US20090090479A1 - Combination of casting process and alloy composition - Google Patents

Combination of casting process and alloy composition Download PDF

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Publication number
US20090090479A1
US20090090479A1 US12/227,689 US22768907A US2009090479A1 US 20090090479 A1 US20090090479 A1 US 20090090479A1 US 22768907 A US22768907 A US 22768907A US 2009090479 A1 US2009090479 A1 US 2009090479A1
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Prior art keywords
weight
die
content
casting
process according
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Abandoned
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US12/227,689
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Inventor
HAkon Westengen
Per Bakke
Amanda Bowles
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Magontec GmbH
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Magontec GmbH
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Assigned to MAGONTEC GMBH reassignment MAGONTEC GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BOWLES, AMANDA, BAKKE, PER, WESTENGEN, HAKON
Publication of US20090090479A1 publication Critical patent/US20090090479A1/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002Castings of light metals
    • B22D21/007Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/08Cold chamber machines, i.e. with unheated press chamber into which molten metal is ladled
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/02Casting exceedingly oxidisable non-ferrous metals, e.g. in inert atmosphere
    • B22D21/04Casting aluminium or magnesium
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C23/00Alloys based on magnesium
    • C22C23/02Alloys based on magnesium with aluminium as the next major constituent
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C23/00Alloys based on magnesium
    • C22C23/04Alloys based on magnesium with zinc or cadmium as the next major constituent

Definitions

  • the present invention relates to a process for casting a magnesium alloy consisting of aluminium, zinc and manganese, and the balance being magnesium and unavoidable impurities, the total impurity level being below given % by weight.
  • Magnesium-based alloys are widely used as cast parts in automotive industries, and with increasing importance in 3C components (3C: computers, cameras and communications). Magnesium-based alloy cast parts can be produced by conventional casting methods, which include die-casting, sand casting, permanent and semi-permanent mould casting, plaster-mould casting and investment casting.
  • Mg-based alloys demonstrate a number of particularly advantageous properties that have prompted an increased demand for magnesium-based alloy cast parts in the automotive industry. These properties include low density, high strength-to-weight ratio, good castability, easy machinability and good damping characteristics.
  • Most common magnesium die-casting alloys are such as Mg—Al-alloys or Mg—Al—Zn-alloys with ⁇ 0.5% Mn, mainly Mg-9% Al-1% Zn (designated AZ91), Mg-6% Al (AM60) and Mg-5% Al (AM50).
  • WO 2006/000022 A1 describes a magnesium-based alloy containing zinc, aluminium, calcium and/or beryllium or optionally manganese by which is provided an attempt to improve the surface finish of cast magnesium components.
  • the WO reference is, however, not particularly concerned with the castability of the alloy.
  • products may be made having excellent surface finish, reasonable ductility and acceptable mechanical properties as well as corrosion properties.
  • the aluminium content is between 5.00 and 13.00% by weight. If less than 10.00% Al is present the Zn content is restricted to 10.00-22.00% by weight. Lower Zn contents give poorer combination of castablity and surface finish.
  • the range of Zn can be extended to 0.00-22.00% still giving satisfactory castability and surface finish.
  • the composition of the alloy is selected in such a way that the aluminium content is between 10.00 and 12.00% by weight and the Zn-content is between 0.00 and 4.00% by weight. Alloys with equivalent castability and surface finish can be prepared if the composition of the alloy is such that the aluminium content is between 6.00 and 12.00% by weight and the Zn-content is between 10.00 and 22.00% by weight. These alloys offer the advantages of lower casting temperature.
  • FIGS. 1A , B each shows schematically cold chamber and hot chamber die casting machines, respectively
  • FIG. 2 is a diagram showing the relationship between the solidification rate and the microstructure (grain size and secondary dendrite arm spacing) of cast Mg alloys,
  • FIG. 3 is a diagram showing the grain size vs. ductility of Mg alloys
  • FIG. 4 is a diagram showing the grain size vs. tensile yield strength of Mg alloys
  • FIG. 5 shows a chart from a prior art reference, G. S Foerster; “New developments in magnesium die casting”, IMA proceedings 1976 p. 35-39, who split the composition range into a castable—, a brittle—and a hot cracking region,
  • FIG. 6 shows the Mg-rich corner of the Mg—Al—Zn phase diagram with lines of constant liquidus temperature
  • FIG. 7 shows a diagram with the fraction solid (expressed in % by weight) on the horizontal axis versus the temperature (OC) on the vertical axis for three different Mg alloys
  • FIGS. 8-10 show three different Mg alloy components being cast with three different dies
  • FIG. 11 is a diagram showing casting defects, average number of cracks and defect ribs on the box die, FIG. 8 , plotted as lines of equal number of defects in a diagram, where the Zn content is plotted along the x-axis and the Al content along the y-axis,
  • FIG. 12 is a diagram showing surface finish represented as a rating from 1 to 5 on the box die, FIG. 8 , plotted as lines of equal rating in a diagram, where the Zn content is plotted along the x-axis and the Al content along the y-axis,
  • FIG. 13 is a diagram showing where the z-axis is representing the tensile strength expressed in MPa, while the x and y-axes are representing the Al and Zn contents, respectively, and where the ductility is represented as lines of equal % elongation in the same diagram,
  • FIG. 14 is a diagram showing corrosion rates in terms of weight loss being represented as lines of equal corrosion rates (mg/cm 2 /day), where the Zn content is plotted along the y-axis and the Al content along the x-axis.
  • each machine has a die 10 , 20 provided with a hydraulic clamping system 11 , 21 , respectively.
  • Molten metal is introduced into the die by means of a shot cylinder 12 , 22 provided with a piston 13 , 23 , respectively.
  • a shot cylinder 12 , 22 provided with a piston 13 , 23 , respectively.
  • an auxiliary system for metering of the metal to the horizontal shot cylinder is required.
  • the hot chamber machine shown in FIG. 1 B, uses a vertical piston system 12 , 23 directly in the molten alloy.
  • the steel die 10 , 20 is equipped with an oil (or water) cooling system controlling the die temperature in the range of 200-300° C.
  • a prerequisite for good quality is a short die filling time to avoid solidification of metal during filling.
  • a die filling time in the order of 10 ⁇ 2 s ⁇ average part thickness (mm) is recommended. This is obtained by forcing the alloy through a gate with high speeds typically in the range 30-300 m/s. Plunger velocities up to 10 m/s with sufficiently large diameters are being used to obtain the desired volume flows in the shot cylinder for the short filling times needed.
  • FIG. 2 there is shown the relationship between the solidification range and the microstructure of a cast alloy.
  • the solidification rate expressed as ° C./s
  • the secondary dendrite arm spacing expressed in ⁇ m is shown, whereas on the right hand vertical scale the grain diameter expressed in ⁇ m is shown.
  • Line 30 indicates the grain size obtained, whereas line 31 is the obtained value for the secondary dendrite arm spacing.
  • cooling rate With die casting grain refining is obtained by the cooling rate. As mentioned above cooling rates in the range of 10-1000° C./s are normally achieved. This typically results in grain sizes in the range of 5-100 ⁇ m.
  • the castability term describes the ability of an alloy to be cast into a final product with required functionalities and properties. It generally contains 3 categories; (1) the ability to form a part with all desired geometry features and dimensions, (2) the ability to produce a dense part with desired properties, and (3) the effects on die cast tooling, foundry equipment and die casting process efficiency.
  • the Mg—Al—Zn alloys with the Al and Zn content as specified in the present invention will start to solidify around 600° C., depending on the Al and Zn content. This is indicated in FIG. 6 where lines of constant liquidus temperature in the Mg-corner of the Mg-AI—Zn phase diagram are shown.
  • the casting temperature typically 70° C. above the liquidus, can be significantly lower than for the conventional AM50, AM60 and AZ91 alloys.
  • the conventional Mg—Al alloys like AM50, AM60 and AZ91 will have a solidification range of nearly 200° C. as shown in the annexed FIG.
  • Mg—Al die casting alloys improves the die castability. This is due to the fact that Mg—Al alloys have a wide solidification range, which makes them inherently difficult to cast unless a sufficiently large amount of eutectic is present at the end of solidification. This can explain the good castability of AZ91D consistent with the cooling curves shown in FIG. 7 . With the large amount of Zn in addition to Al in the present alloys there is an even larger amount of (modified) eutectic present at the end of solidification, explaining the improved castability of the invented Mg—Al—Zn alloys.
  • Magnesium alloys tend to ignite and oxidize (burn) in the molten state unless protected by cover gases such as SF 6 and dry air with or without CO 2 , or SO 2 and dry air. The oxidation aggravates with increasing temperature.
  • cover gases such as SF 6 and dry air with or without CO 2 , or SO 2 and dry air.
  • the oxidation aggravates with increasing temperature.
  • small amounts of beryllium (10-15 ppm by weight) are also added to reduce the oxidation.
  • Beryllium is known to form toxic substances and should be used with care.
  • Especially the treatment of dross and sludge from the cleaning of crucibles requires considerable safety precautions due to an enrichment of Be-compounds in dross/sludge.
  • One advantage of the present invention is that the alloy can be cast at temperatures significantly lower than for conventional alloys, thereby reducing the need for cover gases. For the same reason, beryllium additions can be kept at a minimum.
  • the lower casting temperatures compared to conventional alloys also offer significant advantages as the lifetime of the metering system, the shot cylinder and the die will all be improved. With hot chamber die casting in particular, the lifetime of the gooseneck will be significantly extended.
  • the alloys with lower casting temperature also have a potential for reducing the cycle time, thereby improving the productivity of the die casting operation.
  • the performed tests are the following:
  • Casting defects average number of cracks and defect ribs are plotted in FIG. 11 as lines of equal number of defects in a diagram where the Zn content is plotted along the x-axis and the Al content along the y-axis. It is seen that the lowest numbers of cracks are found in the regions with low Zn ( ⁇ 3%) and high Zn ( ⁇ 10%). It is seen that that particularly good alloys in terms of casting defects are found with Al in the range of 8-10% by weight and with Zn ⁇ 2% by weight; the lower Zn the better. Also, alloys with Al in the range of 7-12% by weight and Zn in the range 12-18% by weight exhibit very few casting defects.
  • Surface finish represented as a rating from 1 to 5 is plotted in FIG. 12 as lines of equal rating in a diagram where the Zn content is plotted along the x-axis and the Al content along the y-axis. It is seen that the best regions in terms of surface finish rating are found with Al>11% by weight and Zn ⁇ 3% by weight; the lower Zn the better. Also, a region roughly defined by 8-12% Al by weight and >10% Zn by weight provides alloys with superior surface finish.
  • the strength and elongation have been measured at room temperature.
  • the results are shown in FIG. 13 .
  • the z-axis is representing the tensile strength expressed in MPa
  • the x and y-axes are representing the Al and Zn contents, respectively.
  • the ductility is represented as lines of equal elongation in the same diagram.
  • tensile strength expressed in MPa increases with increasing content of alloying elements.
  • the effect of increasing Al (% by weight) is significantly greater than the effect of Zn.
  • FIG. 13 also indicates that the ductility in terms of % elongation decreases with increasing content of alloying elements.
  • the line indicating 3% elongation extends almost linearly from 12% Al by weight and 0% Zn to 0% Al and 18% Zn by weight.
  • corrosion rates in terms of weight loss is represented as lines of equal corrosion rates (mg/cm 2 /day), in a diagram where the Zn content is plotted along the y-axis and the Al content along the x-axis. It is seen that for Zn contents lower than approximately 8% by weight, the corrosion rates decrease with increasing Al content and are practically independent of the Zn content, whereas for Zn contents above approximately 12% by weight the corrosion rates increases slightly with increasing Zn content and are practically independent of the Al content. The region defined by 8-12% by weight of Zn represents a transition. Specifically, at 0% Zn the corrosion rate decreases from about 0.09 mg/cm 2 /day at 4% Al by weight to approximately 0.03 mg/cm 2 /day at 9% Al by weight. At constant 9% Al by weight the corrosion rate increases to 0.05 mg/cm 2 /day at 8% Zn by weight and 0.11 mg/cm 2 /day at 14% Zn by weight.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Continuous Casting (AREA)
  • Forging (AREA)
  • Powder Metallurgy (AREA)
US12/227,689 2006-08-18 2007-08-16 Combination of casting process and alloy composition Abandoned US20090090479A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
NO20063703 2006-08-18
NO20063703A NO20063703L (no) 2006-08-18 2006-08-18 Magnesium stopeprosess og legeringssammensetning
PCT/NO2007/000284 WO2008020763A1 (en) 2006-08-18 2007-08-16 Combination of casting process and alloy composition

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US (1) US20090090479A1 (zh)
EP (1) EP2054179A4 (zh)
JP (1) JP2010501721A (zh)
KR (1) KR101082065B1 (zh)
CN (1) CN101505891B (zh)
AU (1) AU2007285076B2 (zh)
BR (1) BRPI0716059A2 (zh)
CA (1) CA2658350C (zh)
EA (1) EA014150B1 (zh)
IL (1) IL197109A0 (zh)
MX (1) MX2009001775A (zh)
NO (1) NO20063703L (zh)
TW (1) TW200813237A (zh)
WO (1) WO2008020763A1 (zh)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1957221A1 (en) 2005-11-10 2008-08-20 Magontec GmbH A combination of casting process and alloy compositions resulting in cast parts with superior combination of elevated temperature creep properties, ductility and corrosion performance
US20110229733A1 (en) * 2008-11-25 2011-09-22 Masatada Numano Magnesium alloy joined part
US20110268986A1 (en) * 2008-12-26 2011-11-03 Sumitomo Electric Industries, Ltd. Magnesium alloy member and method for producing same
US10086429B2 (en) * 2014-10-24 2018-10-02 GM Global Technology Operations LLC Chilled-zone microstructures for cast parts made with lightweight metal alloys
US11248282B2 (en) 2017-01-10 2022-02-15 Fuji Light Metal Co., Ltd. Magnesium alloy
CN114472860A (zh) * 2021-12-30 2022-05-13 深圳市中金岭南有色金属股份有限公司韶关冶炼厂 一种提高锌铝镁合金质量的梯度冷却方法
US11685975B2 (en) * 2018-07-09 2023-06-27 Japan Medical Device Technology Co., Ltd. Magnesium alloy

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KR101561150B1 (ko) * 2008-06-03 2015-10-16 코쿠리츠켄큐카이하츠호징 붓시쯔 자이료 켄큐키코 Mg기 합금
DE102013000746A1 (de) * 2013-01-17 2014-07-17 Kienle + Spiess Gmbh Verfahren zum Herstellen von Gussteilen für elektrische Anwendungen
CN103789591A (zh) * 2014-01-09 2014-05-14 马鞍山市恒毅机械制造有限公司 一种铸造轮毂用镁合金材料及其制备方法
CN103774013A (zh) * 2014-01-09 2014-05-07 马鞍山市恒毅机械制造有限公司 一种电动车轮毂用镁合金材料及其制备方法

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US20040159188A1 (en) * 2003-02-17 2004-08-19 Pekguleryuz Mihriban O. Strontium for melt oxidation reduction of magnesium and a method for adding stronium to magnesium

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US6139651A (en) * 1998-08-06 2000-10-31 Dead Sea Magnesium Ltd Magnesium alloy for high temperature applications
US20030230392A1 (en) * 2002-06-13 2003-12-18 Frank Czerwinski Process for injection molding semi-solid alloys
US20040159188A1 (en) * 2003-02-17 2004-08-19 Pekguleryuz Mihriban O. Strontium for melt oxidation reduction of magnesium and a method for adding stronium to magnesium

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1957221A1 (en) 2005-11-10 2008-08-20 Magontec GmbH A combination of casting process and alloy compositions resulting in cast parts with superior combination of elevated temperature creep properties, ductility and corrosion performance
US20090133849A1 (en) * 2005-11-10 2009-05-28 Magontec Gmbh Combination of casting process and alloy compositions resulting in cast parts with superior combination of elevated temperature creep properties, ductility and corrosion performance
US20110229733A1 (en) * 2008-11-25 2011-09-22 Masatada Numano Magnesium alloy joined part
US20110268986A1 (en) * 2008-12-26 2011-11-03 Sumitomo Electric Industries, Ltd. Magnesium alloy member and method for producing same
US20120111484A1 (en) * 2008-12-26 2012-05-10 Sumitomo Electric Industries, Ltd. Magnesium alloy joined part and production method thereof
US8820614B2 (en) * 2008-12-26 2014-09-02 Sumitomo Electric Industries, Ltd. Magnesium alloy joined part and production method thereof
US10086429B2 (en) * 2014-10-24 2018-10-02 GM Global Technology Operations LLC Chilled-zone microstructures for cast parts made with lightweight metal alloys
US11248282B2 (en) 2017-01-10 2022-02-15 Fuji Light Metal Co., Ltd. Magnesium alloy
US11685975B2 (en) * 2018-07-09 2023-06-27 Japan Medical Device Technology Co., Ltd. Magnesium alloy
CN114472860A (zh) * 2021-12-30 2022-05-13 深圳市中金岭南有色金属股份有限公司韶关冶炼厂 一种提高锌铝镁合金质量的梯度冷却方法

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EP2054179A1 (en) 2009-05-06
AU2007285076B2 (en) 2010-04-01
EA200900196A1 (ru) 2009-06-30
KR101082065B1 (ko) 2011-11-10
CN101505891B (zh) 2011-09-28
CA2658350A1 (en) 2008-02-21
CN101505891A (zh) 2009-08-12
AU2007285076A1 (en) 2008-02-21
IL197109A0 (en) 2009-11-18
CA2658350C (en) 2011-05-31
WO2008020763A1 (en) 2008-02-21
KR20090051722A (ko) 2009-05-22
EA014150B1 (ru) 2010-10-29
NO20063703L (no) 2008-02-19
JP2010501721A (ja) 2010-01-21
MX2009001775A (es) 2009-04-14
EP2054179A4 (en) 2011-04-06
BRPI0716059A2 (pt) 2013-08-06
TW200813237A (en) 2008-03-16

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