EP3921449A1 - Alliages d'aluminium destinés à des applications structurales de coulée sous vide à haute pression - Google Patents

Alliages d'aluminium destinés à des applications structurales de coulée sous vide à haute pression

Info

Publication number
EP3921449A1
EP3921449A1 EP20752262.4A EP20752262A EP3921449A1 EP 3921449 A1 EP3921449 A1 EP 3921449A1 EP 20752262 A EP20752262 A EP 20752262A EP 3921449 A1 EP3921449 A1 EP 3921449A1
Authority
EP
European Patent Office
Prior art keywords
aluminum alloy
blended material
recycled
silicon
manganese
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.)
Pending
Application number
EP20752262.4A
Other languages
German (de)
English (en)
Other versions
EP3921449A4 (fr
Inventor
Kevin Haney
Mike BLOW
Benjamin C. PROBERT
Zach Brown
Brian Springer
Andrea Hill
Xiaoping NIU
Randy BEALS
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Magna International Inc
Original Assignee
Magna International Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Magna International Inc filed Critical Magna International Inc
Publication of EP3921449A1 publication Critical patent/EP3921449A1/fr
Publication of EP3921449A4 publication Critical patent/EP3921449A4/fr
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/14—Machines with evacuated die cavity
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/32—Controlling equipment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/02—Casting exceedingly oxidisable non-ferrous metals, e.g. in inert atmosphere
    • B22D21/04—Casting aluminium or magnesium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B21/00—Obtaining aluminium
    • C22B21/0038—Obtaining aluminium by other processes
    • C22B21/0069—Obtaining aluminium by other processes from scrap, skimmings or any secondary source aluminium, e.g. recovery of alloy constituents
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B21/00—Obtaining aluminium
    • C22B21/0084—Obtaining aluminium melting and handling molten aluminium
    • C22B21/0092—Remelting scrap, skimmings or any secondary source aluminium
    • 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
    • C22C1/02—Making non-ferrous alloys by melting
    • C22C1/026—Alloys based on aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
    • C22C21/04—Modified aluminium-silicon alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/043—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with silicon as the next major constituent

Definitions

  • the present invention relates to an aluminum alloy, a part produced from at least partially recycled material and an aluminum alloy, and methods of manufacturing the same.
  • Casting, extruding, and forging are popular production processes wherein material is melted, shaped, and allowed to cool and solidify into an article.
  • One material used in such processes is aluminum, and more particularly, an Aural series aluminum alloy, which has been shown to exhibit excellent mechanical properties, good castability (fluidity), and an ability to be hardened via heat treatment (precipitation hardening).
  • Articles produced from the Aural series alloys are typically formed by a high pressure die casting process. While exhibiting these qualities, the Aural series alloys are expensive and are typically produced in lower volumes than other more common aluminum alloys. Moreover, workability of the
  • Aural series alloys can be difficult during certain processes, such as smelting.
  • the recycled material is added to molten Aural series alloy material in the furnace and mixed.
  • the recycled material is added at a specific ratio to total molten material, based on differences in chemical composition.
  • master alloy additions such as silicon, manganese, magnesium, and strontium, are also added to compensate for the differences between the composition of the recycled material and the Aural series alloy material.
  • One aspect of the invention provides a method of manufacturing a blended material.
  • the method comprises mixing a recycled aluminum alloy with an improved aluminum alloy to form a blended material.
  • the recycled aluminum alloy comprises, in weight percent (wt.%) based on the total weight of the recycled aluminum alloy, 6.5 wt.% to 7.5 wt.% silicon, up to 0.25 wt.% iron, up to 0.2 wt. % copper, up to 0.1 wt. % manganese, 0.25 wt. % to 0.45 wt. % magnesium, up to 0.1 wt.% zinc, up to 0.2 wt. % titanium, other elements in an amount up to 0.15 wt.% , and a balance of aluminum.
  • the blended material comprises, in weight percent (wt.%) based on the total weight of the blended material 6.0 to 8.0 wt. % silicon, up to 0.25 wt. % iron, 0.40 to 0.60 wt. % manganese, 0.1 to 0.60 wt. % magnesium, 0.01 to 0.03 wt. % strontium, and up to 0.15 wt.% titanium, other elements in an amount up to 0.15 wt, %, and a balance of aluminum; or the blended material comprises, in weight percent (wt.%) based on the total weight of the blended material, 9.5 to 1 1.5 wt. % silicon, up to 0.25 wt. % iron, 0.40 to 0.60 wt.
  • manganese 0.1 to 0.60 wt. % magnesium, 0.01 to 0.025 wt. % strontium, and up to 0.12 wt. % titanium, other elements in an amount up to 0.15 wt. %, and a balance of aluminum.
  • Another aspect of the invention provides a blended material comprising, in weight percent (wt.%) based on the total weight of the blended material, 6.0 to 8.0 wt. % silicon, up to 0.25 wt. % iron, 0.40 to 0.60 wt. % manganese, 0.1 to 0.60 wt. % magnesium, 0.01 to 0.03 wt. % strontium, and up to 0.15 wt. % titanium, other elements in an amount up to 0.15 wt. %, and a balance of aluminum; or the blended material comprises, in weight percent (wt.%) based on the total weight of the blended material, 9.5 to 1 1.5 wt. % silicon, up to 0.25 wt. % iron, 0.40 to 0.60 wt. % manganese, 0.1 to 0.60 wt. % magnesium, 0.01 to
  • the blended material is formed by mixing a recycled aluminum alloy and an improved aluminum alloy.
  • the recycled aluminum alloy comprises, in weight percent (wt.%) based on the total weight of the recycled aluminum alloy, 6.5 wt.% to 7.5 wt% silicon, up to 0.25 wt.% iron, up to 0.2 wt. % copper, up to 0.1 wt. %
  • manganese 0.25 wt. % to 0.45 wt. % magnesium, up to 0.1 wt.% zinc, up to 0.2 wt % titanium, other elements in an amount up to 0.15 wt. %, and a balance of aluminum.
  • Another aspect of the invention provides a method of manufacturing a part for a vehicle.
  • the part is formed of a blended material comprising, in weight percent (wt.%) based on the total weight of the blended material, 6.0 to 8.0 wt. % silicon, up to 0.25 wt. % iron, 0.40 to 0.60 wt. % manganese, 0.1 to 0.60 wt. % magnesium, 0.01 to 0.03 wt % strontium, and up to 0.15 wt. % titanium, other elements in an amount up to 0.15 wt. %, and a balance of aluminum; or the blended material comprises, in weight percent (wt.%) based on the total weight of the blended material, 9.5 to 1 1.5 wt.
  • the blended material is formed by mixing a recycled aluminum alloy and an improved aluminum alloy.
  • the recycled aluminum alloy comprises, in weight percent (wt.%) based on the total weight of the recycled aluminum alloy, 6.5 wt.% to 7.5 wt.% silicon, up to 0.25 wt.% iron, up to 0.2 wt. % copper, up to 0.1 wt.
  • the method further includes casting the blended material to form the part.
  • Figure 1 illustrates an example part at least partially formed from a blended material that includes a recycled alloy and an improved aluminum alloy and which meets Aural series alloy specifications;
  • Figure 2 shows fragments of the recycled aluminum alloy according to an example embodiment
  • Figures 3A and 3B provide microscopic views illustrating porosity of the recycled aluminum alloy according to an example embodiment
  • FIGS 4A through 4D illustrate dendrite arm spacing (DAS) of the blended material after various processing steps according to an example embodiment
  • Figure 5A-51 illustrate steps of a high pressure vacuum die casting process according to an example embodiment
  • Figure 6 is a chart illustrating differences between conventional high pressure die casting HPDC, vacuum assist high pressure die casting, and high vacuum high pressure vacuum die casting;
  • Figures 7A-7H are example parts that can be formed from the blended material;
  • Figure 8 provides a description of a sludge factor for aluminum alloys.
  • Example embodiments will now be described more fully with reference to the accompanying drawings.
  • the subject embodiments are directed to a part produced from at least partially recycled material and an improved alloy, the improved alloy, and a method of blending the improved alloy with the recycled material.
  • the example embodiments are only provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well- known technologies are not described in detail.
  • the present disclosure provides a blended material formed of a recycled aluminum alloy and an improved aluminum alloy, a method of producing the blended material from the recycled aluminum alloy and an improved aluminum alloy, a part formed of the blended material, and a method of producing the part from the blended material.
  • the method allows for relatively inexpensive and efficient production of parts exhibiting excellent material properties, preferably similar or identical to parts formed of Aural series alloys.
  • Figure 1 shows a part 20 made from the blended material formed of the recycled aluminum alloy and the improved aluminum alloy.
  • the part is a structural component for a body of a vehicle, specifically a front body hinge pillar.
  • the blended material could be used to form various other parts used for vehicle applications.
  • the parts are at least partially formed, but preferably entirely formed, from the blended material.
  • the chemical composition of the recycled aluminum alloy can be measured, for example, via an optical emission spectroscopy machine, and the composition of the improved aluminum alloy can be set to achieve the blended material with the desirable composition.
  • the resulting blended material typically and preferably meets the specifications of Aural 2, Aural 5S, or another Aural series alloy,
  • the recycled aluminum alloy used to form the parts is preferably cleaned and shredded before introduction into a furnace.
  • the recycled aluminum alloy includes recycled 356 aluminum alloy, preferably A356.2 aluminum obtained from used wheels and/or rims, as shown in Figure 2.
  • the used wheels or rims are crushed, shredded (or fragmented), and cleaned, without requiring melting and casting into ingots, further reducing the carbon footprint. After fragmentation, the recycled aluminum alloy placed in the furnace, melted, and blending with the improved aluminum alloy.
  • Castings formed of aluminum alloys can be greatly affected by the presence of oxide films and impurities in the molten blended alloy. With the increased surface area of fragmented and crushed wheels, a slightly higher potential risk of oxides and other inclusions may occur in certain embodiments. In order to meet ASTM requirements for tensile testing, proper cleaning of the melt, grain refining additions and modifications prior to casting or blending of the recycled aluminum alloy can be included in the method.
  • the recycled aluminum alloy typically is a recycled 356.2 aluminum alloy and has a composition very similar to that of raw and unused A356.2.
  • the only typical exception is the Fe content, which is typically in the range, in weight percent (wt.%) based on the total weight of the alloy, of .11-, 14% on average (compared to the .12% limit of A356.2).
  • Recycled 356.2 alloy is currently available in the form of sacks suitable for improved handling and logistics. If necessary, the method may include mixing/diluting the recycled 356.2 alloy with primary aluminum to comply exactly with the A356.2 chemistry, although for most embodiments this is not necessary.
  • the recycled aluminum alloy is 356,2 aluminum
  • the recycled 356.2 aluminum approximately or exactly comprises, in weight percent (wt.%) based on the total weight of the alloy: silicon (6.81 wt.%); iron (0.156 wt.%); copper (0.0467 wt.%,); manganese (0.0213 wt%); magnesium (0.353 wt.%); zinc (0.0072 wt.%); titanium (0.1015 wt.%); and the remainder being aluminum and other trace elements.
  • wt.% approximately or exactly comprises, in weight percent (wt.%) based on the total weight of the alloy: silicon (7.0 wt.%); Iron (0.1 1 wt.%); copper (0.004 wt.%,); manganese (0.006 wt.%); magnesium (0.334 wt.%); zinc (0.005 wt.%); titanium (0.12 wt.%); other elements (0.03 wt.%); and the remainder being aluminum.
  • the ftimace is hot enough so that after melting, the recycled 356.2 aluminum alloy approximately or exactly comprises, in weight percent (wt.%) based on the total weight of the alloy: silicon (7.0 wt.%); iron (0.15 wt.%); copper (0,011 wt.%,); manganese (0.006 wt.%); magnesium (0.348 wt.%); zinc (0.005 wt.%); titanium (0.10 wt.%); other elements
  • the recycled 356.2 aluminum alloy is degassed.
  • the recycled 356.2 aluminum alloy can be argon degassed with a Palmer rotary degasser for approximately 20 minutes.
  • the recycled 356.2 aluminum alloy approximately or exactly comprises, in weight percent (wt.%) based on the total weight of the alloy: silicon (7.0 wt.%); iron (0.15 wt.%); copper (0.006 wt.%,); manganese (0,006 wt.%); magnesium (0.338 wt.%); zinc (0.005 wt.%); titanium (0.13 wt.%); other elements (0.03 wt.%); and the remainder being aluminum.
  • the recycled 356.2 aluminum alloy typically includes the following preferred ranges and approximate values of the following elements (which are typical in recycled road wheels and can represent a nominal composition within the preferred embodiment), in weight percent (wt.%) based on the total weight of the recycled aluminum alloy: silicon (minimum 6.5 wt.%, maximum 7.5 wt.%); iron (minimum 0.13 wt.%, maximum .25 wt.%); copper (0.2 wt. % max or 0.10 wt.% max); manganese (0.1 wt. % max or 0.05 wt.% max); magnesium (0.25 wt. % to 0.45 wt. % or 0.3 wt. % to 0.45 wt.%); zinc
  • the following Tables 1-3 provide specific example compositions of the recycled aluminum alloy.
  • the recycled aluminum alloy could include any composition within the ranges of the A356.0 ASTM B108, A356.1 ASTM B179, or A356.2 ASTM B179 specifications.
  • the improved aluminum alloy preferably consists of a chemical composition that, when blended with the recycled aluminum alloy in a furnace, does not need any additional elements or materials to form the desired blended material. More specifically, there is no need to add additional master alloys, such as silicon, manganese, magnesium, and strontium into the furnace during the blending, The improved aluminum alloy is typically formed into an ingot before introduction into the furnace.
  • a first example embodiment of the improved aluminum alloy comprises in weight percent (wt.%) based on the total weight of the alloy: silicon (minimum 7.4 wt.%, maximum 7.9 wt.%); copper (maximum 0.01 wt. % or maximum 0.25 wt.%); iron (minimum 0.16 wt.%, maximum 0.2 wt.%); magnesium (no minimum, maximum
  • This example improved aluminum alloy preferably has a sludge factor of approximately 1.8. When combined in a furnace with the recycled 356.2 aluminum, this improved aluminum alloy is hypoeutectic.
  • a second example embodiment of the improved aluminum alloy comprises in weight percent (wt.%) based on the total weight of the improved aluminum alloy: silicon (minimum 12.5 wt.%, maximum 13 wt.%); copper (maximum 0.01 wt. % or maximum 0,25 wt.%); iron (minimum 0.16 wt.%, maximum 0.2 wt.%); magnesium
  • This improved aluminum alloy preferably has a sludge factor of approximately 1,8. When combined in a furnace with the recycled 356.2 aluminum alloy, this improved aluminum alloy is eutectic.
  • a third example embodiment of the improved aluminum alloy comprises in weight percent (wt.%) based on the total weight of the improved aluminum alloy: silicon (minimum 17 wt.%, maximum 17.5 wt.%); copper (maximum 0,01 wt.%); iron (minimum 0.16 wt.%, maximum 0.2 wt.%); magnesium (minimum .27 wt.%, maximum 0.33 wt.%); zinc (no minimum, maximum 0.03 wt.%); manganese (minimum 1.65 wt.%, maximum 1.70 wt.%); titanium (no minimum, maximum 0.06 wt.%); strontium (minimum 0.06 wt.%, maximum 0.07 wt.%); nickel (trace amounts); chromium (trace amounts); tin (trace amounts); other elements (combined maximum 0.1 wt.%, individual maximum 0.03 wt.%); and the remainder being aluminum.
  • Table 4 provides specific example compositions of the improved aluminum alloys E5.50, E2.50, and E2.70.
  • The“trace amount” disclosed above for the nickel, chromium and tin of the improved aluminum alloys and listed below is up to 0.05 wt. %.
  • the improved aluminum alloys can include trace amounts of nickel, chromium and tin. The total amount of these trace elements is preferably not greater than 0.15 wt. %.
  • Figure 8 provides a description of the“sludge factor" and how it is calculated.
  • the method includes adding equal parts of the improved aluminum alloy and the recycled 356.2 aluminum alloy to the furnace, and blending the resulting molten material.
  • the method includes a longer melting period, in addition to adding more E2.70 alloy than recycled 356.2 aluminum alloy to the furnace, and blending the resulting molten material.
  • the method includes slight adjustments of the composition of the blended material in the furnace after melting.
  • the recycled aluminum alloy includes recycled
  • the recycled aluminum alloy includes silicon in an amount of 6.81 wt. %, iron in a amount of 0.156 wt. %, manganese in an amount of 0.021 wt. %, magnesium in an amount of 0.325 wt. %, titanium in an amount of 0.102 wt. %, and copper in an amount of 0.047 wt. %, based on the total weight of the improved aluminum alloy; and the recycled alumni alloy is mixed with the improved aluminum alloy E5.50 to achieve the blended material comprising silicon in an amount of 7.31 wt.
  • the blended material comprises any composition within the Aural 5S specification, In this case, the blended material comprises, in weight percent (wt.%) based on the total weight of the blended material, 6.0 to 8.0 wt. % silicon, up to 0.25 wt % iron, 0.40 to 0.60 wt. % manganese, 0.1 to 0.60 wt. % magnesium, 0.01 to 0.03 wt. % strontium, and up to 0.15 wt. % titanium, other elements each in an amount up to 0.05 wt. %, other elements in a total amount up to 0.15 wt. %, and a balance of aluminum.
  • wt.% weight percent
  • the blended material comprises any composition within the Aural 2 specification.
  • the blended material comprising, in weight percent (wt.%) based on the total weight of the blended material, 9.5 to 11.5 wt. % silicon, up to 0.25 wt. % iron, 0.40 to 0.60 wt. % manganese, 0.1 to 0.60 wt. % magnesium, 0.01 to 0.025 wt. % strontium, and up to 0.12 wt. % titanium, other elements each in an amount up to 0.05 wt. %, other elements in a total amount up to 0, 15 wt. %, and a balance of aluminum.
  • the recycled aluminum alloy and/or the improved aluminum alloy can undergo additional processing before, during, or after being blended.
  • the alloys could be degassed, fluxed, filtered, and grain boundary strengthened during the production process.
  • the step of degassing includes argon degassing with a Palmer rotary degasser for 20 minutes.
  • the blended material could also undergo one or more of the aforementioned additional processing steps. Furthermore, the resulting blended material can undergo heat treating after casting.
  • the blended material could be heat treated to T6 according to, American Society for Testing and Materials (ASTM), ASTM B917 and T61 with slight modification to ASTM B917 to increase elongation.
  • ASTM American Society for Testing and Materials
  • the blended material can be sand casted and annealed to 540 °C for 9h, quenched in water at 25 °C, and aged to 155 °C for 4 hours the day after.
  • the blended material can be permanently cast into bars, solution annealed to 540 °C for 9h, quenched in water at 25 °C, then aged at 162 °C for 9 hours.
  • the blended material may further be treated by hot isostatic pressing at 535 °C 15000 psi for 2 hours.
  • the blended material can be heated to a temperature of 730 °C and melted, then may further undergo T7 treatment at 860° F for 75 minutes, and forced air quenched at a 14° C per second for two hours at 215° C (419° F).
  • the molten blended material is grain refined with 0.05 %Ti (AI%5Ti lB).
  • the recycled aluminum alloy is modified, and the modifications of the recycled alloy, in certain cases, result in improvements to the blended material. While the specific material properties described in the following paragraphs are related to the recycled aluminum alloy, it should be appreciated that any of the methods of modifying material properties can also be applied to the improved aluminum alloy and/or the blended material before, after, or during, the blending or casting of the part
  • the blended material achieves an ultimate tensile strength of greater than 180, a yield strength of greater than 120, and an elongation of greater than 5%.
  • Table 5 includes material properties of the blended material that comprises E.250 and the recycled A356.2 aluminum alloy obtained from the road wheels after heat treatment.
  • FIGS 3A and 3B are microscopic views that illustrate porosity of the recycled aluminum alloy. Porosity was evaluated by image analysis of the surface. As shown in 3A (from left to right), porosity in the permanent mold bar was 0.67 % for the untreated melt, 0.36 % for the degassed melt, and 0.02 % in the degassed after hipping. Hipping has closed porosity and substantially improved mechanical properties, hence exhibiting improved results for certain embodiments (e.giller from low pressure/counter pressure casting or squeeze casting). Porosity in a sand cast test bar is illustrated in 3B and includes an average value of tensile properties at 0.53%. The lower speed of solidification or in the resin sand mold is the reason for the higher porosity content when compared to permanent mold results presented in
  • Figures 4A through 4D are microscopic views of the blended material illustrating dendrite arm spacing. Dendrite arms spacing is correlated to solidification speed and efficiency. The fast cooling in metal molds produces a finer structure than in a sand mold. Modification by a step of adding strontium is made to transform the acicular eutectic silicon to rounded shapes, which improves elongation.
  • a test bar cast from the blended material including E.250 and the recycled aluminum alloy that is T7 treated is shown in Figure 4A.
  • a test bar cast from blended material including E.5.50 and recycled alloy after T5 heat treatment is shown in Figure 4B.
  • the step of cleaning the recycled aluminum alloy can include an assessment of cleanliness.
  • the metal cleaning can be started with Kmold during the testing.
  • Recycled alloy cleanliness is ideally assessed with a hot porous disk filtration apparatus (PoDFA) in the degassed melt.
  • PoDFA can be used for a molten cleanliness assessment, wherein the molten metal is forced under vacuum to flow through a ceramic filter.
  • the amount of inclusion per kg filtered and inclusion type is measured by metallography and expressed in mm2/kg. PoDFA results of methods that include the recycled 356.2 aluminum alloy have shown excellent results.
  • the recycled aluminum alloy can undergo a step of fluxing.
  • the step of fluxing is carried out with 0.8 g/kg of Promag SI flux, then argon degassed with the Palmer degasser for 20 minutes. An amount of 1.7 lb of dross can be generated. Magnesium in the melt was almost unchanged with 0.32 % after melt treatment (including the 4 hours of operation for pouring and testing the degassed alloy).
  • the example recycled alloy is A356, it could also include a multitude of die casting processes and materials, For example, certain die castings are made from primary alloys (e.g., 365 or A365) which can also be used and undergo the above method and exhibit a similar positive economical and environmental impact. In addition, a multitude of components currently made by die casting (in secondary alloys) could benefit from the higher quality and competitive input material that the recycled 356.2 alloy blended with the improved alloy provides. With improved mechanical properties, these die cast parts can be redesigned in a way that reduces the overall weight of vehicles. Additionally, the die cast parts formed of the blended material with improved properties could be used to replace heavier aluminum (e.g., in permanent mold castings made with thicker walls, or other heavier metal castings).
  • the charging and melting time of the recycled 356.2 alloy will depend on the furnace type and arrangement and the way it is charged. In most cases, there will be little difference in terms of charging time between small ingots, T-bars, or sows if the charging is done in the appropriate way, e.g., with complete sacks (replacing T-bars or sows). Melting time can also depend on the surface area to mass ratio, which is much greater compared to ingots and especially T-bars or sows, so generally shredded recycled material will melt faster, especially if the charge is immersed into molten metal. These features can all be calculated for refining various method steps.
  • melt loss was low and comparable to ingots.
  • steps and results include: first, skimming 0.66 lb or 0.5% of the charge; second, skimming after degassing 5.97 lb or 2.17 % of the charge, amounting to 2.67 % of the charge loss in dross. With clean and dry charge materials like ingots or T-bars, this loss can be in the range of 1- 2%.
  • Oxide testing of a part formed from the blended material can be included in the method via a Kmold Oxide
  • Measurement for example after mixing E2.50 and the recycled aluminum alloy before a fluxing operation.
  • melting loss/dross generation depends on equipment and processing of the metal, surface area to mass ratio of the charge material, and the condition of the surface of the charge material.
  • shredded recycled 356.2 alloy its surface condition is excellent and extremely clean, so it does not contribute additionally to melt loss/dross generation.
  • the recycled 356.2 aluminum alloy is a material that can allow foundries and die casters to achieve very good quality castings - close to 450 MPa (in permanent mould casting).
  • the parts can be formed from the blended material, including the recycled aluminum alloy and the improved aluminum alloy.
  • the parts are formed by high pressure vacuum die casting.
  • molten metal is injected at high velocity and high pressure into a steel mold (die) cavity.
  • the metal is typically injected at a velocity ranging from 90 to 200 feet per second and at a pressure of 5 to 15 ksi.
  • the cavity (die) fill time ranges from a few milliseconds to as long as one half second.
  • Die casting machines are typically rated in clamping tons equal to the amount of pressure they can exert on the die. Machine sizes range from 400 tons to 4000+ tons.
  • Figure 5A-5I illustrate steps of the high pressure vacuum die casting process according to an example embodiment.
  • Figure 5A shows the start position of a die.
  • the die is closed and molten aluminum alloy is poured into a cold chamber.
  • a vacuum is applied to remove the atmosphere inside a die cavity and shot chamber.
  • hydraulic pistons push the metal slowly toward the die cavity.
  • the die cavity is filled in a fraction of a second.
  • the metal solidifies under pressure to form a casting.
  • the die is opened and the casting is removed.
  • a release agent is applied to the die.
  • the casting apparatus is ready for the next cycle
  • Figure 6 is a chart illustrating differences between conventional high pressure die casting HPDC, vacuum assist high pressure die casting, and high pressure vacuum die casting.
  • Figures 7A-7H are example parts that can be formed from the blended material.
  • Figure 7A is a chassis component, particularly a front subframe.
  • Figure 7B is a structural body component, specifically a front shock tower.
  • Figure 7C is a structural body component, specifically a rear rail.
  • Fig. 7D is a structural body components, specifically a front kick-down rail.
  • Figure 7E is a structural body component, specifically a front body hinge pillar.
  • Figure 7F is a structural body component, specifically a tunnel.
  • Figure 7G is a structural body component, specifically a front body hinge pillar.
  • Figure 7H is a structural body component, specifically a rear shock mount.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Manufacture And Refinement Of Metals (AREA)

Abstract

L'invention concerne une pièce de véhicule formée au moins en partie d'un matériau mélangé. Le matériau mélangé est formé par mélange d'un alliage d'aluminium amélioré et d'un alliage d'aluminium recyclé. L'alliage d'aluminium recyclé peut être obtenu à partir de galets de roulement. L'alliage mélangé répond de préférence aux caractéristiques techniques des alliages de série Aural. Le matériau mélangé peut être coulé sous haute pression et sous vide pour former une pièce conçue pour être utilisée dans un châssis ou un corps structural d'un véhicule, par exemple un sous-cadre avant, une tourelle amortisseur avant, un rail arrière, un rail de démarrage avant, un montant de charnière de corps avant, un tunnel, un pilier de charnière de corps avant, ou un support amortisseur arrière.
EP20752262.4A 2019-02-08 2020-02-07 Alliages d'aluminium destinés à des applications structurales de coulée sous vide à haute pression Pending EP3921449A4 (fr)

Applications Claiming Priority (2)

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US201962803000P 2019-02-08 2019-02-08
PCT/US2020/017199 WO2020163707A1 (fr) 2019-02-08 2020-02-07 Alliages d'aluminium destinés à des applications structurales de coulée sous vide à haute pression

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EP3921449A1 true EP3921449A1 (fr) 2021-12-15
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CN115927925A (zh) * 2021-09-24 2023-04-07 通用汽车环球科技运作有限责任公司 低碳足迹铸铝组件
DE102021129329A1 (de) 2021-11-11 2023-05-11 Bayerische Motoren Werke Aktiengesellschaft Verfahren zum Herstellen einer Aluminium-Legierung sowie Bauteil
IT202200011183A1 (it) 2022-05-27 2023-11-27 Ferrari Spa Telaio in alluminio riciclato per un veicolo stradale e corrispondente metodo di produzione

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CN113423853A (zh) 2021-09-21
CN113423853B (zh) 2022-11-15
EP3921449A4 (fr) 2022-10-26
US20220017997A1 (en) 2022-01-20
WO2020163707A1 (fr) 2020-08-13

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