US20010008155A1 - Plastically worked cast aluminum alloy product, a manufacturing method thereof and a coupling method using plastic deformation thereof - Google Patents

Plastically worked cast aluminum alloy product, a manufacturing method thereof and a coupling method using plastic deformation thereof Download PDF

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Publication number
US20010008155A1
US20010008155A1 US09/757,838 US75783801A US2001008155A1 US 20010008155 A1 US20010008155 A1 US 20010008155A1 US 75783801 A US75783801 A US 75783801A US 2001008155 A1 US2001008155 A1 US 2001008155A1
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US
United States
Prior art keywords
mass
aluminum alloy
cast
cave
less
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Abandoned
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US09/757,838
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English (en)
Inventor
Akio Hashimoto
Takaaki Ikari
Hiromi Takagi
Sumi Yoshikawa
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Denso Corp
Nippon Light Metal Co Ltd
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Nippon Light Metal Co Ltd
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Assigned to DENSO CORPORATION, NIPPON LIGHT METAL CO. LTD. reassignment DENSO CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HASHIMOTO, AKIO, IKARI, TAKAAKI, TAKAGI, HIROMI, YOSHIKAWA, SUMI
Publication of US20010008155A1 publication Critical patent/US20010008155A1/en
Priority to US10/144,638 priority Critical patent/US6866085B2/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • 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
    • C22C21/04—Modified aluminium-silicon alloys

Definitions

  • the present invention relates to a cast aluminum alloy product to which another member can be coupled by plastic deformation such as calking, a method of manufacturing thereof and also a coupling method using plastic deformation thereof.
  • a part such as a protector in a braking system for an automobile enclosing a hydraulic circuit therein, has a regulator at an outlet of the hydraulic circuit for regulating a flow rate of oil. Since the regulator is generally made of steel or synthetic resin, which can not be fixed to the aluminum protector by welding, plastic deformation (e.g. calking) of the aluminum member has been adopted for fixing the regulator.
  • the aluminum protector for a braking system of an automobile is estimated to be plastically deformed for fixing other members, as mentioned above.
  • a wrought alloy as Al—Si—Mg relatively high of toughness has been used so far for such the purpose.
  • the wrought alloy is relatively expensive compared with a cast alloy, it is expected to provide a protector made of a cheap cast alloy.
  • a cast aluminum alloy product generally includes such cast defects as blowholes and comprises a metallurgical structure wherein ⁇ -Al phase comes out as a matrix with ununiform grain size. Segregation of an eutectic Si phase grown to a coarse size as well as dispersion of primary Si are often observed in the matrix. Due to such the metallurgical structure, the cast aluminum alloy product is poor of ductility and so regarded as a member improper to be coupled with another member by plastic deformation.
  • JP 6-145866A discloses a cast aluminum alloy product for use as a protector of an automobile braking system, whereby growth of isometric crystals is promoted by addition of Ti and B to reduce occurrence of blowholes. Even the proposed aluminum alloy product is insufficient of ductility, so it can not be yet used as a member to be coupled with another member.
  • the present invention aims at provision of a cast aluminum alloy product useful as a member to be coupled with another member by such plastic deformation as calking without defects as above-mentioned.
  • the cast product is improved in ductility by addition of Ca, Ti and B with reduction of P content and by size-control of ⁇ -Al grains and eutectic particles.
  • the newly proposed cast aluminum alloy product has the composition consisting of 6.5-8.0 mass % Si, 0.25-0.45 mass % Mg, 0.08-0.40 mass % Fe, 0.001-0.01 mass % Ca, P less than 0.0015 mass %, 0.02-0.1 mass % Ti, 0.001-0.01 mass % B, optionally one or two of 0.05-0.3 mass % Cr and 0.05-0.2 mass % Mn, and the balance being Al except inevitable impurities.
  • the cast aluminum alloy product has the metallurgical structure that an ⁇ -Al phase grain in a surface layer from a surface to a depth of 1 mm is of average grain size different by 50 ⁇ m or less from an ⁇ -Al phase grain in an inner part, and an eutectic Si phase is controlled at a particle size of 400 ⁇ m or smaller.
  • Another member is coupled to the cast aluminum alloy product by partial plastic deformation of the cast aluminum alloy product.
  • a molten aluminum alloy is adjusted to the specified composition, it is injected into a cavity of metal dies at a speed of 0.05-0.25 m/second and then cooled at a cooling speed of 20° C./second or higher in a temperature range between liquidus and solidus curves in a state charged with a pressure of 30 MPa or higher.
  • a cast body has a cave or hole for coupling another member thereto.
  • the mating member can be coupled to the cast aluminum alloy product by arranging the mating member in the cave or hole and then plastically deforming a part above or around the cave or hole so as to realize metal flow to the cave or hole.
  • a cast aluminum alloy product generally includes cast defects such as blowholes and segregates of an eutectic phase grown to a coarse particle, with big difference in average grain size of an ⁇ -Al phase between a surface layer and an inner part.
  • the big difference in average grain size, cast defects and segregation of the eutectic Si phase cause partial decrease of elongation of the cast aluminum alloy product, resulting in irregularity of elongation or plastic deformation as well as cracking, so that the cast aluminum alloy product is not regarded as a member suitable to be coupled with another member.
  • the inventors have researched and examined effects of difference in average grain size, cast defects and segregation on ductility from various aspects, and have found that a cast aluminum alloy product capable of coupling another member therewith by plastic deformation is obtained by addition of Ca, Ti and B to an aluminum alloy with reduction of P content to reform an eutectic phase to fine particles and by control of casting conditions to inhibit occurrence of cast defects and to decrease a difference in average grain size of an ⁇ -Al phase grain size between a surface layer and an inner part of the cast product.
  • FIG. 1 is a view for explaining calking a regulator at a cave of an aluminum alloy product.
  • FIG. 2 is a microscopic photograph illustrating a metallurgical structure of an aluminum alloy product according to the present invention.
  • FIG. 3 is another microscopic photograph illustrating a metallurgical structure of an aluminum alloy product having a different composition.
  • FIG. 4 is a graph for comparing maximum sizes of segregates in Sample No. 1 with Sample No. 9 by image-analysis of metallurgical structures.
  • composition, the metallurgical structure and the manufacturing conditions specified in the present invention have meanings explained as follows:
  • Si 6.5-8.0 mass %:
  • Si is an alloying element which precipitates as Mg 2 Si, eutectic Si, etc. effective for improvement of mechanical strength and castability. Such the effect is clearly noted by addition of Si at a ratio of 6.5 mass % or more. However, excessive addition of Si above 8.0 mass % causes segregation of coarse eutectic Si particles and reduces toughness of a cast alloy.
  • Mg is an alloying element which precipitates as Mg2Si effective for improvement of mechanical strength.
  • the effect of Mg on mechanical strength is clealy noted by addition of Mg at a ratio of 0.25 mass % or more.
  • excessive addition of Mg above 0.45 mass % causes various defects such as inclusion of oxides and poor fluidity during casting.
  • Fe 0.08-0.40 mass %
  • Fe is an alloying element effective for inhibiting burning of metal dies. Such the effect is clearly noted by addition of Fe at a ratio of 0.08 mass % or more. However, excessive addition of Fe above 0.40 mass % causes generation of coarse Al—Fe—Mg—Si intermetallic compounds, resulting in reduction of toughness.
  • the additive Ca with reduction of P content to a possible lowest level suppresses generation of primary Si particles and modifies eutectic Si particles, so as to improve a cast aluminum alloy product in ductility as well as strength and toughness.
  • the effect of Ca on modification of eutectic Si particles is clearly noted by addition of Ca at a ratio of 0.001 mass % or more (preferably 0.002 mass % or more). However, such the effect is not realized if P content exceeds 0.0015 mass %. Fluidity and castability of a molten aluminum alloy are degraded by P content above 0.0015 mass % or addition of Ca above 0.01 mass %.
  • Ti and B are well-known alloying elements effective for minimization of an ⁇ -Al phase grain.
  • the inventors have found from various examinations that Ti and B are also effective for suppressing segregation of an eutectic Si phase if an aluminum alloy is cooled at a cooling speed of 20° C./second or higher in a temperature range between liquidus and solidus curves after injection into metal dies.
  • the effect on suppression of segregation is clearly noted by addition of Ti at a ratio of 0.02 mass % or more and B at a ratio of 0.001 mass % or more.
  • excessive additions of Ti above 0.1 mass % and B above 0.01 mass % are likely to cause generation of coarse compounds and to reduce ductility of a cast aluminum alloy product.
  • Cr and Mn are optional elements, which are added to an aluminum alloy as occasion demands. Recrystallization, which unfavorably reduces mechanical strength, of a plastically deformed part coupled with another member is inhibited by addition of Cr. Such the Cr effect is clearly noted by addition of Cr at a ratio of 0.05 mass % or more.
  • the additive Mn precipitates as Al(Fe, Mn)Si effective for suppressing generation of coarse Al—Fe—Mg—Si intermetallic compounds which put harmful influences on toughness of a cast aluminum alloy product. Such the Mn effect is clearly noted by addition of Mn at a ratio of 0.05 mass % or more. However, excessive addition of Cr above 0.3 mass % or Mn above 0.2 mass % degrades castability of a molten aluminum alloy.
  • the cast aluminum alloy product according to the present invention has the metallurgical structure that an ⁇ -Al phase grain in a surface layer from a surface to a depth of 1 mm is differentiated in average grain size by 50 ⁇ m or less from an ⁇ -Al phase grain in an inner part, a size of eutectic Si particles is controlled at 400 ⁇ m or smaller.
  • a size of eutectic Si particles is controlled at 400 ⁇ m or smaller.
  • the cast aluminum alloy product Due to the small difference in size of ⁇ -Al grains between the surface layer and the inner part, the cast aluminum alloy product is good of ductility without discontinuity of physical properties.
  • the cast aluminum alloy product is also plastically deformed for coupling another member thereto without occurrence of cracks, since generation of coarse eutectic Si particles acting as origins to start collapse during plastic deformation is suppressed. If a cast aluminum alloy product contains eutectic Si particles above 400 ⁇ m in maximum particle size on the contrary, it can not be used as a protector for a braking system enclosing a hydraulic circuit therein due to poor cracking resistance, since such coarse eutectic Si particles act as origins for cracking.
  • a molten aluminum alloy is adjusted to a predetermined composition, it is injected into a cavity of metal dies by a die-casting process. Injection of the molten alloy is performed at a speed of 0.05-0.25 m/second. An injection speed of 0.05 m/second or higher ensures fluidization of the molten alloy to every nook and corner of the cavity, while an injection speed of 0.25 m/second or less inhibits occurrence of blowholes which put harmful influences on airtightness.
  • the injected molten aluminum alloy is cooled in the cavity at a speed of 20° C./second or higher in a temperature range between liquidus and solidus curves.
  • Such the controlled cooling speed in the temperature range enables co-presence of Ti and B even after the molten alloy reaches a temperature on the solidus curve, so that Ti and B still effectively minimize ⁇ -Al grains and suppress segregation of eutectic Si particles. If the molten alloy is slowly cooled at a speed below 20° C./second, Ti and B are consumed for minimization of ⁇ -Al grains in prior to precipitation of the eutectic Si phase. Therefore, the effect of Ti and B on suppressing segregation of eutectic Si particles would not be realized.
  • a molten aluminum alloy is cast to a profile having a cave or hole.
  • a cave or hole is easily formed by use of metal dies, which has a tubercle or projection extending to a cavity at a position corresponding to the cave or hole.
  • a cast aluminum alloy product has a shape partially shown in FIG. 1, wherein a passage 1 serving as a part of a hydraulic circuit is formed in a cast aluminum alloy body 2 , and a cave 3 is formed at a position where the passage 1 opens on a surface of the cast body 2 .
  • a regulator 4 is arranged in the cave 3 (FIG.
  • a working pressure F is applied to a part above the cave 3 so as to form a plastically deformed part 5 by metal flow to the cave 3 (FIG. 1( b )). Consequently, the regulator 4 is clamped between a bottom of the cave 3 and the plastically deformed part 5 .
  • the aged cast body was subjected to observation of its metallurgical structure and a mechanical test.
  • average sizes of ⁇ -Al grains in a surface layer from a surface to a depth of 1 mm and in an inner part of the cast body were measured, and a difference therebetween was calculated.
  • Eutectic Si particles segregated at boundaries of ⁇ -Al grains were also observed to measure their maximum particle size.
  • Specific gravity of each die-cast product together with cast products manufactured by gravity casting the same aluminum alloys were measured by Archimedes's method.
  • FIG. 2 is a microscopic photograph illustrating a metallurgical structure of a cast product obtained by casting the aluminum alloy No. 1 under the casting condition No. 1.
  • Sample Nos. 2-4 and 6-8 which were obtained by casting the same aluminum alloys but under different casting conditions, were poor of ductility and had the metallurgical structures that size of an ⁇ -Al grains in a surface layer was greatly different from that in an inner part and that eutectic Si particles were significantly segregated.
  • Sample No. 9 which was obtained by casting the aluminum alloy No. 3 of different composition under the casting condition No. 1, was poor of ductility, although a difference in size of ⁇ -Al grains between a surface layer and an inner part was nearly the same level as that of Sample No. 1.
  • the metallurgical structure of Sample No. 9 was observed, segregation of coarse eutectic Si particles was detected, as shown in FIG. 3.
  • test pieces were prepared from every cast product of Sample Nos. 1-9 and subjected to a calking test as follows: A regulator 4 was arranged in a cave 3 of a cast product 2 , as shown in FIG. 1( a ). A working pressure F was applied to a part above the cave 3 to clamp the regulator 4 between a bottom of the cave 4 and a plastically deformed part 5 , as shown in FIG. 1( a ). Thereafter, the plastically deformed part 5 was inspected to detect occurrence of cracks.
  • a cast aluminum alloy product according to the present invention as above-mentioned is reformed to such the metallurgical structure that an average size of ⁇ -Al grains in a surface layer is near an average size of ⁇ -Al grains in an inner part without segregation of coarse eutectic Si particles by addition of Ti, B and Ca with reduction of P content. Due to the reformed structure, the cast product can be plastically deformed by calking or the like for coupling another member therewith. Therefore, the cast product is useful in various technical fields, instead of an expensive ductile aluminum alloy which has been used so far for such the purpose. The cast product is also superior of airtightness, so useful as a protector for an automobile braking system enclosing a hydraulic circuit therein.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Forging (AREA)
US09/757,838 2000-01-19 2001-01-10 Plastically worked cast aluminum alloy product, a manufacturing method thereof and a coupling method using plastic deformation thereof Abandoned US20010008155A1 (en)

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JP2000-009798 2000-01-19
JP2000009798A JP3808264B2 (ja) 2000-01-19 2000-01-19 塑性加工されたアルミニウム合金鋳物，アルミニウム合金鋳物の製造方法及び塑性変形を利用した締結方法

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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030226651A1 (en) * 2001-10-26 2003-12-11 Taylor's Industrial Services, Llc Low-velocity die-casting
EP1736561A1 (de) * 2004-04-05 2006-12-27 Nippon Light Metal, Co., Ltd. Aluminiumlegierungsgussmaterial für die wärmebehandlung mit hervorragender wärmeleitung und herstellungsverfahren dafür
CN104480357A (zh) * 2014-12-05 2015-04-01 福州大学 一种高硅铝合金缸套及其制备方法
CN109252073A (zh) * 2018-11-13 2019-01-22 天津立中合金集团有限公司 高强韧性铝合金航天材料及其制备方法
EP3943629A4 (de) * 2019-03-20 2022-05-18 Nippon Light Metal Co., Ltd. Aluminiumlegierung und druckgiessmaterial aus aluminiumlegierung
US20230340646A1 (en) * 2022-04-22 2023-10-26 GM Global Technology Operations LLC Multipurpose aluminum alloy composition

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JP4623372B2 (ja) * 2005-07-27 2011-02-02 アイシン・エィ・ダブリュ株式会社 鋳物用アルミニウム合金およびその製造方法、ならびにアルミニウム合金鋳造製品の製造方法
DE102006057660B4 (de) * 2006-12-07 2019-08-22 Bayerische Motoren Werke Aktiengesellschaft Verfahren zum Druckgießen von Bauteilen und Verwendung einer Sprühvorrichtung einer Druckgießvorrichtung
US8214609B2 (en) * 2008-07-16 2012-07-03 International Business Machines Corporation Data transference to virtual memory
JP5251894B2 (ja) * 2010-01-21 2013-07-31 日本軽金属株式会社 熱伝導性に優れたアルミニウム合金鋳造材の製造方法
KR101854356B1 (ko) 2010-02-05 2018-05-03 틱소매트 인코포레이티드 정제된 입자 구조를 가진 가공 원료 형성 방법 및 장치
JP2015045033A (ja) * 2013-08-27 2015-03-12 日信工業株式会社 アルミニウム合金鋳物
JP6140605B2 (ja) * 2013-12-26 2017-05-31 本田技研工業株式会社 Ａｌ合金鋳造品及びその製造方法
CN105238944A (zh) * 2015-10-30 2016-01-13 中信戴卡股份有限公司 一种铝合金细化变质剂以及精炼铝合金的方法
CN108085541B (zh) * 2016-11-23 2020-04-24 比亚迪股份有限公司 一种导热铝合金及其应用
CN109652687A (zh) * 2018-12-28 2019-04-19 广东鸿泰科技股份有限公司 一种压铸铝合金及其压铸工艺
JP2022052437A (ja) * 2020-09-23 2022-04-04 株式会社アイシン アルミニウム合金鋳物及びその製造方法

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JPS59189055A (ja) * 1983-04-12 1984-10-26 Nissan Motor Co Ltd 気孔巣の少ないダイカスト品の製造方法
JP2532129B2 (ja) * 1988-06-21 1996-09-11 三菱化学株式会社 防振性に優れた鋳造用アルミニウム合金
US5230754A (en) 1991-03-04 1993-07-27 Kb Alloys, Inc. Aluminum master alloys containing strontium, boron, and silicon for grain refining and modifying aluminum alloys
JPH06145866A (ja) 1992-11-13 1994-05-27 Ube Ind Ltd 鋳造性に優れた高圧鋳造用アルミニウム合金

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030226651A1 (en) * 2001-10-26 2003-12-11 Taylor's Industrial Services, Llc Low-velocity die-casting
EP1736561A1 (de) * 2004-04-05 2006-12-27 Nippon Light Metal, Co., Ltd. Aluminiumlegierungsgussmaterial für die wärmebehandlung mit hervorragender wärmeleitung und herstellungsverfahren dafür
EP1736561A4 (de) * 2004-04-05 2008-07-23 Nippon Light Metal Co Aluminiumlegierungsgussmaterial für die wärmebehandlung mit hervorragender wärmeleitung und herstellungsverfahren dafür
EP2275584A1 (de) * 2004-04-05 2011-01-19 Nippon Light Metal Company Ltd. Aluminium-Gussmaterial für Wärmebehandlung mit exzellenter Wärmeleitfähigkeit und Herstellungsverfahren hierfür
EP2281909A1 (de) * 2004-04-05 2011-02-09 Nippon Light Metal Company Ltd. Alulegierungsgussmaterial zur Wärmebehandlung mit ausgezeichneter Wärmeleitfähigkeit und Herstellungsverfahren dafür
US20110132504A1 (en) * 2004-04-05 2011-06-09 Nippon Light Metal Company, Ltd. Aluminum Alloy Casting Material for Heat Treatment Excelling in Heat Conduction and Process for Producing the Same
US8936688B2 (en) 2004-04-05 2015-01-20 Nippon Light Metal Company, Ltd. Aluminum alloy casting material for heat treatment excelling in heat conduction and process for producing the same
CN104480357A (zh) * 2014-12-05 2015-04-01 福州大学 一种高硅铝合金缸套及其制备方法
CN109252073A (zh) * 2018-11-13 2019-01-22 天津立中合金集团有限公司 高强韧性铝合金航天材料及其制备方法
EP3943629A4 (de) * 2019-03-20 2022-05-18 Nippon Light Metal Co., Ltd. Aluminiumlegierung und druckgiessmaterial aus aluminiumlegierung
US20230340646A1 (en) * 2022-04-22 2023-10-26 GM Global Technology Operations LLC Multipurpose aluminum alloy composition

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JP2001200325A (ja) 2001-07-24
US6866085B2 (en) 2005-03-15
US20030037848A1 (en) 2003-02-27
JP3808264B2 (ja) 2006-08-09
DE10101960A1 (de) 2001-10-25
DE10101960B4 (de) 2008-06-05

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