.05 0.01 Bal. Comparative aluminum alloy plastic working material 3Present aluminum alloy plastic working material 4 8.1 0.001 0.01 Bal. Comparative aluminum alloy plastic working material 4 Present aluminum alloy plastic working material 5 9.5 0.05 0.05 Bal. Comparative aluminum alloy plastic working material 5 - The obtained present aluminum alloy
plastic working material 3 was subjected to the X-ray diffraction measurement to measure the position pf the peak of the Al4Ca phase. In the X-ray diffraction measurement, a specimen of 20 mm × 20 mm was cut out from the plate-like aluminum alloy plastic working material, the surface layer portion was removed by about 500 µm, and then a θ-2 θ measurement was carried out with respect to the region from a Cu-Ka beam source. The results are shown inFIG. 2 . The intensity ratio (I1/I2) of the highest diffraction peak (I1) attributed to the tetragonal system to the highest diffraction peak (I2) attributed to the monoclinic system was 0.956. - In addition, JIS-14B specimens were cut out from the present aluminum alloy plastic working materials 1 to 5, and the Young's modulus and proof stress were measured by a tensile test. The obtained results are shown in Table 2. In addition, the volume ratio of the dispersed phase (Al4Ca phase) calculated from the structural observation by the optical microscope are shown in Table 2.
- The present aluminum alloy plastic working materials 6 to 9 were obtained in the same manner as in the case of the present aluminum alloy
plastic working material 3 except that the heat treatment temperature was any one of 100 °C, 160 °C, 240 °C and 300 °C. In addition, in the same manner as in the case of the present aluminum alloy plastic working materials 1 to 5, the Young's modulus and proof stress were measured by a tensile test. The obtained results are shown in Table 3. - An aluminum alloy having the composition shown Table 1 was cast into an ingot (billet) of ϕ8 inches by a DC casting method without any homogenization treatment, and then, plastic-working at an extrusion temperature of 500 °C to obtain a plate having a width of 180 mm × a thickness of 8 mm. Thereafter, the cold rolling to a thickness of 5 mm was carried out to obtain the comparative aluminum alloy plastic working materials 1 to 5.
- The obtained comparative aluminum alloy
plastic working material 3 was subjected to the X-ray diffraction measurement to measure the position pf the peak of the Al4Ca phase. In the X-ray diffraction measurement, a specimen of 20 mm × 20 mm was cut out from the plate-like aluminum alloy plastic working material, the surface layer portion was removed by about 500 µm, and then a θ-2 θ measurement was carried out with respect to the region from a Cu-Kα beam source. The results are shown inFIG. 2 . The intensity ratio (I1/I2) of the highest diffraction peak (I1) attributed to the tetragonal system to the highest diffraction peak (I2) attributed to the monoclinic system was 1.375. - In addition, JIS-14B specimens were cut out from the comparative aluminum alloy plastic working materials 1 to 5, and the Young's modulus and proof stress were measured by a tensile test. The obtained results are shown in Table 2.
- The comparative aluminum alloy plastic working materials 6 and 7 were obtained in the same manner as in the case of the present aluminum alloy
plastic working material 3 except that the heat treatment temperature was 90 °C and 310 °C. In addition, in the same manner as in the case of the comparative aluminum alloy plastic working materials 1 to 5, the Young's modulus and proof stress were measured by a tensile test. The obtained results are shown in Table 3. - The comparative aluminum alloy plastic working material 8 was obtained in the same manner as in the case of the present aluminum alloy
plastic working material 3 except that, after casting in an ingot (billet), the homogenization treatment was carried out while holding at 550 °C. In addition, JIS-14B specimen was cut out from the comparative aluminum alloy plastic working material 8, and the Young's modulus and proof stress were measured by a tensile test. The obtained results are shown in Table 4. The Young's modulus and the proof stress of the present aluminum alloyplastic working material 3 which is different only in the presence or absence of homogenization treatment are also shown as comparison data.[Table 2] Heat treatment Volume ratio of dispersed phase Young's modulus Proof stress Tensile strength (%) (GPa) (MPa) (MPa) Present aluminum alloy plastic working material 1 Did 26.7 58 147 245 Present aluminum alloy plastic working material 2 31.2 167 258 Present aluminum alloy plastic working material 335.9 53 169 254 Present aluminum alloy plastic working material 4 39.9 51 208 272 Present aluminum alloy plastic working material 5 44.3 48 173 269 Comparative aluminum alloy plastic working material 1 Non - 67 176 259 Comparative aluminum alloy plastic working material 2 - 64 184 268 Comparative aluminum alloy plastic working material 3 - 61 189 265 Comparative aluminum alloy plastic working material 4 - 57 222 285 Comparative aluminum alloy plastic working material 5 - 56 186 276 - From the results shown in Table 2, when comparing the present aluminum alloy plastic working material having the same composition with the comparative aluminum alloy plastic working material, the Young's modulus of the aluminum alloy plastic working materials of the present invention (the present aluminum alloy plastic working materials 1 to 5) are greatly lower than the Young's modulus of the comparative aluminum alloy plastic working materials 1 to 5 which were not subjected to the heat treatment. On the other hand, the proof stress and tensile strength of the present aluminum alloy plastic working materials 1 to 5 are not greatly reduced as compared with the comparative aluminum alloy plastic working materials 1 to 5. It is clear that the volume ratios of the dispersed phase (Al4Ca phase) in the aluminum alloy plastic working materials of the present invention are 25% or more.
[Table 3] Heat treatment temperature Young's modulus Proof stress Tensile strength (°C) (GPa) (MPa) (MPa) Present aluminum alloy plastic working material 6 100 54 187 267 Present aluminum alloy plastic working material 7 160 54 172 262 Present aluminum alloy plastic working material 8 240 53 167 252 Present aluminum alloy plastic working material 9 300 52 161 240 Comparative aluminum alloy plastic working material 6 90 59 195 275 Comparative aluminum alloy plastic working material 7 310 53 143 231 - From the results shown in Table 3, when the holding temperature of the heat treatment is 90 °C (comparative aluminum alloy plastic working material 6), the Young's modulus shows a high value (almost not lowered). In addition, when the holding temperature of the heat treatment is 310 °C (comparative aluminum alloy plastic working material 7), though the Young's modulus is lowered, the proof stress and tensile strength are simultaneously lowered. From the results, when the holding temperature of the heat treatment was 310 °C, it is considered that the recrystallization of the plastic working structure progressed.
- The structural photographs of the present aluminum alloy
plastic working material 3 and the comparative aluminum alloy plastic working material 8 by an optical microscope are shown inFIG. 3 and FIG. 4 , respectively. In the structure photograph, the black region is the Al4Ca phase, and the average crystal grain size of the Al4Ca phase is measured by image analysis. The obtained results are shown in Table 4.[Table 4 Homogenization treatment Average crystal grain size of Al4Ca phase Young's modulus Proof stress Tensile strength (µm) (GPa) (MPa) (MPa) Comparative aluminum alloy plastic working material 8 Did 1.56 53 158 229 Present aluminum alloy plastic working material 3Non 1.15 53 169 254 - From the results shown in Table 4, when subjecting to the homogenization treatment maintained at 550 °C (comparative aluminum alloy plastic working material 8), it is recognized that the proof stress and the tensile strength are reduced. Here, the average crystal grain size of the Al4Ca phase is increased by the homogenization treatment to 1.56 µm. It is considered that the proof stress and the tensile strength are reduced due to the increase in the average crystal grain size.
Claims (3)
- An aluminum alloy plastic working material, which comprises:5.0 to 10.0 wt% of Ca,optionally at least one or more of 0.05 to 1.0 wt% of Fe and 0.005 to 0.05 wt%. of Ti, andthe remainder aluminum and unavoidable impurities,wherein:a volume ratio of an Al4Ca phase, which is a dispersed phase, is 25% or more,the Al4Ca phase comprises a tetragonal Al4Ca phase and a monoclinic Al4Ca phase,an intensity ratio (I1/I2) of the highest diffraction peak (I1) attributed to the tetragonal system to the highest diffraction peak (I2) attributed to the monoclinic system, which are obtained by an X-ray diffraction measurement, is 1 or less, andan average crystal grain size of the Al4Ca phase is 1.5 µm or less.
- A method for producing an aluminum alloy plastic working material, comprising:a first step for obtaining a plastic workpiece of an aluminum alloy by subjecting an aluminum alloy ingot which contains 5.0 to 10.0 wt% of Ca and optionally contains at least one or more of 0.05 to 1.0 wt% of Fe and 0.005 to 0.05 wt%. of Ti with the remainder aluminum and inevitable impurities, and has a volume ratio of an Al4Ca phase which is a dispersed phase of 25% or more to a plastic processing, anda second step for subjecting to a heat treatment in a temperature range of 100 to 300 °C.
- The method for producing an aluminum alloy plastic working material according to claim 2, wherein, before the first step, the aluminum alloy ingot is not subjected to a heat treatment where the ingot is maintained at a temperature of 400 °C or more.
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