US20040103964A1 - Process for thermally treating light alloy casting - Google Patents

Process for thermally treating light alloy casting Download PDF

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US20040103964A1
US20040103964A1 US10/648,831 US64883103A US2004103964A1 US 20040103964 A1 US20040103964 A1 US 20040103964A1 US 64883103 A US64883103 A US 64883103A US 2004103964 A1 US2004103964 A1 US 2004103964A1
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aluminum alloy
casting
alloy casting
light alloy
pressure
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US10/648,831
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Takeyoshi Nakamura
Katsuhiro Shibata
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Honda Motor Co Ltd
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Honda Motor Co Ltd
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Publication of US20040103964A1 publication Critical patent/US20040103964A1/en
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    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22FCHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/043Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with silicon as the next major constituent
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22FCHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon

Definitions

  • the present invention relates to a process for thermally treating a light alloy casting.
  • a solution heat treatment is conventionally employed for converting the light alloy casting into a homogeneous solid solution after the casting.
  • the quenching is carried out under atmospheric pressure after the heating, and hence there is a possibility that a gas (mainly hydrogen) exceeding a solid solution limit contained in the casting in the casting process, expands during the quenching, resulting in an increase in a porosity of the light alloy casting. There is also a possibility that the gas is transferred to a surface of the casting, generating blisters on the surface. These situations hinder an enhancement in toughness of the light alloy casting.
  • a gas mainly hydrogen
  • a process for thermally treating a light alloy casting comprising: a step of heating a light alloy casting up to a solid solution range and maintaining it at such heating temperature T; and a step of quenching the light alloy casting through a cooling medium while pressurizing it.
  • the above-mentioned heating and quenching can provide an effect similar to that in the usual solution heat treatment, namely, an effect enabling the light alloy casting to be converted into a homogeneous solid solution.
  • the cooling medium under pressure can be brought into close contact with the entire surface of the light alloy casting, whereby the cooling speed can be increased.
  • this thermal treating process can produce a light alloy casting having a high toughness.
  • the heating temperature T is set at T>T S , wherein T S represents a solidus-line temperature for a light alloy forming the light alloy casting.
  • An applied pressure P in the process of quenching is suitable to be in a range of 200 bar ⁇ P ⁇ 2,000 bar. If P ⁇ 200 bar, an effect of the pressurization is not provided. On the other hand, if P>2,000 bar, the effect of the pressurization is not significant for an increment in pressure. However, the applied pressure P is more effective at a higher value in the above-described range (200 bar ⁇ P ⁇ 2,000 bar).
  • Table 1 shows compositions of two types of aluminum alloys used for forming aluminum alloy castings as castings of light alloys, i.e., A356 alloy and ADC3 alloy (JIS), and Table 2 shows solidus-line temperatures T S and liquidus-line temperatures T L of the alloys.
  • JIS A356 alloy and ADC3 alloy
  • Table 2 shows solidus-line temperatures T S and liquidus-line temperatures T L of the alloys.
  • a plurality of aluminum alloy castings I were formed by utilizing a gravitational sand-die-casting process using an A356 alloy, and a plurality of aluminum alloy castings II were formed by utilizing a vacuum-die-casting process using an ADC3 alloy.
  • each of the aluminum alloy castings I and II was subjected to a thermal treatment which will be described below.
  • Each of the aluminum alloy castings I and II was heated up to a solid-solution range (a range of temperature where the casting can exist as a homogeneous solid solution) under atmospheric pressure, and maintained at such heating temperature T.
  • each of the aluminum alloy castings I and II was quenched through a cooling medium under the atmospheric pressure or while being pressurized. Water was used as the cooling medium.
  • each of the heating temperatures T was set in a range of T ⁇ T S (wherein T S is a solidus-line temperature of the aluminum alloy forming each of the aluminum alloy castings I and II).
  • a specific gravity of each of the aluminum alloy castings I and II was measured, and defined as an apparent specific gravity.
  • a specific gravity of each of extrusion compounds comprising the A345 alloy and the ADC3 alloy was also measured, and defined as a true specific gravity.
  • Table 3 shows thermal treating conditions for the aluminum alloy castings I(1), I(2), II(1) and II(2). TABLE 3 Thermal treatment Heating process Quenching process Al alloy Temperature Time Pressure casting (° C.) Pressure (Hr) (bar) Time (min) I (1) 530 Atmospheric 3 Atmospheric 0.2 pressure pressure (2) 1,000 30.0 II (1) 530 Atmospheric 3 Atmospheric 0.2 pressure pressure (2) 1,200 30.0
  • Table 4 shows the content of gas, the pressure in the quenching process, the apparent specific gravity, the true specific gravity, the porosity and the Charpy impact value for each of the aluminum alloy casting I(1), etc.
  • a plurality of aluminum alloy castings IV were formed by utilizing a gravitational sand-die-casting process using an A356 alloy, and a plurality of aluminum alloy castings V were formed by utilizing a vacuum-die-casting process using an ADC3 alloy.
  • each of the aluminum alloy castings VI and V was subjected to a thermal treatment which will be described below.
  • Each of the aluminum alloy castings IV and V was heated up to a solid-solution range, and maintained at such heating temperature T. Then, each of the aluminum alloy castings IV and V was quenched through a cooling medium, while being pressurized. Water was used as the cooling medium.
  • each of the heating temperatures T was set in a range of T>T S (wherein T S is a solidus-line temperature of the aluminum alloy forming each of the aluminum alloy castings IV and V).
  • the heating temperature T is set as described above, a portion of an eutectic (Al+Si) which is a low-melting-point precipitated crystal hindering the toughness as well as an intermetallic compound AlSiFe, can be molten.
  • Table 5 shows thermal treating conditions for the aluminum alloy castings IV(1), IV(2), V(1) and V(2). TABLE 5 Thermal treatment Heating process Quenching process Al alloy Temperature Time Pressure casting (° C.) Pressure (Hr) (bar) Time (min) IV (1) 567 Atmospheric 3 Atmospheric 0.2 pressure pressure (2) 1,000 30.0 V (1) 567 Atmospheric 3 Atmospheric 0.2 pressure pressure (2) 1,200 30.0
  • Table 6 shows the content of gas, the pressure in the quenching process, the apparent specific gravity, the true specific gravity, the porosity and the Charpy impact value for each of the aluminum alloy casting IV(1), etc.
  • TABLE 6 Content Charpy of gas Pressure in Apparent True impact Al alloy (cc/ Quenching specific specific Porosity value casting 100 g) process gravity gravity (%) (J/cm 2 ) IV (1) 0.7 Atmospheric 1.500 2.685 44.13 2.3 pressure (2) 1,000 2.672 0.48 16.4 V (1) 3.0 Atmospheric 1.701 2.687 36.70 1.4 pressure (2) 1,200 2.674 0.48 14.6
  • the aluminum alloy castings IV (2) Due to the rise of the heating temperature T in the heating process, the aluminum alloy castings IV (2) has a Charpy impact value higher than that of the aluminum alloy casting I(2) shown in Table 4 and obtained from the thermal treatment under the same thermal treatment conditions expect for the heating temperature T. This applies to the aluminum alloy castings V(2) and II(2).
  • the characteristics of the aluminum alloy casting can be improved by applying a pressure to the aluminum alloy casting.
  • a pressure to the aluminum alloy casting.
  • a time for raising the pressure in the quenching process can be eliminated, and a time for the quenching process can be greatly shortened. This is effective for providing an enhancement in productivity of the aluminum alloy castings.

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  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Continuous Casting (AREA)

Abstract

A thermal treating process includes a step of heating a light alloy casting up to a solid solution range and maintaining it at such heating temperature T, and a step of quenching the light alloy casting through a cooling medium while pressurizing it. Thus, increase in porosity of the light alloy casting can be suppressed and generation of blisters on a surface of the light alloy casting can be prevented, thereby enhancing the toughness of the light alloy casting.

Description

    BACKGROUND OF THE INVENTION
  • 1. Field of the Invention [0001]
  • The present invention relates to a process for thermally treating a light alloy casting. [0002]
  • 2. Description of the Related Art [0003]
  • To produce a light alloy casting, a solution heat treatment is conventionally employed for converting the light alloy casting into a homogeneous solid solution after the casting. [0004]
  • However, in the solution heat treatment, the quenching is carried out under atmospheric pressure after the heating, and hence there is a possibility that a gas (mainly hydrogen) exceeding a solid solution limit contained in the casting in the casting process, expands during the quenching, resulting in an increase in a porosity of the light alloy casting. There is also a possibility that the gas is transferred to a surface of the casting, generating blisters on the surface. These situations hinder an enhancement in toughness of the light alloy casting. [0005]
  • SUMMARY OF THE INVENTION
  • It is an object of the present invention to provide a thermal treating process, wherein an increase in porosity of the light alloy casting is inhibited, and the generation of blisters on the surface of the light alloy casting is prevented, whereby the toughness of the light alloy casting can be enhanced. [0006]
  • To achieve the above object, according a first feature of the present invention, there is provided a process for thermally treating a light alloy casting, comprising: a step of heating a light alloy casting up to a solid solution range and maintaining it at such heating temperature T; and a step of quenching the light alloy casting through a cooling medium while pressurizing it. [0007]
  • The above-mentioned heating and quenching can provide an effect similar to that in the usual solution heat treatment, namely, an effect enabling the light alloy casting to be converted into a homogeneous solid solution. In addition, since the light alloy casting is quenched through the cooling medium while being pressurized, the expansion of the gas contained in the casting in the process of casting is suppressed, and the transfer of the gas to the surface of the casting is inhibited, whereby the generation of blisters on the surface can be prevented. Further, the cooling medium under pressure can be brought into close contact with the entire surface of the light alloy casting, whereby the cooling speed can be increased. [0008]
  • Therefore, this thermal treating process can produce a light alloy casting having a high toughness. [0009]
  • According to a second feature of the present invention, in addition to the first feature, the heating temperature T is set at T>T[0010] S, wherein TS represents a solidus-line temperature for a light alloy forming the light alloy casting. With this feature, it is possible to provide a thermal treating process by which a light alloy casting having a further enhanced roughness can be produced by employing the above-described means.
  • An applied pressure P in the process of quenching is suitable to be in a range of 200 bar≦P≦2,000 bar. If P<200 bar, an effect of the pressurization is not provided. On the other hand, if P>2,000 bar, the effect of the pressurization is not significant for an increment in pressure. However, the applied pressure P is more effective at a higher value in the above-described range (200 bar≦P≦2,000 bar).[0011]
  • DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
  • Table 1 shows compositions of two types of aluminum alloys used for forming aluminum alloy castings as castings of light alloys, i.e., A356 alloy and ADC3 alloy (JIS), and Table 2 shows solidus-line temperatures T[0012] S and liquidus-line temperatures TL of the alloys.
    TABLE 1
    Chemical constituents (% by weight)
    Al alloy Si Cu Mg Mn Fe Ti Zn Al
    A356 7.43 0.04 0.43 0.03 0.16 0.36 0.02 Balance
    ADC3 9.7 0.3 0.55 0.2 1.1 0.1 Balance
  • [0013]
    TABLE 2
    Solidus-line Liquidus-line
    Al alloy temperature TS temperature TL
    A356 555° C. 610° C.
    ADC3 560° C. 590° C.
  • (Embodiment 1) [0014]
  • (1) A plurality of aluminum alloy castings I were formed by utilizing a gravitational sand-die-casting process using an A356 alloy, and a plurality of aluminum alloy castings II were formed by utilizing a vacuum-die-casting process using an ADC3 alloy. [0015]
  • (2) A content of a gas in each of the aluminum alloy castings I and II was measured. [0016]
  • (3) Each of the aluminum alloy castings I and II was subjected to a thermal treatment which will be described below. Each of the aluminum alloy castings I and II was heated up to a solid-solution range (a range of temperature where the casting can exist as a homogeneous solid solution) under atmospheric pressure, and maintained at such heating temperature T. Then, each of the aluminum alloy castings I and II was quenched through a cooling medium under the atmospheric pressure or while being pressurized. Water was used as the cooling medium. In this case, each of the heating temperatures T was set in a range of T≦T[0017] S (wherein TS is a solidus-line temperature of the aluminum alloy forming each of the aluminum alloy castings I and II).
  • (4) Each of the aluminum alloy castings I and II was subjected to an artificial aging treatment at 160° C. for 6 hours. [0018]
  • (5) A specific gravity of each of the aluminum alloy castings I and II was measured, and defined as an apparent specific gravity. A specific gravity of each of extrusion compounds comprising the A345 alloy and the ADC3 alloy was also measured, and defined as a true specific gravity. A porosity (%) was determined according to an equation: porosity={(true specific gravity−apparent specific gravity)/true specific gravity}×100. [0019]
  • (6) No.3 test pieces were fabricated from each of the aluminum alloy castings I and II in order to carry out a Charpy impact test where a Charpy impact value for each of the test pieces was measured. [0020]
  • Table 3 shows thermal treating conditions for the aluminum alloy castings I(1), I(2), II(1) and II(2). [0021]
    TABLE 3
    Thermal treatment
    Heating process Quenching process
    Al alloy Temperature Time Pressure
    casting (° C.) Pressure (Hr) (bar) Time (min)
    I
    (1) 530 Atmospheric 3 Atmospheric 0.2
    pressure pressure
    (2) 1,000 30.0
    II
    (1) 530 Atmospheric 3 Atmospheric 0.2
    pressure pressure
    (2) 1,200 30.0
  • The reason why the time for the quenching process for the aluminum alloy castings I(2) and II(2) is longer that that for the aluminum alloy castings I(1) and II(1) in Table 3, is that a longer time is required for raising the pressure. [0022]
  • Table 4 shows the content of gas, the pressure in the quenching process, the apparent specific gravity, the true specific gravity, the porosity and the Charpy impact value for each of the aluminum alloy casting I(1), etc. [0023]
    TABLE 4
    Content Pressure in Charpy
    of gas quenching Apparent True impact
    Al alloy (cc/ process specific specific Porosity value
    casting 100 g) (bar) gravity gravity (%) (J/cm2)
    I
    (1) 0.7 Atmospheric 2.670 2.685 0.56 9.5
    pressure
    (2) 1,000 2.670 0.56 15.8
    II
    (1) 3.0 Atmospheric 1.688 2.687 37.18 1.4
    pressure
    (2) 1,200 2.681 0.22 12.4
  • The aluminum alloy castings I(1) and I(2) having the smaller content of gas were compared with each other. As a result, no blister was observed on surfaces of the aluminum alloy castings, and it was found that their apparent specific gravities were substantially the same and their porosities were substantially the same, but the aluminum alloy casting I(2) had the Charpy impact value larger than that of the aluminum alloy casting I(1). It is considered that this is because the cooling medium under pressure was brought into close contact with the entire surface of the aluminum alloy casting I(2), whereby the cooling speed was increased. [0024]
  • The aluminum alloy castings II(1) and II(2) having the larger content of gas were compared with each other. As a result, a plurality of blisters were observed on the surface of the aluminum alloy casting II(1) which was not pressurized in the quenching process, but the generation of blisters was not observed on the surface of the aluminum alloy casting II(2) which was pressurized in the quenching process. In the aluminum alloy casting II(2), its apparent specific gravity was increased, and its porosity was remarkably lower than that of the aluminum alloy casting II(1), whereby a remarkable increase in Charpy impact value was observed. [0025]
  • (Embodiment 2) [0026]
  • (1) A plurality of aluminum alloy castings IV were formed by utilizing a gravitational sand-die-casting process using an A356 alloy, and a plurality of aluminum alloy castings V were formed by utilizing a vacuum-die-casting process using an ADC3 alloy. [0027]
  • (2) A content of a gas in each of the aluminum alloy castings IV and V was measured. [0028]
  • (3) Each of the aluminum alloy castings VI and V was subjected to a thermal treatment which will be described below. Each of the aluminum alloy castings IV and V was heated up to a solid-solution range, and maintained at such heating temperature T. Then, each of the aluminum alloy castings IV and V was quenched through a cooling medium, while being pressurized. Water was used as the cooling medium. In this case, each of the heating temperatures T was set in a range of T>T[0029] S (wherein TS is a solidus-line temperature of the aluminum alloy forming each of the aluminum alloy castings IV and V). If the heating temperature T is set as described above, a portion of an eutectic (Al+Si) which is a low-melting-point precipitated crystal hindering the toughness as well as an intermetallic compound AlSiFe, can be molten.
  • (4) Each of the aluminum alloy castings IV and V was subjected to an artificial aging treatment at 160° C. for 6 hours. [0030]
  • (5) A specific gravity of each of the aluminum alloy castings IV and V was measured, and defined as an apparent specific gravity. A porosity (%) was determined using this apparent specific gravity, the above-described true specific gravity and the above-described equation. [0031]
  • (6) No.3 test pieces were fabricated from each of the aluminum alloy castings IV and V in order to carry out a Charpy impact test, and a Charpy impact value for each of the test pieces was measured. [0032]
  • Table 5 shows thermal treating conditions for the aluminum alloy castings IV(1), IV(2), V(1) and V(2). [0033]
    TABLE 5
    Thermal treatment
    Heating process Quenching process
    Al alloy Temperature Time Pressure
    casting (° C.) Pressure (Hr) (bar) Time (min)
    IV
    (1) 567 Atmospheric 3 Atmospheric 0.2
    pressure pressure
    (2) 1,000 30.0
    V
    (1) 567 Atmospheric 3 Atmospheric 0.2
    pressure pressure
    (2) 1,200 30.0
  • The reason why the time for the quenching process for the aluminum alloy castings IV(2) and V(2) is longer in Table 5, is that a longer time is required for raising the pressure. [0034]
  • Table 6 shows the content of gas, the pressure in the quenching process, the apparent specific gravity, the true specific gravity, the porosity and the Charpy impact value for each of the aluminum alloy casting IV(1), etc. [0035]
    TABLE 6
    Content Charpy
    of gas Pressure in Apparent True impact
    Al alloy (cc/ Quenching specific specific Porosity value
    casting 100 g) process gravity gravity (%) (J/cm2)
    IV
    (1) 0.7 Atmospheric 1.500 2.685 44.13 2.3
    pressure
    (2) 1,000 2.672 0.48 16.4
    V
    (1) 3.0 Atmospheric 1.701 2.687 36.70 1.4
    pressure
    (2) 1,200 2.674 0.48 14.6
  • The aluminum alloy castings IV(1) and IV(2) having the smaller content of gas were compared with each other. As a result, in the aluminum alloy casting IV(1), pores created due to the melting of a portion of an eutectic (Al+Si) in the heating process were expanded in the quenching process, so that the apparent specific gravity was decreased, while the porosity was increased, and consequently, the Charpy impact value was extremely low. In the aluminum alloy casting IV(2), pores are contracted by the pressurization in the quenching process to increase the apparent specific gravity, while decreasing the porosity. Therefore, the Charpy impact value was remarkably high. This applies to the aluminum alloy castings V(1) and V(2). [0036]
  • Due to the rise of the heating temperature T in the heating process, the aluminum alloy castings IV (2) has a Charpy impact value higher than that of the aluminum alloy casting I(2) shown in Table 4 and obtained from the thermal treatment under the same thermal treatment conditions expect for the heating temperature T. This applies to the aluminum alloy castings V(2) and II(2). [0037]
  • Also in the heating process, it can be expected that the characteristics of the aluminum alloy casting can be improved by applying a pressure to the aluminum alloy casting. In this case, if the quenching is carried out under the application of the pressure, a time for raising the pressure in the quenching process can be eliminated, and a time for the quenching process can be greatly shortened. This is effective for providing an enhancement in productivity of the aluminum alloy castings. [0038]
  • According to the first feature of the present invention, it is possible to provide a thermal treating process by which a light alloy casting having an excellent roughness can be produced by employing the above-described means. [0039]
  • According to the second feature of the present invention, it is possible to provide a thermal treating process by which a light alloy casting having a further enhanced roughness can be produced by employing the above-described means. [0040]

Claims (2)

What is claimed is:
1. A process for thermally treating a light alloy casting, comprising a step of: heating a light alloy casting up to a solid solution range and maintaining it at such heating temperature T; and a step of quenching the light alloy casting through a cooling medium while pressurizing it.
2. A process for thermally treating a light alloy casting according to claim 1, wherein the heating temperature T is set at T>TS, wherein TS represents a solidus-line temperature for a light alloy forming the light alloy casting.
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JP2002262890A JP2004099962A (en) 2002-09-09 2002-09-09 Heat treatment method for light alloy casting

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CN103231013A (en) * 2013-04-22 2013-08-07 宁波合力模具科技股份有限公司 Transmission housing pouring method and sand casting mould used in transmission housing pouring method
CN103889746A (en) * 2011-10-11 2014-06-25 Ksm铸造集团有限公司 Cast part
CN108796402A (en) * 2017-05-02 2018-11-13 通用汽车环球科技运作有限责任公司 The method for improving the tensile strength of aluminium casting
EP3540086A1 (en) * 2018-03-15 2019-09-18 Toyota Jidosha Kabushiki Kaisha Method for manufacturing aluminum alloy member

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DE102007035940B4 (en) * 2007-07-31 2018-01-11 Bayerische Motoren Werke Aktiengesellschaft Method of manufacturing a crankcase or engine block
JP6419742B2 (en) * 2016-03-02 2018-11-07 株式会社豊田中央研究所 Aluminum alloy member and manufacturing method thereof
DE102016007450B4 (en) 2016-06-17 2021-07-01 Audi Ag Process for temperature control of a cast part

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US3866301A (en) * 1973-06-28 1975-02-18 Allegheny Ludlum Ind Inc Process for forming sheet material with excellent surface characteristics
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Cited By (7)

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Publication number Priority date Publication date Assignee Title
CN103889746A (en) * 2011-10-11 2014-06-25 Ksm铸造集团有限公司 Cast part
CN103231013A (en) * 2013-04-22 2013-08-07 宁波合力模具科技股份有限公司 Transmission housing pouring method and sand casting mould used in transmission housing pouring method
CN108796402A (en) * 2017-05-02 2018-11-13 通用汽车环球科技运作有限责任公司 The method for improving the tensile strength of aluminium casting
EP3540086A1 (en) * 2018-03-15 2019-09-18 Toyota Jidosha Kabushiki Kaisha Method for manufacturing aluminum alloy member
CN110273091A (en) * 2018-03-15 2019-09-24 丰田自动车株式会社 The method for manufacturing aluminium alloy element
US11214857B2 (en) 2018-03-15 2022-01-04 Toyota Jidosha Kabushiki Kaisha Method for manufacturing aluminum alloy member
US11761070B2 (en) 2018-03-15 2023-09-19 Toyota Jidosha Kabushiki Kaisha Method for manufacturing aluminum alloy member

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