EP4674999A1 - Al-si alloy for casting, al-si alloy casting and method for producing al-si alloy casting - Google Patents

Al-si alloy for casting, al-si alloy casting and method for producing al-si alloy casting

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Publication number
EP4674999A1
EP4674999A1 EP24763767.1A EP24763767A EP4674999A1 EP 4674999 A1 EP4674999 A1 EP 4674999A1 EP 24763767 A EP24763767 A EP 24763767A EP 4674999 A1 EP4674999 A1 EP 4674999A1
Authority
EP
European Patent Office
Prior art keywords
alloy
mass
casting
content
less
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
EP24763767.1A
Other languages
German (de)
French (fr)
Inventor
Ryosuke Inoue
Tomohiro Isobe
Hiroshi Horikawa
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.)
Nippon Light Metal Co Ltd
Nikkei MC Aluminium Co Ltd
Original Assignee
Nippon Light Metal Co Ltd
Nikkei MC Aluminium Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nippon Light Metal Co Ltd, Nikkei MC Aluminium Co Ltd filed Critical Nippon Light Metal Co Ltd
Publication of EP4674999A1 publication Critical patent/EP4674999A1/en
Pending legal-status Critical Current

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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
    • C22C21/02—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
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B9/00—General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals
    • C22B9/10—General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals with refining or fluxing agents; Use of materials therefor, e.g. slagging or scorifying agents
    • 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
    • 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

Definitions

  • the present invention relates to an Al-Si alloy that can be suitably used for casting, particularly for die casting, and an Al-Si alloy casting cast from the Al-Si alloy is suitable for mechanical joining by using rivets (particularly self-piercing rivets) and the like.
  • Al-Si alloys have excellent castability and are therefore used as casting alloys.
  • casting as used herein refers to castings made by known casting methods such as sand casting, metal mold casting, low pressure casting, and die casting, and is not limited to any particular casting method.
  • Brazing, adhesion, welding, friction stir welding, friction welding and the like are used to join aluminum materials, and, in recent years, however, mechanical joining by using a self-piercing rivet or the like has been attracting attention as a simpler joining method.
  • Self-piercing rivet joining is a joining method where two materials to be joined are overlapped, a receiving die is placed on the underside of the lower material, and a self-piercing rivet is driven into the upper material from above, and the shank of the self-piercing rivet expands when driven into the materials to achieve the joining.
  • Patent Literature 1 JP 2020-66751 A discloses a plastically worked material to be used for self-piercing rivet joining, the Al-Mg-Si-based aluminum alloy plastically worked material being containing 0.95% by mass to 1.25% by mass of Si, 0.80% by mass to 1.05% by0 mass of Mg, 0.30% by mass to 0.50% by mass of Cu, 0.40% by mass to 0.60% by mass of Mn, 0.15% by mass to 0.30% by mass of Fe, 0.09% by mass to 0.21% by mass of Cr, and 0.0001% by mass to 0.03% by mass of B, and a content of Zn is 0.25% by mass or less, a content of Zr is 0.05% by mass or less, a content of Ti is 0.10% by mass or less, with the balance being Al and inevitable impurities, and is characterized in that a self-piercing riveted joint between the aluminum alloy plastically worked materials has a shearing tensile maximum load measured according to JIS
  • Patent Literature 2 JP 2002-121635 A discloses an aluminum alloy extrusion material for automobile frames having excellent self-piercing rivet joinability, which is made of an Al-Mg-Si-based aluminum alloy extrusion material containing 0.30 to 0.70% (% by mass, hereinafter the same)of Mg, 0.40 to 0.80% of Si, 0.05 to 0.40% of Cu, 0.05 to 0.30% of Mn, 0.05 to 0.20% of Zr, with the balance being Al and inevitable impurities, and which is subjected to press quenching by air cooling followed by aging treatment to have a yield strength of 200 N/mm 2 or more and a local elongation of 3.5% or more.
  • Patent Literature 1 is a plastically worked Al-Mg-Si-based aluminum alloy material
  • Patent Literature 2 is an extruded aluminum alloy material, and in both cases, the subjects are the aluminum alloy materials whose microstructure and mechanical properties are controlled by plastic working.
  • an object of the present invention is to provide an Al-Si alloy casting which has excellent impact resistance and exhibits excellent mechanical joining properties of rivets or the like, a method for producing the Al-Si alloy casting, and an Al-Si alloy for casting.
  • the present inventors have conducted intensive research as to the relationship among the composition, microstructure and mechanical properties of the Al-Si alloy castings and the cracks during the mechanical joining, and as a result, have found that cracking during mechanical joining is strongly correlated not with total elongation or uniform elongation, but with the limit bending angle (or local elongation) in a VDA bending test.
  • the present invention provides an Al-Si alloy for casting, characterized in that a Ti content is 0.05% by mass or less.
  • the Ti content By setting the Ti content to 0.05% by mass or less, it is possible to effectively suppress the coarsening of the structure of the Al-Si alloy casting. More specifically, by setting the Ti content to 0.05% by mass or less, the dendrite cell size can be made fine, and the limit bending angle in the VDA bending test can be increased.
  • the Ti content is preferably 0.03% by mass or less, more preferably 0.02% by mass or less, and most preferably 0.01% by mass or less.
  • the Si content is 5.0 to 12.0% by mass.
  • the Al--Si alloys have a wide solid-liquid coexistence region, and are excellent in fluidity, which make them suitable for casting. This effect becomes remarkable when the Si content is 5.0% by mass or more.
  • the Al-Si alloy for casting of the present invention further includes Mn: 0.4 to 1.5% by mass, Mg: 0.05 to 0.60% by mass, Cr: 0.1 to 0.5% by mass, and Fe: more than 0 to 0.6% by mass, with the balance being Al and inevitable impurities.
  • the Al-Si alloy for casting of the present invention contains one or more of Cu: 0.05 to 0.50% by mass, Ca: 0.005 to 0.030% by mass, B: 0.001 to 0.020% by mass, Sr: 0.005 to 0.030% by mass, Sb: 0.01 to 0.20% by mass, and Na: 0.002 to 0.020% by mass.
  • the present invention also provides an Al-Si alloy casting, which is made of the Al-Si alloy for casting of the present invention and has a limit bending angle of 33° or more in the VDA bending test specified in VDA238-100.
  • the limit bending angle in the VDA bending test is preferably 34° or more, and more preferably 35° or more.
  • VDA is the German Association of the Automotive Industry Standard (Verband der Automobilindustrie), and VDA238-100 is specified as a plate bending test aimed at evaluating the cracking behavior when a component is crushed.
  • the average dendrite cell size is 7.1 ⁇ m or less.
  • the average dendrite cell size is more preferably 6.9 ⁇ m or less, and most preferably 5.9 ⁇ m or less.
  • the present invention also provides a method for producing an Al-Si alloy casting, comprising:
  • the method for removing TiB 2 from the molten metal is not particularly limited as long as the effects of the present invention are not impaired , and various conventionally known methods can be used.
  • TiB 2 that has precipitated in the molten metal may be removed by any suitable method, or may be removed by using a filter.
  • the Ti content of the molten metal can be reduced to 0.05% by mass or less.
  • the Ti content of the molten metal is preferably 0.03% by mass or less, more preferably 0.02% by mass or less, and most preferably 0.01% by mass or less.
  • the limit bending angle in the VDA bending test specified in VDA238-100 is preferably set to 34° or more, and more preferably to 35° or more.
  • the Ti content may further be reduced.
  • the molten metal used in the casting has a composition of the Al-Si alloy for casting of the present invention.
  • the composition of the molten metal is set to the composition of the Al-Si alloy for casting of the present invention, it is possible to exactly obtain the Al-Si alloy casting which has excellent impact resistance and exhibits excellent mechanical joining properties of rivets or the like.
  • the present invention it is possible to provide the Al-Si alloy casting which has excellent impact resistance and exhibits excellent mechanical joining properties of rivets or the like, the method for producing the Al-Si alloy casting, and the Al-Si alloy for casting.
  • the greatest feature of the Al-Si alloy for casting of the present invention is that the Ti content is 0.05% by mass or less. Each component will be described in detail below.
  • the present invention is directed to Al-Si alloys, and Si is the essential additive element. Further, it is preferable that the Si content is 5.0 to 12.0% by mass. Si has the effect of improving the castability of the aluminum alloy, as well as having the effect of improving the mechanical properties such as tensile strength. This effect becomes significant when the content is 5.0% by mass or more, but when added in excess of 12.0% by mass, since the eutectic Si and primary Si crystals tend to coarsen to reduce local elongation, the cracks are easy to occur when mechanically joining.
  • the added amount of Si is more preferably 6.0 to 9.0% by mass, and most preferably 6.0 to 7.0% by mass.
  • Mn has the effect of preventing seizure onto the mold, and has the effect of suppressing the formation of acicular Al-Si-Fe-based crystallized products, and suppressing the decrease in elongation. These effects become significant at 0.4% by mass or more, whereas when more than 1.5% by mass, the Al-Si-(Fe, Mn)-based crystallized products tend to become coarse, which causes the decrease in elongation.
  • the Mn content is preferably set to 0.5 to 0.7% by mass.
  • Mg has the effect of improving the mechanical properties by solid-dissolving in Al, and has the effect of improving the mechanical properties by aging treatment which is performed to precipitate together with Si as an Mg-Si-based compound. These effects become significant at 0.05% by mass or more, whereas when more than 0.60% by mass, the deformation resistance increases and cracks become more likely to occur when mechanically joining.
  • the added amount of Mg is preferably set to 0.05 to 0.30% by mass, more preferably set to 0.05 to 0.14% by mass.
  • Cr has the effect of preventing seizure onto the mold and improving corrosion resistance. This effect becomes significant at 0.1% by mass or more. On the other hand, when more than 0.5% by mass, the coarse compounds tend to be formed, and elongation tends to decrease.
  • Fe has the effect of improving the mechanical properties such as tensile strength and the effect of preventing mold seizure, but when more than 0.6% by mass, elongation decreases and cracks are more likely to occur when mechanically joining.
  • Cu has the effect of improving the mechanical properties, and this effect becomes significant at 0.05% by mass or more. On the other hand, when more than 0.50% by mass, the corrosion resistance decreases.
  • the content of Cu is preferably set to 0.20 to 0.40% by mass.
  • the Ti content is preferably 0.03% by mass or less, more preferably 0.02% by mass or less, and most preferably 0.01% by mass or less. Further, the contents of V and Zr are also reduced as much as possible, preferably to 0.05% by mass or less, more preferably to 0.03% by mass or less, even more preferably to 0.02% by mass or less, and most preferably to 0.01% by mass or less.
  • the Al-Si alloy casting of the present invention is made from the Al-Si alloy for casting of the present invention, and the greatest feature thereof is that the limit bending angle in the VDA bending test specified in VDA238-100 is 33° or more.
  • the microstructure and mechanical properties will be described in detail.
  • the average dendrite size is 7.1 ⁇ m or less, and thus, the occurrence and propagation of cracks when stress is applied to the Al-Si alloy casting can be extremely effectively suppressed, and excellent local elongation can be imparted to the Al-Si alloy casting. As a result, in the Al-Si alloy casting of the present invention, the occurrence of cracks during mechanical joining is effectively suppressed.
  • the average dendrite size is more preferably 6.9 ⁇ m or less, and most preferably 5.9 ⁇ m or less.
  • the method for confirming the average value of the dendrite size is not particularly limited, and any of various conventionally known microstructure observation techniques may be employed.
  • the mirror-polished cross section of the Al-Si alloy casting can be observed with an optical microscope or a scanning electron microscope (SEM).
  • the average value of the dendrite size can be measured by the intersection method according to the procedure of the DAS measurement method (Dendrite Arm Spacing measurement method). In this case, it is preferable to perform the measurement at a position that avoids the eutectic structure as much as possible.
  • the Al-Si alloy casting of the present invention has excellent tensile properties including high strength, yield strength and ductility. In addition, the occurrence of cracks during mechanical joining is effectively suppressed.
  • the mechanism by which the cracks occur during mechanical joining is complex, and it is difficult to evaluate solely from measured values related to the mechanical properties of the Al-Si alloy casting, such as tensile properties and hardness.
  • the present inventors have conducted intensive research and found that there is a strong correlation between the limit bending angle in the VDA bending test specified in VDA238-100 and the presence or absence of cracks during mechanical joining.
  • the limit bending angle in the VDA bending test specified in VDA238-100 must be 33° or more.
  • the limit bending angle is preferably 34° or more, and more preferably 35° or more.
  • the method for producing the Al-Si alloy casting of the present invention includes a Ti removal step for removing Ti contained as an inevitable impurity in the molten Al-Si alloy, and a casting step for casting by using the molten Al-Si alloy from which the Ti has been removed. In the following, each step will be described in detail.
  • the Ti removal step is a step in which B is added to the molten Al-Si alloy, the Ti in the molten alloy is converted to TiB 2 , and then the TiB 2 is removed to reduce the Ti content in the molten alloy as much as possible, and the Ti content to be 0.05% by mass or less.
  • the method for removing TiB 2 from the molten metal is not particularly limited as long as the effects of the present invention are not impaired , and various conventionally known methods can be used.
  • TiB 2 that has precipitated in the molten metal may be removed by any suitable method, or may be removed by using a filter.
  • the Ti content of the molten metal can be reduced to 0.05% by mass or less.
  • the Ti content of the molten metal is preferably 0.03% by mass or less, more preferably 0.02% by mass or less, and most preferably 0.01% by mass or less.
  • the molten Al-Si alloy to be subjected to the Ti removal step has the composition of the Al-Si alloy for casting of the present invention.
  • the composition of the molten metal is set to the composition of the Al-Si alloy for casting of the present invention, it is possible to exactly obtain the Al-Si alloy casting which has excellent impact resistance and exhibits excellent mechanical joining properties of rivets or the like.
  • the casting method in the casting step is not particularly limited as long as the effects of the present invention are not impaired, and various conventionally known casting methods (sand casting, metal mold casting, gravity casting, low-pressure casting, die casting, and the like) can be used. That is, the aluminum alloy casting of the present invention is not limited to that cast by a specific casting method.
  • casting conditions are not particularly limited as long as the effects of the present invention are not impaired and various conventionally known casting conditions can be used.
  • B was added to the molten raw material to yield TiB 2 , and after degassing treatment, the material was allowed to stand for 1 hour to allow TiB 2 to be precipitated and removed (Ti removal step), and thereafter a PF die casting was performed.
  • the compositions shown in Table 1 are values relating to the molten metal after the Ti removal step. As shown in Table 1, in all the examples, the Ti content is 0.05% by mass or less. [Table 1] Analytical value (% by mass) VDA bending angle (°) Dendrite cell size ( ⁇ m) Si Mn Cr Fe Ti Cu Ca Al Ex. 1 6.8 0.63 0.18 0.13 0.006 0.01 0.0069 Bal. 35.1 5.7 Ex.
  • the obtained Al-Si alloy sheet materials were subjected to the VDA bending test specified in VDA238-100 to evaluate the limit bending angle. For each Al-Si alloy sheet material, three measurements were carried out and the average value was calculated. The obtained limit bending angles are shown in Table 1. As shown in Table 1, it can be seen that in all of the examples, the limit bending angle in the VDA bending test was 33° or more.
  • Example 1 which has a low Ti content
  • the dendrite cell size is finer.
  • the average dendrite cell size was determined from each of the obtained structure photographs by the intersection method (number of intersections: 10) according to the procedure of the DAS measurement method. The values obtained are shown in Table 1. As shown in Table 1, it can be seen that the average dendrite cell size is 7.1 ⁇ m or less in all the examples.
  • the Al-Si alloy sheet material which is comparative Al-Si alloy casting in the present invention, was obtained in the same manner as in the Examples, except that raw material which was mixed to obtain the compositions (% by mass) shown in Table 1 as Comparative Example 1 was used.
  • the limit bending angle in the VDA bending test and the average value of the dendrite cell size of the Al-Si alloy sheet material were measured. The values obtained are shown in Table 1.
  • the Ti content exceeded 0.05% by mass and was 0.110% by mass, and the dendrite cell size was 7.3 ⁇ m, resulting in the low limit bending angle of 32.6° in the VDA bending test.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Continuous Casting (AREA)
  • Forging (AREA)

Abstract

The present invention provides: an Al-Si alloy casting which exhibits excellent mechanical joining properties of rivets or the like, and has excellent impact resistance; a production method for obtaining said Al-Si alloy casting; and an Al-Si alloy for casting. An Al-Si alloy for casting according to the present invention is characterized in that the Ti content is no more than 0.05 mass%. The Al-Si alloy for casting preferably has an Si content of 5.0-12.0 mass%, and preferably has an Mn content of 0.4-1.5 mass%, an Mg content of 0.05-0.6 mass%, a Cr content of 0.1-0.5 mass%, and an Fe content greater than 0 and no greater than 0.6 mass%, with the remainder comprising Al and inevitable impurities.

Description

    THECHNICAL FIELD
  • The present invention relates to an Al-Si alloy that can be suitably used for casting, particularly for die casting, and an Al-Si alloy casting cast from the Al-Si alloy is suitable for mechanical joining by using rivets (particularly self-piercing rivets) and the like.
    • PRIOR ARTS
  • Al-Si alloys have excellent castability and are therefore used as casting alloys. The term casting as used herein refers to castings made by known casting methods such as sand casting, metal mold casting, low pressure casting, and die casting, and is not limited to any particular casting method.
  • Brazing, adhesion, welding, friction stir welding, friction welding and the like are used to join aluminum materials, and, in recent years, however, mechanical joining by using a self-piercing rivet or the like has been attracting attention as a simpler joining method.
  • Self-piercing rivet joining is a joining method where two materials to be joined are overlapped, a receiving die is placed on the underside of the lower material, and a self-piercing rivet is driven into the upper material from above, and the shank of the self-piercing rivet expands when driven into the materials to achieve the joining.
  • For example, Patent Literature 1 ( JP 2020-66751 A ) discloses a plastically worked material to be used for self-piercing rivet joining, the Al-Mg-Si-based aluminum alloy plastically worked material being containing 0.95% by mass to 1.25% by mass of Si, 0.80% by mass to 1.05% by0 mass of Mg, 0.30% by mass to 0.50% by mass of Cu, 0.40% by mass to 0.60% by mass of Mn, 0.15% by mass to 0.30% by mass of Fe, 0.09% by mass to 0.21% by mass of Cr, and 0.0001% by mass to 0.03% by mass of B, and a content of Zn is 0.25% by mass or less, a content of Zr is 0.05% by mass or less, a content of Ti is 0.10% by mass or less, with the balance being Al and inevitable impurities, and is characterized in that a self-piercing riveted joint between the aluminum alloy plastically worked materials has a shearing tensile maximum load measured according to JIS Z3136-1999 is 8.5 kN or more.
  • In the plastically worked Al-Mg-Si-based aluminum alloy material described in Patent Literature 1, it is said that by optimizing the composition, it is possible to provide an Al-Mg-Si-based aluminum alloy plastically worked material having excellent joining strength in self-piercing rivet joining.
  • Further, Patent Literature 2 ( JP 2002-121635 A ) discloses an aluminum alloy extrusion material for automobile frames having excellent self-piercing rivet joinability, which is made of an Al-Mg-Si-based aluminum alloy extrusion material containing 0.30 to 0.70% (% by mass, hereinafter the same)of Mg, 0.40 to 0.80% of Si, 0.05 to 0.40% of Cu, 0.05 to 0.30% of Mn, 0.05 to 0.20% of Zr, with the balance being Al and inevitable impurities, and which is subjected to press quenching by air cooling followed by aging treatment to have a yield strength of 200 N/mm2 or more and a local elongation of 3.5% or more.
  • In the aluminum alloy extrusion material for automobile frames described in Patent Literature 2, it is said that an aluminum alloy extrusion material having the strength (yield strength) required for automobile frames and excellent self-piercing rivet joinability can be obtained by performing the aging treatment on the Al-Mg-Si-based aluminum alloy extrusion material after press quenching by air cooling, which is advantageous in terms of dimensional accuracy and cost.
    • CITATION LIST Patent Literature
    • Patent Literature 1: JP 2020-66751 A
    • Patent Literature 2: JP 2002-121635 A
    SUMMARY OF INVENTION Technical Problem
  • However, the subject of Patent Literature 1 is a plastically worked Al-Mg-Si-based aluminum alloy material, and the subject of Patent Literature 2 is an extruded aluminum alloy material, and in both cases, the subjects are the aluminum alloy materials whose microstructure and mechanical properties are controlled by plastic working.
  • In contrast, there are many cases where aluminum alloy castings such as die-cast materials are necessarily joined to other structural members by using mechanical joining such as self-piercing rivets, and when the mechanical joining is applied to aluminum alloy castings, suppressing of cracks that occur during joining becomes more serious.
  • In view of the problems in the prior arts as described above, an object of the present invention is to provide an Al-Si alloy casting which has excellent impact resistance and exhibits excellent mechanical joining properties of rivets or the like, a method for producing the Al-Si alloy casting, and an Al-Si alloy for casting.
    • Solution to Problem
  • In order to accomplish the above objects, the present inventors have conducted intensive research as to the relationship among the composition, microstructure and mechanical properties of the Al-Si alloy castings and the cracks during the mechanical joining, and as a result, have found that cracking during mechanical joining is strongly correlated not with total elongation or uniform elongation, but with the limit bending angle (or local elongation) in a VDA bending test.
  • Moreover, as a result of further research, it was found that there is a strong correlation between the Ti content of Al-Si alloy castings and the limit bending angle in the VDA bending test, and that the limit bending angle in the VDA bending test increases by reducing the Ti content, and have reached the present invention.
  • Namely, the present invention provides an Al-Si alloy for casting, characterized in that a Ti content is 0.05% by mass or less.
  • By setting the Ti content to 0.05% by mass or less, it is possible to effectively suppress the coarsening of the structure of the Al-Si alloy casting. More specifically, by setting the Ti content to 0.05% by mass or less, the dendrite cell size can be made fine, and the limit bending angle in the VDA bending test can be increased. The Ti content is preferably 0.03% by mass or less, more preferably 0.02% by mass or less, and most preferably 0.01% by mass or less.
  • In the Al-Si alloy for casting of the present invention, it is preferable that the Si content is 5.0 to 12.0% by mass. The Al--Si alloys have a wide solid-liquid coexistence region, and are excellent in fluidity, which make them suitable for casting. This effect becomes remarkable when the Si content is 5.0% by mass or more.
  • Further, it is preferable that the Al-Si alloy for casting of the present invention further includes Mn: 0.4 to 1.5% by mass, Mg: 0.05 to 0.60% by mass, Cr: 0.1 to 0.5% by mass, and Fe: more than 0 to 0.6% by mass, with the balance being Al and inevitable impurities.
  • By adding 0.4% by mass or more of Mn to the Al-Si alloy for casting, it is possible to prevent seizure onto a mold, suppress the formation of acicular Al-Si-Fe-based crystallized products, and suppress the decrease in elongation of the Al-Si alloy casting. Further, by setting the added amount of Mn to 1.5% by mass or less, it is possible to suppress the decrease in elongation of the Al-Si alloy casting, which would be caused by coarsening of the Al-Si-(Fe, Mn)-based crystallized products.
  • In addition, by adding 0.05% by mass or more of Mg, due to solid solution strengthening of Mg and precipitation strengthening of Mg-Si-based compounds, it is possible to improve the mechanical properties of the Al-Si alloy casting. Further, by setting the added amount of Mg to 0.60% by mass or less, since excessive increase in deformation resistance is suppressed, it is possible to suppress the occurrence of cracks during the mechanical joining.
  • Further, it is preferable that the Al-Si alloy for casting of the present invention contains one or more of Cu: 0.05 to 0.50% by mass, Ca: 0.005 to 0.030% by mass, B: 0.001 to 0.020% by mass, Sr: 0.005 to 0.030% by mass, Sb: 0.01 to 0.20% by mass, and Na: 0.002 to 0.020% by mass.
  • By further adding these elements, since the microstructure and mechanical properties of the Al-Si alloy casting can be adjusted, it is possible to further enhance the effect of suppressing cracks. Further, it is possible to impart a desired yield strength to the Al-Si alloy casting.
  • By adding Cu, it is possible to increase the strength and yield strength of the Al-Si alloy casting, and by adding B, it is possible to improve the local elongation of the Al-Si alloy casting. Further, since Ca, Sr, Sb and Na have the effect of refining and granulating the eutectic Si, it is possible to improve the elongation of the Al-Si alloy casting.
  • Further, the present invention also provides an Al-Si alloy casting, which is made of the Al-Si alloy for casting of the present invention and has a limit bending angle of 33° or more in the VDA bending test specified in VDA238-100. The limit bending angle in the VDA bending test is preferably 34° or more, and more preferably 35° or more.
  • Here, the VDA is the German Association of the Automotive Industry Standard (Verband der Automobilindustrie), and VDA238-100 is specified as a plate bending test aimed at evaluating the cracking behavior when a component is crushed.
  • Further, in the Al-Si alloy casting of the present invention, it is preferable that the average dendrite cell size is 7.1 µm or less. As a result of extensive research by the present inventors, it has become clear that the limit bending angle in the VDA bending test for the Al-Si alloy casting is very sensitive to the dendritic cell size, and that by setting the average dendritic cell size to 7.1 µm or less, the occurrence and propagation of cracks when stress is applied to the Al-Si alloy casting can be extremely effectively suppressed, and excellent local elongation can be imparted to the Al-Si alloy casting. As a result, in the Al-Si alloy casting of the present invention, the occurrence of cracks during mechanical joining is effectively suppressed. The average dendrite cell size is more preferably 6.9 µm or less, and most preferably 5.9 µm or less.
  • Furthermore, the present invention also provides a method for producing an Al-Si alloy casting, comprising:
    • a Ti removal step of adding B to a molten Al-Si alloy to convert Ti in the molten alloy to TiB2, and then removing the TiB2; and
    • a casting step of casting the molten alloy that has been subjected to the Ti removal step to obtain an Al-Si alloy casting,
    • wherein the Ti content of the Al-Si alloy casting is set to 0.05% by mass or less by the Ti removal step, and
    • a limit bending angle of the Al-Si alloy casting in the VDA bending test specified in VDA238-100 is set to 33° or more.
  • When Ti is added during casting, since it acts as a nucleus for the crystallization of the α phase to improve castability, Ti is often added to Al-Si alloy castings. However, as a result of extensive research by the present inventors into the relationship between the composition and microstructure of Al-Si alloy castings, it has become clear that when more than 0.05% by mass of Ti is present, the dendrite size in the Al-Si alloy castings increases. In contrast, in the producing method of the Al-Si alloy casting of the present invention, Ti is actively removed from the molten Al-Si alloy by adding B, so that the dendrite size can be effectively reduced and the limit bending angle in the VDA bending test specified in VDA238-100 can be set to 33° or more.
  • The method for removing TiB2 from the molten metal is not particularly limited as long as the effects of the present invention are not impaired , and various conventionally known methods can be used. For example, TiB2 that has precipitated in the molten metal may be removed by any suitable method, or may be removed by using a filter. By removing TiB2, the Ti content of the molten metal can be reduced to 0.05% by mass or less. The Ti content of the molten metal is preferably 0.03% by mass or less, more preferably 0.02% by mass or less, and most preferably 0.01% by mass or less.
  • Further, in the producing method of the Al-Si alloy casting of the present invention, by reducing the Ti content, the limit bending angle in the VDA bending test specified in VDA238-100 is preferably set to 34° or more, and more preferably to 35° or more. Here, when the limit bending angle in the VDA bending test is lower than a desired value, the Ti content may further be reduced.
  • Further, in the producing method of the Al-Si alloy casting of the present invention, it is preferable that the molten metal used in the casting has a composition of the Al-Si alloy for casting of the present invention. When the composition of the molten metal is set to the composition of the Al-Si alloy for casting of the present invention, it is possible to exactly obtain the Al-Si alloy casting which has excellent impact resistance and exhibits excellent mechanical joining properties of rivets or the like.
    • EFFECT OF THE INVENTION
  • According to the present invention, it is possible to provide the Al-Si alloy casting which has excellent impact resistance and exhibits excellent mechanical joining properties of rivets or the like, the method for producing the Al-Si alloy casting, and the Al-Si alloy for casting.
    • BRIEF EXPLANATION OF THE DRAWINGS
    • FIG. 1 is a photograph of the microstructure of the Al-Si alloy sheet material having the composition of Example 1.
    • FIG. 2 is a photograph of the microstructure of the Al-Si alloy sheet material having the composition of Example 2.
    Embodiments for achieving the invention
  • In the following, the Al-Si alloy for casting, the Al-Si alloy casting, and the method for producing the Al-Si alloy casting of the present invention will be described in detail, but the present invention is not limited thereto.
    • 1. Al-Si alloy for casting
  • The greatest feature of the Al-Si alloy for casting of the present invention is that the Ti content is 0.05% by mass or less. Each component will be described in detail below.
    • (1) Essential additive elements Si: 5.0 to 12.0% by mass
  • The present invention is directed to Al-Si alloys, and Si is the essential additive element. Further, it is preferable that the Si content is 5.0 to 12.0% by mass. Si has the effect of improving the castability of the aluminum alloy, as well as having the effect of improving the mechanical properties such as tensile strength. This effect becomes significant when the content is 5.0% by mass or more, but when added in excess of 12.0% by mass, since the eutectic Si and primary Si crystals tend to coarsen to reduce local elongation, the cracks are easy to occur when mechanically joining. The added amount of Si is more preferably 6.0 to 9.0% by mass, and most preferably 6.0 to 7.0% by mass.
    • (2) Optional Added Elements Mn: 0.4 to 1.5% by mass
  • Mn has the effect of preventing seizure onto the mold, and has the effect of suppressing the formation of acicular Al-Si-Fe-based crystallized products, and suppressing the decrease in elongation. These effects become significant at 0.4% by mass or more, whereas when more than 1.5% by mass, the Al-Si-(Fe, Mn)-based crystallized products tend to become coarse, which causes the decrease in elongation. The Mn content is preferably set to 0.5 to 0.7% by mass.
    • Mg: 0.05 to 0.60% by mass
  • Mg has the effect of improving the mechanical properties by solid-dissolving in Al, and has the effect of improving the mechanical properties by aging treatment which is performed to precipitate together with Si as an Mg-Si-based compound. These effects become significant at 0.05% by mass or more, whereas when more than 0.60% by mass, the deformation resistance increases and cracks become more likely to occur when mechanically joining. The added amount of Mg is preferably set to 0.05 to 0.30% by mass, more preferably set to 0.05 to 0.14% by mass.
    • Cr: 0.1 to 0.5% by mass
  • Cr has the effect of preventing seizure onto the mold and improving corrosion resistance. This effect becomes significant at 0.1% by mass or more. On the other hand, when more than 0.5% by mass, the coarse compounds tend to be formed, and elongation tends to decrease.
    • Fe: More than 0 and not more than 0.6% by mass
  • Fe has the effect of improving the mechanical properties such as tensile strength and the effect of preventing mold seizure, but when more than 0.6% by mass, elongation decreases and cracks are more likely to occur when mechanically joining.
    • Cu: 0.05 to 0.50% by mass
  • Cu has the effect of improving the mechanical properties, and this effect becomes significant at 0.05% by mass or more. On the other hand, when more than 0.50% by mass, the corrosion resistance decreases. The content of Cu is preferably set to 0.20 to 0.40% by mass.
    • B: 0.001 to 0.020% by mass
  • B has the effect of improving the local elongation and enhancing the mechanical joinability. This effect becomes significant at 0.001% by mass or more. On the other hand, when more than 0.020% by mass, there is a factor of the increase in production costs.
    • Ca: 0.005 to 0.030% by mass
  • By adding 0.005 to 0.030% by mass of Ca, it is possible to make the eutectic Si fine and granular. When the eutectic Si is fine and granulated, the elongation is improved, and the occurrence of cracks during mechanical joining can be suppressed.
    • Sr: 0.005 to 0.030% by mass
  • By adding 0.005 to 0.030% by mass of Sr, it is possible to make the eutectic Si fine and granular. When the eutectic Si is fine and granulated, the elongation is improved, and the occurrence of cracks during mechanical joining can be suppressed.
    • Sb: 0.01 to 0.20% by mass
  • By adding 0.01 to 0.20% by mass of Sb, it is possible to make the eutectic Si fine and granular. When the eutectic Si is fine and granulated, the elongation is improved, and the occurrence of cracks during mechanical joining can be suppressed.
    • Na: 0.002 to 0.020% by mass
  • By adding 0.002 to 0.020% by mass of Na, it is possible to make the eutectic Si fine and granular. When the eutectic Si is fine and granulated, the elongation is improved, and the occurrence of cracks during mechanical joining can be suppressed.
    • (3) Inevitable impurities
  • Among the inevitable impurities, it is necessary to strictly control the Ti content to 0.05% by mass or less. The Ti content is preferably 0.03% by mass or less, more preferably 0.02% by mass or less, and most preferably 0.01% by mass or less. Further, the contents of V and Zr are also reduced as much as possible, preferably to 0.05% by mass or less, more preferably to 0.03% by mass or less, even more preferably to 0.02% by mass or less, and most preferably to 0.01% by mass or less.
    • 2. Al-Si alloy casting
  • The Al-Si alloy casting of the present invention is made from the Al-Si alloy for casting of the present invention, and the greatest feature thereof is that the limit bending angle in the VDA bending test specified in VDA238-100 is 33° or more. In the following, the microstructure and mechanical properties will be described in detail.
    • (1) Metal structure
  • In the Al-Si alloy casting of the present invention, the average dendrite size is 7.1 µm or less, and thus, the occurrence and propagation of cracks when stress is applied to the Al-Si alloy casting can be extremely effectively suppressed, and excellent local elongation can be imparted to the Al-Si alloy casting. As a result, in the Al-Si alloy casting of the present invention, the occurrence of cracks during mechanical joining is effectively suppressed. The average dendrite size is more preferably 6.9 µm or less, and most preferably 5.9 µm or less.
  • Note that, the method for confirming the average value of the dendrite size is not particularly limited, and any of various conventionally known microstructure observation techniques may be employed. For example, the mirror-polished cross section of the Al-Si alloy casting can be observed with an optical microscope or a scanning electron microscope (SEM).
  • Here, for example, the average value of the dendrite size can be measured by the intersection method according to the procedure of the DAS measurement method (Dendrite Arm Spacing measurement method). In this case, it is preferable to perform the measurement at a position that avoids the eutectic structure as much as possible.
    • (2) Mechanical Properties
  • The Al-Si alloy casting of the present invention has excellent tensile properties including high strength, yield strength and ductility. In addition, the occurrence of cracks during mechanical joining is effectively suppressed.
  • The mechanism by which the cracks occur during mechanical joining is complex, and it is difficult to evaluate solely from measured values related to the mechanical properties of the Al-Si alloy casting, such as tensile properties and hardness. With respect to this, the present inventors have conducted intensive research and found that there is a strong correlation between the limit bending angle in the VDA bending test specified in VDA238-100 and the presence or absence of cracks during mechanical joining.
  • More specifically, in order to suppress cracks during mechanical joining, the limit bending angle in the VDA bending test specified in VDA238-100 must be 33° or more. The limit bending angle is preferably 34° or more, and more preferably 35° or more.
    • 3. Method for producing Al-Si alloy casting
  • The method for producing the Al-Si alloy casting of the present invention includes a Ti removal step for removing Ti contained as an inevitable impurity in the molten Al-Si alloy, and a casting step for casting by using the molten Al-Si alloy from which the Ti has been removed. In the following, each step will be described in detail.
    • (1) Ti removal step
  • The Ti removal step is a step in which B is added to the molten Al-Si alloy, the Ti in the molten alloy is converted to TiB2, and then the TiB2 is removed to reduce the Ti content in the molten alloy as much as possible, and the Ti content to be 0.05% by mass or less.
  • The method for removing TiB2 from the molten metal is not particularly limited as long as the effects of the present invention are not impaired , and various conventionally known methods can be used. For example, TiB2 that has precipitated in the molten metal may be removed by any suitable method, or may be removed by using a filter. By removing TiB2, the Ti content of the molten metal can be reduced to 0.05% by mass or less. The Ti content of the molten metal is preferably 0.03% by mass or less, more preferably 0.02% by mass or less, and most preferably 0.01% by mass or less.
  • It is preferable that the molten Al-Si alloy to be subjected to the Ti removal step has the composition of the Al-Si alloy for casting of the present invention. When the composition of the molten metal is set to the composition of the Al-Si alloy for casting of the present invention, it is possible to exactly obtain the Al-Si alloy casting which has excellent impact resistance and exhibits excellent mechanical joining properties of rivets or the like.
    • (2) Casting step
  • The casting method in the casting step is not particularly limited as long as the effects of the present invention are not impaired, and various conventionally known casting methods (sand casting, metal mold casting, gravity casting, low-pressure casting, die casting, and the like) can be used. That is, the aluminum alloy casting of the present invention is not limited to that cast by a specific casting method.
  • Further, the casting conditions are not particularly limited as long as the effects of the present invention are not impaired and various conventionally known casting conditions can be used.
  • Although representative embodiments of the present invention have been described above, the present invention is not limited to these, and various design changes are possible, and all such design changes are included in the technical scope of the present invention.
    • EXAMPLE <<Examples>>
  • Raw materials which were mixed to obtain the compositions (% by mass) shown in Table 1 as Examples 1 to 6 were melted at 750°C, and, after subjected to the slag removal treatment by using a molten metal cleaning flux and the degassing treatment by blowing an Ar gas therein, PF die casting was performed under the conditions of a high speed injection speed: 2.0 mm/s, a casting pressure: 80 ± 5 MPa, a casting temperature: 730 ± 10°C, and a mold temperature: 100 to 150°C to obtain an Al-Si alloy sheets which are the Al-Si alloy castings according to the present invention. The size of the Al-Si alloy sheet is 110 × 110 × 3 mm.
  • Here, in all examples, B was added to the molten raw material to yield TiB2, and after degassing treatment, the material was allowed to stand for 1 hour to allow TiB2 to be precipitated and removed (Ti removal step), and thereafter a PF die casting was performed. The compositions shown in Table 1 are values relating to the molten metal after the Ti removal step. As shown in Table 1, in all the examples, the Ti content is 0.05% by mass or less. [Table 1]
    Analytical value (% by mass) VDA bending angle (°) Dendrite cell size (µm)
    Si Mn Cr Fe Ti Cu Ca Al
    Ex. 1 6.8 0.63 0.18 0.13 0.006 0.01 0.0069 Bal. 35.1 5.7
    Ex. 2 6.9 0.63 0.18 0.13 0.011 0.01 0.0092 Bal. 33.8 7.1
    Ex. 3 6.8 0.63 0.18 0.13 0.015 0.01 0.0108 Bal. 35.7 7.1
    Ex. 4 6.9 0.63 0.18 0.13 0.020 0.01 0.0099 Bal. 34.9 5.9
    Ex. 5 6.9 0.65 0.19 0.12 0.030 0.01 0.0100 Bal. 34.0 6.4
    Ex. 6 6.9 0.65 0.19 0.12 0.050 0.01 0.0070 Bal. 35.0 6.9
    Com. Ex. 1 6.8 0.64 0.19 0.12 0.110 0.01 0.0100 Bal. 32.6 7.3
  • The obtained Al-Si alloy sheet materials were subjected to the VDA bending test specified in VDA238-100 to evaluate the limit bending angle. For each Al-Si alloy sheet material, three measurements were carried out and the average value was calculated. The obtained limit bending angles are shown in Table 1. As shown in Table 1, it can be seen that in all of the examples, the limit bending angle in the VDA bending test was 33° or more.
  • A specimen for observing the structure was cut out from each Al-Si alloy sheet material, and the cross section was buffed and observed with an optical microscope. As representative examples, the structure photographs of the Al-Si alloy sheet materials having the compositions of Example 1 and Example 2 are shown in FIG. 1 and FIG. 2, respectively. Comparing the microstructures in FIG. 1 and FIG. 2, it can be confirmed that in Example 1, which has a low Ti content, the dendrite cell size is finer. Further, the average dendrite cell size was determined from each of the obtained structure photographs by the intersection method (number of intersections: 10) according to the procedure of the DAS measurement method. The values obtained are shown in Table 1. As shown in Table 1, it can be seen that the average dendrite cell size is 7.1 µm or less in all the examples.
    • <<Comparative Examples>>
  • The Al-Si alloy sheet material, which is comparative Al-Si alloy casting in the present invention, was obtained in the same manner as in the Examples, except that raw material which was mixed to obtain the compositions (% by mass) shown in Table 1 as Comparative Example 1 was used.
  • Further, in the same manner as in the examples, the limit bending angle in the VDA bending test and the average value of the dendrite cell size of the Al-Si alloy sheet material were measured. The values obtained are shown in Table 1. In Comparative Example, the Ti content exceeded 0.05% by mass and was 0.110% by mass, and the dendrite cell size was 7.3 µm, resulting in the low limit bending angle of 32.6° in the VDA bending test.

Claims (8)

  1. An Al-Si alloy for casting, characterized in that a Ti content is 0.05% by mass or less.
  2. The Al-Si alloy for casting according to claim 1, wherein a Si content is 5.0 to 12.0% by mass.
  3. The Al-Si alloy for casting according to claim 1 or 2, further comprising
    Mn: 0.4 to 1.5% by mass,
    Mg: 0.05 to 0.60% by mass,
    Cr: 0.1 to 0.5% by mass,
    Fe: more than 0 and 0.6% by mass,
    with the balance being Al and inevitable impurities.
  4. The Al-Si alloy for casting according to claim 1 or 2, further comprising one or more of the following:
    Cu: 0.05 to 0.50% by mass,
    Ca: 0.005 to 0.030% by mass,
    B: 0.001 to 0.020% by mass,
    Sr: 0.005 to 0.030% by mass,
    Sb: 0.01 to 0.20% by mass, and
    Na: 0.002 to 0.020% by mass.
  5. An Al-Si alloy casting which comprises the Al-Si alloy for casting according to claim 1 or 2, and has a limit bending angle in the VDA bending test specified in VDA238-100 of 33° or more.
  6. The Al-Si alloy casting according to claim 5, wherein an average dendrite cell size is 7.1 µm or less.
  7. A method for producing an Al-Si alloy casting, comprising:
    a Ti removal step of adding B to a molten Al-Si alloy to convert Ti in the molten alloy to TiB2, and then removing the TiB2; and
    a casting step of casting the molten alloy that has been subjected to the Ti removal step to obtain an Al-Si alloy casting,
    wherein the Ti content of the Al-Si alloy casting is set to 0.05% by mass or less by the Ti removal step, and
    a limit bending angle of the Al-Si alloy casting in the VDA bending test specified in VDA238-100 is set to 33° or more.
  8. The method for producing an Al-Si alloy casting according to claim 7, wherein the molten metal used in the casting has a composition of the Al-Si alloy for casting according to claim 1 or 2.
EP24763767.1A 2023-02-28 2024-02-22 Al-si alloy for casting, al-si alloy casting and method for producing al-si alloy casting Pending EP4674999A1 (en)

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