EP4234123A2 - Al-mg-si-mn-fe casting alloys - Google Patents
Al-mg-si-mn-fe casting alloys Download PDFInfo
- Publication number
- EP4234123A2 EP4234123A2 EP23175753.5A EP23175753A EP4234123A2 EP 4234123 A2 EP4234123 A2 EP 4234123A2 EP 23175753 A EP23175753 A EP 23175753A EP 4234123 A2 EP4234123 A2 EP 4234123A2
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- European Patent Office
- Prior art keywords
- aluminum casting
- casting alloy
- alloys
- new aluminum
- alloy
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- 229910045601 alloy Inorganic materials 0.000 title claims abstract description 253
- 239000000956 alloy Substances 0.000 title claims abstract description 253
- 238000005266 casting Methods 0.000 title claims abstract description 197
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 199
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 199
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 79
- 229910052742 iron Inorganic materials 0.000 claims abstract description 56
- 229910052748 manganese Inorganic materials 0.000 claims abstract description 48
- 239000012535 impurity Substances 0.000 claims abstract description 43
- 229910052749 magnesium Inorganic materials 0.000 claims abstract description 43
- 229910052719 titanium Inorganic materials 0.000 claims abstract description 24
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 16
- 229910052720 vanadium Inorganic materials 0.000 claims abstract description 16
- 229910052712 strontium Inorganic materials 0.000 claims abstract description 15
- 229910052726 zirconium Inorganic materials 0.000 claims abstract description 15
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 29
- 239000010703 silicon Substances 0.000 claims description 29
- 229910000838 Al alloy Inorganic materials 0.000 abstract description 19
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 74
- 239000011777 magnesium Substances 0.000 description 55
- 239000011572 manganese Substances 0.000 description 54
- 238000005336 cracking Methods 0.000 description 25
- 239000010936 titanium Substances 0.000 description 22
- 150000001875 compounds Chemical class 0.000 description 17
- 239000000203 mixture Substances 0.000 description 15
- 229910005347 FeSi Inorganic materials 0.000 description 14
- 239000011651 chromium Substances 0.000 description 14
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 10
- 101100072002 Arabidopsis thaliana ICME gene Proteins 0.000 description 8
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 8
- 230000015572 biosynthetic process Effects 0.000 description 8
- 239000002245 particle Substances 0.000 description 5
- 238000005476 soldering Methods 0.000 description 5
- 230000007423 decrease Effects 0.000 description 4
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 3
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 3
- 229910052735 hafnium Inorganic materials 0.000 description 3
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 229910052706 scandium Inorganic materials 0.000 description 3
- SIXSYDAISGFNSX-UHFFFAOYSA-N scandium atom Chemical compound [Sc] SIXSYDAISGFNSX-UHFFFAOYSA-N 0.000 description 3
- 230000035939 shock Effects 0.000 description 3
- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 description 3
- 230000008685 targeting Effects 0.000 description 3
- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 description 3
- 229910021365 Al-Mg-Si alloy Inorganic materials 0.000 description 2
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 2
- 230000006978 adaptation Effects 0.000 description 2
- 238000004512 die casting Methods 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 239000000523 sample Substances 0.000 description 2
- 229910018125 Al-Si Inorganic materials 0.000 description 1
- 229910018520 Al—Si Inorganic materials 0.000 description 1
- 229910019752 Mg2Si Inorganic materials 0.000 description 1
- 229910000676 Si alloy Inorganic materials 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 230000005496 eutectics Effects 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000007734 materials engineering Methods 0.000 description 1
- 238000010120 permanent mold casting Methods 0.000 description 1
- 239000011164 primary particle Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000007670 refining Methods 0.000 description 1
- 229910000679 solder Inorganic materials 0.000 description 1
- 239000006104 solid solution Substances 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 238000012360 testing method 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
- C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
- C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
-
- 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
- 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
- C22F1/047—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 magnesium as the next major constituent
Definitions
- Aluminum alloys are useful in a variety of applications.
- Aluminum casting (foundry) alloys for instance, are used in dozen of industries, including, for instance, the automotive and consumer electronics industries.
- the present disclosure relates to new aluminum casting (foundry) alloys and associated products.
- the new aluminum casting alloys generally comprise (and in some instances consist of or consist essentially of) from 2.5 to 5.0 wt. % Mg, from 0.70 to 2.5 wt. % Si, where the weight ratio of magensium to silicon (Mg/Si) is from 1.7:1 to 3.6:1, from 0.40 to 1.5 wt. % Mn, from 0.10 to 0.60 wt. % Fe, optionally up to 0.15 wt. % Ti, optionally up to 0.10 wt. % Sr, and optionally up to 0.15 wt.
- Mg/Si magensium to silicon
- the new aluminum casting alloys may realize an improve combination of properties, such as an improved combination of two or more of strength, ductility, castability, die soldering resistance and quality index, among others.
- the new aluminum casting alloys generally include from 2.5 to 5.0 wt. % Mg. In one embodiment, a new aluminum casting alloy includes not greater than 4.75 wt. % Mg. In another embodiment, a new aluminum casting alloy includes not greater than 4.60 wt. % Mg. In one embodiment, anew aluminum casting alloy includes at least 2.75 wt. % Mg. In another embodiment, a new aluminum casting alloy includes at least 3.0 wt. % Mg.
- the new aluminum casting alloys generally include from 0.70 to 2.5 wt. % Si.
- a new aluminum casting alloy includes at least 0.80 wt. % Si.
- a new aluminum casting alloy includes at least 0.90 wt. % Si.
- a new aluminum casting alloy includes at least 0.95 wt. % Si.
- a new aluminum casting alloy includes at least 1.00 wt. % Si.
- a new aluminum casting alloy includes at least 1.05 wt. % Si.
- a new aluminum casting alloy includes at least 1.10 wt. % Si.
- a new aluminum casting alloy includes at least 1.15 wt. % Si.
- anew aluminum casting alloy includes at least 1.20 wt. % Si. In one embodiment, a new aluminum casting alloy includes not greater than 2.4 wt. % Si. In another embodiment, a new aluminum casting alloy includes not greater than 2.3 wt. % Si. In yet another embodiment, a new aluminum casting alloy includes not greater than 2.2 wt. % Si. In another embodiment, a new aluminum casting alloy includes not greater than 2.1 wt. % Si. In yet another embodiment, a new aluminum casting alloy includes not greater than 2.0 wt. % Si.
- the weight ratio of magensium to silicon in the new aluminum casting alloys is generally from 1.7:1 to to 3.6:1 (wt. % Mg / wt. % Si). In one embodiment, the weight ratio of magensium to silicon in the new aluminum casting alloy is at least 1.8:1. In another embodiment, the weight ratio of magensium to silicon in the new aluminum casting alloy is at least 1.85:1. In one embodiment, the weight ratio of magensium to silicon in the new aluminum casting alloy is not greater than 3.6:1. In another embodiment, the weight ratio of magensium to silicon in the new aluminum casting alloy is not greater than 3.5:1.
- a new aluminum casting alloy includes an amount of magnesiumn and silicon sufficient to facilitate production of a crack-free cast product (e.g., a crack-free high pressure die cast product).
- a crack-free product is a product sufficiently free of cracks so that it can be used for its intended purpose.
- a new aluminum casting alloy includes an amount of magnesiumn and silicon sufficient to realize a hot cracking tendency index (HCTI) of not greater than 0.30, such as any of the low HCTI values disclosed herein.
- HCTI hot cracking tendency index
- the new aluminum casting alloys generally include from 0.40 to 1.5 wt. % Mn.
- a new aluminum casting alloy includes at least 0.45 wt. % Mn.
- a new aluminum casting alloy includes at least 0.50 wt. % Mn.
- anew aluminum casting alloy includes at least 0.55 wt. % Mn.
- a new aluminum casting alloy includes at least 0.60 wt. % Mn.
- a new aluminum casting alloy includes not greater than 1.45 wt. % Mn.
- a new aluminum casting alloy includes not greater than 1.40 wt. % Mn.
- a new aluminum casting alloy includes not greater than 1.35 wt. % Mn. In another embodiment, a new aluminum casting alloy includes not greater than 1.30 wt. % Mn. In yet another embodiment, a new aluminum casting alloy includes not greater than 1.25 wt. % Mn. In another embodiment, a new aluminum casting alloy includes not greater than 1.20 wt. % Mn.
- the new aluminum casting alloys generally include from 0.10 to 0.60 wt. % Fe.
- a new aluminum casting alloy includes at least 0.12 wt. % Fe.
- a new aluminum casting alloy includes at least 0.15 wt. % Fe.
- a new aluminum casting alloy includes at least 0.20 wt. % Fe.
- a new aluminum casting alloy includes at least 0.25 wt. % Fe.
- a new aluminum casting alloy includes at least 0.30 wt. % Fe.
- a new aluminum casting alloy includes at least 0.35 wt. % Fe.
- a new aluminum casting alloy includes not greater than 0.55 wt. % Fe.
- a new aluminum casting alloy includes not greater than 0.50 wt. % Fe.
- a new aluminum casting alloy includes not greater than 0.45 wt. % Fe.
- a new aluminum casting alloy includes an amount of iron and manganse sufficient to facilitate formation of alpha phase particles while restricting formation of beta phase particles. In one embodiment, at least due to the iron content, a new aluminum casting alloy includes not greater than 0.012 wt. % of ⁇ -Al5FeSi compounds. In another embodiment, anew aluminum casting alloy includes not greater than 0.010 wt. % of ⁇ -Al5FeSi compounds. In yet another embodiment, a new aluminum casting alloy includes not greater than 0.008 wt. % of ⁇ -Al5FeSi compounds. In another embodiment, a new aluminum casting alloy includes not greater than 0.006 wt. % of ⁇ -Al5FeSi compounds.
- a new aluminum casting alloy includes not greater than 0.004 wt. % of ⁇ -Al5FeSi compounds. In another embodiment, a new aluminum casting alloy includes not greater than 0.002 wt. % of ⁇ -Al5FeSi compounds. In yet another embodiment, a new aluminum casting alloy includes not greater than 0.001 wt. % of ⁇ -Al5FeSi compounds. In another embodiment, anew aluminum casting alloy includes not greater than 0.0005 wt. % of ⁇ -Al5FeSi compounds.
- a new aluminum casting alloy may include an amount of magensium, silicon, manganese and iron sufficient to satisfy the following requirements:
- the new aluminum casting alloys may optionally include up to 0.15 wt. % Ti.
- a new aluminum casting alloy includes at least 0.01 wt. % Ti.
- a new aluminum casting alloy includes at least 0.03 wt. % Ti.
- a new aluminum casting alloy includes at least 0.05 wt. % Ti.
- a new aluminum casting alloy includes at least 0.07 wt. % Ti.
- a new aluminum casting alloy includes not greater than 0.13 wt. % Ti.
- a new aluminum casting alloy includes not greater than 0.115 wt. % Ti.
- a new aluminum casting alloy includes not greater than 0.10 wt. % Ti.
- a new aluminum casting alloy include an amount of titanium sufficient to faciltiate grain refining while resticting / avoiding formation of primary titanium-containing particles.
- titanium is included in a new aluminum casting alloy as an impurity.
- the new aluminum casting alloys may optionally include up to 0.10 wt. % Sr.
- a new aluminum casting alloy includes an amount of strontium sufficient to faciltiate modification of the Mg 2 Si eutectic while resticting / avoiding formation of primary strontium-containing particles.
- a new aluminum casting alloy includes at least 0.005 wt. % Sr.
- a new aluminum casting alloy includes not greater than 0.08 wt. % Sr.
- a new aluminum casting alloy includes not greater than 0.05 wt. % Sr.
- strontium is included in a new aluminum casting alloy as an impurity.
- the new aluminum casting alloys may optionally include up to 0.15 wt. % of any of Zr, Sc, Hf, V, and Cr.
- a new aluminum casting alloy includes an amount of zirconiun, scandium, hafnium, vanadium, and/or chromium sufficient to facilitate solid solution strenghtening while resticting / avoiding formation of primary particles containing zirconium, scandium, hafnium, vanadium, and chromium.
- a new aluminum casting alloy includes at least 0.01 wt. % of any of Zr, Sc, Hf, V, and Cr.
- a new aluminum casting alloy includes at least 0.03 wt.
- a new aluminum casting alloy includes at least 0.05 wt. % of any of Zr, Sc, Hf, V, and Cr. In one embodiment, a new aluminum casting alloy includes not greater than 0.10 wt. % of any of Zr, Sc, Hf, V, and Cr.
- zirconium is included in a new aluminum casting alloy as an impurity.
- scandium is included in a new aluminum casting alloy as an impurity.
- hafnium is included in a new aluminum casting alloy as an impurity.
- vanadium is included in a new aluminum casting alloy as an impurity.
- chromium is included in a new aluminum casting alloy as an impurity.
- the balance of the new aluminum casting alloys is generally aluminum and unavoiable impurities.
- a new aluminum casting alloy comprises not greater than 0.30 wt. % of the unavoiable impurities, and wherein the new aluminum casting alloy comprises not greater than 0.10 wt. % of any one element of the unavoiable impurities.
- a new aluminum casting alloy comprises not greater than 0.15 wt. % of the unavoiable impurities, and wherein the new aluminum casting alloy comprises not greater than 0.05 wt. % of any one element of the unavoiable impurities.
- a new aluminum casting alloy comprises not greater than 0.10 wt. % of the unavoiable impurities, and wherein the new aluminum casting alloy comprises not greater than 0.03 wt. % of any one element of the unavoiable impurities.
- the new aluminum casting alloys may be cast using any suitable casting method.
- a new alumimum casting alloy is a direct chill cast as an ingot or billet.
- a new aluminum casting alloy is shape cast into a shape cast product (e.g., a complex shape cast product, such as a complex automotive compontent).
- the shape cast product is an automotive structural component.
- the shape cast product is a door frame.
- the shape cast product is a shock tower.
- the shape cast product is a tunnel structure for an automobile.
- the shape casting comproses high pressure die casting. In another embodiment, the shape casting comprises permanent mold casting.
- the new aluminum casting alloys do not require a solution heat treatment step.
- the new aluminum casting alloys may be provided, therefore, in the appopriate temper, such as in the F temper or the T5 temper.
- the new aluminum casting alloys may realize an improved combination of properties, such as an improved combination of at least two of strength, ductility, castability, die soldering resistance and quality index.
- Mechanical properties may be measured in accordance with ASTM E8 and B557 (e.g., when directionally solidified). Castability may be measured using the HCTI method described herein. Die soldering resistance may be determined by casting the alloy.
- a new aluminum casting alloy realizes an ultimate tensile strength of at least 200 MPa. In another enbodiment, a new aluminum casting alloy realizes an ultimate tensile strength of at least 210 MPa. In yet another enbodiment, a new aluminum casting alloy realizes an ultimate tensile strength of at least 220 MPa. In another enbodiment, a new aluminum casting alloy realizes an ultimate tensile strength of at least 230 MPa.
- a new aluminum casting alloy realizes a tensile yield strength of at least 100 MPa. In another enbodiment, a new aluminum casting alloy realizes an tensile yield strength of at least 105 MPa. In yet another enbodiment, a new aluminum casting alloy realizes an tensile yield strength of at least 110 MPa. In another enbodiment, a new aluminum casting alloy realizes an tensile yield strength of at least 115 MPa. In another enbodiment, a new aluminum casting alloy realizes an tensile yield strength of at least 120 MPa. In another enbodiment, a new aluminum casting alloy realizes an tensile yield strength of at least 125 MPa. Any of the above tensile yield strength values may be realized with any of the above ultimate tensile strength values.
- a new aluminum casting alloy realizes an elongation of at least 7%. In another embodiment, a new aluminum casting alloy realizes an elongation of at least 8%. In yet another embodiment, a new aluminum casting alloy realizes an elongation of at least 9%. In another embodiment, a new aluminum casting alloy realizes an elongation of at least 10%. In yet another embodiment, a new aluminum casting alloy realizes an elongation of at least 11%. In another embodiment, a new aluminum casting alloy realizes an elongation of at least 12%. In yet another embodiment, a new aluminum casting alloy realizes an elongation of at least 13%. In another embodiment, a new aluminum casting alloy realizes an elongation of at least 14%.
- a new aluminum casting alloy realizes an elongation of at least 15%. In another embodiment, a new aluminum casting alloy realizes an elongation of at least 16%, or higher. Any of the above elongation values may be realized with any of the above ultimate tensile strength or tensile yield strength values.
- a new aluminum casting alloy realizes a HCTI of not greater than 0.30. In another embodiment, a new aluminum casting alloy realizes a HCTI of not greater than 0.25. In yet another embodiment, a new aluminum casting alloy realizes a HCTI of not greater than 0.20. In another embodiment, a new aluminum casting alloy realizes a HCTI of not greater than 0.15, or lower.
- a new aluminum casting alloy is die soldering resistant wherein the as-cast aluminum alloy product is removed from the die without damage to the cast product and/or without sticking to the die. Die soldering can occur during high pressure die casting wherein molten aluminum solders to the die surface. In some embodiments, the new aluminum casting alloys described herein may be cast without being soldered to the die.
- Aluminum alloys were cast as pencil probe castings.
- the compositions of the aluminum alloys is given in Table 1, below.
- the aluminum alloy contained not greater than 0.03 wt. % of any one impurity, and contained not greater than 0.10 wt.
- HCTI hot cracking tendency index
- HCTI hot cracking tendency index
- the HCTI value will be 0. If cracking is found in all 7 connection rods (from 4 mm to 16 mm), the HCTI value will be 1. Therefore, a smaller HCTI indicates a higher hot cracking resistance for a specific alloy.
- alloys having from about 1 to about 2 wt. % Si at similar amounts of Fe, Mn, Mg and Ti realized improved hot cracking resistance.
- the Mg/Si ratio for these alloys is from about 2.0 to 3.0.
- Alloy A4 with 1.56 wt. % Si had a Mg to Si ratio of 2.26.
- Example 2 Four additional alloys were cast and their hot cracking susceptibility was determined, as per Example 1. Like Example 1, the silicon content was again varied, but using a lower nominal amount of magnesium and manganese.
- the compositions of the Example 2 alloys are shown in Table 3, below.
- the HCTI results for the Example 2 alloys are shown in the below figure.
- Alloy B2 showed the best hot cracking resistance.
- the Mg/Si ratio for this alloy is about 2.65.
- FIG. 2 shows the experimental measured hot cracking tendency indexes of the Al-2.5Mg-1.1Mn-x%Si alloys.
- Alloy B2 with 0.96 wt. % Si and 2.54 wt. % Mg, showed the best hot cracking resistance.
- the Mg/Si ratio for this alloy is about 2.65.
- Example 3 The compositions of the Example 3 alloys are shown in Table 4, below.
- the HCTI results for the Example 3 alloys are shown in FIG. 3 . As shown, the HCTI for all alloys is generally good. The lowest HCTI was realized by alloy C3 with a Mg/Si ratio of 2.22.
- Examples 1-3 indicate that the Mg/Si (weight ratio) should be from about 1.7 to about 3.6, preferably from about 2.0 to about 3.0 to facilitate hot cracking resistance.
- Example 4 Four additional alloys were cast and their hot cracking susceptibility was determined, as per Example 1. This time, the manganese content was varied, targeting a nominal magnesium amount of 3.6 wt. % and a nominal silicon amount of 1.5 wt. %.
- the compositions of the Example 4 alloys are shown in Table 5, below.
- the HCTI results for the Example 4 alloys are shown in FIG. 4 . As shown, the HCTI for all alloys is generally good. Alloy D4 with 1.20 wt. % Mn realized the best HCTI results.
- Example 5 The compositions of the Example 5 alloys are shown in Table 6, below.
- the HCTI results for the Example 5 alloys are shown in the below figure. As shown, the HCTI for all alloys is generally good. Alloy E4 with 0.29 wt. % Fe realized the best HCTI results.
- FIGS. 5a , 5b and 6 show the correlation between manganese and iron content and the volume fraction on ⁇ -Al 5 FeSi and ⁇ -Al 15 FeMn 3 Si 2 phase particles (for a Al-3.6Mg-1.5Si alloys).
- Adding Mn to the Al-Mg-Si alloys can promote formation of ⁇ -Al 15 FeMn 3 Si 2 phase and restrict or prevent formation of ⁇ -Al 5 FeSi phase.
- a Al-3.6Mg-1.5Si alloy with from 0.4 to 0.6 wt. % Mn using increased iron amounts decreases the amount of ⁇ -Al 5 FeSi phase.
- the amount of ⁇ -Al 5 FeSi phase decreases from about 0.018 wt. % to essentially 0 wt. % by increasing iron from 0.15 wt. % to 0.4 wt. %.
- alloys having improved properties may be realized due to the increase in iron and the corresponding decrease in ⁇ -Al 5 FeSi phase within the alloy.
- the first group (F) targeted a nominal magnesium amount of 3.6 wt. %, a nominal silicon amount of 1.5 wt. %, and a nominal manganese amount of 0.90 wt. %.
- the second group (G) targeted a nominal magnesium amount of 4.0 wt. %, a nominal silicon amount of 1.7 wt. %, and a nominal manganese amount of 0.65 wt. %.
- the compositions of the Example 6 alloys are shown in Table 7, below.
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Abstract
Description
- Aluminum alloys are useful in a variety of applications. Aluminum casting (foundry) alloys, for instance, are used in dozen of industries, including, for instance, the automotive and consumer electronics industries.
- Broadly, the present disclosure relates to new aluminum casting (foundry) alloys and associated products. The new aluminum casting alloys generally comprise (and in some instances consist of or consist essentially of) from 2.5 to 5.0 wt. % Mg, from 0.70 to 2.5 wt. % Si, where the weight ratio of magensium to silicon (Mg/Si) is from 1.7:1 to 3.6:1, from 0.40 to 1.5 wt. % Mn, from 0.10 to 0.60 wt. % Fe, optionally up to 0.15 wt. % Ti, optionally up to 0.10 wt. % Sr, and optionally up to 0.15 wt. % of any of Zr, Sc, Hf, V, and Cr, the balance being aluminum and unavoidable impurities. The new aluminum casting alloys may realize an improve combination of properties, such as an improved combination of two or more of strength, ductility, castability, die soldering resistance and quality index, among others.
- As noted above, the new aluminum casting alloys generally include from 2.5 to 5.0 wt. % Mg. In one embodiment, a new aluminum casting alloy includes not greater than 4.75 wt. % Mg. In another embodiment, a new aluminum casting alloy includes not greater than 4.60 wt. % Mg. In one embodiment, anew aluminum casting alloy includes at least 2.75 wt. % Mg. In another embodiment, a new aluminum casting alloy includes at least 3.0 wt. % Mg.
- As noted above, the new aluminum casting alloys generally include from 0.70 to 2.5 wt. % Si. In one embodiment, a new aluminum casting alloy includes at least 0.80 wt. % Si. In another embodiment, a new aluminum casting alloy includes at least 0.90 wt. % Si. In yet another embodiment, a new aluminum casting alloy includes at least 0.95 wt. % Si. In another embodiment, a new aluminum casting alloy includes at least 1.00 wt. % Si. In yet another embodiment, a new aluminum casting alloy includes at least 1.05 wt. % Si. In another embodiment, a new aluminum casting alloy includes at least 1.10 wt. % Si. In yet another embodiment, a new aluminum casting alloy includes at least 1.15 wt. % Si. In another embodiment, anew aluminum casting alloy includes at least 1.20 wt. % Si. In one embodiment, a new aluminum casting alloy includes not greater than 2.4 wt. % Si. In another embodiment, a new aluminum casting alloy includes not greater than 2.3 wt. % Si. In yet another embodiment, a new aluminum casting alloy includes not greater than 2.2 wt. % Si. In another embodiment, a new aluminum casting alloy includes not greater than 2.1 wt. % Si. In yet another embodiment, a new aluminum casting alloy includes not greater than 2.0 wt. % Si.
- As noted above, the weight ratio of magensium to silicon in the new aluminum casting alloys is generally from 1.7:1 to to 3.6:1 (wt. % Mg / wt. % Si). In one embodiment, the weight ratio of magensium to silicon in the new aluminum casting alloy is at least 1.8:1. In another embodiment, the weight ratio of magensium to silicon in the new aluminum casting alloy is at least 1.85:1. In one embodiment, the weight ratio of magensium to silicon in the new aluminum casting alloy is not greater than 3.6:1. In another embodiment, the weight ratio of magensium to silicon in the new aluminum casting alloy is not greater than 3.5:1.
- In one embodiment, a new aluminum casting alloy includes an amount of magnesiumn and silicon sufficient to facilitate production of a crack-free cast product (e.g., a crack-free high pressure die cast product). A crack-free product is a product sufficiently free of cracks so that it can be used for its intended purpose. In one embodiment, a new aluminum casting alloy includes an amount of magnesiumn and silicon sufficient to realize a hot cracking tendency index (HCTI) of not greater than 0.30, such as any of the low HCTI values disclosed herein.
- As noted above, the new aluminum casting alloys generally include from 0.40 to 1.5 wt. % Mn. In one embodiment, a new aluminum casting alloy includes at least 0.45 wt. % Mn. In another embodiment, a new aluminum casting alloy includes at least 0.50 wt. % Mn. In yet another embodiment, anew aluminum casting alloy includes at least 0.55 wt. % Mn. In another embodiment, a new aluminum casting alloy includes at least 0.60 wt. % Mn. In one embodiment, a new aluminum casting alloy includes not greater than 1.45 wt. % Mn. In another embodiment, a new aluminum casting alloy includes not greater than 1.40 wt. % Mn. In yet another embodiment, a new aluminum casting alloy includes not greater than 1.35 wt. % Mn. In another embodiment, a new aluminum casting alloy includes not greater than 1.30 wt. % Mn. In yet another embodiment, a new aluminum casting alloy includes not greater than 1.25 wt. % Mn. In another embodiment, a new aluminum casting alloy includes not greater than 1.20 wt. % Mn.
- As noted above, the new aluminum casting alloys generally include from 0.10 to 0.60 wt. % Fe. In one embodiment, a new aluminum casting alloy includes at least 0.12 wt. % Fe. In another embodiment, a new aluminum casting alloy includes at least 0.15 wt. % Fe. In yet another embodiment, a new aluminum casting alloy includes at least 0.20 wt. % Fe. In another embodiment, a new aluminum casting alloy includes at least 0.25 wt. % Fe. In yet another embodiment, a new aluminum casting alloy includes at least 0.30 wt. % Fe. In another embodiment, a new aluminum casting alloy includes at least 0.35 wt. % Fe. In one embodiment, a new aluminum casting alloy includes not greater than 0.55 wt. % Fe. In another embodiment, a new aluminum casting alloy includes not greater than 0.50 wt. % Fe. In yet another embodiment, a new aluminum casting alloy includes not greater than 0.45 wt. % Fe.
- In one embodiment, a new aluminum casting alloy includes an amount of iron and manganse sufficient to facilitate formation of alpha phase particles while restricting formation of beta phase particles. In one embodiment, at least due to the iron content, a new aluminum casting alloy includes not greater than 0.012 wt. % of β-Al5FeSi compounds. In another embodiment, anew aluminum casting alloy includes not greater than 0.010 wt. % of β-Al5FeSi compounds. In yet another embodiment, a new aluminum casting alloy includes not greater than 0.008 wt. % of β-Al5FeSi compounds. In another embodiment, a new aluminum casting alloy includes not greater than 0.006 wt. % of β-Al5FeSi compounds. In yet another embodiment, a new aluminum casting alloy includes not greater than 0.004 wt. % of β-Al5FeSi compounds. In another embodiment, a new aluminum casting alloy includes not greater than 0.002 wt. % of β-Al5FeSi compounds. In yet another embodiment, a new aluminum casting alloy includes not greater than 0.001 wt. % of β-Al5FeSi compounds. In another embodiment, anew aluminum casting alloy includes not greater than 0.0005 wt. % of β-Al5FeSi compounds.
- In one embodiment, a new aluminum casting alloy may include an amount of magensium and silicon sufficient to satisfy the following requirement: (0.4567*Mg - 0.5) <= Si <= (0.4567*Mg +0.2).
- In one embodiment, a new aluminum casting alloy may include an amount of magensium, silicon, manganese and iron sufficient to satisfy the following requirements:
- (1)
- (2)
- As noted above, the new aluminum casting alloys may optionally include up to 0.15 wt. % Ti. In one embodiment, a new aluminum casting alloy includes at least 0.01 wt. % Ti. In another embodiment, a new aluminum casting alloy includes at least 0.03 wt. % Ti. In yet another embodiment, a new aluminum casting alloy includes at least 0.05 wt. % Ti. In another embodiment, a new aluminum casting alloy includes at least 0.07 wt. % Ti. In one embodiment, a new aluminum casting alloy includes not greater than 0.13 wt. % Ti. In another embodiment, a new aluminum casting alloy includes not greater than 0.115 wt. % Ti. In another embodiment, a new aluminum casting alloy includes not greater than 0.10 wt. % Ti. In one embodiment, a new aluminum casting alloy include an amount of titanium sufficient to faciltiate grain refining while resticting / avoiding formation of primary titanium-containing particles. In some embodiments, titanium is included in a new aluminum casting alloy as an impurity.
- As noted above, the new aluminum casting alloys may optionally include up to 0.10 wt. % Sr. In one embodiment, a new aluminum casting alloy includes an amount of strontium sufficient to faciltiate modification of the Mg2Si eutectic while resticting / avoiding formation of primary strontium-containing particles. In one embodiment, a new aluminum casting alloy includes at least 0.005 wt. % Sr. In one embodiment, a new aluminum casting alloy includes not greater than 0.08 wt. % Sr. In another embodiment, a new aluminum casting alloy includes not greater than 0.05 wt. % Sr. In some embodiments, strontium is included in a new aluminum casting alloy as an impurity.
- As noted above, the new aluminum casting alloys may optionally include up to 0.15 wt. % of any of Zr, Sc, Hf, V, and Cr. In one embodiment, a new aluminum casting alloy includes an amount of zirconiun, scandium, hafnium, vanadium, and/or chromium sufficient to facilitate solid solution strenghtening while resticting / avoiding formation of primary particles containing zirconium, scandium, hafnium, vanadium, and chromium. In one embodiment, a new aluminum casting alloy includes at least 0.01 wt. % of any of Zr, Sc, Hf, V, and Cr. In another embodiment, a new aluminum casting alloy includes at least 0.03 wt. % of any of Zr, Sc, Hf, V, and Cr. In yet another embodiment, a new aluminum casting alloy includes at least 0.05 wt. % of any of Zr, Sc, Hf, V, and Cr. In one embodiment, a new aluminum casting alloy includes not greater than 0.10 wt. % of any of Zr, Sc, Hf, V, and Cr. In some embodiments, zirconium is included in a new aluminum casting alloy as an impurity. In some embodiments, scandium is included in a new aluminum casting alloy as an impurity. In some embodiments, hafnium is included in a new aluminum casting alloy as an impurity. In some embodiments, vanadium is included in a new aluminum casting alloy as an impurity. In some embodiments, chromium is included in a new aluminum casting alloy as an impurity.
- The balance of the new aluminum casting alloys is generally aluminum and unavoiable impurities. In one embodiment, a new aluminum casting alloy comprises not greater than 0.30 wt. % of the unavoiable impurities, and wherein the new aluminum casting alloy comprises not greater than 0.10 wt. % of any one element of the unavoiable impurities. In another embodiment, a new aluminum casting alloy comprises not greater than 0.15 wt. % of the unavoiable impurities, and wherein the new aluminum casting alloy comprises not greater than 0.05 wt. % of any one element of the unavoiable impurities. In yet another embodiment, a new aluminum casting alloy comprises not greater than 0.10 wt. % of the unavoiable impurities, and wherein the new aluminum casting alloy comprises not greater than 0.03 wt. % of any one element of the unavoiable impurities.
- The new aluminum casting alloys may be cast using any suitable casting method. In one embodiment, a new alumimum casting alloy is a direct chill cast as an ingot or billet. In another embodiment, a new aluminum casting alloy is shape cast into a shape cast product (e.g., a complex shape cast product, such as a complex automotive compontent). In one embodiment, the shape cast product is an automotive structural component. In another embodiment, the shape cast product is a door frame. In another embodiment, the shape cast product is a shock tower. In another embodiment, the shape cast product is a tunnel structure for an automobile.
- In one embodiment, the shape casting comproses high pressure die casting. In another embodiment, the shape casting comprises permanent mold casting.
- The new aluminum casting alloys do not require a solution heat treatment step. The new aluminum casting alloys may be provided, therefore, in the appopriate temper, such as in the F temper or the T5 temper.
- As noted above, the new aluminum casting alloys may realize an improved combination of properties, such as an improved combination of at least two of strength, ductility, castability, die soldering resistance and quality index. Mechanical properties may be measured in accordance with ASTM E8 and B557 (e.g., when directionally solidified). Castability may be measured using the HCTI method described herein. Die soldering resistance may be determined by casting the alloy.
- In one embodiment, a new aluminum casting alloy realizes an ultimate tensile strength of at least 200 MPa. In another enbodiment, a new aluminum casting alloy realizes an ultimate tensile strength of at least 210 MPa. In yet another enbodiment, a new aluminum casting alloy realizes an ultimate tensile strength of at least 220 MPa. In another enbodiment, a new aluminum casting alloy realizes an ultimate tensile strength of at least 230 MPa.
- In one embodiment, a new aluminum casting alloy realizes a tensile yield strength of at least 100 MPa. In another enbodiment, a new aluminum casting alloy realizes an tensile yield strength of at least 105 MPa. In yet another enbodiment, a new aluminum casting alloy realizes an tensile yield strength of at least 110 MPa. In another enbodiment, a new aluminum casting alloy realizes an tensile yield strength of at least 115 MPa. In another enbodiment, a new aluminum casting alloy realizes an tensile yield strength of at least 120 MPa. In another enbodiment, a new aluminum casting alloy realizes an tensile yield strength of at least 125 MPa. Any of the above tensile yield strength values may be realized with any of the above ultimate tensile strength values.
- In one embodiment, a new aluminum casting alloy realizes an elongation of at least 7%. In another embodiment, a new aluminum casting alloy realizes an elongation of at least 8%. In yet another embodiment, a new aluminum casting alloy realizes an elongation of at least 9%. In another embodiment, a new aluminum casting alloy realizes an elongation of at least 10%. In yet another embodiment, a new aluminum casting alloy realizes an elongation of at least 11%. In another embodiment, a new aluminum casting alloy realizes an elongation of at least 12%. In yet another embodiment, a new aluminum casting alloy realizes an elongation of at least 13%. In another embodiment, a new aluminum casting alloy realizes an elongation of at least 14%. In yet another embodiment, a new aluminum casting alloy realizes an elongation of at least 15%. In another embodiment, a new aluminum casting alloy realizes an elongation of at least 16%, or higher. Any of the above elongation values may be realized with any of the above ultimate tensile strength or tensile yield strength values.
- In one embodiment, a new aluminum casting alloy realizes a HCTI of not greater than 0.30. In another embodiment, a new aluminum casting alloy realizes a HCTI of not greater than 0.25. In yet another embodiment, a new aluminum casting alloy realizes a HCTI of not greater than 0.20. In another embodiment, a new aluminum casting alloy realizes a HCTI of not greater than 0.15, or lower.
- In one embodiment, a new aluminum casting alloy is die soldering resistant wherein the as-cast aluminum alloy product is removed from the die without damage to the cast product and/or without sticking to the die. Die soldering can occur during high pressure die casting wherein molten aluminum solders to the die surface. In some embodiments, the new aluminum casting alloys described herein may be cast without being soldered to the die.
- These and other combination of features are disclosed in the below Detailed Description.
-
-
FIG. 1 is a graph showing silicon content versus hot cracking tendency index for Example 1 alloys. -
FIG. 2 is a graph showing silicon content versus hot cracking tendency index for Example 2 alloys. -
FIG. 3 is a graph showing silicon content versus hot cracking tendency index for Example 3 alloys. -
FIG. 4 is a graph showing manganese content versus hot cracking tendency index for Example 4 alloys. -
FIG. 5a is a graph showing beta phase content (shown in wt. %) as a function of Mn and Fe content based on ICME modeling; the amounts of 3.6 wt. % Mg and 1.5 wt % Si were kept constant. -
FIG. 5b is a graph showing alpha phase content (shown in wt. %) as a function of Mn and Fe content based on ICME modeling; the amounts of 3.6 wt. % Mg and 1.5 wt % Si were kept constant. -
FIG. 6 is a graph showing beta phase content (shown in wt. %) as a function of Fe content based on ICME modeling; the amounts of 3.6 wt. % Mg, 1.5 wt % Si and 0.5 wt. % Mn were kept constant. -
FIG. 7a is a graph showing ultimate tensile strength (MPa) versus iron content (wt. %) for Example 6 alloys. -
FIG. 7b is a graph showing elongtion (%) versus iron content (wt. %) for Example 6 alloys. -
FIG. 7c is a graph showing tensile yield strength (MPa) versus iron content (wt. %) for Example 6 alloys. -
FIG. 7d is a graph showing quality index (Q in MPa) versus iron content (wt. %) for Example 6 alloys. -
FIG. 8a is a graph showing HCI (computed hot cracking index) as a function of Si and Mg content based on ICME modeling; the amounts of 0.70 wt. % Mn and 0.25 wt. % Fe were kept constant. -
FIG. 8b is a graph showing non-equilibrium solidificaiton temperature range (in °C) as a function of Si and Mg content based on ICME modeling; the amounts of 0.70 wt. % Mn and 0.25 wt. % Fe were kept constant. -
FIG. 8c is a graph showing showing HCI (computed hot cracking index) as a function of Si and Mn content based on ICME modeling; the amounts of 4.0 wt. % Mg and 0.25 wt. % Fe were kept constant. -
FIG. 8d is a graph showing showing HCI (computed hot cracking index) as a function of Si and Fe content based on ICME modeling; the amounts of 4.0 wt. % Mg and 0.70 wt. % Mn were kept constant. - Six aluminum alloys were cast as pencil probe castings. The compositions of the aluminum alloys is given in Table 1, below.
Table 1 - Composition of Example 1 Alloys (all values in weight percent) Alloy* Si Fe Mn Mg Ti A1 0.06 0.07 1.24 3.51 0.10 A2 0.75 0.07 1.27 3.59 0.09 A3 1.20 0.10 1.20 3.59 0.09 A4 1.56 0.10 1.20 3.52 0.09 A5 1.88 0.11 1.17 3.69 0.09 A6 2.37 0.08 1.26 3.61 0.09 *The balance of the aluminum alloys was aluminum and unavoidable impurities. The aluminum alloy contained not greater than 0.03 wt. % of any one impurity, and contained not greater than 0.10 wt. %, it total, of all impurities. -
- If no cracking is found on any connection rods, the HCTI value will be 0. If cracking is found in all 7 connection rods (from 4 mm to 16 mm), the HCTI value will be 1. Therefore, a smaller HCTI indicates a higher hot cracking resistance for a specific alloy.
Table 2 - Hot Cracking Results of the Example 1 Alloys Alloy Connection size HCTI 16mm 14mm 12mm 10mm 8mm 6mm 4mm C C C C C C C 1 Alloy A-1 C C C C C C C C C C C C C C C C C C C C C C C C C C C C Alloy A-2 OK C OK OK C C OK 0.6 OK C OK OK C C C OK C C OK OK C C C C OK C C C C C C OK C C OK C Alloy A-3 OK OK OK OK OK C OK 0.1 OK OK OK OK OK C OK OK OK OK OK OK OK C OK OK OK C OK OK OK OK OK OK OK OK OK OK Alloy A-4 OK OK OK OK OK OK OK 0.06 OK OK OK OK OK C OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK C Alloy A-5 OK OK OK OK C OK C 0.16 OK OK OK OK OK OK OK OK OK OK OK C OK C OK OK OK OK C C C OK OK OK OK OK C OK Alloy A-6 OK OK OK C C C C 0.39 OK OK OK OK C C C OK OK OK C C C C OK OK C C C C C OK OK OK OK C C C FIG. 1 shows a plot of the silicon content versus the determined HCTI value. As shown, alloys having from about 1 to about 2 wt. % Si at similar amounts of Fe, Mn, Mg and Ti realized improved hot cracking resistance. The Mg/Si ratio for these alloys is from about 2.0 to 3.0. Alloy A4 with 1.56 wt. % Si had a Mg to Si ratio of 2.26. - Four additional alloys were cast and their hot cracking susceptibility was determined, as per Example 1. Like Example 1, the silicon content was again varied, but using a lower nominal amount of magnesium and manganese. The compositions of the Example 2 alloys are shown in Table 3, below. The HCTI results for the Example 2 alloys are shown in the below figure. Alloy B2 showed the best hot cracking resistance. The Mg/Si ratio for this alloy is about 2.65.
Table 3 - Composition of Example 2 Alloys (all values in weight percent) Alloy* Si Fe Mn Mg Ti B1 0.54 0.12 1.12 2.56 0.08 B2 0.96 0.15 1.14 2.54 0.08 B3 1.35 0.15 1.12 2.48 0.08 B4 1.68 0.15 1.11 2.46 0.08 *The balance of the aluminum alloys was aluminum and unavoidable impurities. The aluminum alloy contained not greater than 0.03 wt. % of any one impurity, and contained not greater than 0.10 wt. %, it total, of all impurities. -
FIG. 2 shows the experimental measured hot cracking tendency indexes of the Al-2.5Mg-1.1Mn-x%Si alloys. Alloy B2, with 0.96 wt. % Si and 2.54 wt. % Mg, showed the best hot cracking resistance. The Mg/Si ratio for this alloy is about 2.65. - Four additional alloys were cast and their hot cracking susceptibility was determined, as per Example 1. Like Example 1, the silicon content was again varied, but using a higher nominal amount of magnesium and a lower nominal amount of manganese. The compositions of the Example 3 alloys are shown in Table 4, below. The HCTI results for the Example 3 alloys are shown in
FIG. 3 . As shown, the HCTI for all alloys is generally good. The lowest HCTI was realized by alloy C3 with a Mg/Si ratio of 2.22.Table 4 - Composition of Example 3 Alloys (all values in weight percent) Alloy* Si Fe Mn Mg Ti Mg/Si C1 1.31 0.14 0.95 4.55 0.08 3.48 C2 1.57 0.15 0.92 4.51 0.08 2.87 C3 2.00 0.15 0.91 4.43 0.08 2.22 C4 2.40 0.15 0.91 4.35 0.08 1.81 *The balance of the aluminum alloys was aluminum and unavoidable impurities. The aluminum alloy contained not greater than 0.03 wt. % of any one impurity, and contained not greater than 0.10 wt. %, it total, of all impurities. - The results of Examples 1-3 indicate that the Mg/Si (weight ratio) should be from about 1.7 to about 3.6, preferably from about 2.0 to about 3.0 to facilitate hot cracking resistance.
- Four additional alloys were cast and their hot cracking susceptibility was determined, as per Example 1. This time, the manganese content was varied, targeting a nominal magnesium amount of 3.6 wt. % and a nominal silicon amount of 1.5 wt. %. The compositions of the Example 4 alloys are shown in Table 5, below. The HCTI results for the Example 4 alloys are shown in
FIG. 4 . As shown, the HCTI for all alloys is generally good. Alloy D4 with 1.20 wt. % Mn realized the best HCTI results.Table 5 - Composition of Example 4 Alloys (all values in weight percent) Alloy* Si Fe Mn Mg Ti Mg/Si D1 1.52 0.11 0.47 3.64 0.08 2.39 D2 1.53 0.14 0.81 3.66 0.08 2.39 D3 1.53 0.13 1.09 3.58 0.08 2.34 D4 1.53 0.13 1.20 3.57 0.08 2.33 *The balance of the aluminum alloys was aluminum and unavoidable impurities. The aluminum alloy contained not greater than 0.03 wt. % of any one impurity, and contained not greater than 0.10 wt. %, it total, of all impurities. - Four additional alloys were cast and their hot cracking susceptibility was determined, as per Example 1. This time, the iron content was varied, targeting a nominal magnesium amount of 3.45 wt. %, a nominal silicon amount of 1.55 wt. %, and a nominal manganese amount of 0.90 wt. %. The compositions of the Example 5 alloys are shown in Table 6, below. The HCTI results for the Example 5 alloys are shown in the below figure. As shown, the HCTI for all alloys is generally good. Alloy E4 with 0.29 wt. % Fe realized the best HCTI results.
Table 6 - Composition of Example 5 Alloys (all values in weight percent) Alloy* Si Fe Mn Mg Ti Mg/Si E1 1.54 0.11 0.83 3.46 0.07 2.25 E2 1.55 0.17 0.85 3.46 0.07 2.23 E3 1.55 0.23 0.90 3.44 0.07 2.22 E4 1.55 0.29 0.94 3.45 0.07 2.23 *The balance of the aluminum alloys was aluminum and unavoidable impurities. The aluminum alloy contained not greater than 0.03 wt. % of any one impurity, and contained not greater than 0.10 wt. %, it total, of all impurities. - These results are unexpected. The mechanical properties of Al-Si foundry alloys are adversely affected by iron because the iron is present as large primary or pseudo-primary compounds which increase the hardness but decrease the ductility. Given these improved HCTI results, modeling was conducted (ICME - Integrated Computational Materials Engineering). These results show that, by controlling Fe and Mn contents, formation of unwanted needle-shaped β-Al5FeSi can be potentially avoided.
FIGS. 5a ,5b and6 show the correlation between manganese and iron content and the volume fraction on β-Al5FeSi and α-Al15FeMn3Si2 phase particles (for a Al-3.6Mg-1.5Si alloys). Adding Mn to the Al-Mg-Si alloys can promote formation of α-Al15FeMn3Si2 phase and restrict or prevent formation of β-Al5FeSi phase. For instance, a Al-3.6Mg-1.5Si alloy with from 0.4 to 0.6 wt. % Mn, using increased iron amounts decreases the amount of β-Al5FeSi phase. As shown inFIG. 6 , the amount of β-Al5FeSi phase decreases from about 0.018 wt. % to essentially 0 wt. % by increasing iron from 0.15 wt. % to 0.4 wt. %. Thus, alloys having improved properties (e.g., elongation) may be realized due to the increase in iron and the corresponding decrease in β-Al5FeSi phase within the alloy. - Eight additional alloys were cast via directional solidification. All alloys varied iron content. The first group (F) targeted a nominal magnesium amount of 3.6 wt. %, a nominal silicon amount of 1.5 wt. %, and a nominal manganese amount of 0.90 wt. %. The second group (G) targeted a nominal magnesium amount of 4.0 wt. %, a nominal silicon amount of 1.7 wt. %, and a nominal manganese amount of 0.65 wt. %. The compositions of the Example 6 alloys are shown in Table 7, below.
Table 6 - Composition of Example 5 Alloys (all values in weight percent) Alloy* Si Fe Mn Mg Ti Mg/Si F1 1.53 0.12 0.93 3.61 0.08 2.36 F2 1.55 0.19 0.93 3.63 0.08 2.34 F3 1.56 0.27 0.93 3.63 0.08 2.33 F4 1.53 0.38 0.93 3.60 0.08 2.35 G1 1.72 0.12 0.65 4.01 0.08 2.33 G2 1.73 0.19 0.64 4.03 0.08 2.33 G3 1.73 0.29 0.64 4.02 0.08 2.33 G4 1.73 0.40 0.64 4.00 0.08 2.32 *The balance of the aluminum alloys was aluminum and unavoidable impurities. The aluminum alloy contained not greater than 0.03 wt. % of any one impurity, and contained not greater than 0.10 wt. %, it total, of all impurities. - The mechanical properties of the directionally solidified alloys were tested in accordance with ASTM E8 and B557, the results of which are provided in Table 7, below. The mechanical properties of the Example 5 alloys were also tested, so those results are also included in Table 7. The quality index (Q) is also provided. (Q = UTS+150*log(Elong.)). Various graphs relating to these properties and the alloy compositions are provided in
FIGS. 7a-7d . - Based on the prior experiments, various aluminum alloy compositions were modeled. The results are shown in
FIGS. 8a-8b . These modeling results indicate that for an Al-Mg-Si alloy targeting 0.7 wt. % Mn and 0.25 wt. % Fe, it may be useful to control the magnesium and silicon such that (all values in weight percent): (0.4567*Mg - 0.5) <= Si <= (0.4567*Mg +0.2) - Similar modeling was done on additional aluminum alloys, as shown in
FIGS. 8c-8d . These modeling results indicate that, as the manganese or iron content increases, the silicon content needs to be increased. These results further indicate that it may be useful to control magnesium, silicon, manganese, and iron as per the following: - While various embodiments of the present disclosure have been described in detail, it is apparent that modifications and adaptations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present disclosure.
- Aspects of the present disclosure will be described with reference to the following numbered clauses:
- 1. An aluminum casting alloy comprising:
- from 2.5 to 5.0 wt. % Mg;
- from 0.70 to 2.5 wt. % Si;
wherein a weight ratio of magensium to silicon (wt. % Mg / wt. % Si) is from 1.7:1 to 3.6:1; - from 0.40 to 1.5 wt. % Mn;
- from 0.10 to 0.60 wt. % Fe;
- optionally up to 0.15 wt. % Ti;
- optionally up to 0.10 wt. % Sr;
- optionally up to 0.15 wt. % of any of Zr, Sc, Hf, V, and Cr;
- the balance being aluminum and unavoidable impurities.
- 2. The aluminum casting alloy of clause1, wherein the aluminum casting alloy comprises not greater than 4.75 wt. % Mg, or not greater than 4.60 wt. % Mg.
- 3. The aluminum casting alloy of any of the preceding clauses, wherein the aluminum casting alloy comprises at least 2.75 wt. % Mg, or at least 3.0 wt. % Mg.
- 4. The aluminum casting alloy of any of the preceding clauses, wherein the aluminum casting alloy comprises at least 0.80 wt. % Si, or at least 0.90 wt. % Si, or at least 0.95 wt. % Si, or at least 1.00 wt. % Si, or at least 1.05 wt. % Si, or at least 1.10 wt. % Si, or at least 1.15 wt. % Si, or at least 1.20 wt. % Si.
- 5. The aluminum casting alloy of any of the preceding clauses, wherein the aluminum casting alloy comprises not greater than 2.4 wt. % Si, or not greater than 2.3 wt. % Si, or not greater than 2.2 wt. % Si, or not greater than 2.1 wt. % Si, or not greater than 2.0 wt. % Si.
- 6. The aluminum casting alloy of any of the preceding clauses, wherein the weight ratio of magensium to silicon is at least 1.8: 1, or wherein the weight ratio of magensium to silicon is at least 1.85:1.
- 7. The aluminum casting alloy of any of the preceding clauses, wherein the weight ratio of magensium to silicon is not greater than 3.6:1, or wherein the weight ratio of magensium to silicon is not greater than 3.5:1.
- 8. The aluminum casting alloy of any of the preceding clauses, wherein the aluminum casting alloy comprises at least 0.45 wt. % Mn, or at least 0.50 wt. % Mn, or at least 0.55 wt. % Mn, or at least 0.60 wt. % Mn.
- 9. The aluminum casting alloy of any of the preceding clauses, wherein the aluminum casting alloy comprises not greater than 1.45 wt. % Mn, or not greater than 1.40 wt. % Mn, or not greater than 1.35 wt. % Mn, or not greater than 1.30 wt. % Mn, or not greater than 1.35 wt. % Mn, or not greater than 1.20 wt. % Mn.
- 10. The aluminum casting alloy of any of the preceding clauses, wherein the aluminum casting alloy comprises at least 0.12 wt. % Fe, or at least 0.15 wt. % Fe, or at least 0.20 wt. % Fe, or at least 0.25 wt. % Fe, or at least 0.30 wt. % Fe, or at least 0.35 wt. % Fe.
- 11. The aluminum casting alloy of any of the preceding clauses, wherein the aluminum casting alloy comprises not greater than 0.55 wt. % Fe, or not greater than 0.50 wt. % Fe, or not greater than 0.45 wt. % Fe.
- 12. The aluminum casting alloy of any of the preceding clauses, wherein the aluminum casting alloy comprises at least 0.01 wt. % Ti, or at least 0.03 wt. % Ti, or at least 0.05 wt. % Ti, or at least 0.07 wt. % Ti.
- 13. The aluminum casting alloy of any of the preceding clauses, wherein the aluminum casting alloy comprises not greater than 0.13 wt. % Ti, or not greater than 0.115 wt. % Ti, or not greater than 0.10 wt. % Ti.
- 14. The aluminum casting alloy of any of the preceding clauses, wherein the alloy includes not greater than 0.08 wt. % Sr, or not greater than 0.05 wt. % Sr.
- 15. The aluminum casting alloy of any of the preceding clauses, wherein the alloy includes at least 0.005 wt. % Sr.
- 16. The aluminum casting alloy of any of the preceding clauses, wherein the alloy includes at least 0.01 wt. % of any of Zr, Sc, Hf, V, and Cr, or at least 0.03 wt. % of any of Zr, Sc, Hf, V, and Cr, or at least 0.05 wt. % of any of Zr, Sc, Hf, V, and Cr.
- 17. The aluminum casting alloy of any of the preceding clauses, wherein the aluminum casting alloy comprises not greater than 0.30 wt. % of the unavoiable impurities, and wherein the aluminum casting alloy comprises not greater than 0.10 wt. % of any one element of the unavoiable impurities.
- 18. The aluminum casting alloy of any of the preceding clauses, wherein the aluminum casting alloy comprises not greater than 0.15 wt. % of the unavoiable impurities, and wherein the aluminum casting alloy comprises not greater than 0.05 wt. % of any one element of the unavoiable impurities.
- 19. The aluminum casting alloy of any of the preceding clauses, wherein the aluminum casting alloy comprises not greater than 0.10 wt. % of the unavoiable impurities, and wherein the aluminum casting alloy comprises not greater than 0.03 wt. % of any one element of the unavoiable impurities.
- 20. The aluminum casting alloy of any of the preceding clauses, wherein: (0.4567*Mg - 0.5) <= Si <= (0.4567*Mg +0.2).
- 21. The aluminum casting alloy of any of clauses 1-19, wherein:
- (1)
- (2)
- (1)
- 22. The aluminum casting alloy of any of the preceding clauses, wherein the aluminum casting alloy realizes at least one of:
- an ultimate tensile strength of of at least 200 MPa;
- a tensile yield strength of at least 110 MPa; and
- en elongation of at least 10%.
- 23. The aluminum casting alloy of any of the preceding clauses, wherein the aluminum casting alloy realizes at least two of:
- an ultimate tensile strength of of at least 200 MPa;
- a tensile yield strength of at least 110 MPa; and
- en elongation of at least 10%.
- 24. The aluminum casting alloy of any of the preceding clauses, wherein the aluminum casting alloy realizes all of:
- an ultimate tensile strength of of at least 200 MPa;
- a tensile yield strength of at least 110 MPa; and
- en elongation of at least 10%.
- 25. The aluminum casting alloy of any of the preceding clauses, wherein the aluminum casting alloy comprises not greater than 0.012 wt. % of β-Al5FeSi compounds, or not greater than 0.010 wt. % of β-Al5FeSi compounds, or not greater than 0.008 wt. % of β-Al5FeSi compounds, or not greater than 0.006 wt. % of β-Al5FeSi compounds, or not greater than 0.004 wt. % of β-Al5FeSi compounds, or not greater than 0.002 wt. % of β-Al5FeSi compounds, or not greater than 0.001 wt. % of β-Al5FeSi compounds, or not greater than 0.0005 wt. % of β-Al5FeSi compounds.
- 26. The aluminum casting alloy of any of the preceding clauses, wherein the aluminum casting alloy realizes a hot cracking tendency index of not greater than 0.30, or not greater than 0.25, or not greater than 0.20, or not greater than 0.15.
- 27. A high-pressure die cast product made from any of the aluminum casting alloys of clauses 1-26.
- 28. The high-pressure die cast product of clause 27, wherein the high-pressure die cast product is in an F temper or a T5 temper.
- 29. The high-pressure die cast product of clause 27, wherein the high-pressure die cast product is in the form of an automotive component.
- 30. The high-pressure die cast product of clause 29, wherein the automotive component is a structural component.
- 31. The high-pressure die cast product of clause 29, wherein the automotive component is a door frame, or a shock tower, or a tunnel structure.
- 32. An aluminum casting alloy comprising:
- from 3.0 to 4.60 wt. % Mg;
- from 1.20 to 2.0 wt. % Si;
wherein a weight ratio of magensium to silicon (wt. % Mg / wt. % Si) is from 1.85:1 to 3.5:1; - from 0.60 to 1.20 wt. % Mn;
- from 0.20 to 0.60 wt. % Fe;
- optionally up to 0.15 wt. % Ti;
- optionally up to 0.10 wt. % Sr; and
- optionally up to 0.15 wt. % of any of Zr, Sc, Hf, V, and Cr;
- the balance being aluminum and unavoidable impurities.
- 33. The aluminum casting alloy of clause 32, wherein the aluminum casting alloy is in the form of a complex shape casting.
- 34. The aluminum casting alloy of clause 33, wherein the complex shape casting is an automotive component.
- 35. The aluminum casting alloy of clause 34, wherein the automotive component is a structural component.
- 36. The aluminum casting alloy of clause 34, wherein the automotive component is a door frame, or a shock tower, or a tunnel structure.
- 37. The aluminum casting alloy of clause 32, comprising from 0.35 to 0.60 wt. % Fe.
Claims (1)
- An aluminum casting alloy comprising:from 2.5 to 5.0 wt. % Mg;from 0.70 to 2.5 wt. % Si;
wherein a weight ratio of magensium to silicon (wt. % Mg / wt. % Si) is from 1.7:1 to 3.6:1;from 0.40 to 1.5 wt. % Mn;from 0.10 to 0.60 wt. % Fe;optionally up to 0.15 wt. % Ti;optionally up to 0.10 wt. % Sr;optionally up to 0.15 wt. % of any of Zr, Sc, Hf, V, and Cr;the balance being aluminum and unavoidable impurities.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201862667930P | 2018-05-07 | 2018-05-07 | |
PCT/US2019/030924 WO2019217319A1 (en) | 2018-05-07 | 2019-05-06 | Al-Mg-Si-Mn-Fe CASTING ALLOYS |
EP19773328.0A EP3589766B1 (en) | 2018-05-07 | 2019-05-06 | Al-mg-si-mn-fe casting alloys |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
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EP19773328.0A Division EP3589766B1 (en) | 2018-05-07 | 2019-05-06 | Al-mg-si-mn-fe casting alloys |
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EP4234123A2 true EP4234123A2 (en) | 2023-08-30 |
EP4234123A3 EP4234123A3 (en) | 2023-09-27 |
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EP23175753.5A Pending EP4234123A3 (en) | 2018-05-07 | 2019-05-06 | Al-mg-si-mn-fe casting alloys |
EP19773328.0A Active EP3589766B1 (en) | 2018-05-07 | 2019-05-06 | Al-mg-si-mn-fe casting alloys |
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EP19773328.0A Active EP3589766B1 (en) | 2018-05-07 | 2019-05-06 | Al-mg-si-mn-fe casting alloys |
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US (1) | US20190352745A1 (en) |
EP (2) | EP4234123A3 (en) |
JP (1) | JP7438134B2 (en) |
KR (1) | KR20200140917A (en) |
CN (1) | CN110603341A (en) |
CA (1) | CA3099043A1 (en) |
DE (1) | DE202019105466U1 (en) |
ES (1) | ES2949017T3 (en) |
MX (1) | MX2020011679A (en) |
PL (1) | PL3589766T3 (en) |
WO (1) | WO2019217319A1 (en) |
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KR102441402B1 (en) | 2016-11-16 | 2022-09-07 | 현대자동차주식회사 | Sliding apparatus of bus seat |
Family Cites Families (18)
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GB1384264A (en) | 1972-02-09 | 1975-02-19 | Honsel Werke Ag | Structural parts produced from aluminium-containing alloys |
CH689143A5 (en) * | 1994-06-16 | 1998-10-30 | Rheinfelden Aluminium Gmbh | Aluminum-silicon casting alloys with high corrosion resistance, particularly for safety components. |
JP2002105611A (en) | 2000-09-26 | 2002-04-10 | Ahresty Corp | Method for manufacturing automobile part by die casting |
JP3724362B2 (en) | 2000-11-02 | 2005-12-07 | 日本軽金属株式会社 | Aluminum alloy for die casting |
FR2827306B1 (en) * | 2001-07-10 | 2004-10-22 | Pechiney Aluminium | HIGH DUCTILITY ALUMINUM ALLOY FOR PRESSURE CASTING |
US20030143102A1 (en) * | 2001-07-25 | 2003-07-31 | Showa Denko K.K. | Aluminum alloy excellent in cutting ability, aluminum alloy materials and manufacturing method thereof |
US20050199318A1 (en) * | 2003-06-24 | 2005-09-15 | Doty Herbert W. | Castable aluminum alloy |
JP2009108409A (en) * | 2007-10-12 | 2009-05-21 | Hitachi Metals Ltd | Al-Mg TYPE ALUMINUM ALLOY FOR FORGING, WITH EXCELLENT TOUGHNESS, AND CAST MEMBER COMPOSED THEREOF |
JP5355320B2 (en) * | 2009-09-10 | 2013-11-27 | 日産自動車株式会社 | Aluminum alloy casting member and manufacturing method thereof |
JP5368968B2 (en) | 2009-12-28 | 2013-12-18 | 株式会社神戸製鋼所 | Aluminum alloy plate for heat insulator and manufacturing method thereof |
ES2507865T3 (en) * | 2010-12-28 | 2014-10-15 | Casa Maristas Azterlan | Method to obtain improved mechanical properties in plate-shaped beta-free recycled aluminum molds |
AT511397B1 (en) * | 2011-05-03 | 2013-02-15 | Sag Motion Ag | METHOD OF REFINING AND PERMITTING MODIFICATION OF AIMGSI ALLOYS |
JP5882380B2 (en) | 2013-04-09 | 2016-03-09 | 株式会社神戸製鋼所 | Manufacturing method of aluminum alloy sheet for press forming |
WO2015052776A1 (en) | 2013-10-08 | 2015-04-16 | 国立大学法人 富山大学 | Aluminum alloy for cast production and casting using same |
CN105283568A (en) * | 2013-12-13 | 2016-01-27 | 力拓加铝国际有限公司 | Aluminum casting alloy with improved high-temperature performance |
WO2017210916A1 (en) | 2016-06-10 | 2017-12-14 | GM Global Technology Operations LLC | Magnesium-containing, aluminum-based alloy for thin-wall castings |
CN106191572B (en) * | 2016-06-29 | 2018-03-09 | 余姚市弘顺机械有限公司 | A kind of pressure casting method of auto parts machinery aluminium alloy and auto parts machinery |
JP6836266B2 (en) | 2016-12-27 | 2021-02-24 | 学校法人常翔学園 | Al-Mg-Si based aluminum alloy cast plate and its manufacturing method |
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2019
- 2019-05-06 ES ES19773328T patent/ES2949017T3/en active Active
- 2019-05-06 CN CN201980002032.6A patent/CN110603341A/en active Pending
- 2019-05-06 EP EP23175753.5A patent/EP4234123A3/en active Pending
- 2019-05-06 EP EP19773328.0A patent/EP3589766B1/en active Active
- 2019-05-06 PL PL19773328.0T patent/PL3589766T3/en unknown
- 2019-05-06 DE DE202019105466.2U patent/DE202019105466U1/en active Active
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- 2019-05-06 WO PCT/US2019/030924 patent/WO2019217319A1/en unknown
- 2019-05-06 MX MX2020011679A patent/MX2020011679A/en unknown
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KR20200140917A (en) | 2020-12-16 |
CA3099043A1 (en) | 2019-11-14 |
EP3589766A1 (en) | 2020-01-08 |
PL3589766T3 (en) | 2023-07-31 |
ES2949017T3 (en) | 2023-09-25 |
DE202019105466U1 (en) | 2020-01-13 |
MX2020011679A (en) | 2020-12-10 |
US20190352745A1 (en) | 2019-11-21 |
WO2019217319A1 (en) | 2019-11-14 |
EP4234123A3 (en) | 2023-09-27 |
JP7438134B2 (en) | 2024-02-26 |
EP3589766B1 (en) | 2023-06-28 |
EP3589766A4 (en) | 2020-09-02 |
JP2021523291A (en) | 2021-09-02 |
CN110603341A (en) | 2019-12-20 |
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