EP4137595A1 - Alliage de moulage d'aluminium pour moulage en forme de filet proche de composants structuraux ou non structuraux - Google Patents

Alliage de moulage d'aluminium pour moulage en forme de filet proche de composants structuraux ou non structuraux Download PDF

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Publication number
EP4137595A1
EP4137595A1 EP22201912.7A EP22201912A EP4137595A1 EP 4137595 A1 EP4137595 A1 EP 4137595A1 EP 22201912 A EP22201912 A EP 22201912A EP 4137595 A1 EP4137595 A1 EP 4137595A1
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EP
European Patent Office
Prior art keywords
mass
alloy
mpa
aluminum
alloy according
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
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EP22201912.7A
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German (de)
English (en)
Inventor
Glenn Edwin BYCZYNSKI
Anthony Marco LOMBARDI
Sumanth Shankar
Xiaochun Zeng
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.)
McMaster University
Nemak SAB de CV
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McMaster University
Nemak SAB de CV
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Publication date
Application filed by McMaster University, Nemak SAB de CV filed Critical McMaster University
Priority claimed from EP21180881.1A external-priority patent/EP4083242A1/fr
Publication of EP4137595A1 publication Critical patent/EP4137595A1/fr
Pending legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/10—Alloys based on aluminium with zinc 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
    • 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
    • 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
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/56—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering characterised by the quenching agents
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/0068—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for particular articles not mentioned below
    • 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
    • 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
    • C22F1/053—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 zinc as the next major constituent

Definitions

  • the invention relates to an aluminum casting alloy for near net shaped casting of structural or non-structural components.
  • the alloy contains 2 to 10 % by mass zinc (“Zn”), 0.5 to 5 % by mass magnesium (“Mg”), 0.5 to 5 % by mass iron (“Fe”), ⁇ 4 % by mass copper (“Cu”), ⁇ 0.5 % by mass titanium (“Ti”), ⁇ 0.1 % by mass strontium (“Sr”), ⁇ 0.2 % by mass beryllium (“Be”), ⁇ 0.5 % by mass zirconium (“Zr”), ⁇ 0.5 % by mass vanadium (“V”), 0.5 % by mass chromium (“Cr”), ⁇ 0.5 % by mass scandium (“Sc”), ⁇ 0.1 % by mass sodium (“Na”), ⁇ 0.5 % by mass silicon (“Si”), ⁇ 1 % by mass manganese (“Mn”), ⁇ 5
  • the alloy may be subjected to heat treatment selected from the group consisting of solutionizing, incubation, aging, and two or more heat treatment steps.
  • the alloy known from WO 2018/094535 A1 comprises at least 1,5 % by mass Mg, 4 - 10 % by mass Zn, and 1,5 - 3 % by mass Fe, a first exemplary embodiment of the alloy consisting of 5 % by mass Zn, 2 % by mass Mg, 0.35 % by mass Cu, 1.5 % by mass Fe, and Al as balance and a second exemplary embodiment of the alloy consisting of 5 % by mass, Zn 2 % by mass Mg and 1.5 % by mass Fe, balance Al.
  • Both alloys were cast by high pressure die casting with vacuum assistance, a thin walled part manufactured from the first alloy having a yield strength of 200 MPa, an ultimate tensile strength of 315 MPa and an elongation of 3.80 % in the as-cast state with 21 days of natural aging and a large scale part manufactured from the second alloy showing a yield strength of 201 MPa, an ultimate tensile strength of 312 MPa and an elongation of 4.63 % in the as-cast state.
  • WO 2018/094535 A1 discloses side door impact beams made from alloys which contain 5.0 % by mass Zn, 2.0 % by mass Mg, 0 or 0,35 % by mass of Cu, 1.5 % by mass of Fe, and Al as balance respectively.
  • the optimized mechanical properties of the parts which have been alloyed and manufactured in accordance with the specifications given in WO 2018/094535 A1 have been achieved not only by a purposeful adjustment of the contents of the alloying elements but also by equally purposefully heat treating the respective part.
  • an AlZnMg casting alloy is disclosed.
  • This known alloy consists of 3.0 to 4.5 % by mass Zn, 0.1 to 1.5 % by mass Mg and 0.5 to 1.5 % by mass Fe, balance Al and impurities, wherein the impurities may include contents of Ti, Cr and other elements with a respective content of up to 0.1 % by mass, in particular up to 0.01 % by mass.
  • the exemplary embodiments of the alloy contain 1.88 to 4.05 % by mass of Zn, 0.17 to 1.35 % by mass of Mg, 0.52 to 1.02 % by mass of Fe, balance Al.
  • the castings can also be subjected to age hardening or precipitation hardening, which can be performed as "natural aging” by exposing the castings to room temperature for several days, or as “artificial aging", in which the castings are usually also kept at elevated temperatures for several days to intensify and accelerate the hardness-increasing effect.
  • age hardening or precipitation hardening can be performed as "natural aging” by exposing the castings to room temperature for several days, or as “artificial aging”, in which the castings are usually also kept at elevated temperatures for several days to intensify and accelerate the hardness-increasing effect.
  • the object to be solved by the invention was to provide an aluminum alloy for high pressure die casting that offers a combination of properties that meets the requirements of structural, body-in-white and electrification components (battery enclosures). These requirements include ultimate tensile strengths (UTS), yield strength (YS), tensile elongation (%EI) and sufficient ductility for joinability without the necessity of an elaborate and cost intensive heat treatment.
  • UTS ultimate tensile strengths
  • YS yield strength
  • %EI tensile elongation
  • ductility for joinability without the necessity of an elaborate and cost intensive heat treatment.
  • the further object was to provide a method by means of which parts, which show an optimized combination of mechanical properties can be manufactured by using high pressure die casting in a practice-oriented manner.
  • an aluminum casting alloy for near net shaped casting of structural or non-structural parts thus consists of, in % by mass, Zn: 4.5 - 7.5 %; Mg: 0.7 - 2.0 %; Fe: 0.8 - 2.0 %; Si: ⁇ 0.3 %; Cu: ⁇ 0.1 %; V: ⁇ 0.2 %; Ti: ⁇ 0.2 %; B: ⁇ 0.04%; balance Al and unavoidable impurities, the sum of the contents of the impurities being ⁇ 0.1 %.
  • the invention has selected an aluminum alloy which has an optimized combination of strength, ductility, elongation, and joinability. This enables increased lightweighting opportunities of parts cast from the alloy according to the invention due to the higher strength and comparable performance in energy absorption in the event of a crash.
  • G.P. Zones Guinier-Preston zones, see https://en.wikipedia.org/wiki/Guinier-Preston_zone
  • the range of 4.5 - 7.5 % by mass Zn and 0.7 - 2.0 % by mass Mg are required to have the necessary combination of strength and ductility.
  • the positive influence Zn has on the strength of the parts cast from the alloy according to the invention can reliably be achieved, if the Zn-content of the alloy according to the invention is at least 4.6 % by mass, preferably at least 4.7 % by mass or at least 4.75 % by mass.
  • the Zn content of the alloy according to the invention can be limited to a maximum of 5.5 % by mass, in particular to a maximum of 5.0 % by mass.
  • a high strength variant of the alloy according to the invention can be obtained by setting the minimum Zn content to 5.0 % by mass and the maximum Zn content to 5.5 % by mass.
  • the cast alloy according to the invention shows high elongation properties.
  • the Mg content can be limited to a maximum of 1.5 % by mass, preferably to 1.0 % by mass for this purpose.
  • An aluminum casting alloy according to the invention which provides in the as-cast state ("F-temper") an elongation ranging from 11 to 15 % in combination with a yield strength of 140 to 160 MPa and an ultimate tensile strength in the range of 280 to 300 MPa thus, according to the invention, preferably contains 4.6 to 5.0 % by mass Zn and 0.8 to 1.0 % by mass Mg.
  • the cast part cast from aluminum alloy alloyed in this manner be optionally subjected to a T4 treatment.
  • a high strength variant of the alloy of the invention can be obtained by adjusting the Zn content of the alloy according to the invention to 5.0 to 5.5 % by mass and the Mg content of the alloy according to the invention to 1.6 to 2.0 % by mass, preferably 1.6 to 1.9 % by mass.
  • the embodiment of the alloy according to the invention alloyed in this way has an ultimate tensile strength of 300 to 340 MPa and a yield strength of 180 to 210 MPa in combination with an elongation of 4 to 7 % in the as-cast state ("F-temper").
  • the parts cast from the alloy alloyed in accordance with the invention containing 5.0 to 5.5 % by mass Zn and 1.6 to 2.0 % by mass Mg have a yield strength of 210 to 230 MPa, an ultimate tensile strength of 340 to 387 MPa, and an elongation of 7 to 11 %
  • the parts cast from this alloy have a yield strength ranged from 350 to 400 MPa and an ultimate tensile strength from 380 to 450 MPa, while their elongation ranges between 2 - 5 %.
  • Further lightweighting opportunities can exist using the high strength variant of the alloy according to the invention in applications that require the ultrahigh strength given by this alloy, specifically in the T7 condition, but can tolerate lower elongation/ductility.
  • 0.8 to 2.0 % by mass Fe is present in the alloy according to the invention to enable the formation of Al-Fe based eutectic phases which improve fluidity and reduce hot tearing susceptibility, thereby making the alloy castable to near-net shape in high pressure die casting.
  • Fe contents above 1 % by mass will also significantly reduce the susceptibility to die soldering, which improves die life and reduces distortion in the castings.
  • at least 0.8 % by mass Fe are needed, Fe contents of at least 1.0 % by mass being especially advantageous in this regard.
  • Fe contents of more than 2.0 % by mass should be avoided, to prevent the excessive formation of coarse primary Al13Fe4 platelets which are deleterious to alloy ductility. Negative influences of the presence of Fe in the alloy according to the invention can be prevented if, in particular, the Fe content is limited to a maximum of 1.8 % by mass or to a maximum of 1.5 % by mass.
  • the Si content should be limited to below 0.3 % by mass, in particular below 0.2 % by mass, to prevent the formation of harmful Fe based intermetallic phases such as ⁇ -AlFeSi which would be deleterious to the alloy's ductility.
  • the addition of Si should also be limited to prevent excessive Mg2Si formation, which depletes Mg and reduces the amount of G.P. Zones that are formed during natural aging and would impair alloy strengthening in the F-temper state.
  • the Cu content should be restricted to below 0.1 % by mass as it is deleterious to corrosion resistance and increases hot tearing susceptibility.
  • V can be optionally added as a modifying agent. Vanadium promotes the formation of the fibrous Al 6 Fe eutectic phase in favour of the acicular Al 13 Fe 4 , eutectic which will lead to improved ductility.
  • a minimum V content of at least 0.05 % by mass, in particular of at least 0.1 % by mass can be provided. This can counteract the negative effects of slower cooling rates or interactions with Si if present.
  • the maximum of the optional V content is limited to 0.2 % by mass, in particular to 0.1 % by mass, because higher V contents do not efficiently contribute to the properties of the alloy according to the invention.
  • Ti can be optionally added in amounts of up to 0.2 % by mass for grain refinement and reduction of hot tearing susceptibility. This effect can already be obtained by adding at least 0,05 % by mass Ti, in particular at least 0.1 % by mass.
  • the maximum of the optional Ti content is limited to 0.2 % by mass, in particular to 0.1 % by mass, because higher Ti contents do not contribute to the properties of the alloy according to the invention.
  • the Ti can be added to the melt alloyed in accordance with the invention in the form of an Al-5Ti-1B master alloy, which results in a maximum B content of 0.04 % by mass.
  • the remainder of the alloy according to the invention is formed by Al and technically unavoidable impurities.
  • Elements including Na, Ca, K, Li, Ni, Cr and Mn typically belong to these impurities.
  • the content of the respective impurities is set so low that in each case the respective impurity has no influence on the properties of the alloy and the part cast therefrom.
  • the total content of impurities in an alloy according to the invention is limited to 0.1 % by mass.
  • an aluminum casting alloy provided by the invention enables a combination of high ductility and improved strength compared to currently available alloys in the as-cast (F-temper) condition eliminating the need for heat treatments and associated post-processing. However, if the properties present in the as-cast state are not sufficient, they can be further improved by the heat treatments disclosed here.
  • the alloy according to the invention is especially suitable to be cast into near-net shape components using High Pressure Die Casting ("HPDC") with or without the application of vacuum.
  • HPDC High Pressure Die Casting
  • the alloy is based on the Al-Fe eutectic system, which enables the alloy to be castable in HPDC when Fe content exceeds 1 % by mass. Due to the composition targets provided by the invention additional benefits of the alloy according to the invention include an improved recyclability compared to the state of the art primary aluminum alloys as well as superior HPDC die life.
  • the alloy H700 based on which the properties shown in Fig. 1a to 2b were determined consists of 4.6 % by mass Zn, 0.8 % by mass Mg, 1.2 % by mass Fe, 0.07 % by mass Si and 0.05 % by mass Ti.
  • Figures 1a and 1b show the ultimate tensile strength UTS and the yield strength YS of the H700 in the F-temper state as a function of natural aging time.
  • Figures 2a and 2b show a comparison of the ultimate tensile strength UTS, the yield strength YS and the elongation %EL samples made from the H700 alloy in the F-temper state to samples of the current structural die casting alloys AlSi8MnMg and AlSi10MnMg in F-temper ( Fig. 2a ) and in heat treated T5 or T7 condition ( Fig. 2b ).
  • the T5 treatment which the AlSi8MnMg alloy samples were exposed to, consisted of artificial aging at 210 °C for 1 h followed by cooling in still air
  • the T7 treatment the AlSi10MnMg alloy samples were exposed to, consisted of solutionizing at 450 °C for 12 hours, heating to 475 °C with a heating rate of 5 °C/h, holding the samples at 475 °C for 7 hours followed by water quenching.
  • the samples underwent an natural aging ("incubation") treatment for 24 hours followed by an artificial aging in the course of which the samples were held at 120 °C for 24 hours followed by holding the samples at 160 °C for 24 hours.
  • FIG. 3 shows representative load-displacement curves from 3-point bend test for the H700 alloy samples in F-temper, for the AlSi8MnMg samples in F-temper and for the AlSi10MnMg samples in the T7 temper state.
  • the 3-point bend test was performed in accordance with the Ford BB119-01 specification, which is a modified version of the VDA 238-100 standard test.
  • the H700 alloy according to the invention showed excellent joinability to both aluminum sheets made of aluminum extrusion alloy 6082-T6 and steel sheets made of dual phase steel DP600, material number according to EN 10027-2:1992-09: 1.0936 using self-piercing rivets (SPR), which is a common practice for joining automotive structural components to form the body-in-white.
  • SPR self-piercing rivets
  • Fig. 4a shows a longitudinal section of a SPR joint between a part made of the H700 according to the invention and the sheet made from the 6082-T7 Al alloy.
  • Fig. 4b shows a top view on the SPR joint as seen from the side on which the part cast from the H700 part is arranged.
  • Fig. 4c shows a longitudinal section of a SPR joint between a part made of the H700 according to the invention and the sheet made from the CP600 steel alloy.
  • Fig. 4d shows a top view on the SPR joint as seen from the side on which the part cast from the H700 part is arranged.
  • Fig. 5 shows the development of the yield strength YS of a specimens cast from Al-5Zn-2Mg-1.3Fe alloy according to the invention in response to the duration of a natural aging at room temperature.
  • An aluminum casting alloy for near net shaped casting of structural or non-structural components consisting of, in % by mass, Zn: 4.5 - 7.5 %; Mg: 0.7 - 2.0 %; Fe: 0.8 - 2.0 %; Si: ⁇ 0.3 %; Cu: ⁇ 0.1 %; V: ⁇ 0.2 %; Ti: ⁇ 0.2 %; B: ⁇ 0.04 %; balance Al and unavoidable impurities, the sum of the contents of the impurities being ⁇ 0.1 %.
  • the aluminum casting alloy according to claim 1 characterized in that its Zn content is not more than 5.5 % by mass. 3.
  • the aluminum casting alloy according to any of the preceding claims characterized in that itsZn content is at least 4.6 % by mass. 4. The aluminum casting alloy according to any of the preceding claims characterized in that its Mg content is not more than 1.0 % by mass. 5. The aluminum casting alloy according to any of the preceding claims characterized in that its Mg content is at least 0.8% by mass. 6. The aluminum casting alloy according to claim 1 characterized in that its Fe content is not more than 1.5 % by mass. 7. The aluminum casting alloy according to any of the preceding claims characterized in that its Fe content is at least 1.0 % by mass. 8. The aluminum casting alloy according to any of the preceding claims characterized in that its Si content is less than 0,2 % by mass. 9.
  • the aluminum casting alloy according to any of the preceding claims characterized in that it contains at least 0.05 % by mass of Ti. 10.
  • the aluminum casting alloy according to any of the preceding claims characterized in that it contains at least 0,1 % by mass of V. 11.
  • the aluminum casting alloy according to any of the preceding claims characterized in that the alloy contains 4.6 to 5.0 %by mass Zn and 0.8 to 1.0 % by mass Mg and that it has in the as-cast state ("F-temper") a yield strength of 140 to 160 MPa, an ultimate tensile strength in the range of 280 to 300 MPa and elongation ranging from 11 to 14 %. 12.
  • Method for the manufacture of a cast part which has a yield strength of 180 to 200 MPa, an ultimate tensile strength of 300 to 320 MPa and an elongation of 11 to 14 % comprising the following working steps:

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
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  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
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  • Crystallography & Structural Chemistry (AREA)
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EP22201912.7A 2021-04-30 2021-06-22 Alliage de moulage d'aluminium pour moulage en forme de filet proche de composants structuraux ou non structuraux Pending EP4137595A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP21171617 2021-04-30
EP21180881.1A EP4083242A1 (fr) 2021-04-30 2021-06-22 Alliage de moulage d'aluminium pour le moulage en forme quasi nette de composants structuraux ou non structuraux

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EP4137595A1 true EP4137595A1 (fr) 2023-02-22

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US (1) US20240200172A1 (fr)
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Publication number Priority date Publication date Assignee Title
CN115961195B (zh) * 2022-12-28 2024-05-14 亚太轻合金(南通)科技有限公司 一种高压铸造铝合金及制备方法

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR101469613B1 (ko) 2012-08-21 2014-12-05 한국생산기술연구원 다이캐스팅용 고열전도도 Ａｌ－Ｚｎ 합금
US20150218678A1 (en) * 2012-08-21 2015-08-06 Korea Institute Of Industrial Technology Al-zn alloy for die casting having both high strength and high thermal conductivity
WO2018094535A1 (fr) 2016-11-28 2018-05-31 Sumanth Shankar Alliages d'aluminium destinés à la coulée continue presque aux cotes de pièces structurales et et non structurales, et leurs procédés de fabrication

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR101469613B1 (ko) 2012-08-21 2014-12-05 한국생산기술연구원 다이캐스팅용 고열전도도 Ａｌ－Ｚｎ 합금
US20150218678A1 (en) * 2012-08-21 2015-08-06 Korea Institute Of Industrial Technology Al-zn alloy for die casting having both high strength and high thermal conductivity
WO2018094535A1 (fr) 2016-11-28 2018-05-31 Sumanth Shankar Alliages d'aluminium destinés à la coulée continue presque aux cotes de pièces structurales et et non structurales, et leurs procédés de fabrication
US20190376166A1 (en) * 2016-11-28 2019-12-12 Mcmaster University Aluminium alloys for structural and non-structural near net casting, and methods for producing same

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
J. GILBERT KAUFMAN: "Understanding the Aluminum Temper Designation System", article "Introduction to Aluminum Alloys and Tempers", pages: 39 - 76

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