US20050150577A1 - Magnesium alloy and magnesium alloy die casting - Google Patents

Magnesium alloy and magnesium alloy die casting Download PDF

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US20050150577A1
US20050150577A1 US11/030,967 US3096705A US2005150577A1 US 20050150577 A1 US20050150577 A1 US 20050150577A1 US 3096705 A US3096705 A US 3096705A US 2005150577 A1 US2005150577 A1 US 2005150577A1
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alloy
percent
weight
casting
grain refining
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Kuniteru Suzuki
Kinji Hirai
Hiroshi Nishinaga
Kenji Higashi
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ADVANCED TECHNOLOGIES Inc
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Takata Corp
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Priority claimed from JP2004004285A external-priority patent/JP4589630B2/ja
Priority claimed from JP2004175334A external-priority patent/JP4242807B2/ja
Priority claimed from JP2004252764A external-priority patent/JP4723835B2/ja
Application filed by Takata Corp filed Critical Takata Corp
Assigned to HIGASHI, KENJI, TAKATA CORPORATION reassignment HIGASHI, KENJI ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HIGASHI, KENJI, HIRAI, KINJI, NISHINAGA, HIROSHI, SUZUKI, KUNITERU
Publication of US20050150577A1 publication Critical patent/US20050150577A1/en
Assigned to ADVANCED TECHNOLOGIES, INC. reassignment ADVANCED TECHNOLOGIES, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: TAKATA CORPORATION
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    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D29/00—Independent underground or underwater structures; Retaining walls
    • E02D29/02—Retaining or protecting walls
    • E02D29/0258—Retaining or protecting walls characterised by constructional features
    • E02D29/0266—Retaining or protecting walls characterised by constructional features made up of preformed elements
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C23/00—Alloys based on magnesium
    • C22C23/02—Alloys based on magnesium with aluminium as the next major constituent
    • A—HUMAN NECESSITIES
    • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01G—HORTICULTURE; CULTIVATION OF VEGETABLES, FLOWERS, RICE, FRUIT, VINES, HOPS OR SEAWEED; FORESTRY; WATERING
    • A01G9/00—Cultivation in receptacles, forcing-frames or greenhouses; Edging for beds, lawn or the like
    • A01G9/02—Receptacles, e.g. flower-pots or boxes; Glasses for cultivating flowers

Definitions

  • the present invention relates to a lightweight magnesium alloy having a high specific rigidity.
  • the present invention relates to a die casting magnesium alloy and a magnesium die casting including the same.
  • magnesium alloys are lightest high specific rigidity raw materials having a high electromagnetic shielding property and high thermal conductivity.
  • AZ91 Mg alloy is the most widely used Mg casting alloy for forming housing materials of portable electronic equipment, such as notebook personal computers and cellular phones, portable electric tools, and the like.
  • This AZ91 alloy has excellent strength, corrosion resistance, moldability, and the like, and is widely used as a balanced casting alloy for die casting. However, this AZ91 alloy is believed to be unsuitable for applications to automobiles, motorcycles, and the like required to have high mechanical properties with respect to elongation, bending, and heat resistance. Consequently, in general, an AM60 alloy and an AM50 alloy containing a reduced amount of aluminum and having improved elongation are used for these applications.
  • One of the prior art heat resistant alloys is produced by improving the AM 50 alloy or the AM 60 alloy.
  • the base thereof is Al: 2% to 9% and Sr: 0.5% to 7%, preferably is Al: 4% to 6%, and is Al: 4.5% to 5.5% and Zn: 0.35% or less (AM alloy level).
  • the comparison between the alloy based on the above-described known technology and the AZ91 alloy is described, for example, in Pekguleryuz and Baril, Development of Creep Resistant Mg—Al—Sr Alloys, Magnesium Technology 2001, J. Hryn, Ed., pages 119-125.
  • FIG. 17 is a diagram showing the content of comparisons described in this document.
  • the above-described alloys produced by improving the AM 50 alloy or the AM 60 alloy include the following problems.
  • the lower row indicates an example of the above mentioned prior art alloys hereafter referred to as “known alloys”).
  • the tensile strength of this alloy at room temperature is about 15% lower than that of the AZ91 alloy.
  • the tensile strength at 175° C. is improved by about 7%, the elongation values at room temperature and at 175° C. are reduced.
  • the creep characteristic value and the like is actually improved.
  • the material is used practically, since the material is exposed to from room temperature to a high temperature of about 175° C., the properties at room temperature cannot be neglected. In the above-described known technology, such a point is not taken into consideration and, therefore, reduction of the strength at room temperature cannot be prevented.
  • FIGS. 1A and 1B are diagrams showing the melting point characteristic of an alloy in which Ca and Sr, and Sb, Ca and Sr, respectively, are added to an AZ91 alloy.
  • FIG. 1C is a diagram showing the melting point characteristic of alloys of the third preferred embodiment of the invention.
  • FIG. 2 is a diagram showing the change characteristic of the crystal grain size in the case where Ca is added to the AZ91 alloy.
  • FIG. 3A is a diagram showing the change characteristic of the crystal grain size in the case where Ca and Sr are added to the AZ91 alloy.
  • FIG. 3B is a diagram showing the effect of an addition of a grain refining agent to an AZ91 base alloy.
  • FIG. 3C is a diagram showing the effect of addition of Sr to an AZ91SbCa alloy.
  • FIG. 4 is a diagram showing an example of melting of an AZ91CaSr alloy.
  • FIGS. 5A and 5B are diagrams showing the range of proportion of addition of grain refining agents to the AZ91 alloy in first and second embodiments of the present invention, respectively.
  • FIGS. 6A and 6B are diagrams showing the behavior of change in crystal grain size ratio of the AZ91 alloy versus the AZ91CaSr alloy and the AZ91SbCaSr alloy, respectively.
  • FIGS. 7A and 7B are diagrams showing compositions of alloy ingots according to the first and third embodiments of the invention.
  • FIGS. 8A and 8B are diagrams showing the behavior of filling factor of the alloys.
  • FIGS. 9A and 9B are diagrams showing the behavior of room temperature tensile strength of the alloys.
  • FIGS. 10A and 10B are diagrams showing the behavior of room temperature elongation characteristic of the alloys.
  • FIGS. 11A, 11B and 11 C are diagrams showing the behavior of the relationship between the high-temperature strain rate and the flow stress of the alloys.
  • FIGS. 12A, 12B and 12 C are diagrams showing the behavior of the relationship between the high-temperature strain rate and the creep elongation value of the alloys.
  • FIGS. 13A, 13B and 13 C are diagrams showing the relationship between the high-temperature creep rate and the stress of various magnesium alloys.
  • FIG. 14 is a diagram showing test conditions of a creep test.
  • FIGS. 15A, 15B and 15 C are diagrams showing compositions of raw ingots used in a corrosion resistance test.
  • FIGS. 16A, 16B and 16 C are diagrams showing the results of the corrosion resistance tests.
  • FIG. 17 is a diagram showing the content of comparisons of alloy characteristics described in known technical documents.
  • the embodiments of the invention provide a die casting magnesium alloy capable of improving the high-temperature creep characteristics without causing reduction of the room temperature strength and a magnesium die casting including the same.
  • the magnesium alloy comprises an AZ91 alloy preferably containing a grain refining agent, which preferably comprises at least two different grain refining elements.
  • the alloy contains strontium (Sr) and at least one of calcium (Ca) and antimony (Sb) as the grain refining agent.
  • the alloy contains Sr and Ca as the grain refining agent.
  • the alloy contains Sr and Sb, or Sr, Sb and Ca as the grain refining agent.
  • the base alloy contains at least one element selected from silicon (Si), misch metal containing a simple substance of rare earth (RE), zirconium (Zr), scandium (Sc), yttrium (Y), tin (Sn), and barium (Ba), and a grain refining agent selected from Sr and at least one of Sb and Ca.
  • the AZ91 die casting magnesium alloy preferably comprises a base alloy of magnesium containing Al, Zn and Mn alloying elements, and grain refining agents selected from Sr and at least one of Sb and Ca.
  • the base alloy preferably contains at least 70 percent Mg by weight, such as at least 80 percent Mg by weight, for example about 85 to about 93 percent by weight Mg.
  • the base alloy further comprises 6.0 to 11.0 percent by weight of aluminum, such as 7.0 to 11.0 percent aluminum, preferably 8.5 to 10 percent aluminum, 0.1 to 2.5 percent by weight of zinc, preferably 0.3 to 2.1 percent zinc, and 0.1 to 0.5 percent by weight of manganese, preferably 0.18 to 0.36 percent manganese.
  • the alloy may also contain other unavoidable impurities in a trace amount.
  • the base alloy is AZ91
  • reduction of the strength characteristics at room temperature can be prevented in contrast to the AM60-based alloys.
  • the alloy structure can be improved and the crystal grain size can be made fine, and excellent high-temperature creep characteristics equivalent to or better than the characteristics of an AS21 alloy known as a heat-resistant magnesium alloy can be attained.
  • an alloy having improved high-temperature creep characteristics can be realized without causing reduction of the room temperature strength.
  • the grain refining agents preferably comprise 1.1 to 5 weight percent of the AZ91 alloy.
  • the grain refining agents comprise 1.0 to 3.5 percent by weight of calcium and 0.1 to 1.5 percent by weight of strontium which are added to the AZ91-based alloy.
  • the average crystal grain size can be reliably controlled at 20 ⁇ m or less in a casting, such as 13 to 19 microns, for example. Since Ca and Sr are added to the AZ91 alloy, reduction of the strength characteristics at room temperature is prevented.
  • the alloy structure can be improved by the addition of Ca and Sr, the crystal grain size can be made fine, and the high-temperature creep characteristics can be improved.
  • the above described AZ91 base alloy contains grain refining agents which comprise Sr and at least one of Sb and Ca.
  • the grain refining agents comprise all three of Sr, Sb and Ca.
  • the alloy preferably contains 0.1 to 2.5 percent by weight Sr, such as 0.1 to 1.5 percent Sr, preferably 0.5 to 2.1 percent Sr.
  • the alloy also preferably contains 0 to 1.5 percent by weight Sb, such as 0.1 to 1.5 percent Sb, preferably 0.3 to 1.2 percent Sb.
  • the alloy also preferably contains 0.05 to 3.5 percent by weight Ca, such as 0.2 to 3.5 percent Ca, preferably 0.5 to 2.1 percent Ca.
  • the crystal grain size can be reliably controlled at 20 ⁇ m or less, and excellent high-temperature creep characteristics equivalent to or better than the characteristics of an AS21 alloy known as a heat-resistant magnesium alloy can be reliably attained.
  • an alloy having improved high-temperature creep characteristics can be reliably realized without causing reduction of the room temperature strength.
  • the AZ91 die casting magnesium alloy comprises a base alloy of magnesium containing Al, Zn and Mn alloying elements, at least one alloy element which enters gaps of grain boundary products Mg 17 Al 12 ( ⁇ phase) and/or Al 2 Ca crystals generated by addition of Ca and divide these phases, and grain refining agents selected from Sr and at least one of Sb and Ca.
  • the base alloy preferably contains at least 70 percent Mg by weight, such as at least 80 percent Mg by weight, for example about 85 to about 93 percent by weight Mg.
  • the base alloy further comprises 6.0 to 11.0 percent by weight of aluminum, such as 7.0 to 11.0 percent aluminum, preferably 8.5 to 10 percent aluminum, 0.1 to 2.5 percent by weight of zinc, preferably 0.3 to 2.1 percent zinc, and 0.1 to 0.5 percent by weight of manganese, preferably 0.18 to 0.36 percent manganese.
  • the base alloy also contains at least one element which enters and divides the beta phase and Al 2 Ca crystals, selected from at least any one of silicon (Si): 0.1 to 1.5 percent by weight, misch metal containing a simple substance of rare earth (RE): 0.1 to 1.2 percent by weight, zirconium (Zr): 0.2 to 0.8 percent by weight, scandium (Sc): 0.2 to 3.0 percent by weight, yttrium (Y): 0.2 to 3.0 percent by weight, tin (Sn): 0.2 to 3.0 percent by weight, and barium (Ba): 0.2 to 3.0 percent by weight. Any combination of these elements may be provided in the alloy.
  • the alloy also contains the grain refining agents which comprise Sr and at least one of Sb and Ca.
  • the grain refining agents comprise all three of Sr, Sb and Ca.
  • the alloy preferably contains 0.1 to 2.5 percent by weight Sr, such as 0.1 to 1.5 percent Sr, preferably 0.5 to 2.1 percent Sr.
  • the alloy also preferably contains 0 to 1.5 percent by weight Sb, such as 0.1 to 1.5 percent Sb, preferably 0.3 to 1.2 percent Sb.
  • the alloy also preferably contains 0.05 to 3.5 percent by weight Ca, such as 0.2 to 3.5 percent Ca, preferably 0.5 to 2.1 percent Ca.
  • the alloy may also contain unavoidable impurities.
  • the AZ91 alloy includes elements which improve the high-temperature creep characteristics of the alloy while maintaining the high moldability and the high ambient temperature strength.
  • the addition of Sb, Ca, and Sr grain refining agents improves the alloy structure and the crystal grain size can be made fine.
  • one or more of silicon, misch metal containing a simple substance of rare earth, zirconium, scandium, yttrium, tin, and barium are added to the AZ91 alloy.
  • These alloying elements enter the gaps of grain boundary products Mg 17 Al 12 ( ⁇ phase) and Al 2 Ca crystals generated by addition of Ca, which are assumed to be weak points in the characteristics of the AZ91 alloy, and divide those phases, so that the alloy strength can be increased.
  • harmful effects such as deterioration of moldability, occur.
  • AZ91 alloy contains at least any one of Si, RE, Zr, Sc, Y, Sn, and Ba, which are added to the AZ91 alloy to the extent that the moldability is not significantly changed. Consequently, reduction of the room temperature strength is prevented, and the moldability is maintained. Since these elements deposit (i.e., are located) in the gaps of ⁇ phases, which deposit at grain boundaries and become a cause of weakness, and divide those phases, the high-temperature creep characteristics can be improved reliably.
  • a magnesium die casting (i.e., a die cast part) is made by die-casting of the die casting AZ91-based magnesium alloy of the first, second or third embodiments.
  • the die casting can be produced with good moldability by the use of the above described AZ91 alloys having improved high-temperature creep characteristics without causing reduction of the room temperature strength.
  • the inventors of the present invention conducted various experiments on die casting magnesium alloys and die castings to achieve an alloy having improved high-temperature creep characteristics while maintaining the excellent characteristics of the AZ91 alloy and without causing reduction of the room temperature strength in contrast to known alloys.
  • the crystal grain size becomes about 40 ⁇ m, and crystal grains are significantly made fine compared with the crystal grain size of about 200 to 300 ⁇ m of the alloy subjected to usual gravity casting. Therefore, grain refining agent used previously in the gravity casting were believed in the prior art to be unnecessary for the die-casting.
  • the inventors of the present invention intentionally added the grain refining agent to the die casting alloy, and attempted die-casting of an ingot of this alloy.
  • grain refining agents such as hexachloroethane
  • some grain refining agents have a high refining effect but release a chlorine gas when being added.
  • Other grain refining agents, such as metal Na, are attended with significant danger in its handling.
  • the inventors selected Sr and at least one of Sb and Ca as grain refining agents. The effects of these agents are not impaired by remelting for die-casting.
  • melting points of the AZ91 alloy and an alloy according to the first embodiment in which 1% of Ca and 0.5% of Sr were added to the AZ91 alloy were measured by a furnace cooling method.
  • the alloy including Ca and Sr had a melting point slightly lower than the melting point of the AZ91 alloy, as shown in FIG. 1A .
  • an alloy according to the second embodiment which contains 0.5% Sr, 0.5% Sb and 0.5% Ca had slightly lower melting point and freezing point temperatures than the alloy of the first embodiment.
  • the alloy of the third embodiment as shown in FIG.
  • the alloy melting point temperature is either maintained or reduced compared to the prior art AZ91 alloy.
  • a mixed rare earth metal (“MM”) containing 51% Ce by weight is used as the rare earth source.
  • FIG. 2 shows the measurement results of the crystal grain size in the case where Ca was added to the AZ91 alloy.
  • FIG. 3A shows the results in the case where Sr was added to a melt in which 1% of Ca was added to the AZ91 alloy of the first embodiment.
  • FIG. 3B shows the effect of addition of refining agents to the alloy of the second embodiment.
  • FIG. 3C shows the result when Sr is added to the alloy of the second embodiment containing 0.5% Sb and 0.5% Ca.
  • FIG. 4 shows an example of melting of an AZ91CaSr alloy.
  • FIG. 5A collectively shows the results of measurement of the crystal grain size on a sample basis where the amounts of addition of Ca and Sr were changed in the alloy of the first embodiment.
  • FIG. 5B shows the same results for the alloy of the second and third embodiments.
  • the grain size was 40 ⁇ m, and even when Ca or Sr was added alone, it was unable to make the grain size 20 ⁇ m or less.
  • the grain size was allowed to become 20 ⁇ m or less.
  • Ca is 1.0 percent by weight or more and 3.5 percent by weight or less
  • Sr is 0.1 percent by weight or more and 1.5 percent by weight or less in the alloy of the first embodiment.
  • FIG. 3B shows the results of addition of Sb and Ca to the AZ91 alloy.
  • the result indicated by ⁇ is derived from addition of Sb up to 1% followed by addition of Ca up to 2.5%. It is clear that the effect of Sb alone is slightly smaller, but an effect substantially equivalent to the effect of Ca is provided by the addition of Sb and Ca in combination. Thus, an average grain size between 20 and 30 microns may still be obtained without adding Sr.
  • FIG. 3C shows an example in which Sr was added to the melt after the combined Sb and Ca addition.
  • Sr was added to the melt after the combined Sb and Ca addition.
  • the crystal grain size was reduced to 20 ⁇ m or less.
  • an alloy in which 0.5% to 1.0% each of Si, RE, and Zr are added was subjected to the test, and similar results were exhibited with respect to the crystal grain size. Although respective crystals specific to Si, RE, and Zr appeared dispersedly (i.e., were dispersed in the alloy), the entire crystal grain size was not changed.
  • FIG. 5B shows an example of the examination results of the relationship between Sb, Ca, and Sr specified to be at various levels and the crystal grain size.
  • the AZ alloys comprise the alloys of the second and third embodiments and refer to AZ91+0.5% Si alloy, AZ91+0.5% RE alloy, and AZ91+0.5% Zr alloy, in addition to the AZ91 alloy.
  • the grain size can be made 20 ⁇ m or less when combined addition is performed within the range surrounded by a dotted line, i.e. Sb: 0.5%, Ca: 0.5% to 3.0%, and Sr: 0.1 to 2.5%. As shown in FIG.
  • the present inventors also conducted another experiment, and found out that it was not necessary to add the elements of the third embodiment which enter the beta phase gaps (i.e., Si, RE, Zr, and the like) to the AZ91 alloy to reduce the grain size as described above, and the refining effect as in the above description was able to be attained when Sr: 0.1% to 2.5% and at least any one of Sb: 0.1% to 1.5% and Ca: 0.05% to 3.5% were added.
  • the elements of the third embodiment which enter the beta phase gaps i.e., Si, RE, Zr, and the like
  • the crystal grain size of the die casting was substantially equal to (i.e., about 1 to 1.03 times) the crystal grain size of the alloy cast into a pipe mold.
  • the crystal grain size ratio of the AZ91CaSr alloy of the first embodiment and the AZ91SbCaSr alloy of the second embodiment to the AZ91 alloy was about 0.33 to about 0.34, even under different casting and molding conditions and, therefore, the size was made fine. Since it has been previously believed in the art that the grain refining agent is useless in die castings, this is believed to be a new finding.
  • the alloys exhibited a tensile strength of above 230 MPa at room temperature.
  • the strength of the AZ91 alloy was reduced by the solution treatment.
  • bubbles were observed in some locations of the AZ91 alloy. It is believed that these were responsible for deterioration of the properties and reduction of the filling factor.
  • the Ca and Sr containing alloy and the Sb, Ca and Sr containing alloy were subjected to the solution treatment, reduction of the strength did not occur, nor were any bubbles observed.
  • the tensile strength of these alloys was slightly higher than 250 MPa after the solution treatment.
  • FIGS. 10A and 10B show the elongation value of the alloys of the first and second embodiments, respectively.
  • the elongation of the Ca and Sr containing alloy and the Sb, Ca and Sr containing alloy was substantially equivalent to the AZ91 alloy.
  • Sb and/or Ca and Sr were added to the AZ91 alloy, no bubble was involved in the die casting, the filling factor was increased, and the tensile strength was increased. Consequently, it is clear that the die castability is improved.
  • the alloy of the first and third embodiments exhibited an elongation of about 3.5%.
  • the inventors of the present invention determined an influence exerted on the room temperature tensile strength by the base alloy components of the AZ91 alloy, to which Sb and/or Ca and Sr were added. They found that if the content of Al was less than 6 percent by weight, the above-described effect of improving the room temperature tensile strength was not observed. Therefore, it was assumed to be appropriate that the content of Al in the alloy should be at least 6 percent by weight, preferably 7 percent by weight or more in order to improve the room temperature tensile strength.
  • the melt fluidity was visually inspected as described above, and thereby, the above-described upper limits were determined. It was ascertained that when the contents exceeded these upper limits, the viscosity was increased, and the melt fluidity was adversely affected. With respect to the lower limit values, the room temperature tensile strength of the alloy including them was checked, and the amounts at which the strength was improved were specified to be lower limit values.
  • the present inventors determined that it was appropriate to specify the AZ91-based base alloy to be an alloy in which a predetermined amount of at least any one of Si, RE, Zr, Sc, Y, Sn, and Ba was added to the AZ91 alloy of Al: 6% to 11.0%, Zn: 0.1% to 2.5%, and Mn: 0.1% to 0.5%.
  • These AZ91-based base alloys are collectively called AZ91-based alloys, and each graph shows an average of the entire thereof.
  • Test pieces were cut from 5 die castings, and creep data were determined at 175° C. with a constant-speed high-temperature creep tester. For the purpose of comparison, a common AZ91 alloy or other AZ-based alloy was subjected to a similar measurement.
  • FIGS. 11A, 11B , 11 C, 12 A, 12 B, 12 C, 13 A, 13 B and 13 C show the results of the constant-speed high-temperature creep test at 175° C. for the alloys of the embodiments of the present invention (light bars) and for the alloys of the comparative examples (dark bars)
  • the flow stress for the alloys of the embodiments of the invention ranges from about 130 MPa to about 150 MPa, from about 170 MPa to about 190 MPa and from about 210 MPa to about 240 MPa for strain rates of 10 ⁇ 5 , 10 ⁇ 4 and 10 3 s ⁇ 1 , respectively.
  • FIGS. 12A, 12B and 12 C show data of the creep elongation value at 175 degrees Celsius.
  • the AZ61 alloy exhibits an elongation value of 25% or less depending on the strain rate, whereas the alloys of the first and third embodiment exhibit an elongation value of 29% or more at every strain rate. Specifically, the elongation for the alloy of the first and third embodiments ranged from about 29% to about 41%.
  • the lines corresponding to an alloys according to the first and third embodiments of the invention are located in the upper right hand corner of Figures. These lines indicate that the alloys according to the embodiments of the invention have a creep rate ranging from about 5 ⁇ 10 ⁇ 5 S ⁇ 1 to about 10 ⁇ 3 s ⁇ 1 for a load stress of about 160 MPa to about 240 MPa, respectively, at 175 degrees Celsius.
  • FIG. 14 shows measurement conditions of the creep test of the inventors of the present invention and the creep test of the Japan Magnesium Association, shown in FIGS. 13 A-C.
  • FIGS. 13 A-C a curve of the ZACE05411 alloy of the Nagaoka University of Technology rises crossing the AS21 alloy curve.
  • Other data are the data on basic alloys of Mercer, and levels of the creep resistance of heat-resistant magnesium alloys, AS41, AS21, and AS42, can be understood.
  • the curves corresponding to the alloys according to the embodiments of the present invention are an extension of the creep characteristic curve of the AS21 alloy and, therefore, the creep resistance at 175° C. is assumed to be equivalent to that of the AS21. Therefore, it is clear that an alloy having high-temperature creep characteristics equivalent to or even better than that of the AS21 having excellent high-temperature creep characteristics can be attained by adding Sb and/or Ca and Sr to the AZ91 based alloy.
  • the inventors of the present invention separately determined an influence exerted on the room temperature tensile strength by the component of the AZ91 based alloy, to which Sb and/or Ca and Sr were added, instead of the amounts of the addition of Sb, Ca and Sr, as in the above description.
  • the content of Al exceeded 11 percent by weight, deterioration of the elongation value exceeded 1% and, thereby, it was assumed to be appropriate that the content of Al was specified to be 11 percent by weight or less in order to improve the high-temperature creep characteristics.
  • the AZ91 alloy is an alloy having excellent corrosion resistance among the magnesium alloys.
  • new elements, Sb and/or Ca and Sr are added as grain refining agents.
  • Si, RE, Zr, Sc, Y, Sn, and/or Ba are added to the AZ91 alloy so as to produce the AZ91-based base alloy, and new elements, Sb and/or Ca and Sr, are added as grain refining agents.
  • the present inventors determined that these alloys have sufficient corrosion resistance by conducting a salt spray test on these alloys and on a conventional AZ91 alloy as a comparative example.
  • Salt Spray CASS Test Instrument produced by Suga Test Instruments Co., Ltd.
  • the temperature in a test vessel was 35° C.
  • a spray pressure was 0.098 MPa (1 kgf/cm 2 ).
  • the sample was washed with running water, and was left standing for 16 hours.
  • the degree of occurrence of corrosion was visually evaluated on a 1-to-5 scale, “almost no corrosion was observed: ⁇ 5′′, “slight corrosion was observed: +4′′, “corrosion was observed: ++3′′, “corrosion was observed all over the surface: +++2′′, and “significant corrosion was observed all over the surface: 1′′.
  • FIGS. 16A, 16B and 16 C show the results thereof.
  • the AZ91+1.0% Ca+0.5% Sr alloy according to the first embodiment was evaluated as the above-described “corrosion was observed: ++3′′, and the common AZ91 alloy was also evaluated as “corrosion was observed: ++3′′. Therefore, it was made clear that there was not a significant difference in the corrosion resistance between the above-described two alloys, and the Ca and Sr containing alloy of the first embodiment was able to ensure the corrosion resistance substantially equivalent to that of the common AZ alloy.
  • FIGS. 16B and 16C show the results from the ingots of FIGS. 15B and 15C , respectively. The results in FIGS. 16B and 16C are similar to those of FIG. 16A .
  • a die casting magnesium alloy provided with a room temperature tensile strength equivalent to the AZ91 alloy and provided with excellent high-temperature creep characteristics while ensuring excellent die castability and corrosion resistance can be attained.
  • the alloy according to the embodiments of the present invention is useful for magnesium die castings which covers from a room temperature region to a high-temperature region in applications to automotive parts, such as transmission covers and oil pans in which a weight reduction effect can be exerted, car air conditioner piston portion housings, airbag covers, engine covers, or the like.
  • the alloy of the embodiments of the present invention may be die cast into a die casting (i.e., die cast part) using any suitable die casting method.
  • the alloy of the embodiments of the present invention may be provided in a melted state, such as in a liquid state, into an injection chamber of a die casting machine. The melted alloy is then injected into a mold cavity from the injection chamber by a plunger. The alloy then solidifies into a casting in the mold cavity and is then subsequently removed from the mold cavity after solidification.

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Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
JP2004-004285 2004-01-09
JP2004004285A JP4589630B2 (ja) 2004-01-09 2004-01-09 ダイカスト用マグネシウム合金及びマグネシウムダイカスト製品
JP2004-175334 2004-06-14
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CN102517489A (zh) * 2011-12-20 2012-06-27 内蒙古五二特种材料工程技术研究中心 一种利用回收的硅粉制备Mg2Si/Mg复合材料的方法
US9822432B2 (en) * 2011-01-11 2017-11-21 Korea Institute Of Machinery & Materials Magnesium alloy with excellent ignition resistance and mechanical properties, and method of manufacturing the same
US20190112693A1 (en) * 2015-02-25 2019-04-18 In-Young Lee Plastic deformation magnesium alloy having excellent thermal conductivity and flame retardancy, and preparation method therefor

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US20090188451A1 (en) * 2008-01-25 2009-07-30 Gm Global Technology Operations, Inc. Engine cover with cooling fins
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US8820614B2 (en) * 2008-12-26 2014-09-02 Sumitomo Electric Industries, Ltd. Magnesium alloy joined part and production method thereof
US20120107171A1 (en) * 2009-07-07 2012-05-03 Sumitomo Electric Industries, Ltd. Magnesium alloy sheet
US9334554B2 (en) * 2009-07-07 2016-05-10 Sumitomo Electric Industries, Ltd. Magnesium alloy sheet
US20110067526A1 (en) * 2009-09-21 2011-03-24 Shea Kwang Kim Desulfurizing agent and method for manufacturing the same
US8349050B2 (en) * 2009-09-21 2013-01-08 Korea Institute Of Industrial Technology Desulfurizing agent and method for manufacturing the same
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