US20050000604A1 - Aluminum alloy, cast article of aluminum alloy, and method for producing cast article of aluminum alloy - Google Patents

Aluminum alloy, cast article of aluminum alloy, and method for producing cast article of aluminum alloy Download PDF

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Publication number
US20050000604A1
US20050000604A1 US10/487,940 US48794004A US2005000604A1 US 20050000604 A1 US20050000604 A1 US 20050000604A1 US 48794004 A US48794004 A US 48794004A US 2005000604 A1 US2005000604 A1 US 2005000604A1
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aluminum alloy
cast
mass
set forth
cast products
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US10/487,940
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Inventor
Hiroshi Kawahara
Yoshihiro Shimizu
Yoshio Sugiyama
Toshio Horie
Hiroaki Iwahori
Yoshihiko Sugimoto
Minoru Yamashita
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Toyota Motor Corp
Toyota Central R&D Labs Inc
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Assigned to KABUSHIKI KAISHA TOYOTA CHUO KENKYUSHO, TOYOTA JIDOSHA KABUSHIKI KAISHA reassignment KABUSHIKI KAISHA TOYOTA CHUO KENKYUSHO ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HORIE, TOSHIO, IWAHORI, HIROAKI, KAWAHARA, HIROSHI, OKADA, YUJI, SHIMIZU, YOSHIHIRO, SUGIMOTO, YOSHIHIKO, SUGIYAMA, YOSHIO, YAMASHITA, MINORU
Publication of US20050000604A1 publication Critical patent/US20050000604A1/en
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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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002—Castings of light metals
    • B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C

Definitions

  • the present invention relates to an aluminum alloy, and a process for producing a cast product made of an aluminum alloy. More particularly, it relates to an aluminum alloy which shows castability suitable for even producing thin-thickness cast products and the like, and high strength as well as good ductility even as cast, and a process for producing cast products comprising the aluminum alloy.
  • a highly ductile aluminum alloy die cast which is characterized in that it comprises Mg: 2.5-7.0%, Mn: 0.2-1.0%, and Ti: 0.05-0.2%, and Fe in an amount of 0.3% and Si in an amount of 0.5% or less, a porosity is 0.5% or less at a heavy-thickness part ranging from 1 to 5 mm, the average circle-equivalent diameter of crystallized substances is 1.1 ⁇ m or less, and the areal ratio of crystallized substances is 5% or less.
  • This Al—Mg—Mn—Ti system alloy is such that Fe is treated as an inevitable impurity and the content is limited to less than 0.3%.
  • Ni is an essential constituent element, and the toughness of die-cast products are improved by adjusting the content appropriately. Moreover, since the Mn content is much, the crystallized amount of its compounds is so much that the elongation is 10% approximately as indicated by the examples.
  • the present invention has been done in view of such circumstances. Namely, it is an object to provide an aluminum alloy in which the occurrence and the like of hot tearing and micro porosity is less and accordingly which is good in terms of the castability. In particular, it is an object to provide an aluminum alloy from which cast products of high strength and good ductility can be obtained even as cast. Moreover, it is an object to provide an aluminum alloy whose cast products suffer the time change of mechanical characteristics and so forth less.
  • an aluminum alloy according to the present invention comprises: from 4.0 to 6.0% magnesium (Mg); from 0.3 to 0.6% manganese (Mn); from 0.5 to 0.9% iron (Fe); and the balance of aluminum (Al) and inevitable impurities when the entirety is taken as 100% by mass.
  • the present aluminum alloy (Al—Mg—Mn—Fe alloy) contains Mg, Mn and Fe with an appropriate composition proportion, the castability is improved, and high strength as well as high ductility are revealed.
  • Al—Mg—Mn—Fe alloy contains Mg, Mn and Fe with an appropriate composition proportion
  • the present inventors focused on the relationship between the crystallization form of crystallized substances in the solidification process and the castability or mechanical properties. And, they ascertained that the hot tearing of cast products made of aluminum alloys occurs often in brittle liquid phase portions which reside between primary-crystal Al dendrites growing in the solidification process.
  • shrinkage stresses act on cast products when the cast products are constricted by dies in a temperature range (semi-solidus temperature range) in which the cast products are shaped and begin to have strength in the process in which the cast products are being formed by the development and combination of primary-crystal dendrites; and the stresses concentrate on the brittle liquid phase portions which reside between the dendrites so as to cause the hot tearing frequently.
  • the present inventors thought of adding Fe to Al—Mg-Mn alloys, and changed the crystallization behavior in the solid-liquid coexisting zone by adjusting the Mn and Fe contents according to the Mg content so that they succeeded in obtaining good hot tearing resistance.
  • the crystallization temperature zone of primary-crystal Al was narrowed so that Al—Mn—Fe eutectics were crystallized between the network isthmuses of primary-crystal Al, which had finished crystallizing, without growing the dendrites of primary-crystal Al greatly.
  • the connection between respective solid phases developed rapidly under the circumstance, it is believed that the hot tearing was less likely to occur.
  • the present aluminum alloy can comprise primary-crystal aluminum and compounds which are dispersed uniformly, the primary-crystal aluminum having a dendritic cell size of 10 ⁇ m or less, the compounds having a grain diameter of 5 ⁇ m or less, it is more suitable in view of the strength and ductility. Moreover, it is more preferable when the dendritic cell size of said primary-crystal aluminum can be 5 ⁇ m or less and the grain diameter of said compounds can be 3 ⁇ m or less.
  • the size of the dendritic cells is a length when measured in the longitudinal direction, and is an average value of the measured values for 100 pieces of the cells.
  • the grain diameter of the compounds is assessed in the longitudinal direction (the maximum length), and is an average value of measured values on 10 view fields of a structural photograph (view field area, 70 ⁇ 100 ⁇ m) which is taken with a magnification of 100 times by using an image processor.
  • the present aluminum alloy even when thin-thickness die-cast products are produced, for example, it is possible to obtain cast products provided with sufficient strength and good ductility without hardly causing porosity such as hot tearing and shrinkage cavities. For instance, it is possible to obtain an aluminum alloy which exhibits a 0.2% proof stress of 130 MPa or more and a fracture elongation of 13% or more as cast being free from being subjected to a heat treatment after casting.
  • the aluminum alloy solution-strengthened by Mg and Mn falling in the aforementioned composition range is provided with an advantage that the change of mechanical properties with time is less without scarcely causing the hardness change by natural aging.
  • a cast product comprising the above-described present aluminum alloy can be obtained by the following production process, for example.
  • a process according to the present invention for producing a cast product made of an aluminum alloy comprises the steps of: pouring an aluminum alloy molten metal into a die, the aluminum alloy molten metal comprising: from 4.0 to 6.0% Mg; from 0.3 to 0.6% Mn; from 0.5 to 0.9% Fe; and the balance of Al and inevitable impurities when the entirety is taken as 100% by mass; and solidifying the aluminum alloy molten metal by cooling it after the pouring step.
  • said solidifying step can be a step being solidified by cooling at a cooling rate of 20° C./sec. or more.
  • the cooling rate can be 50° C./sec. or more.
  • the “aluminum alloy” set forth in the present invention not only involves aluminum alloys as a raw material for casting but also cast products (manufactured goods) made of aluminum alloys after casting.
  • the present invention can be grasped as a cast product made of an aluminum alloy, the cast product comprising: from 4.0 to 6.0% Mg; from 0.3 to 0.6% Mn; from 0.5 to 0.9% Fe; and the balance of Al and inevitable impurities when the entirety is taken as 100% by mass.
  • the “castability” set forth in the present specification is a concept which involves not only the molten metal fluidity, the releasability and the like but also the occurrence rate and so forth of hot tearing and shrinkage cavities (porosity)
  • FIG. 1 is a cross-sectional view for illustrating avertical die-casting machine equipped with a die for assessing hot tearing, die which is capable of varying the constriction length.
  • FIG. 2 is a cross-sectional view taken along the line “A-A” in FIG. 1 .
  • FIG. 3 is a bar graph for illustrating the relationship between the constriction length and castability on each test sample.
  • FIG. 4 is a graph for illustrating the relationship between the hot tearing characteristics and the Fe content.
  • Mg is an element which solves in the matrix of aluminum to improve the mechanical strength (for example, the tensile strength) of aluminum alloys. Moreover, Mg is an element which exerts influences on the ductility and castability of aluminum alloys as well.
  • Mg is comprised less than 4.0% (percentage by mass, being the same hereinafter), the improvement of mechanical strength is not sufficient, especially, it is difficult to secure a proof stress (a 0.2% proof stress, being the same hereinafter) of 130 MPa or more.
  • a proof stress a 0.2% proof stress, being the same hereinafter
  • Mg is comprised in excess of 6.0%, the oxidation of molten metals is significant.
  • the composition of Mn and Fe whose coarse crystallized substances start crystallizing as primary crystals according to the Mg content increment moves to a lower concentration side, the ductility is deteriorated by the crystallization of the coarse crystallized substances when the Mg content exceeds 6% in the case where Mn and Fe fall in the aforementioned composition range.
  • Mg can be comprised from 4.0 to 6.0%, and it is further preferable that it can be comprised from 4.0 to 5.0%, when the entirety is taken as 100% by mass.
  • Mn is an element which improves the mechanical strength of aluminum alloys by solving in the matrix of aluminum similarly to Mg, or by generating compounds with aluminum to precipitate them micro-finely in the matrix. Moreover, it also produces an effect of improving the anti-seisurability to dies.
  • Mn is comprised less than 0.3%, the improvement of mechanical strength is not sufficient, and when it is comprised in excess of 0.6%, it is not preferable because coarse crystallized substances crystallize to result in lowering the ductility.
  • Mn can be comprised from 0.3 to 0.6%, and it is further preferable that it can be comprised from 0.3 to 0.5%, when the entirety is taken as 100% by mass.
  • Fe is an element which changes the crystallization process in solidification to inhibit hot tearing resulting from solidification shrinkage. Moreover, Fe also produces an effect of improving the anti-seisurability to dies when die-casting is carried out.
  • Fe When Fe is comprised less than 0.5%, it is insufficient to change the crystallization process greatly, and the effect of inhibiting hot tearing is less. On the other hand, when Fe is comprised in excess of 0.9%, it is not preferable because coarse crystallized substances crystallize to lower the ductility. Therefore, it is preferable that Fe can be comprised from 0.5 to 0.9% when the entirety is taken as 100% by mass.
  • Fe can be comprised from 0.5 to 0.8% or from 0.5 to 0.7%.
  • Cr is an element which improves the mechanical strength of aluminum alloys by solving in the matrix of aluminum similarly to Mg and Mn.
  • Cr can be comprised from 0.1 to 0.7%, and it is further preferable that it can be comprised from 0.2 to 0.5%, when the entirety is taken as 100% by mass.
  • Ti and B become the nucleation site of primary-crystal Al. Accordingly, when those elements are added to increase, the respective crystalline grain diameters of primary-crystal Al diminish. As a result, a solid-liquid fluidic state is maintained to a higher solid-phase ratio side, and consequently the timing of stress occurrence by solidification shrinkage is put off on a lower temperature side so that it is believed that the resistance against hot tearing is improved. Specifically, it is believed as follows.
  • Ti becomes the nucleation site of ⁇ -Al, constitutes micro-fine structures, and reveals the effects of inhibiting hot tearing as well as improving the ductility, moreover, can improve the proof stress of aluminum alloys as well.
  • Ti can be includedwhen the entirety is taken as 100% by mass. It results from the fact that, when Ti is comprised less than 0.01%, no micro-fine structure can be obtained; and when Ti is comprised in excess of 0.3%, coarse crystallized substances (Al 3 Ti and the like) crystallize to result in lowering the ductility. It is more preferable that Ti can be comprised from 0.1 to 0.2%.
  • B When B is comprised less than 0.01%, no micro-fine structure can be obtained, and when it is comprised in excess of 0.05%, it is not economical because the variation of crystalline grain diameters is less. Therefore, in the coexistence with Ti, it is suitable that 0.01-0.05% boron (B) can be included when the entirety is taken as 100% by mass. It is more suitable that it can be comprised from 0.03 to 0.05%. Note that it is economical that B can be added as titanium boride such as TiB 2 in addition to the case where it is added as a simple substance.
  • Be reveals an effect on the oxidation resistance even independently, and inhibits decrease of Mg resulting from oxidation when it dissolves.
  • Be beryllium
  • Mo produces an effect of inhibiting the slag generation accompanied by the oxidation of Al—Mg alloy molten metals.
  • Mo can be comprised from 0.05 to 0.3%, and it is further preferable that it can be comprised from 0.1 to 0.2%, when the entirety is taken as 100% by mass.
  • the types and contents are not limited, however, the present inventors found out that the castability of aluminum alloys, and the strength or ductility can be improved by controlling the content of Si and Cu, inevitable impurities.
  • Si an inevitable impurity
  • Cu can be comprised 0.3% or less.
  • Mg 2 Si is an inevitable impurity which is included in aluminum bare metal, and, when it is contained in excess of 0.5%, it is not preferable because Mg 2 Si precipitates in the matrix by natural aging to change the mechanical characteristics of aluminum alloys with time.
  • Cu not only promotes hot tearing but also lowers corrosion resistance. Therefore, when an aluminum alloy according to the present invention is used as structural members, especially, it is preferable that it can be comprised 0.3% or less.
  • the present aluminum alloy or process for producing a cast product can be utilized in a variety of cast products made of aluminum alloys.
  • the present aluminum alloy is of high strength and high ductility even as cast, it is naturally advisable to carry out cold working or heat treatments after casting.
  • Aluminum alloys were used which had an alloy composition of Sample Nos. 1 through 5 and Sample Nos. C1 through C7 set forth in Table 1, test samples were produced for each of the samples, test samples whose constriction length was changed variously, and each of the hot tearing characteristics was assessed. Note that Table 1 indicates themwhile Al, the major component, is abbreviated (being the same hereinafter).
  • FIG. 1 various test samples were produced by a vertical die-casting machine equipped with a die whose cavity had a cross-section of 7 mm in thickness and 10 mm in width and constriction length was changeable variously, and the hot tearing characteristics assessment was carried out.
  • the casting conditions were such that the melting temperature was 750° C.; the die temperature was from 50 to 100° C.; the casting pressure was 63.7 MPa; and the plunger speed was 0.6 m/s. After the respective molten metals were poured by pressurizing with the plunger (a pouring step), they were solidified at a cooling rate of 100° C./sec. approximately (a solidifying step).
  • FIG. 2 a cross-sectional view taken along the line “A-A” in FIG. 1 .
  • Aluminum alloys were used which had an alloy composition of Sample Nos. 6 through 14 and Sample Nos. C8 through C10 set forth in Table 1, and plate-shaped cast products whose thickness was 2 mm, width was 50 mm and length was 70 mm were produced by the vertical die-casting machine.
  • the casting conditions were such that the melting temperature was 750° C.; the die temperature was from 50 to 100° C.; the casting pressure was 63.7 MPa; and the plunger speed was 1.4 m/s. Moreover, after the molten metals were poured by pressurizing with the plunger (a pouring step), they were solidified at a cooling rate of 100° C./sec. approximately (a solidifying step)
  • plate-shaped tensile test samples were produced whose flat-surface portions were as-cast surfaces.
  • the respective test samples were used to examine the tensile strength, 0.2% proof stress and fracture elongation.
  • the results are set forth in Table 2. Note that the tensile test on the respective test samples was carried out with an autograph tensile testing machine made by SHIMAZU, and the aforementioned characteristics were found from the stress-strain diagram obtained for the respective test samples.
  • Aluminum alloys were used which had an alloy composition of Sample Nos. 15 through 19 and Sample Nos. C11 and C12 set forth in Table 1, and as-cast plate-shaped cast products were produced in the same manner as Example No. 2.
  • the Vickers hardness was such that ahardness meter made by AKASHI was used; a load of 5 kg was loaded for 30 seconds; and the hardness was determined by converting the size of the indentation made in this instance.
  • test samples were produced in the same manner as Example No. 1, test samples which comprised the alloy composition of Sample Nos. 20 through 26 set forth in Table 4 and had various constriction lengths. The respective samples were such that the Fe content was varied mainly while the Mg, Mn and Ti contents were made equal approximately. Assessing the hot tearing resistance by the constriction length at which a crack occurred was the same as the case of Example No. 1 as well. The thus obtained test results of the respective test samples are illustrated in FIG. 4 .
  • Al alloy molten metals were prepared which comprised the alloy composition of Sample No. 27 and Sample No. 28. The respective molten metals weremeasured for the weight in advance. Thesemolten metals were put in a crucible made of alumina, and were held at 750° C. for 5 hours in an aerial atmosphere.
  • Sample No. 7 an aluminum alloy of Sample No. 6 with Ti contained, was such that the crystal grains were more micro-fined so that the ductility was further improved.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Continuous Casting (AREA)
US10/487,940 2001-09-04 2002-08-30 Aluminum alloy, cast article of aluminum alloy, and method for producing cast article of aluminum alloy Abandoned US20050000604A1 (en)

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JP2001267932 2001-09-04
JP2001-267932 2001-09-04
PCT/JP2002/008854 WO2003023080A1 (fr) 2001-09-04 2002-08-30 Alliage d'aluminium, article moule fait d'un alliage d'aluminium, et procede de production d'un article moule fait d'un alliage d'aluminium

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CN100393450C (zh) * 2006-12-13 2008-06-11 中国铝业股份有限公司 3104铝合金扁锭低温铸造方法
CN100393451C (zh) * 2006-12-13 2008-06-11 中国铝业股份有限公司 3104铝合金扁锭铸造方法
US20120121825A1 (en) * 2010-11-16 2012-05-17 Sang-Joon Park Bottom chassis, method of fabricating the same, and liquid crystal display including the same
US20150044090A1 (en) * 2012-02-29 2015-02-12 Nsk Ltd. Strength Evaluation Method of Die Casting Product and Die Casting Product
US20160228946A1 (en) * 2013-10-09 2016-08-11 Tohoku University Semisolid casting and forging device and method, and cast and forged product
US20160250684A1 (en) * 2011-09-15 2016-09-01 Tohoku University Die-casting apparatus, die-casting method, and diecast article
GB2568310A (en) * 2017-11-14 2019-05-15 Jaguar Land Rover Ltd Aluminium alloy for high presure die casting
CN113286912A (zh) * 2019-01-16 2021-08-20 丰田自动车株式会社 铝合金的再生方法
US11203801B2 (en) 2019-03-13 2021-12-21 Novelis Inc. Age-hardenable and highly formable aluminum alloys and methods of making the same
CN115786785A (zh) * 2022-11-17 2023-03-14 大连科天新材料有限公司 一种高强韧免热处理压铸铝镁合金、其制备方法及应用

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CN105886856B (zh) * 2014-12-29 2018-12-25 通力股份公司 一种铝合金,由其制造的机械部件,以及其用途
JP6900199B2 (ja) * 2017-02-10 2021-07-07 エス・エス・アルミ株式会社 鋳造用アルミニウム合金、アルミニウム合金鋳物製品およびアルミニウム合金鋳物製品の製造方法
EP3878991A4 (fr) * 2018-11-07 2021-12-15 Nippon Light Metal Co., Ltd. Alliage d'aluminium destiné à une coulée sous pression et matériau d'alliage d'aluminium coulé sous pression

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US6214479B1 (en) * 1996-10-23 2001-04-10 Kabushiki Kaisha Toyota Chuo Kenkyusho Covered member and method of producing the same
US6132531A (en) * 1997-07-18 2000-10-17 Aluminum Company Of America Alloy and cast alloy components
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Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN100393450C (zh) * 2006-12-13 2008-06-11 中国铝业股份有限公司 3104铝合金扁锭低温铸造方法
CN100393451C (zh) * 2006-12-13 2008-06-11 中国铝业股份有限公司 3104铝合金扁锭铸造方法
US20120121825A1 (en) * 2010-11-16 2012-05-17 Sang-Joon Park Bottom chassis, method of fabricating the same, and liquid crystal display including the same
US8580359B2 (en) * 2010-11-16 2013-11-12 Samsung Display Co., Ltd. Bottom chassis, method of fabricating the same, and liquid crystal display including the same
US20160250684A1 (en) * 2011-09-15 2016-09-01 Tohoku University Die-casting apparatus, die-casting method, and diecast article
US10384262B2 (en) * 2011-09-15 2019-08-20 Tohoku University Die-casting apparatus, die-casting method, and diecast article
US20150044090A1 (en) * 2012-02-29 2015-02-12 Nsk Ltd. Strength Evaluation Method of Die Casting Product and Die Casting Product
US20160228946A1 (en) * 2013-10-09 2016-08-11 Tohoku University Semisolid casting and forging device and method, and cast and forged product
US10118219B2 (en) * 2013-10-09 2018-11-06 Tohoku University Semisolid casting/forging apparatus and method as well as a cast and forged product
GB2568310A (en) * 2017-11-14 2019-05-15 Jaguar Land Rover Ltd Aluminium alloy for high presure die casting
CN113286912A (zh) * 2019-01-16 2021-08-20 丰田自动车株式会社 铝合金的再生方法
US11203801B2 (en) 2019-03-13 2021-12-21 Novelis Inc. Age-hardenable and highly formable aluminum alloys and methods of making the same
US11932924B2 (en) 2019-03-13 2024-03-19 Novelis, Inc. Age-hardenable and highly formable aluminum alloys and methods of making the same
CN115786785A (zh) * 2022-11-17 2023-03-14 大连科天新材料有限公司 一种高强韧免热处理压铸铝镁合金、其制备方法及应用

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JP4145242B2 (ja) 2008-09-03
DE60220835D1 (de) 2007-08-02
EP1477577A4 (fr) 2004-11-17
EP1477577B1 (fr) 2007-06-20
WO2003023080A1 (fr) 2003-03-20
EP1477577A1 (fr) 2004-11-17
DE60220835T2 (de) 2008-03-06
JPWO2003023080A1 (ja) 2004-12-24

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