EP4215634A1 - Aluminium casting alloy - Google Patents

Aluminium casting alloy Download PDF

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Publication number
EP4215634A1
EP4215634A1 EP21869849.6A EP21869849A EP4215634A1 EP 4215634 A1 EP4215634 A1 EP 4215634A1 EP 21869849 A EP21869849 A EP 21869849A EP 4215634 A1 EP4215634 A1 EP 4215634A1
Authority
EP
European Patent Office
Prior art keywords
casting
alloy
calcium
aluminum
zinc
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
EP21869849.6A
Other languages
German (de)
English (en)
French (fr)
Inventor
Viktor Khrist'yanovich MANN
Aleksandr Nikolaevich ALABIN
Aleksandr Yur'evich KROKHIN
Dmitrij Olegovich FOKIN
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.)
Obshchestvo S Ogranichennoj Otvetstvennost'yu "institut Legkikh Materialov I Tekhnologij"
Original Assignee
Obshchestvo S Ogranichennoj Otvetstvennost'yu "institut Legkikh Materialov I Tekhnologij"
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
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Publication of EP4215634A1 publication Critical patent/EP4215634A1/en
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
    • 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
    • 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
    • C22C1/00—Making non-ferrous alloys
    • C22C1/02—Making non-ferrous alloys by melting
    • C22C1/03—Making non-ferrous alloys by melting using master alloys
    • 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
    • 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
    • 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
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/10—Alloys based on aluminium with zinc as the next major constituent
    • 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 invention refers to the field of metallurgy, in particular, to aluminum-based alloys characterized by high corrosion resistance.
  • the alloy can be used in the manufacture of thin-walled complex-shaped castings by casting in a metal mold.
  • Industrial non-heat-treatable alloys of the A-Si system such as A413.2 or AK12pch (GOST1583) are characterized by high processability when casting and a relatively low level of strength properties; in particular, the yield strength usually does not exceed 60-80 MPa, depending on the thickness of the castings.
  • a higher level of strength properties of castings already in the as-cast condition is provided by the addition of copper; in particular, alloys such as AA383.1 or AK12M2 are known.
  • the increase in mechanical properties in this case is accompanied by a significant decrease in elongation and deterioration of corrosion resistance.
  • Non-heat-treatable and corrosion-resistant alloys include the solid solution alloys based on the Al-Mg system, for example, AMg6L, AMg5K, AMg5Mz (GOST1583), Magsimal ® 59 (Rheinfelden Alloys) and others characterized by satisfactory processability when casting, good corrosion resistance, a high level of strength properties and elongation.
  • the disadvantages of alloys of this system include high linear shrinkage and insufficient tightness of thin-walled castings.
  • NITU MISIS invention disclosed in patent RU2660492 is known.
  • Material for use in the as-cast condition contains (wt. %): 5.4-6.4% calcium, 0.3-0.6% silicon, and 0.8-1.2% iron.
  • the disadvantages of the proposed invention include low relative elongation, which did not exceed 2.6%, which limits the use of the material in critical cast parts.
  • Al-Ni-Mn casting alloy for structural components for automotive and aerospace applications is known as an alternative to branded silumins, developed by Alcoa and disclosed in patent US6783730B2 (published on 31.08.2004 ).
  • This alloy can be used to produce castings with a good combination of casting and mechanical properties in the case of (wt. %) 2-6% Ni, 1-3% Mn, 1% Fe, less than 1% silicon, as well as in the case of other unavoidable impurities.
  • the disadvantages of the proposed invention include the fact that the high level of casting and mechanical properties is ensured by using high-purity aluminum grades and with a high nickel content, which significantly increases the cost of the castings produced.
  • the proposed material is non-heat-treatable in the entire concentration range, which limits its use. At the same time, the corrosion resistance of the castings decreases significantly in the area of high nickel concentrations.
  • Cast aluminum alloys based on Al-Ni and Al-Ni-Mn systems and a method of producing cast parts from them are known, which are described in Alcoa invention US8349462B2 (published on 08.01.2013 ) and application EP2011055318 of Rheinfelden Alloys GmbH & Co. KG .
  • the invention proposes alloy compositions for casting applications. Common in the proposed inventions is a high nickel content of 1-6%, which determines the main disadvantage - a significant decrease in corrosion resistance. With a relatively low nickel and manganese content, cast alloys have a low level of strength characteristics.
  • the closest material to the proposed one is the material containing (wt.%) Al-3.5%Ca-0.9%Mn-0.5%Fe-0.1%Zr-0.1%Sc disclosed in the publication available at https://doi.org/10.1016/j.msea.2019.138410.
  • the authors of the publication consider the material as a deformed alloy, the process chain of which excludes water quenching.
  • the publication shows the non-obviousness of using the alloy mentioned in the publication for castings and use in the as-cast condition.
  • the disadvantages of the proposed invention include the presence of expensive scandium, as well as the need to use heat treatment to achieve the hardening effect of the joint addition of zirconium and scandium.
  • the object of the invention is to create a new casting aluminum alloy designed to produce thin-walled castings by various methods of casting into a metal mold, in particular, gravity casting, high-pressure casting, low-pressure casting, liquid forging, but not limited to, satisfying the specified requirements for a set of process and corrosion characteristics.
  • the technical result of the invention is to provide a given combination of process characteristics in casting and corrosion resistance.
  • the technical result is achieved by proposing an aluminum-based casting alloy with the following concentrations of alloying elements, wt. %: Calcium 1.5-5.1 Zinc 0.1-1.8 Iron up to 0.7 Silicon up to 1.0 optionally, at least one element selected from the group Manganese 0.2-2.5 Titanium 0.005-0.1 Zirconium 0.05-0.14 Chromium 0.05-0.15
  • Aluminum and unavoidable impurities - the rest In the particular version, calcium and zinc are predominantly represented in the structure in the form of eutectic particles.
  • the alloy is made in the form of castings.
  • the proposed alloy is characterized by a narrow crystallization interval, which in combination with a large amount of eutectic phase provides a good level of casting characteristics, and thanks to the elements dissolved in aluminum solid solution - a satisfactory level of strength properties in the as-cast condition.
  • the corrosion resistance within the claimed area is maintained at a good level.
  • the basic criterion for the acceptable choice of alloying elements was the formation of the desired structure, excluding the presence of coarse primary crystals and/or coarsening of the eutectic phase; the justification of the concentration range is given below.
  • Concentrations (wt. %) of calcium in the range 1.5-5.1% and zinc in the range 0.1-1.8% provide good casting properties because calcium and zinc predominantly form a sufficient amount of the eutectic phase.
  • the main effect of the joint introduction of calcium and zinc is the formation of a joint eutectic phase Al4(Ca,Zn), where the zinc atom replaces that of calcium.
  • the level of strength properties is further increased. If the calcium content is less than the declared level, it will lead to a decrease in casting characteristics. If zinc is reduced below the declared level, no significant increase in strength properties will be observed. Calcium and zinc content above the declared level will lead to the formation of a coarse structure and a significant decrease in mechanical properties.
  • iron and silicon content is primarily determined by the purity of the aluminum used to make the alloy.
  • iron and silicon can also be used as alloying elements because silicon in amounts of up to 1.0 wt. % is redistributed between solid solution and eutectics, which, on the one hand, provides an increase in strength properties due to additional solid-solution hardening in the as-cast condition and, on the other hand, positively affects the alloy casting characteristics by increasing the eutectics. With a higher silicon content, the morphology of the eutectic phase deteriorates, which generally reduces the strength characteristics. Iron in amounts of up to 0.5 wt.
  • % predominantly forms phases of eutectic origin, which positively affects the casting characteristics of the alloy by increasing the amount of eutectics.
  • An increase in iron concentration above 0.5 wt. % may lead to coarsening of the eutectic phase and, as a consequence, a decrease in mechanical properties.
  • Manganese in amounts of up to 2.5 wt. % is necessary to increase the strength properties, primarily in the as-cast condition, by providing solid-solution hardening. With manganese content above 2.5 wt. %, primary crystals of the Al 6 (Fe,Mn) phase can be formed in the structure, which can lead to a decrease in mechanical characteristics. A manganese content of less than 0.2 wt. % will not result in significant solid-solution hardening and, as a consequence, a weak increase in strength characteristics.
  • Zirconium and chromium in the declared limits (wt. %) of 0.05-0.14% and 0.05-0.15%, respectively, are necessary to provide solid-solution hardening. Lower concentrations of these elements do not result in a significant increase in strength characteristics in the as-cast condition. Larger quantities would require higher casting temperatures than typical, which would reduce the stability of the casting molds; otherwise, there would be a high probability of forming primary crystals of the Al 7 Cr and Al 3 Zr phase, which would not increase the level of mechanical properties from the introduction of these elements.
  • Titanium in an amount of 0.005-0.1 wt. % is needed to modify the aluminum solid solution.
  • a higher titanium content in the structure may result in the appearance of primary crystals, which will reduce the overall level of mechanical properties, while a lower titanium content will not achieve the positive effect of this element.
  • Titanium can be introduced as a multicomponent ligature, such as Al-Ti-B and/or Al-Ti-C, so that the alloy may contain boron and carbon in compounds with titanium in quantities proportional to the content of the corresponding ligature. Boron and carbon, as independent elements, had no significant effect on the mechanical and casting properties for the range in question. Besides, in the presence of titanium, a decrease in the propensity to form hot cracks during casting was noted in some cases.
  • the following charge materials were used to prepare the alloys (wt. %): Aluminum grade A99 and A8, zinc grade C0, calcium as metallic calcium and ligature Al-6Ca, manganese as ligature Al-10%Mn, ligature Al-10%Zr, Al-10%Cr, Al-5%Ti.
  • the content of other elements typically did not exceed 0.05 wt. %.
  • the chemical composition of the alloy was chosen from the condition of obtaining a structure consisting of an aluminum solid solution and eutectic component. Specimens were cast gravitationally in a metal mold "Separately Cast Sample". The mold temperature could vary in the range of 20-60 °C. The casting was a tensile specimen 10 mm in diameter with an estimated length of 50 mm, which was tensile tested (with a determination of yield strength, tensile strength, and elongation) immediately after casting without machining. The structure of the specimens was evaluated from the specimen heads.
  • compositions of Table 1 mainly consists of aluminum solid solution and eutectic phases formed by the corresponding elements.
  • calcium and zinc in all experimental alloys are predominantly represented in the form of eutectic particles.
  • compositions 2, 5, and 12 are preferred because of their good yield strength to elongation ratio for use in the as-cast condition.
  • the corrosion resistance by the example of compositions 2, 5, 8, and 11 of the claimed alloy was evaluated by the method of accelerated corrosion tests conducted by exposure to neutral salt fog under the following program: 1 cycle - soaking in a salt fog chamber at spraying of 5% NaCl solution for 8 hours at a temperature of 25 ⁇ 1 °C, then soaking at 35 ⁇ 3 °C without spraying the solution for 16 hours, a total of 7 cycles.
  • the result was evaluated by changing the surface appearance of the specimens and the depth of corrosion damage (metallographic method).
  • the ADC6 type alloy was used as a reference, which is characterized by the highest corrosion resistance among cast aluminum alloys.
  • Casting characteristics were evaluated using the hot brittleness (HB) parameter using the "harp casting", where the best indicator is to obtain a casting with the maximum “rod” length ( Fig. 2 ).
  • the propensity for hot cracks was assessed using alloys 2, 4, and 12 as examples (Table 1).
  • ADC6 type alloy was used as a comparison.
  • the absence of cracks in alloys 2, 4, and 12 was shown (Table 1), which is a good indicator at the level of most Al-Si alloys, in contrast to the ADC6 alloy, the casting from which about 40% of the rods failed starting from the maximum length.

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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)
  • Continuous Casting (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Mold Materials And Core Materials (AREA)
EP21869849.6A 2020-09-16 2021-09-15 Aluminium casting alloy Pending EP4215634A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
RU2020130578A RU2745595C1 (ru) 2020-09-16 2020-09-16 Литейный алюминиевый сплав
PCT/RU2021/050295 WO2022060253A1 (ru) 2020-09-16 2021-09-15 Литейный алюминиевый сплав

Publications (1)

Publication Number Publication Date
EP4215634A1 true EP4215634A1 (en) 2023-07-26

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EP21869849.6A Pending EP4215634A1 (en) 2020-09-16 2021-09-15 Aluminium casting alloy

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US (1) US20230212717A1 (es)
EP (1) EP4215634A1 (es)
JP (1) JP2023542129A (es)
KR (1) KR20230069152A (es)
CN (1) CN116057193A (es)
CA (1) CA3195581A1 (es)
MX (1) MX2023003144A (es)
RU (1) RU2745595C1 (es)
WO (1) WO2022060253A1 (es)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2024072262A1 (ru) * 2022-09-28 2024-04-04 Общество с ограниченной ответственностью "Институт легких материалов и технологий" Литейный алюминиевый сплав
DE202023107201U1 (de) 2023-05-30 2024-03-28 Hyundai Mobis Co., Ltd. Fahrzeugbeleuchtungseinrichtung

Family Cites Families (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB546899A (en) * 1941-10-23 1942-08-04 Nat Smelting Co Improvements in or relating to aluminium base alloys
US5573606A (en) * 1995-02-16 1996-11-12 Gibbs Die Casting Aluminum Corporation Aluminum alloy and method for making die cast products
US6783730B2 (en) 2001-12-21 2004-08-31 Alcoa Inc. Al-Ni-Mn casting alloy for automotive and aerospace structural components
US8349462B2 (en) 2009-01-16 2013-01-08 Alcoa Inc. Aluminum alloys, aluminum alloy products and methods for making the same
RU2478131C2 (ru) 2010-10-29 2013-03-27 Федеральное государственное образовательное учреждение высшего профессионального образования "Национальный исследовательский технологический университет "МИСиС" Термостойкий литейный алюминиевый сплав
KR101402896B1 (ko) * 2011-05-20 2014-06-02 한국생산기술연구원 알루미늄 합금 및 그 제조방법
EP3640355B1 (en) * 2017-05-30 2023-02-22 Obshchestvo s Ogranichennoy Otvetstvennost'yu "Obedinennaya Kompaniya Rusal Inzhenerno- Tekhnologicheskiy Tsentr" High-strength aluminium-based alloy
WO2018236241A1 (ru) * 2017-06-21 2018-12-27 Общество с ограниченной ответственностью "Объединенная Компания РУСАЛ Инженерно-технологический центр" Сплав на основе алюминия
RU2660492C1 (ru) * 2017-11-03 2018-07-06 Федеральное государственное автономное образовательное учреждение высшего образования "Национальный исследовательский технологический университет "МИСиС" Литейный алюминиево-кальциевый сплав
RU2672653C1 (ru) * 2017-11-16 2018-11-16 Федеральное государственное автономное образовательное учреждение высшего образования "Национальный исследовательский технологический университет "МИСиС" Коррозионностойкий литейный алюминиевый сплав

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Publication number Publication date
WO2022060253A1 (ru) 2022-03-24
KR20230069152A (ko) 2023-05-18
MX2023003144A (es) 2023-06-16
JP2023542129A (ja) 2023-10-05
US20230212717A1 (en) 2023-07-06
CA3195581A1 (en) 2022-03-24
RU2745595C1 (ru) 2021-03-29
CN116057193A (zh) 2023-05-02

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