KR101864788B1 - Aluminum alloy for die casting and cast - Google Patents
Aluminum alloy for die casting and cast Download PDFInfo
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- KR101864788B1 KR101864788B1 KR1020180012406A KR20180012406A KR101864788B1 KR 101864788 B1 KR101864788 B1 KR 101864788B1 KR 1020180012406 A KR1020180012406 A KR 1020180012406A KR 20180012406 A KR20180012406 A KR 20180012406A KR 101864788 B1 KR101864788 B1 KR 101864788B1
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/02—Alloys based on aluminium with silicon as the next major constituent
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
- C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
Abstract
Description
The present invention relates to an aluminum alloy, and more particularly to an aluminum alloy for general casting and die casting for high strength aluminum with high corrosion resistance.
In general, aluminum is not only excellent in formability but light weight, and can be adjusted in strength through various alloy compositions, and is used in various fields as a lightweight metal material. Such aluminum has recently replaced cast iron castings or nonferrous metals such as copper and zinc with the development of casting technology and cast alloy. In particular, die casting, which is a high-speed high-pressure casting with high pressure, is most suitable for making automobile parts because it provides strength, dimensional accuracy and high-speed productivity over ordinary cast iron even when using the same aluminum casting alloy. Therefore, in recent years, various metal parts of automobile parts have been replaced by aluminum products for automobiles due to weight reduction, improvement of fuel efficiency and improvement of automobile performance. In particular, most of the castings in automotive parts are being replaced by die casting products.
These aluminum alloys for die casting are standardized to various international standards (KS, JIS, ASTM, ISO) including various countries in Korea. In the case of the ADC10 / 12 alloy, the addition of Cu improves the mechanical properties and is most widely used due to excellent castability and machinability, and is widely used in various fields as an inexpensive recycled material. Thus, the ADC10 / 12 alloy accounts for more than 90% of the total aluminum alloy usage.
However, the ADC10 / 12 alloy is becoming more and more harsh in automobile operating environments, and in electric and electronic high-precision complementary parts such as new electric cars and environment-friendly cars, damage due to lack of durability, It shows limitations of use due to corrosion due to new operating environment or generation of white rust peculiar to aluminum. In addition, in order to meet the exhaust gas regulation standards through the improvement of fuel efficiency, we have developed a new alloy for aluminum casting with superior mechanical properties and casting moldability along with the development of a new method to reduce the weight of automobile parts. However, Of the total population.
Among the conventional cast alloys, alloys excellent in corrosion resistance are mainly Al-Mg alloys and pure Al alloys. However, these alloys are excellent in corrosion resistance, but have poor castability, and many casting defects occur, and it is very difficult to produce stable castings, so that the mass production is low and they are not put into practical use (Refer to KS D6006 aluminum die casting Table 1 Alloy type and characteristics )
The present invention has been made to solve the above-mentioned problems, and it is an object of the present invention to provide an aluminum alloy which can maintain or enhance the mechanical strength and corrosion resistance of the aluminum alloy by optimizing the composition and composition ratio, The present invention has been made in view of the above problems.
In particular, it is an object of the present invention to provide a casting and die-casting aluminum alloy capable of improving lightweight and suppressing the occurrence of a back-burning phenomenon to the maximum.
In order to achieve the above object, the casting and die casting alloy of the present invention comprises aluminum (Al) as a main component, a balance amount of magnesium (Mg) of 3.6 to 7.8% by weight, silicon (Si) of 3.0 to 7.0% Mn) of 0.5 to 2.0% by weight, and Mg / Si of 1.0 to 2.0.
The present invention is characterized in that the Al-Mg 2 Si-based process structure is within 30% -80%.
The present invention is characterized by having a yield strength of 120 MPa or more and a tensile strength of 180 MPa or more.
The present invention is characterized in that the tensile strength is 190 MPa or more at an elongation of 2% to 4%.
The present invention has a yield strength and tensile strength of 120 MPa or more and 200 MPa or more in general casting, and yield strength and tensile strength in diecasting are 180 MPa or more and 270 MPa or more.
The present invention is characterized in that Al-Mg 2 Si process structure, which is a main strengthening phase, is dispersed and distributed between the aluminum resin phases, and AlSiMn intermetallic compound particles are distributed together.
The present invention is characterized in that the size of the Mg 2 Si and AlSiMn particles is 1 to 5 μm.
The present invention as described above can be applied to an aluminum alloy in which additives such as existing Cu and Fe are not mixed with the compositional components of aluminum alloys and magnesium, silicon and manganese are mixed with aluminum in order to maintain the strength, corrosion resistance, It is possible to provide an aluminum alloy for casting and die casting which has high strength, high corrosion resistance and high composition, and light weight.
Particularly, it is possible to provide an aluminum alloy for casting and die casting that can reduce weight and cost and can minimize occurrence of white rust because the conventional additives such as Cu and Fe are omitted.
Therefore, it is possible to provide a metal product or an aluminum alloy for automobile parts which is improved in corrosion resistance, light weight and mechanical strength compared with existing cast alloy as a material of a harsh environment or a new automobile part. In addition, It is possible to provide a structural metal product or an aluminum alloy for automobile security parts which can be reduced in cost and durability.
In addition, it is possible to improve the productivity by reducing the casting defects and defects through high corrosion resistance, high strength and excellent casting, and further improve the corrosion resistance of the casting or die casting parts by at least 500% It is possible to provide an aluminum alloy for casting and die casting which can improve the strength by at least 10% or more.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a photograph showing a comparison between a quasi-binary system structure of a conventional commercial alloy and a microstructure of an aluminum alloy according to an embodiment of the present invention.
Figure 2 is a photograph of a cast specimen for testing castability and mechanical properties of alloys of the invention and other alloys.
3 is a table showing test results of a cast alloy according to an embodiment of the present invention.
Fig. 4 is a table showing the fluidity and corrosion resistance of the alloy shown in Fig. 3. Fig.
5 is a table showing test results of a die casting alloy according to an embodiment of the present invention.
6 is a table showing the corrosion resistance of the alloy shown in Fig.
Hereinafter, an aluminum alloy for casting and die casting according to an embodiment of the present invention will be described.
The aluminum alloy for casting and die casting according to the embodiment of the present invention is made of magnesium, an additive made of silicon and manganese, and aluminum to which such additive is added. That is, the aluminum alloy of the embodiment is composed of aluminum and a residual additive which constitute the main component. Such an aluminum alloy is composed of 3.6 to 7.8 wt% of magnesium (Mg), 3.0 to 7.0 wt% of silicon (Si), 0.5 to 2.0 wt% of manganese (Mn), and the balance aluminum.
Magnesium (Mg) is added for high strength, high corrosion resistance and high alloy composition. Such magnesium is not added amount in this case 3.6% by weight is below, to obtain a level of the amount of the Al-Mg 2 Si based process desired when Si is added in the amount of shortage of the generated possible Al-Mg 2 Si based process, and thus high strength, high corrosion-resistant The desired physical properties can not be obtained because the number of cats in the process of implementing the main composition is reduced. When the added amount of magnesium exceeds 7.8% by weight, the amount of Al-Mg 2 Si-based process increases, and the process is structured in the sub-process, and problems of coarsening and hot crack generation of brittle Mg 2 Si compound occur, The mechanical properties are deteriorated. Therefore, magnesium is preferably composed of 3.6 to 7.8% by weight as described above.
Silicon (Si) is added for casting. When the addition amount is less than 3.0 wt%, the effect of improving the casting composition is insignificant. When the addition amount is more than 7.0 wt%, Mg 2 Si particles as main reinforcing particles are excessively produced, and the corrosion resistance and casting defects are increased, Is lowered. Therefore, it is preferable that silicon is composed of 3.0 to 7.0% by weight.
Manganese (Mn) is added to prevent the mold from sticking. When the amount of manganese added is less than 0.5 wt%, the effect of preventing the occurrence of sintering is insignificant. When the amount of manganese is more than 2.0 wt%, coarse rod-shaped intermetallic compounds are produced and the strength is lowered. Therefore, manganese is preferably composed of 0.5 to 2.0% by weight.
Here, it is preferable that the above-mentioned magnesia and silicon are mixed with aluminum at the time of adding Mn and mixed with a Mg / Si ratio of 1.0 to 2.0 so that desired physical properties (strength and corrosion resistance) and structure are realized. If the ratio of Mg / Si is less than 1.0, the size of Si produced by itself becomes too large to expect a desired quality. If the ratio of Mg / Si exceeds 2.0, not only the primary Mg 2 Si is generated but also excessive process tissue So that it is difficult to expect the strength or casting to be described later. Therefore, it is preferable that the Mg / Si ratio is configured as described above.
Unlike the conventional alloy, the aluminum alloy according to the embodiment of the present invention does not contain Cu, Fe, or Zn for improving strength or castability. The aluminum alloy according to the embodiment of the present invention can be produced by the above-mentioned conventional additives without any additives, as described below by the composition components and the mixing ratios described above, the Al-Mg 2 Si quasi- An alloy having a texture could be obtained. Accordingly, the aluminum alloy according to the embodiment of the present invention provides an alloy which is improved compared to conventional commercial alloys, that is, compared to the alloy for current die casting parts, light weight, high strength, high corrosion resistance and castability without adding the conventional additives I could.
Meanwhile, FIG. 1 is a photograph comparing the microstructure of the conventional commercial alloy with the microstructure of the aluminum alloy according to the embodiment of the present invention. As shown in FIG. (Shown as "Comparative") Comparative Example 1, a conventional alloy is a part of the aluminum base, Al-Mg-Cu finely process the intermetallic compound Mg 2 Si particles distributed Al-Mg 2 Si It is close to process organization. On the other hand, the alloy according to the embodiment of the present invention is superior to the conventional quasicrystal process structure in that it is made of dendrites of primary Al (white) as shown in the embodiment of Fig. 1 And a process Al-Mg 2 Si (black) structure in the shape of a reinforcing merchandiser. This process is dispersed and distributed in the form of Mg 2 Si plate-like particles (black) of 1-5 μm thickness (size) between the aluminum resin assumptions. In addition, AlSiMn intermetallic compounds in the form of a dark color particle are formed in the size of 1-3 mu m in the interior of the aluminum resin assumption and distributed together. When the size of the particles exceeds 5 mu m, it is difficult to produce an alloy having a tensile strength of 250 MPa and a yield strength of 160 MPa or more as a target in the present invention. When the size of the Mg 2 Si particles is less than 1 mu m, It is difficult to achieve desired physical properties and moldability as well as difficulty in actual production.
The above results show that the use of an alloy amount (eg, Cu, Fe, Zn, etc.) for excessive Mg alloy amount and strength enhancement is minimized by mixing appropriate alloying elements such as Si and Mn at an optimum mixing ratio in addition to Mg To thereby obtain a casting structure effectively satisfying the strength, castability and corrosion resistance. This is the biggest difference from the existing technology using Al-Mg binary industrial aluminum casting alloy (ALDC5), Al-Mg 2 Si process and precursor Mg 2 Si.
Here, the structure of the Al-Mg 2 Si process according to the embodiment of the present invention described above is present in the range of about 30-80% with respect to the resin assumption of the preliminary Al as shown in FIG. That is, the alloy according to the embodiment of the present invention has a ratio of the structure of the Al-Mg 2 Si process to the assumption of the primary Al-resin is 1: 0.3 to 0.8. In the Al-Mg 2 Si process, when the composition is less than 0.3 times as high as that of the superalloy Al resin, the amount of Mg 2 Si, which is the strengthening phase, is insufficient and the strength is low. And when it exceeds 0.8 times, the processability of brittleness is increased, so that ductility is decreased and tensile strength is lowered. Particularly, when the ratio exceeds 1, a primary crystal Mg 2 Si phase is formed, resulting in an increase in brittleness due to a coarse particle shape of polygonal shape, and also an elongation ratio of 1% or less and a problem of lowering tensile strength. Therefore, it is preferable that the Al-Mg2Si process structure is constituted in the above-mentioned ratio.
The Al-Mg 2 Si process structure can control the above-mentioned ratio by controlling the composition range of the alloy and the Mg / Si mixture ratio in the range of 1-2.
On the other hand, the aluminum alloy of the present invention can be manufactured by a die casting method for producing a high-precision casting product as well as a general die casting method. As a result, it is possible to prevent the risk of corrosive tissues such as Cu and Fe, which deteriorates the corrosion resistance, while having excellent castability and strength in the production of the alloy (ACD10 / 12) used in the conventional die casting products, Compared with the die casting alloy (ADC5), it has excellent flowability and castability and improves filling defects due to casting degradation, hot cracking, and casting defects caused by shrinkage voids. That is, the aluminum casting alloy of the present invention can manufacture cast products with higher functionality and higher strength while utilizing the conventional die casting or die casting process. This can solve the problem of lack of strength and backlash which existing aluminum casting products and die casting parts have.
Figure 2 is a photograph of a cast specimen for testing castability and mechanical properties of alloys of the invention and other alloys. The specimen shown in (a) is cast as a die casting specimen with a thickness of 6 mm and tested for general casting characteristics. The specimen shown in (b) is cast as a rod-like tensile specimen in which the mechanical properties can be examined as a die casting specimen, and the mechanical properties of each alloy are tested. The specimen shown in (c) was cast as an alloy according to an embodiment of the present invention as a general die casting specimen to test castability and corrosion resistance.
For the test of the aluminum alloy according to the embodiment of the present invention, four alloys having the composition shown in the table of Fig. 3 were prepared. Comparative Example 1 was made of a general commercial diecasting alloy ADC12 component, and Comparative Example 2 was made of a conventional alloy. Examples 1 and 2 were made from the alloy of the composition range according to the embodiment of the present invention. That is, Comparative Examples 1 and 2 were made of a conventional alloy to which additives such as Cu, Fe, or Zn were added, and Examples 1 and 2 were made of alloys without the additives described above.
First, the casting specimens were manufactured by die casting of the plate-shaped specimen shown in Fig. 2, and then the specimens were processed into plate-like tensile specimens and subjected to a tensile test. The results are shown in the table of Fig. The yield strengths of Comparative Examples 1 and 2 are higher than those of Examples 1 and 2 of 125 MPa and 132 MPa at 140 MPa and 135 MPa, respectively. This is because the amount of the alloy is larger than that of the embodiment of the invention, and the Cu component which increases the strength is included. However, the tensile strengths of Examples 1 and 2 were higher than those of Comparative Examples 1 and 2. This is because the amount of the alloy (residual component other than AL) according to the embodiment of the present invention is smaller than that of the conventional alloy, the sub-Al phase of the sub-step provides ductility and the elongation is 3-4% It is confirmed that the tensile strength is ultimately increased.
In conclusion, the embodiment according to the present invention has a lower yield strength (approximately 120-135 MPa) than the commercial ADC12 (Comparative Example 1) or the conventional alloy (Comparative Example 2) in general casting, But exhibits a tensile strength (greater than about 180-230 MPa) higher than conventional ADC12 or conventional alloys due to an elongation of 3% to 4%, thus providing performance comparable to currently used alloys. That is, the embodiment of the present invention can provide an alloy capable of replacing a general aluminum alloy due to a tensile strength of 180 MPa or more (especially 200 MPa or more) due to a yield strength of about 120 MPa or more and an elongation of 3-4%.
FIG. 4 is a table showing flow test results confirming the casting for the alloys shown in the table of FIG. 3, and test results of corrosion resistance test by spraying salt water for 48 hours, and contents relating to the tensile properties are also shown. The flow rate of the molten metal showing the main composition (see the "fluidity" in FIG. 4) was the most excellent in the conventional commercial diecasting alloy ADC12 of Comparative Example 1, while the Comparative Example 2 was somewhat reduced. On the other hand, Example 1 made of the alloy according to the present invention exhibited fluidity almost similar to that of Comparative Example 2, and Example 2 having an Si content higher than that of Example 1, which was made of the alloy according to the present invention, And showed almost fluidity to the ADC12 of Comparative Example 1. [ Therefore, the test results of FIG. 4 show that the alloy of Example 2, which was prepared with the composition according to the present invention and to which no additive such as Cu, Fe, or Zn was added, It can be seen that it provides almost the same fluidity as in Example 1, and that the tensile strength is strengthened rather than Comparative Example 1. It can be seen that Example 1 produced with the composition according to the present invention has somewhat lower fluidity than Example 2 but has a rather excellent tensile strength. As a result, it was confirmed that the present invention can provide a product similar to or better than the most widely used aluminum alloy in the case of producing the product as in Example 2.
On the other hand, as shown in FIG. 4, the corrosion resistance of the conventional ADC12 alloy of Comparative Example 1 was insufficient, and aluminum corrosion, that is, white rust was largely occurred. On the other hand, in Comparative Example 2, which was made of a conventional corrosion-resistant alloy, the corrosion resistance was greatly reduced as compared with Comparative Example 1, but a thin white rust was formed on the entire surface. Particularly, And corrosion resistance is limited.
On the other hand, Examples 1 and 2 made of the alloy according to the present invention maintain a very stable casting surface shape and show excellent corrosion resistance. The corrosion rate of aluminum whiteness, that is, the occurrence of white rust, was about 90% at the depth of the whitestock of about 0.2-1. Mm in the used alloy ADC12 of Comparative Example 1, and the corrosion resistance of the corrosion- , But a part of back rust of 0.1-0.3 mm depth occurred in about 30% of the total area. On the other hand, in Example 1 according to the present invention, the surface state of the casting was substantially maintained, and only about 1% or less of the total area of the white rust was generated. In Example 2, Only about 3% of the area was generated. As a result, it was confirmed that the alloy according to the embodiment of the present invention is superior to the conventional commercial alloy ADC12 in the generation of white rust by 1/30 level, and the corrosion resistance is improved by at least 500%.
On the other hand, the application of the die casting method has been greatly increased in addition to the conventional die casting, which is a representative example of the aluminum casting alloy. The inventors of the present invention fabricated the tensile specimen of FIG. 2 having the composition as shown in FIG. 5 as an alloy according to the embodiment of the present invention, and manufactured castings having the same shape as the actual product. Fig. 5 shows the tensile test results of the samples of the comparative examples and the examples cast by the tensile specimen.
As a result of the die casting test piece casting through the table of FIG. 5, Comparative Example 1 made of the commercial alloy ADC12 had a yield strength of 158 MPa, satisfying the average value of 150 MPa of the normal product of an aluminum die casting die cast material, It can be seen that casting has been cast with quality of casting. However, in Comparative Example 1, the yield strength is the lowest compared with other alloys. Comparative Example 2, which is made of the conventional invention alloy, shows a high yield strength. In Examples 3 to 5 of the present invention, the yield strength is higher than that of Comparative Example 1, which is a commercial alloy, so that the yield strength is excellent even without the above-mentioned additives.
5, the tensile strength of the commercial alloy ADC12 of Comparative Example 1 was confirmed to be 245 MPa as in the yield strength, and the tensile strength of the commercial ADC12 was satisfactory. Which is lower than Examples 3 to 5. Comparative Example 2 has a tensile strength of 285 MPa which is slightly better than Comparative Examples 1 and 3, but is weaker than Examples 4 and 5. From these results, it can be seen that the alloy according to the embodiment of the present invention is 275-320 MPa in strength, which is about 10% to 30% better than the conventional alloy (Comparative Examples 1 and 2).
In particular, when the elongation ratios are examined, the alloys of Examples 3 to 5 according to the present invention exhibit an elongation of about 2 to 4%, which is about 2 to 4 times higher than that of Comparative Examples 1 and 2 of about 1%. Accordingly, it can be seen that the embodiments according to the present invention have an increased tensile strength as a result of an increase in elongation, and thus, toughness, that is, impact resistance is superior to conventional alloys. As shown in FIG. 5, the embodiments of the present invention exhibited a tensile strength of about 300 MPa in excess of 190 MPa due to the elongation described above.
On the other hand, FIG. 6 shows a result of a salt water spray test of die cast castings (salt water is sprayed for 48 hours). Comparative Example 1 shown in FIG. 6 is a commercial alloy ADC12, Comparative Example 2 is a conventional alloy, and Example 4 is a die cast casting as shown in FIG. 2 with the embodiment alloy of FIG. As shown in the photograph of FIG. 6, the corrosion resistance of the casting mold of the present invention described above was significantly lower than that of the commercial alloy ADC12 of the comparative examples 1 and 2 and the conventional alloy, but the occurrence of aluminum corrosion, that is, The same tendency was shown to have the best corrosion resistance. However, as shown in the comparative examples and Example 4, the degree of white-on-green phenomenon was slightly reduced in the die casting as compared with the die casting material. Thus, it was found that the corrosion resistance of the same alloy was lowered in die casting than in the case of the die casting as a whole, and it was also found that the effect of suppressing the white rust of the alloy according to the present invention was also excellent in die casting.
As described above, the aluminum alloy according to the embodiment of the present invention provides excellent strength and elongation, and stable casting both in die casting and die casting. In addition, the aluminum alloy according to the embodiment of the present invention can improve strength and corrosion resistance by 10% and 500%, respectively, compared with the conventional alloy.
It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to be illustrative of the present invention and are not intended to limit the scope of the present invention. Change, partial omission, or supplement). In addition, the above-described embodiments may combine some or many of the features with each other. Therefore, the structure and configuration of each component shown in the embodiments of the present invention can be implemented by modifications or combinations, and it goes without saying that modifications and combinations of these structures and configurations fall within the scope of the appended claims of the present invention.
Claims (4)
A yield strength of 120 MPa and a tensile strength of 180 MPa or more,
Wherein the tensile strength is 190 MPa or more at an elongation of 2% to 4%.
Aluminum alloy for casting and die casting characterized in that an Al-Mg 2 Si process structure, which is a main strengthening phase, is dispersed and distributed among the aluminum resin assumptions, and AlSiMn intermetallic compound particles are distributed together.
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Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH108175A (en) * | 1996-06-26 | 1998-01-13 | Kobe Steel Ltd | Aluminum alloy excellent in machinability and its manufacture |
| KR0158803B1 (en) | 1995-12-30 | 1998-11-16 | 배순훈 | Electric pressure rice cooker |
| KR0158795B1 (en) | 1996-03-06 | 1998-11-16 | 신기석 | Method for extract of vanilla |
| US20030143101A1 (en) * | 2000-10-25 | 2003-07-31 | Nissan Motor Co., Ltd | Aluminum die casting alloy, aluminum die cast product and production process |
| US6929706B2 (en) | 2000-03-31 | 2005-08-16 | Corus Aluminium Voerde Gmbh | Aluminum die-casting alloy |
| KR101620204B1 (en) | 2014-10-15 | 2016-05-13 | 현대자동차주식회사 | Alloy for die-casted automotive parts and manufacturing method thereof |
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- 2018-01-31 KR KR1020180012406A patent/KR101864788B1/en active IP Right Grant
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR0158803B1 (en) | 1995-12-30 | 1998-11-16 | 배순훈 | Electric pressure rice cooker |
| KR0158795B1 (en) | 1996-03-06 | 1998-11-16 | 신기석 | Method for extract of vanilla |
| JPH108175A (en) * | 1996-06-26 | 1998-01-13 | Kobe Steel Ltd | Aluminum alloy excellent in machinability and its manufacture |
| US6929706B2 (en) | 2000-03-31 | 2005-08-16 | Corus Aluminium Voerde Gmbh | Aluminum die-casting alloy |
| US20030143101A1 (en) * | 2000-10-25 | 2003-07-31 | Nissan Motor Co., Ltd | Aluminum die casting alloy, aluminum die cast product and production process |
| KR101620204B1 (en) | 2014-10-15 | 2016-05-13 | 현대자동차주식회사 | Alloy for die-casted automotive parts and manufacturing method thereof |
Non-Patent Citations (1)
| Title |
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| 문헌1 한국표준규격 KS D6006 알루미늄 다이캐스팅 |
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