GB2583482A - A casting magnesium alloy for providing improved thermal conductivity - Google Patents

A casting magnesium alloy for providing improved thermal conductivity Download PDF

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Publication number
GB2583482A
GB2583482A GB1905971.6A GB201905971A GB2583482A GB 2583482 A GB2583482 A GB 2583482A GB 201905971 A GB201905971 A GB 201905971A GB 2583482 A GB2583482 A GB 2583482A
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thermal conductivity
casting
magnesium
alloy
alloys
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GB201905971D0 (en
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Ji Shouxun
Dong Xixi
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Brunel University
Brunel University London
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Brunel University
Brunel University London
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Priority to GB1905971.6A priority Critical patent/GB2583482A/en
Publication of GB201905971D0 publication Critical patent/GB201905971D0/en
Priority to EP20727156.0A priority patent/EP3947763A1/en
Priority to PCT/EP2020/061769 priority patent/WO2020221752A1/en
Priority to US17/606,487 priority patent/US20220195564A1/en
Publication of GB2583482A publication Critical patent/GB2583482A/en
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    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C23/00Alloys based on magnesium
    • C22C23/06Alloys based on magnesium with a rare earth metal as the next major constituent
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002Castings of light metals
    • B22D21/007Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/02Casting exceedingly oxidisable non-ferrous metals, e.g. in inert atmosphere
    • B22D21/04Casting aluminium or magnesium

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

Abstract

A magnesium alloy for improved thermal conductivity with 1-5 wt.% of Lanthanum and 1 to 5 wt % of Cerium or a combination thereof, and from 0.5 wt.% to 3 wt% of Neodymium, from 0.5-3 wt % of Gadolinium or a combination thereof, and from 0.0 wt.% to 0.2 wt% of Yttrium, and up to 0.8 wt.% of Praseodymium, and up to 0.8 wt.% Manganese, and up to 1.0 wt. % Aluminium, and up to 0 8 wt.% Zinc, and up to 20ppm Beryllium, and with the balanced magnesium and inevitable impurities, preferably 1-3 wt. % La, 1-3 wt. % Ce, 0.5-1.5 wt.% Nd, 0.5-1.5 wt. % Gd, 0.1-0.3 wt. % Mn with 20 ppm Berylium. The thermal conductivity reported is comparable to aluminium alloys at 105-120 W/m K at 20 degrees Celsius.

Description

A casting magnesium alloy for providing improved thermal conductivity The invention relates to a casting magnesium alloy, in particular the die-casting magnesium alloy that can provide the significantly improved thermal conductivity in comparison with the commonly used AZ91D (Mg-9wt.10A1-1wt.%Zn) die-casting magnesium alloy. The typical thermal conductivity of the alloys of the present invention is at a level of 110 W/m.K (that is, Watts per metre-Kelvin) under as-cast condition and room temperature ( about 20°C), which is close to the thermal conductivity of the commonly used A380 (A1-9wt.%Si-3wt.%Cu) die-casting aluminium alloy.
In competing with aluminium alloys as structural materials, magnesium alloys have advantages of low density, high strength ratio, and better electromagnetic shielding properties and castability. These result in the preferential applications of magnesium alloys in the components where the lightweight and electromagnetic shielding is critical.
However, the currently used magnesium alloys have inferior thermal conductivity in comparison with its competitive materials of aluminium alloys. For examples, the thermal conductivity of pure magnesium is 156 W/m* K at 25°C, but that of pure aluminium is 205 W/m*K at 25°C. Similarly, the most commonly used die-casting alloys show significant differences in the thermal conductivity. The commonly used AZ91D die-casting magnesium alloy has the thermal conductivity of 51 W/m*K at 20°C, and the commonly used A380 die-casting aluminium alloy has the thermal conductivity of 108 W/m-K at 20°C. Therefore, the ratio of thermal conductivity is 0.76 between pure Mg and Al but is 0.47 between AZ91D and A380.
Although the thermal conductivity of a component having the same weight is similar for aluminium and magnesium, the thermal conductivity for AZ91D magnesium components is about half that of comparable A380 aluminium components. Therefore, it is desirable to produce magnesium alloys having improved thermal conductivity.
High thermal conductivity is desirable for increasing the capacity of heat exchange and heat sink of engineering components. Improved thermal conductivity can reduce the working temperatures of final products and therefore increase the energy efficiency and product life.
This is particularly important when combined with the advantages of magnesium alloys, namely their low density, electromagnetic shielding properties and castability.
In general, the addition of solute elements into pure magnesium reduces the thermal conductivity, although alloying is in many instances essential in order that the pure metals can be useful in engineering. Therefore, it is a favoured method to use alloying elements to improve the thermal conductivity of magnesium alloys. Prior attempts to provide improved thermal conductivity of magnesium alloys using different alloying elements at different levels have been disclosed and a number of these disclosures are set out in Table 1 below, in which the alloys include casting alloys and wrought alloys.
Table 1
Patent No Composition (wt.%) (balanced with Mg) Thermal conductivity (W/m.K) CN101113502A 2.5-11 Zn, 0.15-1.5 Zr, 0.1-2.5 Ag, 0.3-3.5 Ce, 0-1.5 Nd, 0-2.5 La, 0-0.5 Pr (casting alloys) >120 at 20°C CN101113504A 1.5-10Ag, 0.15-2.0 Zr, 0.3-3.5Ce, 0-1.5Nd, 0-2.5La, 0-0.5Pr (casting alloys) or, >120 at,,, LO u CN101113503A 1.5-11Zn, 0.5-5 Cu, 0.15-1 Mn, 0.1-2.5Ag (casting alloys) >120 at 20°C CN104032195A 0.1-0.8, 0.1-0.6 Ca, 0.1-0.6Mn, 0.05-0.4 La (wrought alloys) >125 at am ien b. t CN104046868A 0.5-2.0Mn, 0.3-1.5 Ca, 0.3-1.0 Al (wrought alloys) >125 at ambient CN104046867A 0.5-3.0 Zn, 0.2-0.6 Zr, 0.2-1.0 Ca, 0.1-0.5Mn >120 at ambient CN102251161A 0.5-5.5Zn, 0.2-5 Sn (casting alloys) >110 at ambient CN101709418A 1.0-6.5 Zn, 0.2-2.5Si (casting alloys) >120 at ambient CN104152769A 0.8-3.0Zn, 0.25-0.48Mn, 0.05-1.0Ce, impurities <0.15 (casting alloys) >130 at ambient CN102719716A 0.1-3 Zn, 0.1-3 Ca, 0.1-3 La, 0.1-3 Ce (casting alloys) >125 at ambient US20090068053 3-9 Al, 3.5-9 Zn, 0.15-1 Mn, 0.01-2 Sb, 0-2 (Re, Ca, Si) (casting alloys) >140 at ambient JP2012197490 1.5-4.3 Zn, 0.3 -2 Si, 0.1-0.5 Mn (casting alloys) CN102560210A 0.2-5Sn, 0.5-2Ca, 0.5-5Zn, 0.2-1Zr (casting alloys) >120 at 25°C US3094413 0.1-0.7Zr, 0.1-10A1, 0.1-10Sn, 0.1-5Si, 0.1-2Ni, 0.1-2Co, 0.1-2Sb, 0.01-0.1Fe, 0.005-0.03Be, 0.5-2Mn -The technical routes of the prior arts can be described as (1) using the currently available magnesium alloys as thermal conductive alloys, which include Mg-Si-Zn based alloys; (2) modifying the existing magnesium alloys with special elements at low levels, which include alkaline earth metals and rare earth (Re) elements; (3) developing new alloys, such Mg-Sn-Zn-Zr based alloys.
However, the existing research in the field of high thermal conductive casting magnesium alloys has the following problems: (1) in casting alloys, the magnesium alloys contain high solute contents cannot provide sufficient thermal conductivity such as the commonly used AZ91 D alloy, more particularly, are not capable of competing with its aluminium alloy counterparts; (2) in wrought alloys, low level solutes are used. Therefore, the alloy can provide better thermal conductivity than casting alloys. However, the current market share of wrought magnesium alloys is less than 5%; (3) the contradiction between the thermal conductivity and castability of the alloy is a serious problem for the development of thermal conductive magnesium alloys. The castability is often not sufficiently good for the new magnesium alloys that have better thermal conductivity in comparison with the popular AZ91D alloy; (4) precious metals such as Ag are used, thus increasing the materials cost, limiting the material source and making the alloys difficult to popularize and put into civil use; (5) heat treatment of the alloy is usually employed, which increases the energy consumption during manufacturing.
In addition, it has been discovered that many of the prior art alloys shown in Table 1 have at least some of the following disadvantages: * they are not suitable for high pressure diecasting (HPDC) because the alloy is more likely to stick to the mould * also HPDC results in defects in the alloy * they are unlikely to have a good thermal conductivity at higher temperatures that ambient (for example over 150°C) The present invention intends to provide a casting magnesium alloy for significantly improved thermal conductivity in comparison with the commonly used commercial AZ91D alloy. In particular, the claimed alloy can provide the thermal conductivity at a level that A380 Aluminium alloy can. Moreover, the claimed alloy provides good castability and works well under as-cast condition with excellent mechanical properties. In accordance with the advantages of the present invention, there is provided a magnesium alloy for providing improved thermal conductivity more than 100 W/m.K including: a. from 1 wt.% to 5 wt.% of a first lanthanide (preferably lanthanum), from 1 wt.% to 5 wt.% of a second lanthanide (preferably cerium) or a combination thereof, wherein the first and second lanthanide is the same of different, and b. from 0.5 wt.% to 3 wt.% of Neodymium, from 0.5 wt.% to 3 wt.% of Gadolinium or a combination thereof, and c. from 0.0 wt.% to 0.2 wt.% of Yttrium, and d. from 0.0 wt.% to 0.8 wt.% of Praseodymium, and e. up to 0.8 wt.% Manganese (with the amount of manganese being non-zero), and f up to 1.0 wt.% Aluminium (with the amount of aluminium being non-zero), and g. up to 0.8 wt.% Zinc (with the amount of zinc being non-zero), and h. from 0 to 2Oppm beryllium, and i. with balanced magnesium and inevitable impurities.
Preferably, the magnesium alloy contains: * one or more elements that is more reactive with aluminium than magnesium in the alloy melt during solidification and therefore forming eutectic phase without destroy the continuity of a-Mg phase in the matrix to reduce the solute concentration in the primary a-Mg phase * an appropriate amount of manganese to neutralise impurities and improve die releasing capability * and a small amount of beryllium and/or other elements to protect the oxidation during casting operation In a preferred embodiment, there is provided a casting magnesium alloy material for providing significantly improved thermal conductivity under as-cast condition comprising at least two elements from rare earth elements, each is at a level of more than I wt.% and less than 5wt.%, one of which is used to provide the improvement of castability and the other one is used to provide strengthening of the alloy. The alloy is capable of providing a thermal conductivity at a level of 110W/ m-K under as-cast condition and room temperature (20°C). Without wishing to be constrained by theory, it is believed that the improved thermal conductivity available with the invention, particularly in combination with good casting characteristics results from the combination of Mg with Re within the given ranges because Re in the alloy can reduce the liquidus temperature and improve the castability. Accordingly, the method used in this patent is that to use Re solute elements to improve the castability. In the meantime, some of the Re elements have high solubility in Mg matrix and capable of providing materials strengthening.
Although the rare earth elements can be any in the Lanthanoids, it is preferred to have La and Ce or any other low-cost rare-earth elements. Therefore, the elements such as Nd and Gd should be added in a controlled amount in the alloy. More importantly, La or Ce can be obtained from recycled materials, which is an effective way to reduce the alloy cost. The elements used in the present invention can be replaced by other elements that promote the formation of intermetallic phases easier than Mg-Al phase in the Mg matrix.
Another element in the alloy is required to have a high solubility in the primary a-Mg phase at elevated temperatures close to its eutectic solidification but has very low solubility at ambient temperature. The element can improve the castability and mechanical properties of the magnesium alloy, and it promotes the formation of precipitates in the primary a-Mg phase after solidification, which can provide effective strengthening in the alloy and reduce the solute concentration in the primary a-Mg phase More importantly, this can reduce the solute content in the primary a-Mg phase to improve the thermal conductivity.
The maximum solid solubility for alloying elements in magnesium have been reported (at.%) as Ag (3.8), A1(11.6), Ca(0.8), Ce (0.1), Cu (0.15), Gd (4.5), In (19.4), La (0.1), Li (18), Mn (1.0), Nd (0.1), Si (0.003), Sn(3.35), Sr (0), Tb (4.6), Th (0.52), Y (3.35), Zn (2.4), Zr (1.0), Zn(2.4), Tm (6.3), Sc (15), Pb(7.75), Sn (0.35), Yb (1.2), Bi (1.1), Ca (0.82), Ti (0.1) and Au (ft 1). Therefore, the options are apparent for the element that has very low solubility at ambient temperature. The elements including Ca, Ce, Cu, La, Nd, Sr, Th, Zr, Sn, Yb, Bi, Ca, Ti and Au can be the candidates. Clearly, the rare earth elements are one of the preferred options because of their low solubility in primary magnesium phase and the multiple functions to promote the formation of eutectic phase. The other elements including Ca, Cu, Sr, Zr, Sn, Bi, Ti and Au are good options for the alloy. All these elements should be controlled within the maximum solubility at the eutectic reaction temperature.
Manganese (Mn) is an important alloying element for all embodiments of the casting magnesium alloy according to the present invention. The role of Mn includes the neutralisation of Fe to form compact Fe-rich intermetallics, and to promote die releasing during die-casting, which allows the alloy to be die castable for massive production. For these reasons, Mn content is lower in the castings made by sand casting and other method without using a metallic mould, but higher in the casting methods using metallic mould. The Mn level is in the range of 0.1 to 0.8wt.%. A more preferred Mn level is in the range of 0.1 to 0.3%.
Beryllium (Be) is commonly added to casting magnesium alloys to prevent oxidation of the magnesium alloy. As little as up to 20ppm causes a protective beryllium oxide film to form on the surface. Preferably, as usual, the Be level is controlled to be about 20ppm.
The present invention also consists in products made from the casting magnesium alloys set out a variety of casting operations, which including the common casting methods including but not limited to sand casting, investment casting, lost foam casting, gravity and permanent mould die casting, low pressure die casting, high pressure die casting, and squeeze casting. By the present invention, the alloying elements are selected to promote the alloy not only having improved thermal conductivity, but also having good castability. Therefore, it is suitable For common castings methods, in particular in die-casting operations without soldering problems. This is a huge advantage because die-casting is dominant process for magnesium alloys. In the meantime, die-casting can make thin wall components. Therefore, the alloy is particularly suited for manufacturing products having requirements where the high conductivity and light-weighting are desirable.
In an embodiment of the casting magnesium alloy according to the invention the following levels for the alloying element are selected (all composition percentages are by weight): La 1.0-5.0 wt.%, Ce 1.0-5.0 wt %, Nd 0.5-2wt.%, Gd 0.5-1.5wt.%, Y 0-0.2wt.%, Pr <0.6wt.%, Mn 0.1-0.4 wt.%, and Al<1.0wt.%, Zn<0.8wt.%, with Be 20ppm and the balanced magnesium and inevitable impurities.
In another embodiment of the casting aluminium alloy according to the present invention of the preferred levels of the alloying element are selected: La 1.0-3.0 wt.%, Ce 1.0-3.0 wt%, Nd 0.5-1.5wt.%, Gd 0.5-1.5wt.%, Y 0-0.15vvt.%, Pr <0.5wt.%, Mn 0.1-0.3 wt.%, and Al<0.6wt.%, Zn<0.5wt.%, with Bel2ppm and the balanced magnesium and inevitable impurities.
A number of preferred embodiments of the invention will now be described with reference to the following non-limiting examples.
EXAMPLE 1
Pure magnesium ingots, Mg-5wt.%Mn master alloys and a master alloy containing the is mixture of La and Ce in magnesium were used as starting materials. Each element was weighted at a special ratio with an extra amount for burning loss during melting. During alloy making, a top loaded electrical resistant furnace was used to melt the metal in a steel crucible under protection of N2 + (0.05-0.1)vol.% SF6.
A batch of 10 kg alloy was melted at a temperature of 730 °C each time. After the melt was homogenised in the crucible, a mushroom sample with (1)60x10 mm testing part for composition analysis was made by casting melt directly into a steel mould. The casting was cut off 3mm from the bottom before performing composition analysis. The composition was analysed using an optical mass spectroscopy, in which at least five spark analyses were carried out and the average value was taken as the chemical composition of the alloy. The actual compositions of the alloy was Mg-5.5(La, Ce, Nd, Gd, Y)-0.5A1-03Zn-0.3Mn (wt.%), with Be also being present at about 2Oppm with balanced Mg.
After composition analysis, the casting samples were made by a 4500 kN cold chamber HPDC machine, in which all casting parameters were fully monitored and recorded. The pouring temperature was controlled at 700 °C, which was measured by a K-type thermocouple. The die to make standard samples for mechanical properties and thermal conductivity were made under the corresponding optimised condition. The dies were heated by the circulation of mineral oil at 250 °C. The samples for thermal conductivity were 12x20 mm round bars. The mechanical properties and thermal conductivity were measured following a standard method defined by ASTM.
A number of other samples were made in accordance with the method of Example 1 using high pressure die casting and gravity and permanent mould die casting. The thermal conductivity was tested under as-cast condition and various temperatures. The thermal conductivity at room temperature is shown in Table 2. The castability was assessed to the commercial A380 and AZ91D alloy and the value in the following Table 2 is a ratio between the filling lengths in permanent mould casting. The thermal conductivity at various elevated temperatures is shown in Figure 1.
It can be seen that the magnesium alloy samples which are not in accordance with the invention (Samples 2-4) have a lower thermal conductivity than the reference aluminium alloy (Sample 1). However, the magnesium alloy samples which are in accordance with the invention (Samples 5-8) have a comparable thermal conductivity to Sample 1.
Table 2
Sample Alloy composition (wt. %)* Thermal conductivity (20°C, W/m*K) Castability (ratio value) 1 A1-9Si-3Cu-1Fe (A380**) 110 100 2 Mg-9A1-1Zn-0.2Mn (AZ91 D**) 50 95 3 Mg-4A1-3.5Re-0.25Mn-0.2Zn (AE44**) 82 80 4 Mg-3.5A1-4Re-0.3NIn-0.2Zn (AE44**) 85 85 Mg-1.5La-1.1Ce-0.9Nd-1.6Gd-0.1Y0.2Zn-0.5A1-0.3Mn 110 95 6 Mg-1.1La-1.8Ce-1.2Nd-1.5Gd-0.1Y0.3Zn-0.6A1-0.2Mn 107 90 7 Mg-1.6La-1.2Ce-1.0Nd-1.0Gd-0.1Y-90 0.2Zn-0.4A1-0.1Mn 8 Mg-2.1La-1.3Ce-0.8Nd-1.2Gd-0.1Y-108 90 0.2Zn-0.5A1-0.3Mn * Be also present in amounts of up to 20ppm ** Commercially available alloys All optional and preferred features and modifications of the described embodiments and dependent claims are usable in all aspects of the invention taught herein. Furthermore, the individual features of the dependent claims, as well as all optional and preferred features and modifications of the described embodiments are combinable and interchangeable with one another.

Claims (3)

  1. Claims 1. A magnesium alloy including: a. from 1 wt.% to 5 wt.% of lanthanum, from 1 wt.% to 5 wt.% of cerium or a combination thereof, and b. from 0.5 wt.% to 3 wt.% of Neodymium, from 0.5 wt.% to 3 wt.% of Gadolinium or a combination thereof, and c. from 0.0 wt.% to 0.2 wt.% of Yttrium, and d. from 0.0 wt.% to 0.8 wt.% of Praseodymium, and e. up to 0.8 wt.% Manganese, and f up to 1.0 wt.% Aluminium, and g. up to 0.8 wt.% Zinc, and h. from 0 to 20ppm beryllium, and i. with the balance being magnesium and inevitable impurities.
  2. 2. A magnesium alloy as claimed in claim I including: La 1.0-5.0 wt.%, Ce 1.0-5.0 wt.%, Nd 0.5-2wt.%, Gd 0.5-1.5wt.%, Y 0.0-0.2wt.%, Pr <0.6wt.%, Mn 0.1-0.4 wt.%, and Al<0.8wt.%, Zn<0.8wt.%, with Be 2Oppm with the balance being magnesium and inevitable impurities.
  3. 3. A magnesium alloy for providing improved thermal conductivity as claimed in claims land 2 more preferably including: La 1.0-3.0 wt.%, Ce 1.0-3.0 wt.%, Nd 0.5-1.5wt.%, Gd 0.5-1.5wt.%, Y 0.0-0.15wt.°710, Pr <0.5wt.%, Mn 0.1-0.3 wt.%, and Al<0.6wt.%, Zn<0.5wt.%, with Be 20ppm with the balance being magnesium and inevitable impurities.
GB1905971.6A 2019-04-29 2019-04-29 A casting magnesium alloy for providing improved thermal conductivity Withdrawn GB2583482A (en)

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GB1905971.6A GB2583482A (en) 2019-04-29 2019-04-29 A casting magnesium alloy for providing improved thermal conductivity
EP20727156.0A EP3947763A1 (en) 2019-04-29 2020-04-28 A casting magnesium alloy for providing improved thermal conductivity
PCT/EP2020/061769 WO2020221752A1 (en) 2019-04-29 2020-04-28 A casting magnesium alloy for providing improved thermal conductivity
US17/606,487 US20220195564A1 (en) 2019-04-29 2020-04-28 A casting magnesium alloy for providing improved thermal conductivity

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CN113444947B (en) * 2021-07-15 2023-02-28 重庆大学 Heat-resistant magnesium alloy with high electromagnetic shielding performance and preparation method thereof

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