1229699 玖、發明說明 (發明說明應敘明：發明所屬之技術領域、先前技術、內容、實施方式及圖式簡單說明） 一、發明所屬之技術領域 本發明係有關壓鑄用鋁合金，特別是關於一種壓鑄極 薄件用之鋁合金。 二、先前技術 近年來3 C產業發展迅速，其中筆記型電腦、數位相 機及通訊手機等之機殼，皆要求輕、薄及防電磁輻射之特 性，為此乃廣泛使用鎂合金及鋁合金經高壓壓鑄作成成型 件。而這兩年來的趨勢則是大量走向鎂合金，乃因其相同 厚度之禱件比銘合金者要輕約3〇%。另一因素是現有世界 各國鋁合金成份之流動性均較有限，即使在高壓壓鑄下亦 難做到W以下的厚度，無法滿足-些機殼要求，如筆記 型電腦之機殼鑄件。 目前鎖合金雖是這方面應用的主&，但使用鎮合金有 以下諸多缺點及代價： 1.鎂合金原料價格每公斤較鋁合金稍貴。 2·鎂合金鑄件料頭等廢料（約為成品重量1.5_2倍）由 於雜質（如鐵、錄、銅、碎）含量的提高及氧化物加报 難在廠内回收再嫁使用，通常以賤價賣回給原廠處理因 此旗合金由進料到成品件之使用^量比例極低，約35%〜 40%左右，形成極大的資源及能源浪#。反_合° 廠内再生使用幾乎達到1〇〇%’因此以相同厚度禱件之相 1229699 對原料成本而言，鋁合金鑄件要比鎂合金鑄件減少35%〜 50% 0 3·鎂合金比紹·合金對空氣中的氧反應（氧化）更活潑， 其湯液形成的氧化物極易造成鑄件夾渣缺陷，因此一般鎂 合金壓鑄鑄件不良率往往要比鋁合金者高許多，前者通常 在60-80%，而後者可達75-95%。 4·鎂合金鑄件後續處理較鋁合金昂貴50%以上，主要 是因為鎂合金需化成皮膜處理且往往表面缺陷需相當人工 之補土過程。 基於以上因素要降低3 C機殼壓鑄鑄件成本乃需大量 採用銘合金，但如前所述，現有世界各國鋁合金之流動性 均較有限，很難做到 1mm以下薄件。 本案發明人之台灣發明專利第483938號『壓鑄極薄件 用之鋁合金』，即針對此一困難加以改進，主要揭露一種鋁 _矽-銅-錳合金，該第483938號專利案之合金在高壓壓鑄情 況下’將可做到〇.6_L2mm壁厚鑄件，特別適合3c產品機 殼應用’且在生產成本上將可比鎂合金低l5 2〇c/。以上。 惟，如何精益求精以提供一種更好之合金，發明人仍不斷 加以研究改進。 三、發明内容 本發明之目的，在於提供一種極薄件壓鳟紹合金，其 流動性佳，裂件傾向低，同時在高溫強度好，能減少鑄件 脫膜時變形。 1229699 本發明之壓鑄極薄件用鋁合金，其主成份大致包括（a) 鋁，其重量百分比為78-87% ; (b)矽，其重量百分比為 10·0-14·0% ; (c)銅，其重量百分比為2 5_4 5% ;以及（d) 鎳，其重量百分比為0.5-3.5%。本發明之極薄件壓鑄鋁合 金，允許一些次要元素及雜質，包括鐵重量百分比為〇_〇 5 %、猛重1百分比為0-10%、始重量百分比為〇_〇.5%、 鎂重量百分比為0_0·5%、鈦重量百分比為〇_〇 2〇%、鋅重 量百分比0_3.0%、魏重量百分比為〇_〇 〇7%、及其他未說 明之雜質元素每一種之重量百分比皆小於〇 3%，該雜質之 總重量百分比小於2.0%。 本發明之極薄件壓鑄鋁合金，配合適當鋁湯處理及壓 鑄機台設備與操作將可在高良品率下生產〇7〜1〇mm壁 厚之鑄件。這將比目前市面上採用熱室壓鑄法鎮合金鑄件 1.0〜1.2mm壁厚要薄20〜25%，因而可彌補鋁合金比鎂合 金密度高約45%的缺點。根據估計本發明用於3 c機殼鑄 件將可比鎮合金者節省成本15〜20%左右，其間也包括對 能源電力的節省15%以上。 本發明雖是針對3 C機殼需求而開發，但同樣可應用 於一般鋁合金壓鑄件上，因此一個鋁壓鑄廠將可採用本合 金生產各式鑄件。 四、實施方式 目前世界上較常用的高壓壓鑄用鋁合金，其成份和基 本機械性能如下表所列： 10 1229699 合金 代號 矽 鐵 鎂 錳 銅 鋅 其他 鋁 抗張 強度 (ksi) 降伏 強度 (ksi) 伸長率 (%)標距 長 50mm A360 9.0- <1.5 0.4-0. <0.6 平衡 46 24 5.0 10.0 6 364 8.0- <1.5 0.2-0. <0.2 <0.15 0.35Cr 平衡 43 23 7.5 9.0 4 0.03Be A380 8.0- <1.3 <0.1 3.0-4.0 <3.0 035Cr 平衡 47 23 4.0 9.0 0.03Be 383 10.0- <0.13 <0.1 2.0-3.0 <3.0 平衡 43 21 8.0 11.0 A384 10.5- <0.13 <0.1 3.2-4.2 <3.0 平衡 47 23 4.0 12 365 9.5· <0.15 0.1- 0.40- 平衡 34 18 * 15 11.5 0.6 0.60 <0.01 0.005 平衡 0.15- <0.03 0.35- 83-9.7 34 23 3.0 AZ91D 0.50 1.0 附註··以上表列及本文均使用重量百分比（wt % )， 二白未$主明者一般代表<0.1%雜質含量。 附註：該等合金代號（A360至AZ91D)之合金係為習 知之合金，為此項技藝領域的人所熟知，於此不再——贅 述。 *係在真空壓鑄下並作T6熱處理的機械性質。 本發明特色在於使用相當高之矽含量以增加流動性， 特適鑄薄件；同時使用相當高含量之鎳以防止黏模現象（即 鑄件局部銲接於模具上）。傳統上壓鑄用鋁合金大都採用高 鐵含量（0·5〜I5wt·% )以防止黏模現象，但含鐵量高將 1229699 相害伸長率及耐衝擊性耐疲勞性等機械性能。本發 鎳取代鐵，不會有這方面缺點。同時鎳還能幫助流動性增 加及增強高溫強度，減少鑄件脫膜時變形。 曰 、〇‘5 3.5wt.%銻於壓鑄銘合金是本發明最大特 色。縱觀美國、日本、歐洲有關銘-石夕-銅合金專利均未發 現有類似之添加者。以最接近的美國Aluminum As咖⑽η _ 出版的365合金（原系德國Reinfelden|g公司在歐洲申請 =專利EP68774W)亦僅含〇4·〇_ %猛，未見錄有^ 量的添加。故本發明不會與現有世界鋁合金專利有所衝突。 本案發明人之台灣發明專利第4 8 3 9 3 8號『壓鑄極薄件 用之鋁合金』’主要為鋁_矽_銅_錳合金，而本發明則為鋁_ 矽-銅-鎳合金，兩者在鑄造性能上接近，但後者在流動性 方面更好一些，且裂件傾向更低，同時其高溫強度更好， 能減少鑄件脫膜時變形。1229699 发明 Description of the invention (The description of the invention should state: the technical field, prior art, content, embodiments, and drawings of the invention briefly) I. Technical field to which the invention belongs The present invention relates to aluminum alloys for die-casting, and particularly to An aluminum alloy for die-casting extremely thin parts. 2. The previous technology The 3C industry has developed rapidly in recent years. Among them, the casings of notebook computers, digital cameras, and communication mobile phones all require lightness, thinness, and anti-electromagnetic radiation characteristics. For this reason, magnesium alloys and aluminum alloys are widely used. High-pressure die-casting made into shaped parts. The trend in the past two years has been to move towards magnesium alloys in large quantities, because prayer pieces of the same thickness are about 30% lighter than those of Ming alloys. Another factor is that the fluidity of aluminum alloy components in various countries in the world is limited. Even under high-pressure die-casting, it is difficult to achieve a thickness of less than W, which can not meet some casing requirements, such as the casing casting of notebook computers. Although lock alloys are currently the main application in this regard, the use of town alloys has the following disadvantages and costs: 1. The price of magnesium alloy raw materials is slightly more expensive per kilogram than aluminum alloys. 2. Magnesium alloy castings and other scraps (approximately 1.5_2 times the weight of the finished product) Due to the increase in the content of impurities (such as iron, copper, copper, and scrap) and the addition of oxides, it is difficult to recycle and remarry in the factory, usually at a low price. It is sold back to the original factory for processing, so the usage ratio of flag alloy from feeding to finished parts is extremely low, about 35% ~ 40%, forming a great resource and energy wave #. Anti-recycling ° Recycling in the plant almost reaches 100% ', so the phase of the same thickness of 1229699 For the cost of raw materials, aluminum alloy castings are reduced by 35% ~ 50% compared to magnesium alloy castings. 0 3 · Magnesium alloy ratio Shao alloy is more active to the oxygen reaction (oxidation) in the air, and the oxides formed by its soup solution can easily cause slag inclusion defects. Therefore, the general defect rate of magnesium alloy die castings is often much higher than that of aluminum alloys. The former is usually in 60-80%, while the latter can reach 75-95%. 4. The subsequent treatment of magnesium alloy castings is more than 50% more expensive than that of aluminum alloys, mainly because magnesium alloys need to be chemically treated and often have surface defects that require relatively artificial soil refilling processes. Based on the above factors, in order to reduce the cost of 3C casing die-casting, a large number of Ming alloys are required. However, as mentioned earlier, the current aluminum alloys in various countries in the world are relatively limited in fluidity, and it is difficult to achieve thin parts below 1mm. The inventor of this case, Taiwan Invention Patent No. 483938 "Aluminum alloy for die-casting extremely thin parts", is an improvement on this difficulty. It mainly discloses an aluminum-silicon-copper-manganese alloy. The alloy in the 483938 patent is In the case of high-pressure die-casting, '0.6_L2mm wall thickness castings can be achieved, which is particularly suitable for 3c product casing applications' and the production cost will be 1520c / lower than that of magnesium alloys. the above. However, the inventor continues to study and improve how to improve to provide a better alloy. 3. Summary of the Invention The purpose of the present invention is to provide an extremely thin piece of pressed alloy, which has good fluidity, low tendency to crack pieces, and good high temperature strength, and can reduce the deformation of the casting when it is stripped. 1229699 The aluminum alloy for die-casting extremely thin parts of the present invention, the main components of which roughly include (a) aluminum, whose weight percentage is 78-87%; (b) silicon, whose weight percentage is 10 · 0-14 · 0%; ( c) copper, whose weight percentage is 2 5_4 5%; and (d) nickel, whose weight percentage is 0.5-3.5%. The ultra-thin die-cast aluminum alloy of the present invention allows some minor elements and impurities, including 5% by weight of iron, 0% by weight of 1% by weight, 0% by weight of 5% by weight, The weight percentage of magnesium is 0_0 · 5%, the weight percentage of titanium is 〇〇〇2〇%, the weight percentage of zinc is 0_3.0%, the weight percentage of Wei is 〇〇〇〇7%, and the weight of each of the other unspecified impurity elements The percentages are all less than 03%, and the total weight percentage of the impurities is less than 2.0%. The ultra-thin die-cast aluminum alloy of the present invention, combined with proper aluminum soup processing and die-casting machine equipment and operations, can produce castings with a wall thickness of 0-7 mm at a high yield. This will be 20-25% thinner than the current market thickness of 1.0 ~ 1.2mm of alloy castings using hot-cell die-casting, which can make up for the shortcomings of aluminum alloys that are about 45% denser than magnesium alloys. It is estimated that the present invention can save about 15% to 20% of the cost of comparable alloys used in 3c casing casting, including the energy and power savings of more than 15%. Although the present invention was developed to meet the requirements of the 3 C chassis, it can also be applied to general aluminum alloy die castings. Therefore, an aluminum die casting plant can use this alloy to produce various types of castings. 4. Implementation Modes The components and basic mechanical properties of aluminum alloys for high-pressure die-casting currently used in the world are listed in the following table: 10 1229699 Alloy code Silicon iron magnesium manganese copper zinc Other aluminum tensile strength (ksi) Falling strength (ksi) Elongation (%) Gage length 50mm A360 9.0- < 1.5 0.4-0. ≪ 0.6 balanced 46 24 5.0 10.0 6 364 8.0- < 1.5 0.2-0. ≪ 0.2 < 0.15 0.35Cr balanced 43 23 7.5 9.0 4 0.03Be A380 8.0- < 1.3 < 0.1 3.0-4.0 < 3.0 035Cr balance 47 23 4.0 9.0 0.03Be 383 10.0- < 0.13 < 0.1 2.0-3.0 < 3.0 balance 43 21 8.0 11.0 A384 10.5- < 0.13 < 0.1 3.2-4.2 < 3.0 balance 47 23 4.0 12 365 9.5 · < 0.15 0.1- 0.40- balance 34 18 * 15 11.5 0.6 0.60 < 0.01 0.005 balance 0.15- < 0.03 0.35- 83-9.7 34 23 3.0 AZ91D 0.50 1.0 Remarks · The above table and this article use weight percentages (wt%). Those who do not know the main representative generally represent < 0.1% impurity content. Note: The alloys of these alloy codes (A360 to AZ91D) are conventional alloys, which are well known to those skilled in the art, and will not be repeated here. * Mechanical properties of T6 heat treatment under vacuum die casting. The invention is characterized by using a relatively high silicon content to increase fluidity, and is particularly suitable for casting thin parts; at the same time, using a relatively high content of nickel to prevent mold sticking (that is, the casting is locally welded to the mold). Traditionally, most aluminum alloys for die-casting use high iron content (0.5-5 I5wt ·%) to prevent sticking, but high iron content will damage the mechanical properties such as elongation, impact resistance, and fatigue resistance. Nickel instead of iron has no disadvantages in this regard. At the same time, nickel can also help increase fluidity and enhance high-temperature strength, reducing deformation when the casting is stripped. Said, 0'5 3.5wt.% Antimony in die-casting alloy is the biggest feature of the present invention. Throughout the United States, Japan, and Europe related Ming-Shixi-copper alloy patents have not found similar adders. The 365 alloy published by the closest American Aluminum As coffee （_ (originally German company Reinfelden | g company applied in Europe = patent EP68774W) also contains only 0.4%, and no addition of ^ has been recorded. Therefore, the present invention will not conflict with the existing world aluminum alloy patents. The inventor's Taiwan invention patent No. 4 8 3 9 3 8 "aluminum alloy for die-casting extremely thin parts" is mainly aluminum_silicon_copper_manganese alloy, while the present invention is aluminum_silicon-copper-nickel alloy The two are similar in terms of casting performance, but the latter is better in terms of fluidity, and has a lower tendency to crack, and at the same time, its high temperature strength is better, which can reduce the deformation of the casting when it is peeled.
習知鋁-矽合金類的鑄造合金，可添加至多〇 2〇Μ%鈦 及至多0.07wt%鳃以使鑄件微觀組織能再進一步的細化而 有助於機械性質的提升，所以本發明合金在必要需求下亦 可添加此兩元素加以改善。 本發明合金一些次要元素及雜質，包括鐵重量百分比 為0-0.5%、錳重量百分比為（m.o%、鈷重量百分比為〇_〇·5 %、鎮重里百分比為0-〇·5%、鈦重量百分比為2〇%、 鋅重量百分比0-3.0%、鳃重量百分比為〇_〇 〇7%、及其他 未說明之雜質元素每一種之重量百分比皆小於〇 3%，該雜 質之總重量百分比小於2.0%。 12 1229699 為使本發明之技術思想具體化，乃以實驗加以證明， 以下實施例即說明此一技術思想是正確的。 實施例一： 依表一之成份範圍，以純鋁、純矽、純銅及鋁-鎳母合金 在電熱之坩堝爐中熔解，除氣除渣後以壓鑄機壓鑄成厚度 0.8mm、面積為200x300mm之鑄片，經切片分割成2〇片 20mmxl50mm之矩形，再車削成片狀拉伸試片2〇支，每支 試片皆具有寬度12.5mm長50mm之標距（gage)，所得機械 性質平均值如表中所示。 表一It is known that aluminum-silicon alloy casting alloys can add up to 020M% titanium and up to 0.07wt% gills to further refine the microstructure of the casting and contribute to the improvement of mechanical properties, so the alloy of the present invention If necessary, these two elements can be added for improvement. Some minor elements and impurities of the alloy of the present invention include iron weight percentage of 0-0.5%, manganese weight percentage (mo%, cobalt weight percentage of 0-0.5%, ballast percentage of 0-0.5%, The weight percentage of titanium is 20%, the weight percentage of zinc is 0-3.0%, the weight percentage of gills is 0-007%, and the weight percentage of each of the other unspecified impurity elements is less than 0%. The total weight of the impurities The percentage is less than 2.0%. 12 1229699 In order to embody the technical idea of the present invention, it is proved by experiments. The following examples show that this technical idea is correct. Example 1: According to the composition range of Table 1, pure aluminum, Pure silicon, pure copper, and aluminum-nickel master alloy are melted in an electric crucible furnace. After degassing and slag removal, they are die-casted with a die-casting machine into a thickness of 0.8mm and an area of 200x300mm. After slicing, they are divided into 20 pieces of 20mmxl50mm rectangles. Then, 20 pieces of sheet-shaped tensile test pieces were turned, and each piece had a gage with a width of 12.5 mm and a length of 50 mm, and the average value of the obtained mechanical properties is shown in the table.
實施例二： 依表二之成份範圍及實施例一之熔鑄程序壓鑄成厚度 〇.8mm、面積為200x300mm之鑄片，經切片分割成片 2〇mmxl5〇mm之矩形，再車削成片狀拉伸試片2〇支每支 試寬度5()mm之標距（gage)，所得機械 性質平均值如表中所示。 13 1229699 表二 矽 鐵 鎂 鎳 銅 鋅 鋁 抗張強 度(ksi) 降伏強 度(ksi) 伸長率 ⑼標距 長 50mm 12.5 <0.5 <0.4 1.5 3.8 <2.0 平衡 47 26 5.4 註：使用重量百分比（Wt·% ) 實施例三··Second embodiment: According to the composition range of Table 2 and the melting process of the first embodiment, die-casting into a thickness of 0.8mm and an area of 200x300mm, and slicing into a rectangle of 20mmx150mm, and then turning into a sheet-like drawing Twenty test pieces were stretched, and each test piece had a gage with a width of 5 (mm). The average mechanical properties were as shown in the table. 13 1229699 Table 2. Silicon-Fe-Mg-Ni-Cu-Zn-Al tensile strength (ksi) drop strength (ksi) elongation ⑼ gauge length 50mm 12.5 < 0.5 < 0.4 1.5 3.8 < 2.0 balance 47 26 5.4 Note: Use weight percentage (Wt ·%) Example Three ··
依表三之成份範圍及實施例一之溶鑄程序壓鑄成厚度 0.8mm、面積為200x300mm之鑄片，經切片分割成20片 2Ommxl 5 0mm之矩形，再車削成片狀拉伸試片20支，每支 試片皆具有寬度12.5mm長50mm之標距（gage)，所得機械 性質平均值如表中所示。 表三 矽 鐵 鎂 鎳 銅 鋅 鋁 抗張強 度(ksi) 降伏強 度(ksi) 伸長率 (%)標距 長 50mm 13.4 <0.5 <0.4 2.6 3.5 <2.0 平衡 47 25 5.0According to the composition range of Table 3 and the dissolution casting procedure of Example 1, die-casting into a thickness of 0.8mm and an area of 200x300mm was carried out. After slicing, it was divided into 20 pieces of 20mmxl50mm rectangles, and then turned into 20 sheet-shaped tensile test pieces Each test piece has a gage with a width of 12.5mm and a length of 50mm. The average value of the obtained mechanical properties is shown in the table. Table 3 Silicon iron magnesium nickel copper zinc aluminum tensile strength (ksi) drop strength (ksi) elongation (%) gauge length 50mm 13.4 < 0.5 < 0.4 2.6 3.5 < 2.0 balance 47 25 5.0
註··使用重量百分比（wt·% ) 實施例四： 依表四之成份範圍及實施例一之熔鑄程序壓鑄成厚度 0.8mm、面積為200x300mm之鑄片，經切片分割成20片 2Ommxl 5 0mm之矩形，再車削成片狀拉伸試片20支，每支 試片皆具有寬度12.5mm長50mm之標距（gage)，所得機械 性質平均值如表中所示。 14 1229699 表四 矽 鐵 鎂 鎳 銅 鋅 鋁 抗張強 度(ksi) 降伏強 度(ksi) 伸長率 (%)標距 長 50inm 12.4 <0.5 <0.4 3.3 4.0 <2.0 平衡 47 26 5.5 註··使用重量百分比（Wt·% ) 由以上實施例可知本發明合金不但能獲得大面積肉薄 的鑄件’同時仍可獲得優秀的機械性質，較習知使用的 AZ91D鎂合金之抗張強度、降伏強度及伸長率為佳。此外， 本實施例之研究亦發現鎳的添加，尚能有助於流動性增加 及高溫強度之增強，進而減少鑄片脫膜時變形的現象，此 將可實際提升極薄鑄件的良品率。 綜上所述，可知本發明之『極薄件壓铸銘合金』不作 具有新賴性、進步性，而且可供產業利雜，與發明要件 相符。惟，以上所述者，從 僅為本發明之實施例而已，凡依據 本發明之各種修飾與變 仍應包含於本申請專利之範圍 五、圖式簡單說明 益 15Note ·· Using weight percentage (wt ·%) Example 4: According to the composition range of Table 4 and the casting procedure of Example 1, die-casting into a thickness of 0.8mm and an area of 200x300mm, and slicing into 20 pieces 20mmxl 50mm The rectangular shape was turned into 20 sheet-shaped tensile test pieces, and each test piece had a gage with a width of 12.5 mm and a length of 50 mm. The average value of the obtained mechanical properties is shown in the table. 14 1229699 Table 4: Silicon iron magnesium nickel copper zinc aluminum tensile strength (ksi) yield strength (ksi) elongation (%) gage length 50inm 12.4 < 0.5 < 0.4 3.3 4.0 < 2.0 balance 47 26 5.5 Note ·· Using weight percentage (Wt ·%) From the above examples, it can be known that the alloy of the present invention can not only obtain large-area thin castings, but also obtain excellent mechanical properties. Compared with the conventionally used AZ91D magnesium alloy, the tensile strength, yield strength, and The elongation is good. In addition, the study of this embodiment also found that the addition of nickel can still help increase fluidity and enhance high-temperature strength, thereby reducing the deformation of the cast film when it is stripped, which can actually improve the yield of very thin castings. In summary, it can be seen that the "ultra-thin die-casting alloy" of the present invention is not new, it is progressive, and it can be used for industrial miscellaneous, which is consistent with the requirements of the invention. However, the above is only an embodiment of the present invention, and various modifications and changes according to the present invention should still be included in the scope of the patent for this application.