US20050238528A1 - Heat treatable Al-Zn-Mg-Cu alloy for aerospace and automotive castings - Google Patents

Heat treatable Al-Zn-Mg-Cu alloy for aerospace and automotive castings Download PDF

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Publication number
US20050238528A1
US20050238528A1 US11/111,212 US11121205A US2005238528A1 US 20050238528 A1 US20050238528 A1 US 20050238528A1 US 11121205 A US11121205 A US 11121205A US 2005238528 A1 US2005238528 A1 US 2005238528A1
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aluminum alloy
concentration
alloy
shaped casting
casting
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Abandoned
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US11/111,212
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English (en)
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Jen Lin
Cagatay Yanar
Michael Brandt
Xinyan Yan
Wenping Zhang
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Automotive Casting Technology Inc
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Individual
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Priority to US11/111,212 priority Critical patent/US20050238528A1/en
Priority to JP2007509667A priority patent/JP2007534840A/ja
Priority to KR1020067024490A priority patent/KR20070004987A/ko
Priority to PCT/US2005/013769 priority patent/WO2005106058A2/en
Priority to AU2005238479A priority patent/AU2005238479A1/en
Priority to EP05738780A priority patent/EP1759027A4/en
Priority to MXPA06012243A priority patent/MXPA06012243A/es
Priority to CA002564080A priority patent/CA2564080A1/en
Assigned to ALCOA INC. reassignment ALCOA INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BRANDT, MICHAEL K., LIN, JEN C., YAN, XINYAN, YANAR, CAGATAY, ZHANG, WENPING
Publication of US20050238528A1 publication Critical patent/US20050238528A1/en
Priority to NO20065387A priority patent/NO20065387L/no
Assigned to AUTOMOTIVE CASTING TECHNOLOGY, INC. reassignment AUTOMOTIVE CASTING TECHNOLOGY, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ALCOA INC.
Assigned to WACHOVIA BANK, NATIONAL ASSOCIATION, AS US AGENT reassignment WACHOVIA BANK, NATIONAL ASSOCIATION, AS US AGENT SECURITY AGREEMENT Assignors: AUTOMOTIVE CASTING TECHNOLOGY, INC.
Assigned to COMPASS AUTOMOTIVE FINCO, LLC reassignment COMPASS AUTOMOTIVE FINCO, LLC SECURITY AGREEMENT Assignors: AUTOMOTIVE CASTING TECHNOLOGY, INC.
Assigned to AUTOMOTIVE CASTING TECHNOLOGY, INC., NOW KNOWN AS SHIPSTON ALUMINUM TECHNOLOGIES (MICHIGAN), INC. reassignment AUTOMOTIVE CASTING TECHNOLOGY, INC., NOW KNOWN AS SHIPSTON ALUMINUM TECHNOLOGIES (MICHIGAN), INC. RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: WELLS FARGO BANK, NATIONAL ASSOCIATION, SUCCESSOR BY MERGER TO WACHOVIA BANK, NATIONAL ASSOCIATION, AS AGENT
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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
    • C22C21/10—Alloys based on aluminium with zinc as the next major constituent

Definitions

  • This invention is an aluminum alloy for aerospace and automotive shaped castings, castings comprised of the alloy, and methods of making cast components of the alloy.
  • Cast aluminum parts are used in structural applications in automobile suspensions to reduce weight.
  • the most commonly used group of alloys, Al—Si 7 —Mg has well established strength limits. In order to obtain lighter weight parts, higher strength material is needed with established material properties for design.
  • cast materials made of A356.0, the most commonly used Al—Si 7 —Mg alloy can reliably guarantee ultimate tensile strength of 290 MPa (42,060 psi), and tensile yield strength of 220 MPa (31,908 psi) with elongations of 8% or greater.
  • forged products are often used. These are usually more expensive than cast products. There exists the potential for considerable cost savings if cast products can be used to replace forged products with no loss of strength, elongation, corrosion resistance, fatigue strength, etc. This is true in both automotive and aerospace applications.
  • Casting alloys exhibiting higher tensile strength and fatigue resistance than the Al—Si 7 —Mg material are desirable. Such improvements could be used to reduce weight in new parts or in existing parts which can be redesigned to use the improved material properties to great advantage.
  • the alloy of the present invention is an Al—Zn—Mg base alloy for low pressure permanent or semi-permanent mold, squeeze, high pressure die, pressure or gravity casting, lost foam, investment casting, V-mold, or sand mold casting with the following composition ranges (all in weight percent):
  • Silicon up to about 1.0% may be employed to improve castability. Lower levels of silicon may be employed to increase strength. For some applications, manganese up to about 0.3% may be employed to improve castability. In other alloys, manganese is to be avoided.
  • the alloy may also contain grain refiners such as titanium diboride, TiB 2 or titanium carbide, TiC and/or anti-recrystallization agents such as zirconium or scandium. If titanium diboride is employed as a grain refiner, the concentration of boron in the alloy may be in a range from 0.0025% to 0.05%. Likewise, if titanium carbide is employed as a grain refiner, the concentration of carbon in the alloy may be in the range from 0.0025% to 0.05%.
  • Typical grain refiners are aluminum alloys containing TiC or TiB 2 .
  • Zirconium if used to prevent grain growth during solution heat treatment, is generally employed in a range below 0.2%. Scandium may also be used in a range below 0.3%.
  • the alloy demonstrated 50% higher tensile yield strength than is obtainable from A356.0-T6, while maintaining similar elongations. This will allow part designs requiring higher strength than alloys which are readily available today in Al—Si—Mg alloys such as A356.0-T6 or A357.0-T6. Fatigue performance in the T6 temper is increased over the A356.0-T6 material by 30%.
  • the present invention is an aluminum alloy including from about 3.5-5.5% Zn, from about 1-3% Mg, about 0.05-0.5% Cu and it contains less than about 1% Si.
  • the present invention is a heat treatable shaped casting of an aluminum alloy including from about 3.5-5.5% Zn, from about 1-3% Mg, from about 0.05-0.5% Cu, and less than about 1% Si.
  • the present invention is a method of preparing a heat treatable aluminum alloy shaped casting.
  • the method includes preparing a molten mass of an aluminum alloy including from about 3.5-5.5% Zn, from about 1-3% Mg, from about 0.05-0.5% Cu, and less than about 1% Si.
  • the method further includes casting at least a portion of the molten mass in a mold configured to produce the shaped casting, permitting the molten mass to solidify, and removing the shaped casting from the mold.
  • FIG. 1 is a photograph of a cut surface of a cut sample of prior art A356.0 alloy cast in a shrinkage mold showing the shrinkage cracking tendency of the prior art A356.0 alloy;
  • FIG. 2 is a photograph, similar to FIG. 1 , of a cut surface of a second sample of prior art A356.0 cast in a shrinkage mold showing the shrinkage cracking tendency of the prior art A356.0 alloy;
  • FIG. 3 is a photograph of a cut surface of a sample of the alloy of the present invention cast in a shrinkage mold showing a lack of shrinkage cracking
  • FIG. 4 is a photograph, similar to FIG. 3 , of a cut surface of a second sample of the alloy of the present invention cast in a shrinkage mold showing a lack of shrinkage cracking.
  • FIG. 5 presents strength and elongation data for directionally solidified samples of the present invention in T6 condition
  • FIG. 6 is a photograph of a front knuckle casting of an alloy according to the present invention, showing locations from which tensile test samples were obtained;
  • FIG. 7 is a plot of strength and elongation data for tensile test samples cut from the casting shown in FIG. 6 after T5 and also after T6 heat treatments;
  • FIG. 9 is a graph showing staircase fatigue testing of the present alloy in T6 condition compared to the response of prior art A356.0-T6 with the mean fatigue strength for A356.0-T6.
  • FIG. 10 is a graph showing depth of attack after an intergranular corrosion test of the alloy of the present invention compared to the prior art alloy A356.
  • FIG. 11 is a photomicrograph of an alloy according to the present invention after an intergranular corrosion test, on the as cast side of the sample.
  • FIG. 12 is a photomicrograph of an alloy according to the present invention after an intergranular corrosion test, on a machined side of the sample.
  • FIG. 13 is a photomicrograph of the prior art alloy A356 after an intergranular corrosion test.
  • FIG. 14 is a graph presenting results of a stress corrosion test on alloys of the present invention, with varied levels of copper.
  • FIG. 15 is a graph showing the effect of copper and magnesium levels on stress corrosion cracking for alloys of the present invention.
  • any numerical range of values herein are understood to include each and every number and/or fraction between the stated range minimum and maximum.
  • a range of about 3.5 to 5.5 wt % zinc, for example, would expressly include all intermediate values of about 3.6, 3.7, 3.8 and 3.9%, all the way up to and including 5.3, 5.35, 5.4, 5.475 and 5.499% Zn.
  • Table I presents composition data for the alloys which were tested.
  • the first and third lines showing compositions is for directionally solidified castings.
  • the second line is for the composition used in a shaped casting.
  • the shaped casting was the front knuckle shown in FIG. 6 .
  • TABLE I Alloy Composition Composition of test samples (Weight %) Zn Mg Si Cu Mn Fe Ti B DS Casting 4.28 1.99 0.04 0.01 0.00 0.04 0.00 0.0005 Cast 4.2 2 ⁇ 0.1 0.2 0.05 ⁇ 0.1 0.06 0.02 Knuckle DS Casting 4.57 2.03 0.04 0.31 0.04 0.05 0.06 0.02
  • Table II presents room temperature mechanical properties of the directionally solidified alloys having the compositions shown in the first and third data lines of Table I.
  • the first data line in Table II is for a directionally solidified casting comprised of the alloy of the first data line in Table I after five weeks of natural ageing.
  • the second data line in Table 2 is for the same alloy after T5 heat treatment, and the third data line is for that alloy after T6 heat treatment.
  • the fourth and fifth data lines in Table II are for the alloy in the bottom line of Table 1, which is a high copper alloy. This alloy, also, was subjected to a T6 heat treatment.
  • FIG. 5 The development of mechanical properties of directionally solidified samples of the present invention during heat treatment is presented in FIG. 5 .
  • the composition of these samples was presented in the first data row in Table 1.
  • the solution heat treatment was at 1030° F. (554° C.) for 8 hours, which was followed by the cold water quench, and then artificial ageing. Samples were taken out of the oven and subjected to mechanical testing after various amounts of artificial ageing. The properties measured were TYS, UTS and percent elongation. The duration of the artificial ageing was 15 hours. During the first 6 hours, the temperature was 250° F. (121° C.). For the subsequent 9 hours, the temperature was 320° F. (160° C.). Values for the TYS and UTS are referenced to the scale on the left, values of percent elongation are referenced to the scale on the right.
  • Table III presents data for front knuckle castings as shown in FIG. 6 .
  • This is an alloy according to the present invention, and has the composition presented in the second data row in Table 1.
  • the locations of tensile test samples 1, 2 and 3 are indicated in FIG. 6 .
  • Tests were performed on one casting subjected to a T5 heat treatment consisting of 160° C. for 6 hours, and one casting subjected to a T6 heat treatment of solution heat treatment at 554° C. for 8 hours followed by a cold water hen by artificial ageing at 121° C. for 6 hours and 160° C. for 6 hours.
  • FIG. 8 shows the S-N fatigue response of the alloy of the present invention in comparison to the response of the prior art alloy A356.0-T6.
  • FIG. 9 is a graph showing staircase fatigue testing of the alloy of the present invention in T6 condition compared to the response of the prior art alloy, A356.0-T6 with a calculated mean value for A356.0-T6.
  • the composition of the alloy of the present invention was as presented in the second data row of Table 1.
  • the samples were solution heat treated at 526° C. or 554 ° C., quenched and artificially aged at 160° C. for 6 hours. As seen earlier, the fatigue response of these samples is appreciably improved when compared to A356.0-T6 material.
  • the mean fatigue strength of the alloy of the present invention was 109.33 MPa with a standard deviation of 9.02 MPa.
  • the standard deviation of the mean fatigue strength was 3.01 MPa.
  • the calculated mean fatigue strength at 10 7 cycles of A356.0 T6 is 70 MPa.
  • Corrosion resistance of the alloy of the present invention was tested using the ASTM G110 corrosion test, which is the “Standard Practice for Evaluating Intergranular Corrosion Resistance of Heat Treatable Aluminum Alloys by Immersion in Sodium Chloride+Hydrogen Peroxide Solution”.
  • specimens are immersed in a solution that contains 57 g/L NaCl and 10 mL/L H 2 O 2 (30%) for 6-24 hours.
  • the specimens are then cross-sectioned and examined under optical microscope for type (intergranular corrosion or pitting) and depth of corrosion attack.
  • FIG. 10 is a graph presenting the depth of attack following the ASTM G110 corrosion test after 6 hours and 24 hours for an alloy according to the present invention and for the alloy A356.0.
  • FIGS. 11 and 12 are photomicrographs of an alloy according to the present invention after 24 hours exposure to the ASTM G110 corrosion test. Very little intergranular corrosion can be seen in these photomicrographs.
  • FIG. 13 is a photomicrograph of the A356.0 alloy after 24 hours of exposure to the ASTM G110 corrosion test. Considerable intergranular corrosion can be seen in this photomicrograph.
  • Corrosion tests were also performed employing the ASTM G44 test, which is the “Standard Practice for Exposure of Metals and Alloys by Alternate Immersion in Neutral 3.5% Sodium Chloride Solution”.
  • ASTM G44 test is the “Standard Practice for Exposure of Metals and Alloys by Alternate Immersion in Neutral 3.5% Sodium Chloride Solution”.
  • stressed specimens are subject to a 1-hour cycle which includes immersion in 3.5% NaCl solution for 10 minutes and then in lab air for 50 minutes. This 1-hour cycle is continuously repeated. During the test, the specimens are regularly inspected for cracks and failures.
  • Table IV presents the compositions of various alloys according to the present invention, which were employed in ASTM G44 tests.
  • Alloy Composition Sample Number Zn Mg Cu Ti B Zr 59 4.23 1.5 0.29 0.029 0.0055 ⁇ 0.001 86 4.41 1.49 0.23 0.036 0.0038 n/a 110 4.39 1.74 0.28 0.057 0.0129 ⁇ 0.001 117 4.39 1.74 0.28 0.057 0.0129 ⁇ 0.001 138 4.19 1.99 0.26 0.073 0.015 ⁇ 0.001 159 4.31 1.93 0.24 0.105 0.0252 0.1127 A 4.43 2.05 0.06 0.0208 B 4.5 2 0.2 0.06 0.02 n/a C 4.5 1.2 D 4.5 1.2
  • Table V presents the test results for the alloy compositions presented in Table IV.
  • TABLE V ASTM G44 Test of Alloys with Various Mg and Cu Contents Run or S Stress Percentage Days to Number Temper Level(MPa) of TYS F/N Failure 59 (Knuckle) T5 152.37 75% 0/5 86 (Knuckle) T6 239.25 75% 4/5 17, 17, 22, 28 110 (Knuckle) T5 154.44 75% 0/5 117 (Knuckle) T6 196.50 75% 0/5 138 (Knuckle) T6 247.52 75% 2/5 45, 61 159 (Knuckle) T6 270.27 75% 3/5 11, 11, 11 A T5 186.16 75% 5/5 4, 4, 4, 7, 64 B T6 182.02 50% 4/4 7, 11, 13, 19 C T5 135.83 75% 0/5 D T6 194.43 75% 0/5
  • FIG. 14 is a graph presenting the results of these tests. It is seen that, for alloys of the present invention, and at these high magnesium levels, increasing copper provides increased resistance to stress corrosion cracking.
  • FIG. 15 is a graph showing the effect of copper and magnesium levels on stress corrosion cracking for alloys of the present invention. This shows that for alloys according to the present invention which have magnesium in the range from 1.5-2%, it is desirable to include copper in the range from0.25-0.3%.
  • Table VI and VII present the results of plant trials in which repeated shots were made from a single liquid metal reservoir. One trial was performed on April 4, one was performed on June 4 and one on September 4. On each day, the composition for all the castings made varied very little.
  • Table VI presents the ranges of the compositions of samples taken on each of the test days.
  • the compositions contained high levels of magnesium and copper, which were expected to provide exceptionally high strength levels.
  • TABLE VI MCC plant trial alloy composition ranges Date Si Fe Mn Cu Mg Zn Ti B Zr Apr- 0.05-0.09 0.03-0.04 0.03-0.04 0.22-0.27 1.9-2.2 4.1-4.7 0.03-0.06 0.001-0.0007 0.00-0.15 04 Jun- 0.03-0.09 0.04-0.08 0.04-0.05 0.24-0.29 1.5-2.0 4.6-4.9 0.03-0.11 0.008-0.025 0.00-0.12 04 Sep- 0.04-0.05 0.14-0.20 0.03-0.04 0.27-0.32 2.1-2.3 4.4-4.9 0.04-0.07 0.0006-0.0037 0.13-0.14 04
  • Table VII presents the stress data, ultimate tensile strength, tensile yield strength, and elongation for four different locations in each casting.
  • the column for sample numbers labels the individual castings.
  • the column for location defines individual mechanical test samples cut from the casings.

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US11/111,212 2004-04-22 2005-04-21 Heat treatable Al-Zn-Mg-Cu alloy for aerospace and automotive castings Abandoned US20050238528A1 (en)

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US11/111,212 US20050238528A1 (en) 2004-04-22 2005-04-21 Heat treatable Al-Zn-Mg-Cu alloy for aerospace and automotive castings
MXPA06012243A MXPA06012243A (es) 2004-04-22 2005-04-22 Aleacion termotratable de al-zn-mg-cu para piezas aeroespaciales y automotrices moldeadas por vaciado.
CA002564080A CA2564080A1 (en) 2004-04-22 2005-04-22 Heat treatable al-zn-mg-cu alloy for aerospace and automotive castings
KR1020067024490A KR20070004987A (ko) 2004-04-22 2005-04-22 항공우주선 및 자동차 주물용 열 처리가능한Ａｌ-Ｚｎ-Ｍｇ-Ｃｕ 합금
PCT/US2005/013769 WO2005106058A2 (en) 2004-04-22 2005-04-22 Heat treatable al-zn-mg-cu alloy for aerospace and automotive castings
AU2005238479A AU2005238479A1 (en) 2004-04-22 2005-04-22 Heat treatable Al-Zn-Mg-Cu alloy for aerospace and automotive castings
EP05738780A EP1759027A4 (en) 2004-04-22 2005-04-22 Heat treatable al-zn-mg-cu alloy for aerospace and automotive castings
JP2007509667A JP2007534840A (ja) 2004-04-22 2005-04-22 航空宇宙及び自動車の鋳物品用の熱処理可能なＡｌ−Ｚｎ−Ｍｇ−Ｃｕ合金
NO20065387A NO20065387L (no) 2004-04-22 2006-11-22 Varmebehandlet Al-Zn-Mg-legering for stopegods for luftfarts- og kjoretoyindustrien

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US11/111,212 US20050238528A1 (en) 2004-04-22 2005-04-21 Heat treatable Al-Zn-Mg-Cu alloy for aerospace and automotive castings

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