US20120100385A1 - Process for production of roughly shaped material for engine piston - Google Patents

Process for production of roughly shaped material for engine piston Download PDF

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Publication number
US20120100385A1
US20120100385A1 US13/381,423 US201013381423A US2012100385A1 US 20120100385 A1 US20120100385 A1 US 20120100385A1 US 201013381423 A US201013381423 A US 201013381423A US 2012100385 A1 US2012100385 A1 US 2012100385A1
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Prior art keywords
mass
shaped material
roughly shaped
primary
additive amount
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US13/381,423
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Inventor
Hideki Takemura
Hiroaki Murakami
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Resonac Holdings Corp
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Showa Denko KK
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    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D7/00—Modifying the physical properties of iron or steel by deformation
    • C21D7/13—Modifying the physical properties of iron or steel by deformation by hot working
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J1/00—Preparing metal stock or similar ancillary operations prior, during or post forging, e.g. heating or cooling
    • B21J1/04—Shaping in the rough solely by forging or pressing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/18—Making machine elements pistons or plungers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/001—Continuous casting of metals, i.e. casting in indefinite lengths of specific alloys
    • B22D11/003—Aluminium 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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/043—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with silicon as the next major constituent
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F3/00—Pistons 
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F2200/00—Manufacturing
    • F02F2200/04—Forging of engine parts
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12229—Intermediate article [e.g., blank, etc.]

Definitions

  • the present invention relates to a production method of a roughly shaped material for an engine piston made of aluminum alloy excellent in wear resistance and high-temperature characteristics, and also relates to the roughly shaped material for an engine piston.
  • An engine piston for use in an engine to be mounted to a vehicle such as an automobile is required to have lightweight property to reduce the inertia force as much as possible, high-temperature strength at a raised maximum temperature, durability at the raised maximum temperature, low thermal expansibility to reduce clearance fluctuations due to thermal expansion, and wear resistance to reduce abrasion of ring grooves due to sliding of piston rings and/or abrasion of a skirt portion due to contact with a cylinder surface.
  • the present invention was made in view of the aforementioned technical background, and aims to provide a production method of a roughly shaped material for an engine piston made of aluminum alloy excellent in wear resistance and high-temperature characteristics, and to provide the roughly shaped material for an engine piston.
  • the present invention provided the following means.
  • a production method of a roughly shaped material for an engine piston comprising:
  • a continuous casting step for obtaining a cast rod having a diameter of 85 mm or less by continuously casting a molten metal consisting of Si: 11.0 to 13.0 mass %, Fe: 0.6 to 1.0 mass %, Cu: 3.5 to 4.5 mass %, Mn: 0.25 mass % or less; Mg: 0.4 to 0.6 mass %, Cr: 0.15 mass % or less, Zr: 0.07 to 0.15 mass %, P: 0.005 to 0.010 mass %, Ca: 0.002 mass % or less, and the balance being Aluminum and inevitable impurities with a temperature of the molten metal before pouring into a continuous casting mold set to 720° C. or higher; and
  • a forging step for obtaining a roughly shaped material for an engine piston by forging a forging material obtained by subjecting the cast rod to a homogenization treatment at a temperature of 370 to 500° C.
  • a roughly shaped material for an engine piston produced by the production method of a roughly shaped material for an engine piston as recited in the aforementioned Item 1 or 2,
  • a roughly shaped material for an engine piston produced by forging wherein a composition of the roughly shaped material consists of Si: 11.0 to 13.0 mass %, Fe: 0.6 to 1.0 mass %, Cu: 3.5 to 4.5 mass %, Mn: 0.25 mass % or less; Mg: 0.4 to 0.6 mass %, Cr: 0.15 mass % or less, Zr: 0.07 to 0.15 mass %, P: 0.005 to 0.010 mass %, Ca: 0.002 mass % or less, and the balance being Aluminum and inevitable impurities.
  • the present invention by adjusting the compositional elements of the molten metal so as to fall within predetermined ranges and producing a roughly shaped material for an engine piston according to the production method of the present invention, a roughly shaped material for an engine piston made by aluminum alloy excellent in wear resistance and high-temperature characteristics can be obtained. Therefore, in the engine piston produced by the aforementioned roughly shaped material, the performance efficiency of the engine can be improved, and the fuel usage in automobiles and motorcycles can be reduced.
  • an engine piston produced by the roughly shaped material can control abrasion of at least the skirt portion and the piston ring groove.
  • FIG. 1 is a bottom view of a roughly shaped material for an engine piston according to an embodiment of the present invention.
  • FIG. 2 is a front view of the roughly shaped material.
  • FIG. 3 is a cross-sectional view taken along the line X-X in FIG. 2 .
  • FIG. 4 is a front view of the engine piston produced by the roughly shaped material.
  • FIG. 5 is a schematic cross-sectional view of a horizontal continuous casting device.
  • FIG. 6 is a schematic cross-sectional view of a hot top continuous casting device.
  • FIG. 7 is a cross-sectional view of a mold of a forging device showing one example of a step of forging a forging material using the forging device.
  • FIG. 8 is a cross-sectional view of a mold of a forging device showing another example of a step of forging a forging material using the forging device.
  • FIG. 9 is a perspective view of an analysis sample of a molten aluminum alloy.
  • FIG. 10 is a compositional picture of Example 1 photographed under microstructure observation.
  • FIG. 11 is a compositional picture of Comparative Example 3 photographed under microstructure observation.
  • FIG. 12 is a drawing showing a relation between the additive amount of P and the additive amount of Si in Examples 8 to 11 and Comparative Examples 15 to 22.
  • excellent in high-temperature characteristics means “excellent in strength at 250° C.,” in other words, “at 250° C., the tensile strength (i.e., high-temperature tensile strength) is 110 MPa or more and the fatigue strength (i.e., high-temperature fatigue strength) is 60 Mpa or more.”
  • the numeral “ 11 ” denotes a roughly shaped material for an aluminum alloy engine piston according to an embodiment of the present invention.
  • the numeral “ 1 ” denotes an aluminum alloy engine piston made from the roughly shaped material 11 .
  • the top-and-bottom direction denotes a “fore-and-aft direction” and the right-and-left direction denotes a “right-and-left direction”, and on a plane of a paper showing FIGS. 2 and 3 , the top and-bottom direction is an “up-and-down direction”.
  • the engine piston 1 is integrally provided with a crown surface portion 2 having a circular-shape as seen from the above, a land portion 3 formed below the crown surface portion 2 , a pair of skirt portions 4 , a pair of pin boss portions 5 , and a pair of side wall portions 6 , wherein the pair of skirt portions 4 , the pair of pin boss portions 5 , and the pair of side wall portions 6 are each disposed below the land portion 3 so as to oppose with each other.
  • a plurality of piston ring groove portions 7 in which a plurality of piston rings (example: pressure rings, oil rings) are to be mounted are formed.
  • a roughly shaped material 11 for an engine piston is made by forging, and, in the same manner as in the engine piston 1 , is integrally provided with a portion corresponding to the crown surface portion 2 (crown surface portion corresponding portion 12 ), a land portion corresponding portion 13 formed below the crown surface portion 2 , a pair of skirt portion corresponding portions 14 and 14 , a pair of pin boss portion corresponding portions 15 and 15 , and a pair of side wall portions corresponding portions 16 and 16 .
  • the pair of skirt portions corresponding portions 14 and 14 , the pair of pin boss portions corresponding portions 15 and 15 , and the pair of side wall portions corresponding portions 16 and 16 are disposed below the land portion corresponding portion 13 so as to oppose with each other.
  • the outer circumferential surface of the land portion corresponding portion 13 and the inner vicinity thereof is a portion where a plurality of piston ring groove portions 7 are formed at the time of the finishing process, or a portion which constitutes the piston ring groove portion corresponding portion 17 .
  • the roughly shaped material 11 there exists a primary Si at least in the skirt portion corresponding portion 14 and the piston ring groove portion corresponding portion 17 . Furthermore, in the entire roughly shaped material, there exists no primary Si having a maximum grain diameter of 50 ⁇ m or larger and no Al—Fe—Cr—Mn series giant crystal having a maximum grain diameter of 50 ⁇ m or larger. Further, in the entire roughly shaped material, there exists no segregation of primary Si.
  • “there exists primary Si” specifically means that, for example, when a sample is mirror polished and then the mirror polished surface of the sample is subjected to a microstructure analysis under a metallurgical microscope, there exists a gray-brown block-shaped crystal.
  • the maximum diameter of the primary Si denotes a diameter measured at a portion where the primary Si has a maximum size.
  • the maximum diameter of the Al—Fe—Cr—Mn series giant crystal denotes a diameter measured at a portion where the giant crystal has a maximum size.
  • the following method can be exemplified.
  • a sample is mirror polished and then the mirror polished surface of the sample is subjected to a microstructure analysis under a metallurgical microscope, a gray-brown block-shaped crystal is considered to be primary Si, and by measuring the maximum length of the crystal using an image analysis device, the maximum diameter of the primary Si can be obtained.
  • an image analysis device a device named “LUZEX” manufactured by Nireco Corporation can be used, for example.
  • the maximum diameter of the Al—Fe—Cr—Mn series giant crystal As a specific measuring method of the maximum diameter of the Al—Fe—Cr—Mn series giant crystal, the following method can be exemplified. For example, when a sample is mirror polished and then the mirror polished surface of the sample is subjected to a microstructure analysis under a metallurgical microscope, a light gray crystal is considered to be an Al—Fe—Cr—Mn series giant crystal, and by measuring the maximum length of the giant crystal using an image analysis device, the maximum diameter of the Al—Fe—Cr—Mn series giant crystal can be obtained.
  • an image analysis device a device named “LUZEX” manufactured by Nireco Corporation can be used, for example.
  • an Al—Fe—Cr—Mn series crystal having a maximum diameter of 50 ⁇ m or larger is especially called an Al—Fe—Cr—Mn series giant crystal.
  • the Al—Fe—Cr—Mn series giant crystal is also called an Al—Fe—Cr—Mn series giant intermetallic compound (giant compound).
  • the criterion for judging whether or not there exists segregation of primary Si is not especially limited.
  • the criterion of judgment is that when 5 or more primary Si (preferably 3 or more) are gathered to form primary crystal Si aggregation and there exists primary crystal Si aggregation in which at least one of the distances between primary Si is smaller than the grain diameter of the primary Si, it is judged that there exists segregation of primary Si, and when there exists no such primary Si aggregation, it is judged that there exists no segregation of primary Si.
  • a production method of the roughly shaped material 11 includes a continuous casting step of obtaining a cast bar by continuously casting a molten metal having a predetermined composition, and a forging step of obtaining a roughly shaped material by forging a forging material obtained by subjecting the cast bar to a homogenization treatment.
  • the molten metal temperature before pouring into a continuous casting mold is set to 720° C. or higher to continuously cast the molten metal. Furthermore, the diameter of the cast bar obtained with the continuous casting step should be 85 mm or less.
  • the composition of the molten metal includes Si: 11.0 to 13.0 mass %, Fe: 0.6 to 1.0 mass %, Cu: 3.5 to 4.5 mass %, Mn: 0.25 mass % or less; Mg: 0.4 to 0.6 mass %, Cr: 0.15 mass % or less, Zr: 0.07 to 0.15 mass %, P: 0.005 to 0.010 mass %, Ca: 0.002 mass % or less, and the balance being Aluminum and inevitable impurities.
  • the forging material should be a cast bar homogenized at a temperature of 370 to 500° C.
  • Si is an element that controls thermal expansion of aluminum alloy to keep small and improves the wear resistance.
  • the wear resistance can be improved by appropriately controlling the crystallization of primary Si.
  • the appropriate thermal expansion coefficient is determined by the material of an opposing member of the engine piston 1 , i.e., the material of a cylinder block (e.g., steel, aluminum).
  • a cylinder block e.g., steel, aluminum
  • the thermal expansion coefficient is as smaller as possible.
  • the engine piston 1 and selecting the piston ring they are each designed based on a size when they reached a high temperature.
  • the additive amount of Si is as large as possible in terms of reducing the thermal expansion.
  • the preferable thermal expansion coefficient is 19 to 21 ⁇ 10 ⁇ 6 /K in the range of 25 to 250° C., and the additive amount of the Si that can obtain such thermal expansion coefficient is 11.0 to 13.0 mass %.
  • the present inventors could find specific alloy composition and specific production conditions capable of attaining high temperature strength and high temperature fatigue strength while maintaining wear resistance, even in cases where an additive amount of Si was around the eutectic point, and completed the present invention.
  • the composition of the molten metal according to the present invention by adding Ca and P which will be explained later, even when an additive amount of Si is around the eutectic point, primary Si is crystallized stably by interaction with them, which improves wear resistance. It is more preferable that the additive amount of Si exceeds 12.0 mass %
  • the additive amount of Si is less than 11.0 mass %, it is not preferable because the thermal expansion becomes large, and crystallization of primary Si is controlled to decrease wear resistance.
  • the additive amount of Si exceeds 13 mass %, such additive amount causes segregation of crystallized primary Si, forming an origin of fatigue fracture, which causes deterioration of high temperature fatigue strength, and therefore it is not preferable.
  • Fe is crystallized as an Al—Fe—Cr—Mn series intermetallic compound, and the crystal becomes a dispersion strengthening phase which is stable even at high temperatures, which contributes to improvement of high temperature strength.
  • the additive amount of Fe is less than 0.6 mass %, the amount of the dispersion strengthening phase becomes small, resulting in less improved high temperature strength, and therefore it is not preferable.
  • Cu is precipitated as an Al—Cu (—Mg) series intermetallic compound, and the existence improves the strength and the fatigue strength under 150° C. (hereinafter referred to as “normal temperature strength” and “normal temperature fatigue strength,” respectively).
  • the additive amount of Cu is less than 3.5 mass %, the precipitation amount of Al—Cu (—Mg) series intermetallic compound becomes small, which less improves the normal temperature strength and the normal temperature fatigue strength, and therefore it is not preferable.
  • Mn is an element which will be crystallized as an intermetallic compound together with Fe and/or Cr to become a dispersion strengthening phase, which contributes to improvement of high temperature strength.
  • Mn more likely forms Al—Fe—Cr—Mn series giant crystals. Therefore, the additive amount of Mn is set to 0.25 mass % or less.
  • the additive amount of Mn is preferred to be as small as possible, especially preferable to be below the detection limit.
  • the most preferable additive amount of Mn is 0 mass %.
  • Mg is an element which improves the normal temperature strength and the normal temperature fatigue strength by coexisting with Si and/or Cu. If the additive amount of Mg is less than 0.4 mass %, the aforementioned effects can be less expected, which is not preferable. However, even if Mg is added so as to exceed 0.6 mass %, the aforementioned effects will be saturated. Therefore, the additive amount of Mg is set to 0.4 to 0.6 mass %.
  • Cr is an element which will be crystallized as an intermetallic compound together with Fe and Mn to become a dispersion strengthening phase, which contributes to improvement of high temperature strength.
  • the additive amount of Cr is set to 0.15 mass % or less.
  • the additive amount of Cr is preferred to be as small as possible, especially preferable to be below the detection limit.
  • the most preferable additive amount of Cr is 0 mass %.
  • Zr is an element which that precipitates Al—Zr series intermetallic compound at 350° C. or above to improve the high temperature strength of the alloy material. If the additive amount of Zr is below 0.07 mass %, the aforementioned effects can be less expected, and therefore it is not preferable. Even if the additive amount of Zr exceeds 0.15 mass %, the aforementioned effects will be saturated. Therefore, the additive amount of Zr is set to 0.07 to 0.15 mass %.
  • P is an element which shifts the lower limit of the additive amount of Si at which primary Si is crystallized toward a lower Si amount side, and refines the grain diameter of the primary Si crystal.
  • the additive amount of Si is relatively large, no addition of P causes coarse primary Si.
  • the additive amount of P is below 0.005 mass %, the aforementioned defects can be less expected, and therefore it is not preferable.
  • the additive amount of P exceeding 0.010 mass % causes saturation of the aforementioned effects, and also accelerates formation of needle-shaped eutectic Si to deteriorate toughness, and therefore it is not preferable. Therefore, the additive amount of P is set to 0.005 to 0.010 mass %. This additive amount can result in the maximum diameter of primary Si of 50 ⁇ m or less.
  • the additive amount of P satisfies the following formula (I). Satisfying the formula makes it possible to assuredly stabilize crystallization of primary Si by continuous casting. This assuredly results in existence of primary Si in the entire roughly shaped material, assuredly prevents segregation of primary Si, and further assuredly causes spheroidized eutectic Si. As a result, a roughly shaped material for an engine piston excellent in wear resistance and high temperature characteristics can be assuredly obtained.
  • the melting amount of P i.e., the additive amount of P
  • the additive amount of P into a molten metal
  • Ca is an element which hinders refinement and hardening of primary Si due to P. Therefore, flux including magnesium chloride (MgCl 2 ) is added to the molten metal and agitated to thereby control so that the amount of Ca in the molten metal decreases and the additive amount of Ca becomes 0.002 mass % or less. More preferably, the additive amount of Ca and P (unit:mass %) is set to P>6 ⁇ Ca, so that even in cases where an additive amount of Si is around the eutectic point, P is not depleted by Ca. As a result, AlP is created, and the AlP effectively works as a nucleus for forming heterogeneous nucleus of primary Si, which causes minute and even crystallization of primary Si. In this way, the wear resistance can be improved.
  • the additive amount of Ca is preferably as small as possible, especially below the detection limit.
  • the most preferable additive amount of Ca is 0 mass %.
  • the reason for setting the temperature of the molten metal to 720° C. or above is as follows.
  • the casting temperature is set to 720° C. or higher. This can be realized by setting the molten metal temperature before pouring into a continuous casting mold to 720° C. or higher.
  • the preferable molten metal temperature is 740° C. or higher.
  • the crystallization state of primary Si on an outer circumferential portion of the cast bar corresponding to the skirt portion 4 and the piston ring grove portion 7 of the engine piston 1 can be refined and evenly.
  • the upper limit of the molten metal temperature is not especially limited, and can be, for example, 850° C. (preferably 750° C.).
  • the reason for setting the diameter of the cast bar to 85 mm or less is as follows.
  • the diameter of the cast bar (casting diameter) becomes larger, the cooling rate of the center portion of the ingot becomes low, which readily causes Al—Fe—Cr—Mn series giant crystals, and furthermore disturbs refinement and even distribution of primary Si in the center portion of the cast bar.
  • the diameter of the cast bar is 85 mm or smaller, the difference between the cooling rate of the center portion of the cast bar and that of the outer circumferential portion of the cast bar can be kept small. This preferably makes the cooling rate difference to be 200° C./s or less, which in turn can control formation of Al—Fe—Cr—Mn series giant crystals. Therefore, the diameter of the cast bar is set to 85 mm or less.
  • the crystallization state of primary Si can be refined such as less than 50 ⁇ m in maximum diameter and evenly distributed.
  • the lower limit of the diameter of the cast bar is not especially limited, and can be, for example, 20 mm.
  • the reason for homogenizing the cast bar at 370 to 500° C. is as follows.
  • the Al—Fe—Cr—Mn series crystals resist plastic deformation at a high temperature, which results in hard plastic deformation at a high temperature. As a result, the high temperature strength and the high temperature fatigue strength are improved.
  • a homogenization treatment generally performed at immediately below the solidus temperature to improve forging performance is high in processing temperature, which causes decoupling and spheroidizing of Al—Si series crystals and/or Al—Fe—Cr—Mn series crystals to reduce the area of the boundary surface.
  • the upper limit of the processing temperature is set to a temperature at which no decoupling and spheroidizing of Al—Si series crystals and/or Al—Fe—Cr—Mn series crystals occur.
  • the homogenization treatment temperature is too low, deformability becomes insufficient, causing cracks during forging.
  • the homogenization treatment temperature is set between 370 to 500° C., more preferably set to be as low as possible within a range in which no cracks are generated in the material at the time of forging the material into the engine piston shape.
  • the retention time of the homogenization treatment is preferably 4 hours or longer.
  • the continuous casting device As a continuous casting device, as long as a cast bar having a diameter of 85 mm or less can be obtained in a state in which the molten metal temperature is maintained at 720° C. or above, the continuous casting device is not limited in type, and can be, for example, a vertical semi-continuous casting device, a hot top continuous casting device, a horizontal continuous casting device, and a gas pressurizing type continuous casting device.
  • FIG. 5 is a cross-sectional view showing one example of a horizontal continuous casting device for performing horizontal continuous casting.
  • This continuous casting device 20 A is provided with a molten metal receptor 21 that stores aluminum alloy molten metal 30 and a solidification continuous casting water-cooling mold (water-cooled mold) 22 having a molten metal passage 22 a .
  • the mold 22 is arranged horizontally and in communication with the molten metal receptor 21 via the molten metal pouring inlet 23 .
  • the reference numeral “ 24 ” denotes a cooling water passage formed in the mold 22 .
  • the mold 22 and the cast bar 31 drawn through the mold 22 are cooled by the cooling water 25 discharged from the cooling water passage 24 .
  • FIG. 6 is a cross-sectional view showing one example of a hot top continuous casting device.
  • the continuous casting device 20 B is provided with a molten metal receptor 21 and a solidification continuous casting water-cooled mold (water-cooled mold) 22 having a molten metal passage 22 a and arranged below the molten metal receptor 21 .
  • the mold 22 is arranged in communication with the molten metal receptor 21 via the molten metal pouring inlet 23 so that the outlet of the molten metal passage 22 a faces downward.
  • the aluminum alloy molten metal 30 in the molten metal receptor 21 is introduced into the cooled mold 22 through the molten metal pouring inlet 23 from above.
  • the molten metal 30 introduced into the mold 22 is, at the portion contacting the mold 22 , is drawn downward from the mold 22 while forming a solidified shell.
  • the cast bar 31 drawn from the mold 22 is cooled by the cooling water 25 discharged from the cooling water passage 24 .
  • the temperature at the position C immediately before pouring the molten metal 30 into the mold 22 is defined as a molten metal temperature, and the temperature is preferably set to 720° C. or higher.
  • the temperature of the molten metal 30 at the position C is defined as a molten metal temperature.
  • the furnace can accommodate the cast bar and conduct a homogenization treatment thereof at a temperature of 370 to 500° C.
  • the furnace can be any conventional widely used furnace.
  • the furnace in the case of a circulating hot air furnace, the furnace can be either a direct heating furnace or a radiant tube furnace, and in the case of a carrier system furnace, the furnace can be either a continuous furnace or a batch furnace.
  • the device As a forging device, it is sufficient as long as the device is equipped with a forging mold for forging a forging material into an engine piston shaped roughly shaped material. It is particularly desirable that the device is further equipped with a preliminary heating device and a lubricant applying device. Furthermore, it is preferred that the forging mold is a closed forging mold. More specifically, as the forging device, a knuckle joint press, a crank press, a friction press, a hydraulic press, and a servo press, can be used.
  • the production method of a roughly shaped material of this embodiment is performed as follows.
  • a molten metal having a predetermined composition is continuously cast into a cast bar having a diameter of 85 mm or less [Continuous casting step]. It is preferable that the cross-sectional shape of the cast bar is a circle shape. In other words, it is preferable that the cast bar is in a cylindrical bar shape.
  • the cast bar is subjected to a homogenization treatment at a temperature of 370 to 500° C. to thereby obtain a forging material.
  • the outer circumferential surface of the material is subjected to a peeling treatment (i.e., the outer circumferential surface cutting treatment).
  • this material is cut in the longitudinal direction to have a predetermined length (thickness) into a disk or cylinder shape.
  • the cross-sectional surface of the cast bar becomes an upper or lower surface of the material, and the outer circumferential surface or the inner side vicinity of the cast bar becomes an outer circumferential surface of the material.
  • the material is subjected to upset processing, lubrication processing, and preheating processing.
  • the material is forged into a roughly shaped material of an engine piston shape with a forging device [Forging step].
  • FIGS. 7 and 8 are drawings that show forging steps for forging the material with the respective forging devices.
  • the molds 41 of the forging devices 40 shown in FIGS. 7 and 8 include an upper die 42 and a lower die 43 .
  • a disk-shaped or cylinder-shaped material 32 is forged in a sealed forming space 44 , and a roughly shaped material 11 for an engine piston is obtained.
  • the reference numeral “ 32 A” is a long bar shaped forging material 32 A obtained by subjecting the cast bar to a homogenization treatment.
  • the disk-shaped or cylinder-shaped material 32 obtained by cutting the bar-shaped material 32 A into a predetermined length (thickness) is disposed in the lower die 43 of the forging device 40 , and then, by being pressed in the axial direction of the material 32 by the upper die 42 fitted into the lower die 43 , the material 32 is forged into a predetermined shape in the sealed forming space 44 and the roughly shaped material 11 for an engine piston is obtained.
  • the mold 41 of this forging device 40 shown in FIG. 7 is structured so that the skirt portion corresponding portions (not shown) and the pin boss portion corresponding portions 15 and 15 are forwardly extruded.
  • the material 32 is forged in the same manner as in the forging method shown in FIG. 7 , and a roughly shaped material 11 for an engine piston is obtained.
  • the mold 41 of the forging device 40 shown in FIG. 8 is structured so that the skirt portion corresponding portions (not shown) and the pin boss portion corresponding portions 15 and 15 are backwardly extruded.
  • the material 32 is disposed in the lower die 43 in such a manner that the upper surface or the lower surface of the material 32 becomes a crown surface portion corresponding portion 12 of the roughly shaped material 11 and the outer circumferential portion of the material 32 becomes a piston ring groove portion corresponding portion 17 and the skirt portion corresponding portions (not shown).
  • the processing temperature for the preheating process to be performed immediately before forging and the material temperature during the forging are preferably 470° C. or lower in as a short time period as possible. It is more preferred to be a temperature lower than the homogenization treatment temperature.
  • the heating time can be the shortest amount of time during which the material temperature can be raised to the processing temperature (i.e., 470° C. or below).
  • the roughly shaped material 11 obtained in this manner is subjected to a solution treatment or an aging treatment.
  • the solution treatment temperature is preferably set to be the same as or lower than the solidus temperature because the state of Al—Si series crystals or Al—Fe—Cr—Mn series crystals after the homogenization treatment can be maintained.
  • the aging treatment temperature and the aging treatment time it is preferable that slight over aging is performed by adjusting the temperature and the time. Such adjustment enables controlling of the dimensional growth due to the aging during the use of the product.
  • the roughly shaped material 11 is subjected to a final finish processing, such as, e.g., machining processing. Thereafter, other members, such as, e.g., piston rings, are attached to the roughly shaped material to obtain an engine piston.
  • a final finish processing such as, e.g., machining processing.
  • other members such as, e.g., piston rings, are attached to the roughly shaped material to obtain an engine piston.
  • an engine piston 1 produced using the roughly shaped material 11 is excellent in wear resistance, and also excellent in normal temperature tensile characteristics, high temperature characteristics (i.e., high temperature tensile characteristics and high temperature fatigue characteristics).
  • the unit of the Aluminum alloy composition in Table 1 is “mass %.”
  • a round bar-shaped cast bar was obtained by continuously casting the aluminum alloy molten metal having the composition shown in Table 1 using a hot top continuous casting device (see FIG. 6 ).
  • the molten metal temperatures before pouring into the continuous casting mold were set as shown in the “Temp. of molten metal” column of Table 2.
  • the diameters of the obtained cast bars are described in the “Diameter of cast bar” column.
  • the molten metal was casted in a mold according to JIS Z 2611 to obtain an analysis sample 50 of an approximately disk-shape as shown in FIG. 9 .
  • quantitative analysis of the compositional element of the motel metal was performed by emission spectral analysis in conformity to JIS H 1305.
  • the reference numeral “51” denotes an analysis portion of the analysis sample 50.
  • This analysis portion 51 was analyzed after being cut into a thickness of 0.5 mm (0.3-0.6 mm) with a milling machine.
  • the cast bar was cut into a length of 6,000 mm. Then, the cut cast bar was subjected to a homogenization treatment.
  • the treatment temperature was set as shown in the “Homogenization treatment temperature” column of Table 2. The treatment time was 7 hours for each case.
  • the outer circumference of the cast bar was cut out to have a diameter of 50 mm, and further, the cast bar was cut into a length of 60 mm to thereby obtain a cylindrical forging material.
  • the material was upset forged into a thickness of 10 mm by pressing the material from its end surface in the axial direction.
  • the upset forging corresponds to the forging in the forging step of the present invention, and the forging was conducted at the forging processing rate corresponding to the forging processing rate of actually forging the material into the roughly shaped material for an engine piston.
  • the upset forged product was subjected to a T6 heat treatment.
  • the upset forged product was subjected to a solution treatment at a temperature of 495° C., and thereafter an artificial aging treatment was conducted under the conditions of aging temperature of 200° C. and aging time of 6 hours.
  • the upset forged product to which the T6 heat treatment was executed was subjected to a visual inspection to check whether or not there exists cracks and hole defects on the surface of the upset forged product by a solvent removable penetrant testing method (color check). Thereafter, the upset forged product was cut, and the cut surface was mirror-polished.
  • the mirror polished surface was subjected to a microscopic inspection to inspect the structure from the center portion to the outer circumferential portion of the upset forged product using a metallurgical microscope to check whether or not there exists primary Si, primary Si having a maximum diameter of 50 ⁇ m or larger, Al—Fe—Cr—Mn series giant crystals, and segregation of primary Si.
  • the metallographic structure photograph of Example 1 is shown in FIG. 10 as a representative example of the metallographic structure photographs of Examples 1 to 7 photographed during the microscopic inspection. Further, the metallographic structure photograph of Comparative Example 3 is shown in FIG. 11 as a representative example of the metallographic structure photographs of Comparative Examples 1 to 14 photographed during the microscopic inspection.
  • a device named “LUZEX” manufactured by Nireco Corporation was used as an image analysis device analyzing the image of the metallographic structure photograph.
  • the Al—Fe—Cr—Mn series crystal is shown as a light gray colored crystal
  • the primary Si is shown as a gray-brown colored block-shaped crystal
  • the eutectic Si is shown as a gray-brown colored crystal smaller than the primary Si and having an average grain diameter of about 5 ⁇ m.
  • a number of eutectic Si existed in a dispersed manner and the average grain diameter was about 5 ⁇ m.
  • a number of primary Si existed in a distributed manner, and the maximum diameter was about 25 ⁇ m, and the average diameter is about 20 ⁇ m. However, there existed no primary Si having a maximum diameter of 50 ⁇ m or more.
  • a number of Al—Fe—Cr—Mn series crystals existed in a dispersed manner, and the average grain diameter was about 5 ⁇ m. However, there existed no Al—Fe—Cr—Mn series giant crystals having a maximum diameter of 50 ⁇ m or more.
  • FIG. 11 (Comparative Example 3), a number of eutectic Si existed in a dispersed manner and the average grain diameter was about 5 ⁇ m. The primary Si were unevenly distributed, the maximum diameter was about 35 ⁇ m, and the average diameter was about 20 ⁇ m.
  • the evaluation method of the normal temperature tensile characteristics was as follows.
  • the evaluation method of the high temperature tensile property was as follows.
  • the evaluation method of the high temperature fatigue property was as follows.
  • a fatigue test piece was obtained from the upset forged product.
  • a fatigue test of the test piece was performed at 250° C. using a Ono-type rotary bending fatigue testing machine.
  • a stress value at which no breakage occurs at 10,000,000 cycles was defined as fatigue strength, and it was evaluated as “Good” when the stress value was 60 MPa or above and evaluated as “Poor” when the stress value was less than 60 MPa. The results are shown in the column of “High temp. fatigue property” in Table 2.
  • Examples 1-7 satisfy all of requirements of the present invention, and therefore it was confirmed that no cracks were generated, there existed primary Si along the entire upset forged product, there existed no primary Si having a maximum diameter of 50 ⁇ m or more, there existed no Al—Fe—Cr—Mn series giant crystals having a maximum diameter of 50 ⁇ m or more, and there existed no segregation of primary Si. Further, it was confirmed that they were excellent in normal temperature tensile property, high temperature tensile property and high temperature fatigue property.
  • the unit of Al alloy composition is “mass %.”
  • FIG. 12 is a drawing showing the relationship between the additive amount of P and the additive amount of Si in Examples 8-11 and Comparative Examples 15-22.
  • [P] denotes an additive amount of P (unit: mass %)
  • [Si] denotes an additive amount of Si (unit:mass %).
  • the cast bar was cut into a length of 6,000 mm. Then, the cut cast bar was homogenized under the conditions of the temperature of 470° C. and the holding time of 7 hours.
  • the outer periphery of the cast bar was cut to have a diameter of 50 mm and then cut into a length of 60 mm to thereby obtain a columnar forging material.
  • This upset forging corresponds to the forging of the forging step of the present invention, and was performed at the forging processing rate corresponding to the forging processing rate for actually forging the material into a roughly shaped material for an engine piston.
  • the upset forging product was subjected to a T6 heat treatment. That is, the upset forged product was subjected to a solution treatment at 495° C., and then artificial aging was performed under the conditions of the aging temperature of 200° C. and the aging time of 6 hours.
  • the upset forged product to which T6 heat treatment was performed was cut, and the cut surface was mirror polished.
  • the polished surface was subjected to a microscopic inspection from the center portion to the outer peripheral portion of the upset forged product using a metallurgical microscope to investigate whether there exists primary Si at the center portion and the peripheral portion of the upset forged product, whether there exists segregation of primary Si, and to investigate the shape of eutectic Si.
  • Eutectic Si is a gray-brown colored block-shaped crystal smaller than primary Si. By measuring the size of the crystal, it was judged that the eutectic Si was formed into a needle-shape when the “maximum length/minimum length” was 3 or more, and it was judged that the eutectic Si was formed into a spherical shape when the “maximum length/minimum length” was less than 3.
  • the additive amount of Si was within the range of 11.0 to 13.0 mass %, and the additive amount of P was within the range of 0.005 to 0.010 mass %. Furthermore, the additive amount of P satisfies the aforementioned formula (I). Therefore, the crystallization of primary Si by continuous castingwas stabilized. As a result, primary Si existed along the entire region from the center portion to the outer peripheral portion of the upset forged product, and there existed no segregation of primary Si. Further, eutectic Si was formed into a spherical shape. Therefore, a good microstructure was obtained.
  • the term “preferably” is non-exclusive and means “preferably, but not limited to.”
  • means-plus-function or step-plus-function limitations will only be employed where for a specific claim limitation all of the following conditions are present in that limitation: a) “means for” or “step for” is expressly recited; b) a corresponding function is expressly recited; and c) structure, material or acts that support that structure are not recited.
  • the terminology “present invention” or “invention” may be used as a reference to one or more aspect within the present disclosure.
  • the present invention can be applicable to a production method of a roughly shaped material for producing an engine piston for an engine to be mounted on a vehicle such as an automobile or a motorcycle, and also can be applicable to a roughly shaped material for an engine piston.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Combustion & Propulsion (AREA)
  • Pistons, Piston Rings, And Cylinders (AREA)
  • Forging (AREA)
US13/381,423 2009-07-03 2010-07-02 Process for production of roughly shaped material for engine piston Abandoned US20120100385A1 (en)

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PCT/JP2010/061329 WO2011002082A1 (ja) 2009-07-03 2010-07-02 エンジンピストン用素形材の製造方法

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US20130036608A1 (en) * 2011-06-27 2013-02-14 Wolfgang Issler Forging method for producing a piston or piston skirt
US20150190855A1 (en) * 2014-01-09 2015-07-09 Rolls-Royce Plc Forging apparatus
GB2522716A (en) * 2014-02-04 2015-08-05 Jbm Internat Ltd Method of manufacture
US20190107076A1 (en) * 2017-10-10 2019-04-11 Lombardini S.R.L. Piston and method of manufacturing thereof
CN116324009A (zh) * 2020-10-30 2023-06-23 株式会社力森诺科 汽车的车轮用铝合金以及汽车的车轮
CN116507749A (zh) * 2020-10-30 2023-07-28 株式会社力森诺科 滑动部件用铝合金以及滑动部件

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JP6417133B2 (ja) * 2014-07-04 2018-10-31 昭和電工株式会社 連続鋳造用アルミニウム合金及び連続鋳造材の製造方法
WO2016136084A1 (ja) * 2015-02-27 2016-09-01 ヤマハ発動機株式会社 鞍乗型車両用の内燃機関および鞍乗型車両
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US20130036608A1 (en) * 2011-06-27 2013-02-14 Wolfgang Issler Forging method for producing a piston or piston skirt
US8904634B2 (en) * 2011-06-27 2014-12-09 Mahle International Gmbh Forging method for producing a piston or piston skirt
US20150190855A1 (en) * 2014-01-09 2015-07-09 Rolls-Royce Plc Forging apparatus
US9718118B2 (en) * 2014-01-09 2017-08-01 Rolls-Royce Plc Forging apparatus
GB2522716A (en) * 2014-02-04 2015-08-05 Jbm Internat Ltd Method of manufacture
GB2522716B (en) * 2014-02-04 2016-09-14 Jbm Int Ltd Method of manufacture
US20190107076A1 (en) * 2017-10-10 2019-04-11 Lombardini S.R.L. Piston and method of manufacturing thereof
CN116324009A (zh) * 2020-10-30 2023-06-23 株式会社力森诺科 汽车的车轮用铝合金以及汽车的车轮
CN116507749A (zh) * 2020-10-30 2023-07-28 株式会社力森诺科 滑动部件用铝合金以及滑动部件

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WO2011002082A1 (ja) 2011-01-06
CN102482752B (zh) 2013-09-11
JP5526130B2 (ja) 2014-06-18
EP2453034A1 (en) 2012-05-16
JPWO2011002082A1 (ja) 2012-12-13
EP2453034A4 (en) 2017-08-23

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