GB2023665A - The manufacture of composite aluminium coated articles - Google Patents
The manufacture of composite aluminium coated articles Download PDFInfo
- Publication number
- GB2023665A GB2023665A GB7920510A GB7920510A GB2023665A GB 2023665 A GB2023665 A GB 2023665A GB 7920510 A GB7920510 A GB 7920510A GB 7920510 A GB7920510 A GB 7920510A GB 2023665 A GB2023665 A GB 2023665A
- Authority
- GB
- United Kingdom
- Prior art keywords
- aluminium
- intermediate layer
- alloy
- process according
- cast
- 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.)
- Withdrawn
Links
- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 21
- 239000004411 aluminium Substances 0.000 title claims abstract description 21
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 17
- 239000002131 composite material Substances 0.000 title claims abstract description 14
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 10
- 238000000034 method Methods 0.000 claims abstract description 20
- 229910000838 Al alloy Inorganic materials 0.000 claims abstract description 16
- 229910052751 metal Inorganic materials 0.000 claims abstract description 14
- 239000002184 metal Substances 0.000 claims abstract description 14
- 238000005507 spraying Methods 0.000 claims abstract description 6
- 238000000926 separation method Methods 0.000 claims abstract description 3
- 238000005266 casting Methods 0.000 claims description 10
- -1 aluminium-silicon-magnesium Chemical compound 0.000 claims description 8
- 229910000831 Steel Inorganic materials 0.000 claims description 7
- 239000010959 steel Substances 0.000 claims description 7
- GANNOFFDYMSBSZ-UHFFFAOYSA-N [AlH3].[Mg] Chemical compound [AlH3].[Mg] GANNOFFDYMSBSZ-UHFFFAOYSA-N 0.000 claims description 3
- 238000004512 die casting Methods 0.000 claims description 3
- 150000002739 metals Chemical class 0.000 claims description 3
- 229910000789 Aluminium-silicon alloy Inorganic materials 0.000 claims description 2
- 229910000640 Fe alloy Inorganic materials 0.000 claims description 2
- 229910001060 Gray iron Inorganic materials 0.000 claims description 2
- 229910001296 Malleable iron Inorganic materials 0.000 claims description 2
- 229910000861 Mg alloy Inorganic materials 0.000 claims description 2
- KMWBBMXGHHLDKL-UHFFFAOYSA-N [AlH3].[Si] Chemical compound [AlH3].[Si] KMWBBMXGHHLDKL-UHFFFAOYSA-N 0.000 claims description 2
- 229910045601 alloy Inorganic materials 0.000 claims description 2
- 239000000956 alloy Substances 0.000 claims description 2
- 238000007750 plasma spraying Methods 0.000 claims description 2
- 229910001018 Cast iron Inorganic materials 0.000 claims 1
- 239000011248 coating agent Substances 0.000 abstract description 4
- 238000000576 coating method Methods 0.000 abstract description 4
- 238000009792 diffusion process Methods 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 239000010935 stainless steel Substances 0.000 description 3
- 229910001220 stainless steel Inorganic materials 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 230000032798 delamination Effects 0.000 description 2
- 230000008021 deposition Effects 0.000 description 2
- 238000010285 flame spraying Methods 0.000 description 2
- 238000007654 immersion Methods 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 description 1
- 238000009499 grossing Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 235000000396 iron Nutrition 0.000 description 1
- 238000010409 ironing Methods 0.000 description 1
- 229910001338 liquidmetal Inorganic materials 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
- B60B3/00—Disc wheels, i.e. wheels with load-supporting disc body
- B60B3/06—Disc wheels, i.e. wheels with load-supporting disc body formed by casting
Abstract
A composite aluminium coated article, resistant to separation, is made by coating a metal part with an intermediate layer of aluminium or an aluminium alloy by spraying at high temperature, and then an aluminium alloy is cast onto the intermediate layer. The process is used for manufacturing sheets, and semi-finished and finished products, in particular steel-aluminium composite wheels for automobiles.
Description
SPECIFICATION
Processes for the manufacture of composite materials or articles
The invention relates to processes for the manufacture of a composite material or article, resistant to separation, involving a metal part and a coating or part of aluminium alloy.
The term composite casting is taken to mean a process in which two metals-one in the solid, the other in the liquid state-are brought into contact in such a way that a diffusion zone forms between the two metals, and thus an uninterrupted metallic transition (i.e. a metallic connection) from one metal to the other is obtained.
Casting processes, in which there is mechanical clamping by the cast liquid metal onto irregularities in the surface of the solid part to give a mechanical connection, do not comply with the definition of composite casting given above.
Steel composite cast parts coated with aluminium have been used for a range of technical applications in which the better thermal conductivity of the aluminium and the higher strength of the ferrous material at elevated temperatures are exploited.
The use of intermediate aluminium or aluminium alloy layers to improve adhesion is known. For example such processes as flame spraying, vapour deposition, immersion, or roll bonding with aluminium have been employed for this purpose.
However, these known processes exhibit the following disadvantages: -In the case of immersion coating the item must be dipped into the liquid aluminium several times, i.e. the process is time and labour consuming and is not limited to specific areas as the whole of the surface of the item is coated.
-Flame spraying does not permit high production rates and requires a stoving process.
-Roll bonding is possible only in the case of simple geometrical shapes and is therefore very limited in application.
-Vapour deposition is very expensive and therefore can hardly be considered in practice.
The inventors therefore set themselves the task of developing a simple, economic process for providing an intermediate layer with high strength of adhesion, by means of which process the above-mentioned disadvantages are overcome.
This object is achieved by way of the invention in that a metal part is first coated with an intermediate layer of aluminium or an aluminium alloy by spraying at a high temperature, and then an aluminium alloy is cast onto the intermediate layer.
The intermediate layer is usefully, in terms of the invention, produced by means of arc spraying or plasma spraying. The coating metal can for example be pure aluminium (99.5%), aluminium-magnesium alloy, or aluminium-silicon alloy.
The aluminium is sprayed onto the metal part until preferably the layer is 50-200 sssm thick, more preferably 100-150 jum thick.
The metal part is preferably made of steel, grey cast iron, malleable cast iron, spherolitic iron, non-ferrous metals, aluminium, or aluminium alloy.
Preferably, after the part has been heated to a temperature of 200-300"C, an aluminium alloy is cast onto the intermediate layer using a known casting process such as permanent mould casting, low pressure casting, or pressure die casting. By pre-heating as described, the diffusion between the various metals is improved considerably.
The aluminium alloys for casting onto the intermediate layer can be aluminium-silicon, aluminium-silicon-magnesium, aluminiummagnesium, aluminium-silicon-copper, or aluminium-manganese-iron alloys.
The invention can be used in the production of simple material, e.g. sheets resistant to delamination, and also in the production of semi-finished or finished products. From the above-mentioned material combinations one can manufacture composite items which, for example because of the shape, technical requirements or economics could not, or only with great difficulty, be manufactured by means of previous mornal processes. These include, for example, stainless steel cookware with aluminium on the base, the base of smoothing irons for ironing clothes, cooker hot plates with wear-resistant stainless steel covers, automobile wheels.
The invention will now be explained in greater detail with the help of the accompanying drawings, viz.:
Figure 1. A micro-section (magnification 200 X)through a steel-aluminium composite cast piece.
Figure 2. A micro-section through the part shown in Fig. 1, but bent through an angle of 110'.
Figure 3. A schematic cross section through a composite cast steel-aluminium wheel for an automobile.
The micro-section at a magnification of 200 X in Fig. 1 shows a portion of a 0.8 mm thick 1 8/8 stainless steel sheet adjacent to one face, onto which-an approx. 100 ym thick intermediate layer of aluminium (99.5%) has been sprayed, and onto which in turn an aluminium-manganese-i ron alloy has been cast by pressure die casting. This micro-section shows the connection between the steel sheet 10 and the intermediate layer 11, and the connection between the intermediate layer 11 and the die cast aluminium alloy 1 2. The steel sheet 10 and the intermediate layer 11 are connected by means of a metallic or diffusion bond, the intermediate layer 11 and the die cast aluminium alloy by a mechanical bond and by partial melting of both layers.
The test piece was heated to 450"C and then cooled in air again twenty times without any observable change in the micro-section taking place.
The composite part shown in Fig. 2 is of the same kind as that in Fig. 1, but has been bent 1 10 in the direction of the plane of the drawing. As can be seen from Fig. 2, no delamination has taken place, and there are no cracks to be seen. Fig. 2 shows that no brittle zone has formed between the steel sheet 10 and the intermediate layer 11, such as may occur-with other processes, with the result that the bonding is good.
Fig. 3 shows a steel rim 14 of a wheel, coated partly with a layer 1 5 applied by spraying at high temperature. The inner part 1 3 of the wheel has been pressure die cast onto this intermediate layer 1 5.
Claims (8)
1. A process for the manufacture of a composite material or article, resistant to separation, in which a metal part is first coated with an intermediate layer of aluminium or an aluminium alloy by spraying at high temperature, and then an aluminium alloy is cast onto the intermediate layer.
2. A process according to claim 1, in which the metal part is of steel, grey cast iron, malleable cast iron, spherolitic cast iron, nonferrous metals, aluminium or aluminium alloy.
3. A process according to claim 1 or claim 2, in which the intermediate layer is of pure aluminium (99.5%), aluminium-magnesium alloy, or aluminium-silicon alloys, deposited by arc spraying or plasma spraying.
4. A process according to claim 3, in which the intermediate layer is 500-200 ym thick.
5. A process according to any of claims 1 to 4, in which the metal part provided with the intermediate layer is heated to a temperature of 200-300"C, before the aluminium alloy is cast on.
6. A process according to any of claims 1 to 5, in which the alloy cast on is an aluminium-silicon, aluminium-silicon-magnesium, aluminium-magnesium, aluminium-silicon-copper, or aluminium-manganese-iron alloy.
7. A process according to any of claims 1 to 6, in which the casting of the aluminium alloy onto the intermediate layer takes place by means of permanent mould casting, low pressure casting, or pressure die casting.
8. Production of steel-aluminium composite wheels for automobiles, by a process according to any of claims 1 to 7.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CH651078A CH632437A5 (en) | 1978-06-15 | 1978-06-15 | METHOD FOR PRODUCING A COMPOSITE. |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| GB2023665A true GB2023665A (en) | 1980-01-03 |
Family
ID=4310744
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB7920510A Withdrawn GB2023665A (en) | 1978-06-15 | 1979-06-13 | The manufacture of composite aluminium coated articles |
Country Status (10)
| Country | Link |
|---|---|
| BE (1) | BE876981A (en) |
| BR (1) | BR7903779A (en) |
| CH (1) | CH632437A5 (en) |
| DE (1) | DE2841446C2 (en) |
| ES (1) | ES8100355A1 (en) |
| FR (1) | FR2428495A1 (en) |
| GB (1) | GB2023665A (en) |
| IT (1) | IT1121797B (en) |
| SE (1) | SE7905255L (en) |
| YU (1) | YU140879A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11203807B2 (en) | 2016-11-24 | 2021-12-21 | Universität Siegen | Coating for a carrier material, core part for producing a composite part, composite part, and method for producing a composite part |
Families Citing this family (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE19745725A1 (en) * | 1997-06-24 | 1999-01-07 | Ks Aluminium Technologie Ag | Method of making a composite casting |
| DE19736790A1 (en) * | 1997-08-23 | 1999-02-25 | Honsel Gusprodukte Gmbh | Compound casting process |
| DE19746167A1 (en) * | 1997-10-18 | 1999-04-22 | Volkswagen Ag | Cast light metal component with insert incorporated during casting |
| DE19750687A1 (en) * | 1997-11-15 | 1999-05-20 | Ks Aluminium Technologie Ag | Method for casting in inserted parts |
| DE10324279B4 (en) | 2003-05-28 | 2006-04-06 | Daimlerchrysler Ag | Use of FeC alloy to renew the surface of cylinder liners |
| DE102006043855B4 (en) * | 2006-09-19 | 2010-05-20 | Audi Ag | Composite casting and method of making a composite casting |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE760193C (en) * | 1940-02-06 | 1953-06-15 | Bayerische Motoren Werke Ag | Process for the production of bodies composed of steel and light metal |
| CH426440A (en) * | 1963-10-04 | 1966-12-15 | S W Farber Inc | A method of manufacturing an article consisting of a sheet of a first metal assembled with a sheet of a second metal |
| US3484137A (en) * | 1968-01-25 | 1969-12-16 | Shelby Parts Co Inc | Composite non-ferrous wheel having a steel rim and method of making the same |
| DE2207771A1 (en) * | 1972-02-18 | 1973-08-23 | Thurner Bayer Druckguss | Steel bushed magnesium wheel - with aluminium separation between the two materials |
| DE2745163C2 (en) * | 1977-10-07 | 1984-11-22 | Aluminium-Walzwerke Singen Gmbh, 7700 Singen | Method for manufacturing a wheel for air or gas-filled tires of motor vehicles |
-
1978
- 1978-06-15 CH CH651078A patent/CH632437A5/en not_active IP Right Cessation
- 1978-09-23 DE DE2841446A patent/DE2841446C2/en not_active Expired
-
1979
- 1979-06-08 ES ES481399A patent/ES8100355A1/en not_active Expired
- 1979-06-13 GB GB7920510A patent/GB2023665A/en not_active Withdrawn
- 1979-06-13 IT IT23538/79A patent/IT1121797B/en active
- 1979-06-13 BR BR7903779A patent/BR7903779A/en unknown
- 1979-06-14 FR FR7915302A patent/FR2428495A1/en not_active Withdrawn
- 1979-06-14 SE SE7905255A patent/SE7905255L/en not_active Application Discontinuation
- 1979-06-14 YU YU01408/79A patent/YU140879A/en unknown
- 1979-06-14 BE BE0/195737A patent/BE876981A/en unknown
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11203807B2 (en) | 2016-11-24 | 2021-12-21 | Universität Siegen | Coating for a carrier material, core part for producing a composite part, composite part, and method for producing a composite part |
Also Published As
| Publication number | Publication date |
|---|---|
| ES481399A0 (en) | 1980-11-01 |
| ES8100355A1 (en) | 1980-11-01 |
| IT1121797B (en) | 1986-04-23 |
| YU140879A (en) | 1983-01-21 |
| CH632437A5 (en) | 1982-10-15 |
| BR7903779A (en) | 1980-02-05 |
| IT7923538A0 (en) | 1979-06-13 |
| DE2841446C2 (en) | 1982-08-19 |
| BE876981A (en) | 1979-10-01 |
| FR2428495A1 (en) | 1980-01-11 |
| DE2841446A1 (en) | 1979-12-20 |
| SE7905255L (en) | 1979-12-16 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |