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
  • C22C—ALLOYS
  • C22C21/00—Alloys based on aluminium
  • C22C21/003—Alloys based on aluminium containing at least 2.6% of one or more of the elements: tin, lead, antimony, bismuth, cadmium, and titanium
• • 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
  • B22D18/00—Pressure casting; Vacuum casting
  • B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
  • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
  • B22D21/002—Castings of light metals
  • B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
• • 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 a casting alloy based on aluminum, iron and nickel with the addition of boron. Further the invention relates to the use of the alloy for high pressure die casting or gravity die casting.
• the alloy according to the invention is used for the production of rotors and stators for electric motors and heat exchangers, cooling and heating elements in the electronics sector or in vehicle construction.
• Rotor-Aluminum e.g. in qualities of 99.7% Al
• a metallic body is placed in the die-casting mold and the aluminum rotor or stator is cast into this metallic body.
• difficulties that arise when casting such an alloy are avoided, above all the high tendency to stick to steel, which otherwise leads to rapid wear of the casting mold.
• Other typical disadvantages are high shrinkage, very high casting temperatures, poor mechanical machinability and particularly low strength (e.g. Rp0.2 of 20-40 MPa for the alloy Al99.7E).
• alloys of the AlSi type are often used, e.g. the alloy AlSi9Sr (Castasil-21). Compared to Rotor-Aluminum, these alloy type is better castable. The tendency to stick to the casting mold, shrinkage, mold fillability and casting temperatures are more advantageous. However, the lower electric and thermal conductivity compared to Rotor-Aluminum are disadvantageous. With the help of a heat treatment, an electric conductivity of up to 28 MS / m can be achieved, the thermal conductivity is then 190 (W / K m). The yield strength of such an alloy (Rp0.2) is 80-100 MPa.
• the applicant's patent EP3 235 916 B1 discloses an alloy of the AlMg4Fe2 (Castaduct-42) type, which is preferably used for crash-relevant structural components in automobile construction.
• the metallurgical basis of this alloy is the Al3Fe eutectic.
• the electric conductivity is 16-17 MS / m.
• One object of the invention is, that at least one disadvantage of the alloys known from the prior art is solved.
• the alloy has an electric conductivity, preferably of least 23 MS / m, more preferred over 30 MS / m.
• the alloy should provide a high strength, preferably a Rp0.2 of at least 74 MPa, more preferred over 95 MPa.
• the alloy according to the inventions consists of: Iron (Fe) 0,8 to3,0 % by weight Nickel (Ni) 0,1 to 3,5 % by weight Boron (B) 40 to 300 ppm Zinc (Zn) 0 - 5 % by weight Tin (Sn) 0 - 5 % by weight Copper (Cu) 0 - 3 % by weight Manganese (Mn) 0 - 1 % by weight Magnesium (Mg) 0 - 0,6 % by weight Phosphorus (P) 0- 500 ppm Silicon (Si) 0 - 0.4% and 0- 0.8% by weight of an element or a group of elements selected from chromium (Cr), lithium (Li), vanadium (V), titanium (Ti), calcium(Ca), molybdenum (Mo) and zirconium (Zr) and the remainder aluminum and inevitable impurities.
• the iron content lies between 1.0-2.5% by weight.
• iron content lies between 1.2-2.0% by weight.
• the iron content lies between 1.4-1.9% by weight.
• the nickel content lies between 0.3-3.0% by weight.
• nickel content lies between 0.8-2.0% by weight.
• the boron content lies between of 70-200 ppm.
• the boron content lies between 100-1 60 ppm.
• the boron content lies between 80-150 ppm.
• the silicon content lies between 0- 0.3% by weight silicon.
• the copper content lies between 0.2-3% by weight.
• the copper content lies between 1.0-3.0% .
• the zinc content lies 0-3% by weight zinc.
• the zinc content lies between 0.5% to 4.0 by weight of zinc.
• magnesium content lies between 0-0.4% by weight of magnesium.
• the magnesium content lies between of 0.2-0.4%.
• the manganese content lies between 0-0.1% by weight.
• tin content lies between 0- 2.5% by weight.
• tin content lies between 0.2-2.5% by weight.
• the cast alloy is used for high pressure die-casting, preferably for high pressure die casting of rotors and stators for electric motors and heat exchangers, cooling and heating elements in the electronics sector or in vehicle construction.
• a high pressure die casted product preferably rotors and stators for electric motors and heat exchangers, cooling and heating elements in the electronics sector or in vehicle construction are manufactured from a cast alloy according to the invention.
• the castability of the alloy according to the invention is achieved by adding the alloying elements iron and nickel, whereby eutectic phases are formed (eutectic phases improve the castability of an alloy).
• an Al9FeNi phase should be achieved which is, according to the literature, created in the ideal ternary system with a composition of 1.75 wt% Fe and 1.25 wt% Ni.
• an Al3Fe or Al3Ni phase may also exist.
• the Al3Ni phase occurs with a high Ni and at the same time a low Fe content.
• the Fe content should be high and promote the formation of Al9FeNi together with a smaller amount of Al3Fe eutectic. In this way the tendency of the alloy to stick is reduced and the castability is improved.
• the alloy according to the invention hardly reacts to heat treatments.
• Heat treatment can have a positive effect on electric conductivity and thermal conductivity.
• the metallurgical background is mostly an agglomeration of additional elements and a coarsening of the phases, which leads to a better conductivity of the Alpha-AI.
• the Si content should not exceed 0.4% in order to ensure Si-free eutectics. Up to this level, only an enrichment in the alpha-AI phase is to be expected, which can slightly increase the strength.
• Mg An element for increasing strength is Mg. It does not form phases with Fe, has a high solubility in Alpha-AI and however, has a negative effect on conductivity (electric and thermal conductivity). In addition, MgNi-containing phases can be formed, which interfere with the formation of an Al9FeNi phase.
• the alloy according to the invention should therefore either be Mg-free or contain only a small proportion of Mg, preferably maximum 0.6%.
• Further elements which may have a strength-increasing effect are Sn, Mn, Cr, Li, V, Ti, Ca, Ga, Bi, Mo and Zr.
• Variants I and J both alloys, known from the prior art named Castaduct-42 and Castasil-21 are shown.
• Variant T is a further known alloy named, Rotors-Al99.7.
• Variant K to O refer to gravity die casting (GDC).
• GDC gravity die casting

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Materials Engineering (AREA)
• Metallurgy (AREA)
• Organic Chemistry (AREA)
• Physics & Mathematics (AREA)
• Thermal Sciences (AREA)
• Crystallography & Structural Chemistry (AREA)
• Induction Machinery (AREA)
• Molds, Cores, And Manufacturing Methods Thereof (AREA)
• Sealing Battery Cases Or Jackets (AREA)
• Conductive Materials (AREA)

Priority Applications (5)

Applications Claiming Priority (1)

Publications (1)

Family

ID=77155681

Family Applications (1)

Country Status (5)

Citations (5)

• 2021
  • 2021-07-30 EP EP21188809.4A patent/EP4124668A1/fr active Pending
• 2022
  • 2022-07-28 CN CN202210897320.6A patent/CN115679158A/zh active Pending
  • 2022-07-29 US US17/876,661 patent/US20230043878A1/en active Pending
  • 2022-07-29 JP JP2022121099A patent/JP2023021070A/ja active Pending
  • 2022-07-29 KR KR1020220094634A patent/KR20230019055A/ko unknown

Patent Citations (5)

Non-Patent Citations (1)

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