US20080031768A1 - Wear-resistant aluminum alloy for casting engine blocks with linerless cylinders - Google Patents

Wear-resistant aluminum alloy for casting engine blocks with linerless cylinders Download PDF

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Publication number
US20080031768A1
US20080031768A1 US11/499,165 US49916506A US2008031768A1 US 20080031768 A1 US20080031768 A1 US 20080031768A1 US 49916506 A US49916506 A US 49916506A US 2008031768 A1 US2008031768 A1 US 2008031768A1
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United States
Prior art keywords
alloy
casting
aluminum
silica sand
sand mold
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Abandoned
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US11/499,165
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English (en)
Inventor
Salvador Valtierra-Gallardo
Jose Talamantes-Silva
Andres Fernando Rodriguez-Jasso
Jose Alejandro Gonzalez-Villarreal
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Nemak SAB de CV
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Individual
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Priority to US11/499,165 priority Critical patent/US20080031768A1/en
Assigned to TENEDORA NEMAK, S.A. DE C.V. reassignment TENEDORA NEMAK, S.A. DE C.V. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GONZALEZ-VILLARREAL, JOSE ALEJANDRO, RODRIGUEZ-JASSO, ANDRES FERNANDO, TALAMANTES-SILVA, JOSE, VALTIERRA-GALLARDO, SALVADOR
Priority to KR1020097004541A priority patent/KR20090048492A/ko
Priority to PCT/IB2007/004235 priority patent/WO2008053363A2/en
Priority to CA002660137A priority patent/CA2660137A1/en
Priority to AU2007315791A priority patent/AU2007315791A1/en
Priority to EP07866603A priority patent/EP2054535A4/en
Priority to CN200780037074A priority patent/CN101627138A/zh
Priority to BRPI0714884-4A priority patent/BRPI0714884A2/pt
Priority to MX2009001319A priority patent/MX2009001319A/es
Publication of US20080031768A1 publication Critical patent/US20080031768A1/en
Priority to US12/728,975 priority patent/US20100288461A1/en
Abandoned legal-status Critical Current

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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
    • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
    • C22C21/04—Modified aluminium-silicon alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings

Definitions

  • the invention relates to aluminum alloys that can be cast into high-quality aluminum cylinder blocks, utilizing a low-cost low pressure sand casting process, for automotive engines having good mechanical properties and wear and scuffing resistance; so that according to the present invention the engine blocks can be manufactured without the need for insertion of iron (or costly aluminum) liners in order to have effective cylinder walls.
  • U.S. Pat. No. 4,068,645 issued Jan. 17, 1978 to David Charles Jenkinson teaches that the microstructure of a hypereutectic Al—Si alloy can be modified with strontium and/or sodium for obtaining Brinell hardness in the range of 70-150 by including magnesium up to about 4 wt. %.
  • This patent teaches that the desired microstructure must avoid the formation of primary aluminum or primary silicon phases and that there must be a high-volume fraction of finely dispersed eutectic silicon which provides the wear resistance to the cast article.
  • the desired microstructures are provided by careful selection and combination of four parameters: (a) silicon content, (b) modifier content, (c) growth rate during solidification and (d) temperature gradient at the solid/liquid interphase during solidification.
  • Ni, Fe and Mn are interchangeable with each other, being the ranges as follows: Fe+Mn between 0.2 and 1.5%; Fe+Ni between 1.1 and 3.0%; and Fe+Ni+Mn between 1.2 and 4.0%.
  • Titanium is added to improve castability and the mechanical properties of this alloy.
  • This alloy however has a high cost due to the high content of Ni, in contrast with the alloy of the present invention having less than about 0.4-0.8% Ni.
  • the lower concentration Ni thus particularly makes the alloy of the present invention more competitive.
  • U.S. Pat. No. 4,648,918 issued Mar. 10, 1087 to Kasuhiko Asano, et al. teaches an abrasion-resistance aluminum alloy having a composition comprising: 7.5-15% Si; 3.0-6.0% Cu, 0.3-1.0% Mg, 0.25-1.0% Fe; 0.25-1.0% Mn; and a balance of Al and other components.
  • the alloy of this patent is directed to improve the extrudability, forgeability and mechanical properties of ingots.
  • the Cu content is higher than the alloy of the present invention and the heat treatment and final processing of this alloy are far different from the sand-casting process of the present invention.
  • U.S. Pat. No. 5,019,178 issued May 28, 1991 to John Barlow et al. discloses a production method of an aluminum-silicon liner produced from a melt consisting essentially of 14-16% Si; 1.9-2.2% Cu; 1.0-1.4 Ni; 0.4-0.55 Mg; 0.6-1.0% Fe; 0.02-0.1% Sr; and 0.3-0.6 Mn.
  • the alloy of this patent is formed into cylinder liners under pressure during the solidification stage of the casting process. This patent does not teach or suggest that the whole engine block be made of the claimed alloy in a low-pressure sand-casting process.
  • U.S. Pat. No. 5,217,546 issued Jun. 8, 1993 to John A. Eady, et al. discloses a cast hypereutectic Al—Si alloy having 12-15% Si; ore than 0.10% Sr; more than 0.005% Ti; 1.5-5.5% Cu;1.00-3.00Ni; 0.1-1.0 Mg; 0.1-1.0% Fe; and other components.
  • the microstructure obtained is such that any primary Si formed is substantially uniformly dispersed and is substantially free of segregation, with the microstructure predominantly comprising an eutectic matrix.
  • the alloy of this patent however relies on Ti and an excessive amount of Ni, which makes it too expensive an alloy for competitive mass production of engine blocks.
  • U.S. Pat. No. 5,316,070 issued May 31, 1994 to Kevin P. Rogers, et al. teaches a process for controlled casting of a hypereutectic Al—Si alloy in permanent molds. Permanent molds can be fully equipped with cooling systems and with precise temperature control so that a pre-established solidification program can be implemented and therefore the desired microstructure of the cast article may be achieved. The teachings of this patent can not be applied to sand-casting processes.
  • U.S. Pat. No. 5,484,492 issued Jan. 16, 1996 to Kevin P. Rogers et al. discloses a hypereutectic Al—Si alloy essentially having at least one element selected from a first group of elements consisting of 0.005% up to 0.25% of Cr, Mo, Nb, Ta, Ti, Zr, V and Al; at least one element selected from a second group of elements consisting of 0.1 to 3.0% Ca, Co, Cr, Cs, Fe, K, Li, Mn, Na, Rb, Sr, Y, Ce, elements of the Lanthanide series and elements of the Actinide series; and a third group of elements consisting of: 12-15% Si; 1.5-5.5 Cu; 1.0-3.0% Ni; 0.1-1.0% Mg; 0.1-1.0% Fe; 0.1-0.8% Mn; 0.01-0.1 Zr; 0-3.0% Zn; 0-0.2% Sn; 0-0.2% Pb; 0-0.1% Cr; 0.001-0.1% Sr or Na; a maximum of
  • U.S. Pat. No. 6,399,020 issued Jun. 4, 2002 to Jonathan A. Lee et al. discloses an aluminum alloy suitable for high-temperature applications, such as pistons and other internal combustion engines applications, having the following composition: 11.0-14.0% Si; 5.6-8.0% Cu; 0-0.08 Fe; 0.5-1.5 Mg; 0.05-0.9 Ni; 0-1.0 Mn; 0.05-1.2 Ti; 0.12-1.2 Zr; 0.05-1.2 V; 0.05-0.9 Zn; 0.01-0.1 Sr; with the balance Al.
  • the ratio of Si/Mg is 10-25, and the ratio of Cu/Mg is 4-15.
  • the alloy of the applicants' invention differs from the alloy composition disclosed in this patent, mainly in the Si/Mg ratio and in the amount of Sr. Since Sr is an expensive element, the alloy of the present invention is more cost-competitive. In addition, the present invention does not include Zr or V and has a maximum of 0.3% Mg.
  • U.S. Pat. No. 6,592,687 issued Jul. 15, 2003 and U.S. Pat. No. 6,918,970 issued Jul. 19, 2005, both to Jonathan A. Lee et al. disclose an aluminum-silicon alloy having the following composition in weight percent: 14-25.0 Si; 5.5-8.0 Cu; 0.05-1.2 Fe; 0.5-1.5 Ni; 0.05-0.9 Mn; 0.05-1.2 Ti; 0.05-1.2 Zr; 0.05-1.2 V; 0.05-0.9 Zn; 0.001-0.1 P; and with the balance being Aluminum.
  • the '970 patent's alloy has an extended range of Si (6.0-25.0%) plus Sr (with a range of 0.001-0.1).
  • the Si/Mg ratio is 10-25 and the Cu/Mg ratio is 4-15.
  • This alloy has as key elements Ti, V and Zr that modify the lattice parameters of the aluminum matrix by forming compounds of the type Al 3 X having L1 2 crystal structures, wherein X stands for Ti, V or Zr.
  • the alloy comprises by weight, 9.5-12.5% Si; 0.1-1.5% Fe; 1.5-4.5% Cu; 0.2-3% Mn; 0.1-0.6 Mg; 2.0% maximum Zn; 0-1.5% Ni; 0.25% maximum Ti; up to 0.05% Sr; with the balance being aluminum.
  • An important feature of this Patentee's invention is the proportion of Mn to Fe.
  • the weight ratio Mn/Fe is between 1.2 to 1.75 or higher when the Fe content is equal to or greater than 0.4% and the weight ratio Mn/Fe is at least 0.6 to 1.2 when the Fe content is less than 0.4% of the alloy.
  • the Si range of the present invention is 13-14%.
  • the desired microstructures in the Al—Si alloys are produced by a right combination of growth rate during solidification and temperature gradient.
  • the proposed invention herein described and claimed is an aluminum-silicon alloy composition which, when cast, meets the manufacturing and performance conditions required for cylinder engine blocks and further can be cast using low-cost casting processes such as silica-sand molds.
  • the alloy of the present invention comprises (in weight percent):
  • FIG. 1 shows a microphotograph of the microstructure (100 ⁇ m) obtained from an unlined aluminum cylinder surface of an engine block cast from the alloy of the present invention.
  • FIG. 2 shows a contrasting microphotograph of the microstructure (100 ⁇ m) obtained from an unlined aluminum cylinder surface of an engine block cast from the alloy known as A390.
  • FIG. 3 is a schematic phase diagram of Al—Si alloys showing the preferred range of Si content for the alloy of the invention as contrasted to prior art alloys known as A380, A390, A413, and DuraboreTM (a GM alloy understood to be exemplified by U.S. Pat. No. 6,921,512).
  • the aluminum alloy blocks to be manufactured demand strictly controlled characteristics and mechanical properties in order to perform as expected in modern vehicles.
  • Blocks without liner inserts must have high wear resistance in the running surfaces and withstand high pressures on the order of 100 to 200 bar in those engines having high peak firing pressures.
  • the porosity level must be below 1% and the maximum pore size must be below 500 microns in the running surfaces.
  • the aluminum alloy has a high thermal conductivity in order to sustain high heat transfer rates from the hot areas of the engine to the cooling liquid of the engine cooling system, as well as having good corrosion resistance to the cooling media.
  • the high-efficiency modern engines also demand that the alloys from which the engine blocks are cast show high strength and high resistance to fatigue and creep at elevated temperatures, in the range of 180°-200° C.
  • machining high-silicon alloys means greater wear of tools and high machining cost, as in the case of the A390 alloy.
  • primary silicon formation is suppressed resulting in a fully eutectic microstructure despite its high silicon content. This characteristic of the microstructure of the castings of the invention assures good machinability. Tool life is comparable to machining an A356 alloy but with superior surface finish.
  • the alloy of the present invention is based on the Al—Si—Cu—Mg—Ni—Mn—Fe system to enhance maximum wear resistance. It provides the required characteristics demanded by modern engine blocks having unlined cylinders, while also maintaining a competitive low manufacturing cost.
  • the casting process of the invention utilizes a thermal core (or massive chill) in combination with silica-sand cores and molds.
  • the chill provides the right direction of the solidification process as well as the necessary solidification rate which results in high fatigue properties of the castings.
  • the alloy of the present invention is particularly suited for the production of linerless aluminum alloy blocks at a lower cost than the currently used alloys.
  • the following table 1 compares the typical concentration of the elements of the prior-art alloys with the composition of the present invention.
  • Alloy 390 (A) is the historical choice for wear-resistance cast motor elements, but as discussed above it is not applicable for sand casting processes.
  • Alloy 3HA (B) is also an alloy of choice for those applications, but its cost is high because of its high content of nickel (2%). The high concentration of Ni increases the alloy cost by 35% ($15,000 US/Ton of Ni), and the 2000 ppm of Sr further combines to make it even more expensive.
  • FIGS. 1 and 2 showing respectively a microphotograph of the microstructure (100 ⁇ m) obtained from an unlined aluminum cylinder surface of an engine block cast from the alloy of the present invention, and of the microstructure (100 ⁇ m) obtained from an unlined aluminum cylinder surface of an engine block cast from the alloy known as A390, it is evident that the alloy of the present invention shown in FIG. 1 provides a microstructure where primary Si phase grains are very small and uniformly dispersed as compared with the microstructure of the prior art alloy shown in FIG. 2 .
  • FIG. 1 applicants have represented in a phase diagram of an Al—Si alloy system the position of some of the prior art alloys and the distinct position of the alloy of the present invention. It can be seen in this phase diagram that hypoeutectic and eutectic alloys are easier to handle in silica sand casting processes since these alloys are liquid at lower temperatures than hypereutectic alloys. In view of this property of the Al—Si alloys, increasing Si content requires that the molten alloy be poured in the sand molds at a higher temperature and therefore more heat needs to be dissipated from the solidifying metal through the sand molds and cores.
  • the alloy of the present invention provides sufficient Si content for achieving the desired wear resistance in the casting surfaces and the other components of the alloy make it suitable for its casting in silica sand molds having relatively lower heat dissipation properties than molds of other casting processes. At the same time, the alloy of the present invention is less expensive than other prior art alloys having similar wear resistance particularly because of its lower Ni content.
  • the alloy of the present invention provides a cost competitive process for massive engine blocks casting without the need of cylinder liners, particularly when cast in silica sand molds and cores.
  • the alloy and casting method of the present invention present the following advantages:
  • the wear resistance provided by the alloy avoids the necessity of inserting iron liners in the cylinder bores. Consequently, the manufactured blocks are smaller and lighter, (saving the weight and cost of iron liners) and can increase the engine capacity without increasing engine size (for example from 2.3 to 3.0 liters).
  • the alloy of the invention has better thermal characteristics regarding heat dissipation (particularly with the absence of iron cylinder liners).
  • Applicants' blocks run about 10° C. cooler than currently used aluminum blocks having iron liners blocks, due to the fact that the interface between the iron liners and block is eliminated.
  • the alloy also allows for tighter clearances because the thermal expansion coefficients of both pistons and the blocks are similar (in contrast with the greater differentiation of thermal expansion coefficients between the piston aluminum alloy and the iron liners). This advantage provides a quieter engine operation and makes the engines environmentally cleaner.
  • the linerless engines made from the alloy of the present invention are also easier to recycle, since no separation of iron cylinder liners from aluminum is required.
  • the alloy of the invention further provides very good machining characteristics, and although the tool life is comparable and similar to machining of the currently-known A356 alloy, the surface finish in the cylinder bores is significantly better.
  • the manufacturing cost of unlined engine blocks is reduced by about 40% by using the alloy and method of the invention as compared with the manufacturing cost when using the known alloys of the prior art.
  • Al—Si alloy was prepared according to the present invention and a block was cast in silica sand molds and cores.
  • the alloy had the following composition (in weight percent):
  • test set-up provides a reciprocating line contact between a dowel and a plate.
  • the hardened dowel is used to simulate the piston ring while a flat ground plate is used to simulate the cylinder liner.
  • the oil used was a commercially available automotive petrol engine mineral oil heated to 100 C°.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
US11/499,165 2006-08-04 2006-08-04 Wear-resistant aluminum alloy for casting engine blocks with linerless cylinders Abandoned US20080031768A1 (en)

Priority Applications (10)

Application Number Priority Date Filing Date Title
US11/499,165 US20080031768A1 (en) 2006-08-04 2006-08-04 Wear-resistant aluminum alloy for casting engine blocks with linerless cylinders
MX2009001319A MX2009001319A (es) 2006-08-04 2007-08-03 Aleacion de aluminio resistente al desgaste para monobloques para motor fabricados sin camisas en los cilindros de combustion.
AU2007315791A AU2007315791A1 (en) 2006-08-04 2007-08-03 Wear-resistant aluminum alloy for casting engine blocks with linerless cylinders
PCT/IB2007/004235 WO2008053363A2 (en) 2006-08-04 2007-08-03 Wear-resistant aluminum alloy for casting engine blocks with linerless cylinders
CA002660137A CA2660137A1 (en) 2006-08-04 2007-08-03 Wear-resistant aluminum alloy for casting engine blocks with linerless cylinders
KR1020097004541A KR20090048492A (ko) 2006-08-04 2007-08-03 라이너가 없는 실린더를 갖는 엔진 블록을 주조하기 위한 내마모성 알루미늄 합금
EP07866603A EP2054535A4 (en) 2006-08-04 2007-08-03 WEAR-RESISTANT ALUMINUM ALLOY FOR FORMING BY CASTING CYLINDER BLOCK WITHOUT INNER SHIRT
CN200780037074A CN101627138A (zh) 2006-08-04 2007-08-03 用于浇铸具有无衬套汽缸的发动机组的耐磨铝合金
BRPI0714884-4A BRPI0714884A2 (pt) 2006-08-04 2007-08-03 liga de alumÍnio resistente À abrasço, mÉtodo para produÇço de um bloco de cilindro de motor de alumÍnio, mÉtodo para produÇço de um fundido de uma liga al-si e bloco de motor de alumÍnio
US12/728,975 US20100288461A1 (en) 2006-08-04 2010-03-22 Wear-resistant aluminum alloy for casting engine blocks with linerless cylinders

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US11/499,165 US20080031768A1 (en) 2006-08-04 2006-08-04 Wear-resistant aluminum alloy for casting engine blocks with linerless cylinders

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US11/499,165 Abandoned US20080031768A1 (en) 2006-08-04 2006-08-04 Wear-resistant aluminum alloy for casting engine blocks with linerless cylinders
US12/728,975 Abandoned US20100288461A1 (en) 2006-08-04 2010-03-22 Wear-resistant aluminum alloy for casting engine blocks with linerless cylinders

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US12/728,975 Abandoned US20100288461A1 (en) 2006-08-04 2010-03-22 Wear-resistant aluminum alloy for casting engine blocks with linerless cylinders

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US (2) US20080031768A1 (ko)
EP (1) EP2054535A4 (ko)
KR (1) KR20090048492A (ko)
CN (1) CN101627138A (ko)
AU (1) AU2007315791A1 (ko)
BR (1) BRPI0714884A2 (ko)
CA (1) CA2660137A1 (ko)
MX (1) MX2009001319A (ko)
WO (1) WO2008053363A2 (ko)

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RU2468105C1 (ru) * 2011-11-18 2012-11-27 Открытое акционерное общество "Всероссийский институт легких сплавов" (ОАО "ВИЛС") Быстрозакристаллизованный сплав на основе алюминия для изготовления поршней
CN102794395A (zh) * 2011-05-24 2012-11-28 昆山市瑞捷精密模具有限公司 一种利用石膏型浇注锌锡合金模具的方法
CN102794396A (zh) * 2011-05-24 2012-11-28 昆山市瑞捷精密模具有限公司 一种利用石膏型浇注锌铝合金模具的方法
CN103030530A (zh) * 2011-09-29 2013-04-10 南昌洋浦天然香料香精有限公司 一种从杉木根中提取柏木醇的方法
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US9771635B2 (en) 2012-07-10 2017-09-26 GM Global Technology Operations LLC Cast aluminum alloy for structural components
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