US20100310414A1 - High corrosion resistance aluminum alloy for sand and permanent mold processes - Google Patents
High corrosion resistance aluminum alloy for sand and permanent mold processes Download PDFInfo
- Publication number
- US20100310414A1 US20100310414A1 US12/480,912 US48091209A US2010310414A1 US 20100310414 A1 US20100310414 A1 US 20100310414A1 US 48091209 A US48091209 A US 48091209A US 2010310414 A1 US2010310414 A1 US 2010310414A1
- Authority
- US
- United States
- Prior art keywords
- percent
- weight
- aluminum
- alloy
- casting
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 229910000838 Al alloy Inorganic materials 0.000 title claims description 19
- 238000005260 corrosion Methods 0.000 title abstract description 14
- 230000007797 corrosion Effects 0.000 title abstract description 14
- 239000004576 sand Substances 0.000 title abstract description 11
- 238000000034 method Methods 0.000 title abstract description 8
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 36
- 239000000956 alloy Substances 0.000 claims abstract description 36
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 29
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 29
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 20
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 claims abstract description 14
- 229910052748 manganese Inorganic materials 0.000 claims abstract description 14
- 239000011572 manganese Substances 0.000 claims abstract description 14
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 12
- 229910052802 copper Inorganic materials 0.000 claims abstract description 12
- 239000010949 copper Substances 0.000 claims abstract description 12
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 11
- 239000010703 silicon Substances 0.000 claims abstract description 11
- 229910052742 iron Inorganic materials 0.000 claims abstract description 10
- 238000004519 manufacturing process Methods 0.000 claims 1
- 238000005266 casting Methods 0.000 abstract description 15
- 238000007528 sand casting Methods 0.000 abstract description 10
- 238000010120 permanent mold casting Methods 0.000 abstract description 9
- 238000004512 die casting Methods 0.000 description 10
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 7
- 238000005476 soldering Methods 0.000 description 5
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 239000004411 aluminium Substances 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 229910052749 magnesium Inorganic materials 0.000 description 2
- 239000011777 magnesium Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000001939 inductive effect Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 230000035945 sensitivity Effects 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- 239000011135 tin Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
Classifications
-
- 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
Definitions
- This invention relates to aluminum alloys; particularly, to aluminum casting alloys; and more particularly, to aluminum casting alloys used for sand and permanent mold casting processes.
- Components formed from casting of known aluminum alloys may not be sufficiently resistant to corrosion for certain automotive applications.
- U.S. Pat. No. 6,733,726 B2 provides for an aluminum alloy that is suitable for die-casting components for automotive applications.
- the aluminum die casting alloy is characterized by a very low copper content, a manganese content that is sufficient to enhance the stability of the alloy and have a positive influence on the strength properties, and a silicon content that is sufficient to impart excellent fluidity, hot tear resistance and feeding characteristics for good die-castability.
- the aluminum die casting alloy contains about 4.5 to about 12 percent silicon by weight, at least 87 percent aluminum by weight, about 0.25 percent to about 0.5 percent manganese by weight, and a maximum of 0.08 percent copper by weight.
- the resulting aluminum alloy has improved corrosion resistance and excellent strength characteristics; however, the alloy is formulated mainly for die-casting processes in which the alloy is subjected to high gauge pressure for introducing molten alloy into the die-cast dies.
- Sand and permanent mold casting may be a more cost efficient alternative to die-casting for forming certain components. As compared to die-casting, both sand and permanent mold casting processes require very low to no gauge pressure in introducing the molten aluminum alloy into the mold.
- Sand casting is a process in which molten metal is poured into a mold formed of sand under gravity or low pressure or in vacuum and held until the alloy is cooled and solidified.
- Permanent mold casting is similar to sand casting except that the mold is typically formed of a metal that has a higher melting point than the alloy that is poured into the mold.
- Components formed from sand and permanent mold casting can be heat treated to obtain the desired mechanical properties. Components formed from aluminum alloys designed for die casting cannot be heat treated, and therefore requires the alloy formulation be tailored to provide the desired mechanical properties in an as-cast component.
- an aluminum casting alloy best suited for sand and permanent mold casting processes, in which the alloy is highly resistant to corrosion yet exhibits adequate strength similar to that of the aluminum alloy for die-casting as disclosed in U.S. Pat. No. 6,733,726 B2. It is also desirable to have an aluminum casting alloy that is amenable to heat treatment. It is still further desirable to have an aluminum casting alloy that has a reduced natural affinity for the aluminium to attack and dissolve the tooling steel, a condition referred to as soldering.
- This invention is directed to aluminum alloys having improved corrosion resistance and excellent strength characteristics for sand and permanent mold casting processes.
- the aluminum alloys of this invention are characterized by a very low copper content, a manganese content that is sufficient to input excellent strength properties, a silicon content that is suitable for fluid flow of molten alloy into a mold under normal gravity, and an iron content sufficient to minimize soldering of metallic molds.
- the lower silicon content provides for improved mechanical properties, while the lower iron content provides for increased strength and better creep characteristics at moderately elevated temperatures and improved ductility.
- an aluminum casting alloy having improved corrosion resistance and excellent sand and permanent casting properties includes a relatively low copper content that is effective to achieve enhanced corrosion resistance, in conjunction with a relatively lower silicon content for improved mechanical properties, and a lower iron content to increase tensile strength and ductility as well as to reduce shrinkage and soldering.
- the aluminum alloys of this invention typically have a silicon content of from about 4.0 percent by weight to about 8.5 percent by weight; preferably between about 4.0 to about 7.0 percent by weight.
- Iron is preferably added to the aluminum alloys of this invention to decrease the tendency for mold sticking or soldering during casting.
- a suitable amount of iron is from about 0.2 percent to about 0.8 percent by weight.
- Conventional aluminum casting alloys typically contain relatively high amounts of copper in order to improve the machinability, strength, and hardness of the casting.
- copper reduces resistance to general corrosion, and therefore, is present in the aluminum alloys of this invention in relatively low amounts, if at all.
- the aluminum alloys of this invention typically contain 0.08 percent copper by weight or less, and more preferably 0.05 percent or less.
- Aluminum casting alloys have an aluminum content of about 86 percent by weight or less.
- the most commonly used aluminum die casting alloy (alloy 380.0) contains from about 79 to about 83 percent aluminum by weight.
- the aluminum alloys of this invention for sand and permanent mold casting have a relatively high aluminum content, and as a result, exhibit a thermal conductivity that is about 20 percent greater than that of alloy 380.0.
- Manganese is present in an amount from about 0.25 to about 0.5 percent by weight to enhance strength, and more preferably from about 0.3 to about 0.5, with about 0.40 percent manganese being most preferred. These levels of manganese have been found to compensate, at least in part, for the relatively low levels of copper, to enhance strength properties without significantly adversely affecting corrosion resistance.
- Magnesium, nickel, zinc and tin may be present in the alloy in relatively minor amounts, preferably about 1.5 percent or less, more preferably about 1 percent or less, and even more preferably about 0.6 percent or less.
- the aluminum alloys of this invention use lower silicon and higher iron and manganese contents, as compared to known aluminum alloys, to increase strength and control the grain structure.
- An advantage of having higher manganese content is the increase in the sensitivity of heat treating in obtaining the desired properties.
- Another advantage of having higher manganese content is that the manganese combines with magnesium to insure a greater degree of stability to the alloy.
- the higher iron aids in reducing the natural affinity for aluminium to attack and dissolve tooling steel, a condition referred to as soldering.
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
- Prevention Of Electric Corrosion (AREA)
Abstract
An aluminum-based casting alloy having improved corrosion resistance and casting characteristics for sand and permanent mold casting processes. The aluminum-based casting alloy contains from about 4.0 to about 7.0 percent silicon by weight, at least 87 percent aluminum by weight, from about 0.25 percent to about 0.5 percent manganese by weight, a maximum of 0.08 percent copper by weight, and from about 0.2 percent to about 0.8 percent iron by weight.
Description
- This invention relates to aluminum alloys; particularly, to aluminum casting alloys; and more particularly, to aluminum casting alloys used for sand and permanent mold casting processes.
- Components formed from casting of known aluminum alloys may not be sufficiently resistant to corrosion for certain automotive applications. Aluminum automotive components that are exposed to temperature extremes, water, snow, ice and humidity, as well as corrosion inducing materials such as salt, and dirt and road grime that can retain moisture and salt, eventually tend to exhibit significant corrosion.
- U.S. Pat. No. 6,733,726 B2 provides for an aluminum alloy that is suitable for die-casting components for automotive applications. The aluminum die casting alloy is characterized by a very low copper content, a manganese content that is sufficient to enhance the stability of the alloy and have a positive influence on the strength properties, and a silicon content that is sufficient to impart excellent fluidity, hot tear resistance and feeding characteristics for good die-castability. The aluminum die casting alloy contains about 4.5 to about 12 percent silicon by weight, at least 87 percent aluminum by weight, about 0.25 percent to about 0.5 percent manganese by weight, and a maximum of 0.08 percent copper by weight. The resulting aluminum alloy has improved corrosion resistance and excellent strength characteristics; however, the alloy is formulated mainly for die-casting processes in which the alloy is subjected to high gauge pressure for introducing molten alloy into the die-cast dies.
- Sand and permanent mold casting may be a more cost efficient alternative to die-casting for forming certain components. As compared to die-casting, both sand and permanent mold casting processes require very low to no gauge pressure in introducing the molten aluminum alloy into the mold. Sand casting is a process in which molten metal is poured into a mold formed of sand under gravity or low pressure or in vacuum and held until the alloy is cooled and solidified. Permanent mold casting is similar to sand casting except that the mold is typically formed of a metal that has a higher melting point than the alloy that is poured into the mold. Components formed from sand and permanent mold casting can be heat treated to obtain the desired mechanical properties. Components formed from aluminum alloys designed for die casting cannot be heat treated, and therefore requires the alloy formulation be tailored to provide the desired mechanical properties in an as-cast component.
- It is desirable to have an aluminum casting alloy best suited for sand and permanent mold casting processes, in which the alloy is highly resistant to corrosion yet exhibits adequate strength similar to that of the aluminum alloy for die-casting as disclosed in U.S. Pat. No. 6,733,726 B2. It is also desirable to have an aluminum casting alloy that is amenable to heat treatment. It is still further desirable to have an aluminum casting alloy that has a reduced natural affinity for the aluminium to attack and dissolve the tooling steel, a condition referred to as soldering.
- This invention is directed to aluminum alloys having improved corrosion resistance and excellent strength characteristics for sand and permanent mold casting processes. Relative to known aluminum alloys, the aluminum alloys of this invention are characterized by a very low copper content, a manganese content that is sufficient to input excellent strength properties, a silicon content that is suitable for fluid flow of molten alloy into a mold under normal gravity, and an iron content sufficient to minimize soldering of metallic molds. The lower silicon content provides for improved mechanical properties, while the lower iron content provides for increased strength and better creep characteristics at moderately elevated temperatures and improved ductility.
- These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification and claims.
- In accordance with the principles of this invention, an aluminum casting alloy having improved corrosion resistance and excellent sand and permanent casting properties includes a relatively low copper content that is effective to achieve enhanced corrosion resistance, in conjunction with a relatively lower silicon content for improved mechanical properties, and a lower iron content to increase tensile strength and ductility as well as to reduce shrinkage and soldering.
- The aluminum alloys of this invention typically have a silicon content of from about 4.0 percent by weight to about 8.5 percent by weight; preferably between about 4.0 to about 7.0 percent by weight.
- Iron is preferably added to the aluminum alloys of this invention to decrease the tendency for mold sticking or soldering during casting. A suitable amount of iron is from about 0.2 percent to about 0.8 percent by weight.
- Conventional aluminum casting alloys typically contain relatively high amounts of copper in order to improve the machinability, strength, and hardness of the casting. However, copper reduces resistance to general corrosion, and therefore, is present in the aluminum alloys of this invention in relatively low amounts, if at all. In order to achieve excellent corrosion resistance, the aluminum alloys of this invention typically contain 0.08 percent copper by weight or less, and more preferably 0.05 percent or less.
- Most aluminum casting alloys have an aluminum content of about 86 percent by weight or less. For example, the most commonly used aluminum die casting alloy (alloy 380.0) contains from about 79 to about 83 percent aluminum by weight. The conventional corrosion resistant aluminum die casting alloys, alloys 360.0 and 413.0, contain from about 85 to about 86.5 percent aluminum by weight and from about 82 percent to about 84 percent aluminum by weight, respectively. In contrast, the aluminum alloys of this invention for sand and permanent mold casting have a relatively high aluminum content, and as a result, exhibit a thermal conductivity that is about 20 percent greater than that of alloy 380.0.
- Manganese is present in an amount from about 0.25 to about 0.5 percent by weight to enhance strength, and more preferably from about 0.3 to about 0.5, with about 0.40 percent manganese being most preferred. These levels of manganese have been found to compensate, at least in part, for the relatively low levels of copper, to enhance strength properties without significantly adversely affecting corrosion resistance.
- Magnesium, nickel, zinc and tin may be present in the alloy in relatively minor amounts, preferably about 1.5 percent or less, more preferably about 1 percent or less, and even more preferably about 0.6 percent or less.
- Other elements are not desirable, and are preferably present in an amount of less than 0.5 percent by weight, and more preferably less than 0.03 percent by weight.
- The aluminum alloys of this invention use lower silicon and higher iron and manganese contents, as compared to known aluminum alloys, to increase strength and control the grain structure. An advantage of having higher manganese content is the increase in the sensitivity of heat treating in obtaining the desired properties. Another advantage of having higher manganese content is that the manganese combines with magnesium to insure a greater degree of stability to the alloy. Also, the higher iron aids in reducing the natural affinity for aluminium to attack and dissolve tooling steel, a condition referred to as soldering.
- It will be understood by those who practice the invention and those skilled in the art, that various modifications and improvements may be made to the invention without departing from the spirit of the disclosed concept. The scope of protection afforded is to be determined by the claims and by the breadth of interpretation allowed by law.
Claims (7)
1. An aluminum-based alloy comprising:
at least about 87 percent aluminum by weight;
from about 4.0 percent to about 8.5 percent silicon by weight;
from about 0.25 percent to about 0.5 percent manganese by weight;
a maximum of about 0.08 percent copper by weight; and
from about 0.2 percent to about 0.8 percent iron by weight.
2. The alloy of claim 2 , wherein the silicon is present in an amount of from about 4.0 to 7.0 percent by weight.
3. The alloy of claim 1 , having a maximum of 0.05 percent copper by weight.
4. The alloy of claim 1 , wherein the aluminum is present in the alloy in an amount of at least 88 percent by weight.
5. The alloy of claim 1 , wherein the aluminum is present in the alloy in an amount of at least 89 percent by weight.
6. The alloy of claim 1 , wherein the manganese is present in an amount of from about 0.3 percent to about 0.5 percent by weight.
7. An article of manufacture made from an aluminum alloy comprising:
at least about 87 percent aluminum by weight;
from about 4.0 percent to about 8.5 percent silicon by weight;
from about 0.25 percent to about 0.5 percent manganese by weight;
a maximum of about 0.08 percent copper by weight; and
from about 0.2 percent to about 0.8 percent iron by weight.
Priority Applications (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US12/480,912 US20100310414A1 (en) | 2009-06-09 | 2009-06-09 | High corrosion resistance aluminum alloy for sand and permanent mold processes |
| EP10164100A EP2261384A2 (en) | 2009-06-09 | 2010-05-27 | High corrosion resistance aluminum alloy for sand and permanent mold processes |
| CN2010101988481A CN101921936A (en) | 2009-06-09 | 2010-06-08 | The high corrosion resistance aluminum alloy that is used for sand casting process and permanent mold casting technology |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US12/480,912 US20100310414A1 (en) | 2009-06-09 | 2009-06-09 | High corrosion resistance aluminum alloy for sand and permanent mold processes |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| US20100310414A1 true US20100310414A1 (en) | 2010-12-09 |
Family
ID=42782054
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US12/480,912 Abandoned US20100310414A1 (en) | 2009-06-09 | 2009-06-09 | High corrosion resistance aluminum alloy for sand and permanent mold processes |
Country Status (3)
| Country | Link |
|---|---|
| US (1) | US20100310414A1 (en) |
| EP (1) | EP2261384A2 (en) |
| CN (1) | CN101921936A (en) |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6376375B1 (en) * | 2000-01-13 | 2002-04-23 | Delphi Technologies, Inc. | Process for preventing the formation of a copper precipitate in a copper-containing metallization on a die |
| US6586110B1 (en) * | 2000-07-07 | 2003-07-01 | Delphi Technologies, Inc. | Contoured metal structural members and methods for making the same |
| US6733726B2 (en) * | 2001-02-05 | 2004-05-11 | Delphi Technologies, Inc. | High corrosion resistance aluminum alloy |
Family Cites Families (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CH297680A (en) * | 1942-05-07 | 1954-03-31 | Lurgi Thermie Gmbh | Process for the production of an aluminum-silicon alloy. |
| JPH01283335A (en) * | 1988-05-10 | 1989-11-14 | Showa Alum Corp | Aluminum alloy for vacuum |
| JP3164587B2 (en) * | 1996-09-03 | 2001-05-08 | トヨタ自動車株式会社 | Alloys with excellent thermal fatigue resistance, aluminum alloys with excellent thermal fatigue resistance, and aluminum alloy members with excellent thermal fatigue resistance |
| ATE422000T1 (en) * | 2001-07-25 | 2009-02-15 | Showa Denko Kk | ALUMINUM ALLOY HAVING EXCELLENT MACHINABILITY AND ALUMINUM ALLOY MATERIAL AND PRODUCTION PROCESS THEREOF |
| JP4053793B2 (en) * | 2002-03-08 | 2008-02-27 | 古河スカイ株式会社 | Manufacturing method of aluminum alloy composite for heat exchanger and aluminum alloy composite |
| CN101120894B (en) * | 2006-08-08 | 2010-05-12 | 上海市机械制造工艺研究所有限公司 | Technology method relating to component in manufacturing artificial limb knee-joint |
| CN101338392B (en) * | 2008-08-07 | 2011-08-03 | 中铝河南铝业有限公司 | Method for producing aluminum alloy medicinal foil by hot-rolling method |
-
2009
- 2009-06-09 US US12/480,912 patent/US20100310414A1/en not_active Abandoned
-
2010
- 2010-05-27 EP EP10164100A patent/EP2261384A2/en not_active Withdrawn
- 2010-06-08 CN CN2010101988481A patent/CN101921936A/en active Pending
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6376375B1 (en) * | 2000-01-13 | 2002-04-23 | Delphi Technologies, Inc. | Process for preventing the formation of a copper precipitate in a copper-containing metallization on a die |
| US6586110B1 (en) * | 2000-07-07 | 2003-07-01 | Delphi Technologies, Inc. | Contoured metal structural members and methods for making the same |
| US6733726B2 (en) * | 2001-02-05 | 2004-05-11 | Delphi Technologies, Inc. | High corrosion resistance aluminum alloy |
Also Published As
| Publication number | Publication date |
|---|---|
| CN101921936A (en) | 2010-12-22 |
| EP2261384A2 (en) | 2010-12-15 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| AS | Assignment |
Owner name: DELPHI TECHNOLOGIES, INC., MICHIGAN Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:O'CONNOR, KURT F.;REEL/FRAME:022798/0450 Effective date: 20090609 |
|
| STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |