US20140093420A1 - Alloy production method and alloy produced by the same - Google Patents

Alloy production method and alloy produced by the same Download PDF

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US20140093420A1
US20140093420A1 US14/119,080 US201214119080A US2014093420A1 US 20140093420 A1 US20140093420 A1 US 20140093420A1 US 201214119080 A US201214119080 A US 201214119080A US 2014093420 A1 US2014093420 A1 US 2014093420A1
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compound
magnesium
aluminum
molten metal
alloy
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US14/119,080
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English (en)
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Se-Kwang KIM
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Korea Institute of Industrial Technology KITECH
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Korea Institute of Industrial Technology KITECH
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/02—Casting exceedingly oxidisable non-ferrous metals, e.g. in inert atmosphere
    • B22D21/04—Casting aluminium or magnesium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/02—Making non-ferrous alloys by melting
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/02—Making non-ferrous alloys by melting
    • C22C1/03—Making non-ferrous alloys by melting using master 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
    • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C23/00—Alloys based on magnesium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C23/00—Alloys based on magnesium
    • C22C23/02—Alloys based on magnesium with aluminium as the next major constituent

Definitions

  • the present disclosure relates to an alloy production method and an alloy produced by the same, and more particularly, to an alloy production method in which a mother alloy is used in casting, and an alloy produced by the same.
  • various compounds may be formed on a matrix of the alloy.
  • the intermetallic compound when an intermetallic compound having a high hardness is distributed on a matrix of an alloy, the intermetallic compound functions as a structure suppressing the movement of dislocations to improve the strength of the alloy.
  • Such a compound may be crystallized as a thermodynamically stable phase while a liquid phase metal is solidified in casting, or after being solidified, precipitated through a proper mechanical processing or heat treatment.
  • the present disclosure provides an aluminum alloy and a method of producing the same that can improve mechanical characteristics by distributing an intermetallic compound (hereinafter, magnesium-silicon compound) including magnesium and silicon in an aluminum matrix without a heat treatment.
  • an intermetallic compound hereinafter, magnesium-silicon compound
  • the above subject matter is only exemplary, and the scope of the present disclosure is not limited by the subject matter.
  • the present disclose provides an alloy production method that may easily distribute a compound in a matrix of an alloy while maintaining the quality of a molten metal, and an alloy produced by the same.
  • the above subject matter is only exemplary, and the scope of the present disclosure is not limited by the subject matter.
  • a method of producing an alloy A molten metal in which a mother alloy including at least one kind of first compound and a casting metal are melted is formed.
  • the molten metal is cast.
  • the mother alloy may be a magnesium mother alloy or aluminum mother alloy.
  • the first compound may have a higher melting point than the casting metal.
  • the casting metal may be any one selected from the group consisting of tin, aluminum, zinc, magnesium, copper, nickel, cobalt, iron, titanium, vanadium, molybdenum, tungsten, and alloys thereof.
  • the first compound may be a compound formed by exhausting at least a portion of a second compound in which at least two components are bonded in a magnesium molten metal or aluminum molten metal.
  • the first compound may be a compound in which a component supplied from the exhausted second compound and a metal component in the magnesium molten metal are bonded to each other, and the metal component may be magnesium or aluminum.
  • the first compound may be a compound produced by a bonding between components respectively supplied from the at least two kinds of exhausted second compounds.
  • the first compound may be a compound formed by melting at least a portion of any one of calcium or strontium in the magnesium molten metal or aluminum molten metal.
  • the first compound may be a compound added to a molten metal of the mother alloy.
  • the first compound may be produced by a mechanical alloying.
  • the first compound may include a magnesium compound.
  • the magnesium compound may include at least one selected from the group consisting of a magnesium-calcium compound, a magnesium-aluminum-calcium compound, a magnesium-strontium compound, and a magnesium-silicon compound.
  • the first compound may include an aluminum compound.
  • the aluminum compound may include at least one selected from an aluminum-calcium compound, an aluminum-strontium compound, and an aluminum-cesium compound.
  • the first compound may include a calcium-silicon compound.
  • the second compound may include a calcium-based compound, a strontium-based compound, a silicon-based compound, or a rare earth metal-based compound.
  • the producing of the magnesium mother alloy may include: adding at least one kind of second compound in which two or more components are bonded to a magnesium molten metal; exhausting at least a portion of the second compound; and casting the magnesium molten metal to produce a first magnesium mother alloy.
  • the producing of the magnesium mother alloy may further include: adding the first magnesium mother alloy to a magnesium molten metal and diluting the magnesium molten metal to form a second magnesium mother alloy.
  • the producing of the aluminum mother alloy may include: adding at least one kind of second compound in which at least two components are bonded to an aluminum molten metal; exhausting at least a portion of the second compound; and casting the aluminum molten metal to produce a first aluminum mother alloy.
  • the producing of the aluminum mother alloy may further include: adding the first aluminum mother alloy to an aluminum molten metal and diluting the aluminum molten metal to form a second aluminum mother alloy.
  • the second compound may be dispersively added to a surface of an upper layer portion of the magnesium molten metal, and the upper layer portion of the magnesium molten metal may be stirred.
  • the stirring may be performed in the upper layer portion from a surface of the magnesium molten metal to a point which is not more than 20% of a total depth of the magnesium molten metal.
  • the producing of the mother alloy may include: adding calcium or strontium to a mother alloy molten metal; and exhausting at least a portion of the calcium or strontium in the magnesium molten metal.
  • the aluminum mother alloy may be produced by adding a magnesium alloy in an aluminum molten metal, and the magnesium alloy is produced by a process including: adding calcium or strontium to a magnesium molten metal; and melting at least a portion of the calcium or strontium in the magnesium molten metal.
  • the aluminum mother alloy may be produced by adding an aluminum alloy in an aluminum molten metal, and the aluminum alloy is produced by a process including: adding calcium or strontium to an aluminum molten metal; and melting at least a portion of the calcium or strontium in the aluminum molten metal.
  • the magnesium mother alloy may be produced by adding an aluminum alloy in a magnesium molten metal, and the aluminum alloy is produced by a process including: adding calcium or strontium to an aluminum molten metal; and melting at least a portion of the calcium or strontium in the aluminum molten metal.
  • the magnesium mother alloy may be produced by adding a magnesium alloy in a magnesium molten metal, and the magnesium alloy is produced by a process including: adding calcium or strontium to a magnesium molten metal; and melting at least a portion of the calcium or strontium in the magnesium molten metal.
  • an alloy in accordance with another exemplary embodiment, includes a metal matrix, and a first compound existing in the metal matrix.
  • the first compound may be a compound which is included in a magnesium mother alloy or aluminum mother alloy and is added to a molten metal produced so as to cast the alloy.
  • the metal matrix may include any one selected from the group consisting of tin, aluminum, zinc, magnesium, copper, nickel, cobalt, iron, titanium, vanadium, molybdenum, tungsten, and alloys thereof.
  • the first compound may include a magnesium compound, an aluminum compound, or a calcium-silicon compound.
  • the alloy may include an inclusion at a concentration which is lower than that of an inclusion of an alloy in which a mother alloy no containing the first compound is added and which is produced under the same condition.
  • FIG. 1 is a flow diagram showing an embodiment of a method of producing an alloy according to the present disclosure
  • FIG. 2 is a flow diagram showing an embodiment of a method of producing a magnesium mother alloy according to the present disclosure
  • FIG. 3 is a schematic view showing a decomposition process of calcium oxide in an upper layer portion of a magnesium molten metal when calcium oxide is added in the magnesium molten metal;
  • FIG. 4 is a flow diagram showing an embodiment of a method of producing an aluminum mother alloy according to the present disclosure
  • FIGS. 5A through 5D show composition analysis results of magnesium mother alloys produced by adding calcium oxide according to an embodiment of the present disclosure
  • FIGS. 6A through 6E show results analyzing components of an aluminum alloy in which a magnesium mother alloy is added and an aluminum alloy in which pure magnesium is added;
  • FIGS. 7A and 7B show results observing states of an aluminum molten metal in which a magnesium mother alloy produced by an embodiment of the present disclosure is added, and an aluminum molten metal in which pure magnesium is added;
  • FIG. 8 is a graph showing oxidation resistance test results of an aluminum alloy according to an embodiment of the present disclosure.
  • FIG. 9 is a graph showing comparison results of oxidation resistance of a related art aluminum-magnesium alloy having the same composition as an aluminum-magnesium alloy according to an embodiment of the present disclosure.
  • a mother alloy including at least one kind of compound is produced, and then is added in a molten metal to produce an alloy.
  • the compound included in the mother alloy is called a ‘first compound’.
  • FIG. 1 is a flow diagram of a method of producing an alloy according to an exemplary embodiment.
  • a molten metal in which a casting metal is melted is formed (S 11 ).
  • the casting metal is a metal that may be added to a mother alloy, and may be any selected from the group consisting of tin (Sn), zinc (Zn), magnesium (Mg), aluminum (Al), copper (Cu), nickel (Ni), cobalt (Co), iron (Fe), titanium (Ti), vanadium (V), molybdenum (Mo), and tungsten (W), or an alloy thereof.
  • a mother alloy including a first compound is added to the molten metal of the casting metal (S 12 ).
  • a molten metal in which the mother alloy and the casting metal are melted is cast to produce an alloy (S 13 ).
  • the alloy may be produced by a method in which the mother alloy and the casting metal are installed together in a melting furnace and then melted at the same time. This is equally applied to the adding of a method of producing a mother alloy to be described later.
  • the mold may be any selected from the group consisting of a metal mold, a ceramic mold, a graphite mold, and equivalents.
  • examples of the casting may include a sand casting, a die casting, a gravity casting, a continuous casting, a low pressure casting, a squeeze casting, a lost wax casting, a thixo casting, and the like.
  • the mother alloy may use pure magnesium or a magnesium alloy as a mother material, and the pure magnesium and the magnesium alloy are all called a magnesium mother alloy.
  • the mother alloy may use pure aluminum or an aluminum alloy as a mother material, and the pure aluminum and the aluminum alloy are called an aluminum mother alloy.
  • the magnesium molten metal is defined for convenience as indicating pure magnesium molten metal or a magnesium alloy molten metal in which a different alloy element is added in the pure magnesium molten metal, and this definition is equally applied to the aluminum molten metal.
  • the magnesium mother alloy molten metal and the aluminum mother alloy molten metal may be commonly called a mother alloy molten metal.
  • At least one kind of first compound included in the mother alloy may be one which is formed by adding a second compound in which at least two components are bonded in the magnesium molten metal and then exhausting at least a portion of the second compound.
  • a method of producing a magnesium mother alloy including a first compound will be described in detail.
  • FIG. 2 is a flow diagram showing an exemplary embodiment of a method of producing a magnesium mother alloy.
  • the method of producing a magnesium mother alloy includes forming a magnesium molten metal (S 21 ), adding a second compound (S 22 ), stirring (S 23 ), and casting (S 24 ).
  • the heating temperature may be in a range of 400° C. to 800° C.
  • a molten metal is formed at 600° C. or higher
  • a molten metal may be formed at a temperature not higher than 600° C. and not lower than 400° C. due to a melting point drop that may appear by alloying.
  • the heating temperature is less than 400° C., it is difficult to form a magnesium molten metal, and when the heating temperature exceeds 800° C., sublimation in the magnesium molten metal occurs or there is a danger of ignition.
  • the magnesium alloy used in the forming (S 21 ) of the magnesium molten metal may be any one selected from the group consisting of AZ91D, AM20, AM30, AM50, AM60, AZ31, AS141, AS131, AS121X, AE42, AE44, AX51, AX52, AJ50X, AJ52X, AJ62X, MRI153, MRI230, AM-HP2, Mg—Al, Mg—Al—Re, Mg—Al—Sn, Mg—Zn—Sn, Mg—Si, Mg—Zn—Y, and equivalents thereof, but the present disclosure is not limited thereto. Any magnesium alloy may be used if it is generally used in industry fields.
  • the protection gas includes SF 6 , SO 2 , CO 2 , HFC-134a, NovecTM612, inert gases and equivalents thereof, and mixture gases thereof, and may suppress ignition of the molten metal.
  • the second compound is added to the magnesium molten metal.
  • the second compound may be a compound in which two or more components are bonded, and is partly or completely exhausted in the magnesium molten metal.
  • a first compound in which a portion of components constituting the second compound, and a metal component in the magnesium molten metal are bonded may be formed.
  • a first compound in which components supplied from each of the second compounds are bonded may be formed.
  • the second compound after being added to the magnesium molten metal, the second compound performs a role as a supply source supplying a component constituting the first compound.
  • the second compound may be a calcium-based compound, and may include any one of, for example, calcium oxide (CaO), calcium cyanide (CaCN 2 ), and calcium carbide (CaC 2 ).
  • a metal component of the alkali earth metal group and a non-metal component bonded thereto may be decomposed from each other.
  • a metal component supplied from the alkali earth metal-based compound may be bonded to magnesium that is a metal component in the magnesium molten metal to form a magnesium compound.
  • Such a magnesium compound may be any one of a magnesium-calcium compound, a magnesium-strontium compound, and a magnesium-aluminum-calcium compound.
  • a magnesium-calcium compound such as Mg 2 Ca and the like
  • strontium (Sr) decomposed from strontium oxide may form a magnesium-strontium compound, such as Mg 2 Sr, Mg 23 Sr 6 , Mg 38 Sr 9 , Mg 17 Sr 2 , etc.
  • aluminum may be melted as metal component other than magnesium in the magnesium molten metal, and the aluminum may be bonded to an alkali earth metal element to form an aluminum compound.
  • the aluminum compound may include at least one of an aluminum-calcium compound and an aluminum-strontium compound.
  • calcium decomposed from calcium oxide may be boned to aluminum to form an aluminum-calcium compound, such as Al 2 Ca, Al 4 Ca, or the like, and strontium (Sr) decomposed from strontium oxide may be bonded to aluminum to form an aluminum-strontium compound such as Al 4 Sr, or the like.
  • the magnesium component and the aluminum component in the magnesium molten metal may be bonded together to form a composite oxide such as (Mg,Al) 2 Ca, or the like.
  • the second compound may be a silicon-based compound.
  • the silicon-based compound may include, for example, silicon oxide (SiO 2 ), and the like.
  • silicon (Si) decomposed from silicon oxide may be boned to a magnesium component to form a magnesium-silicon compound, such as Mg 2 Si, or the like.
  • the second compound may be a rare earth compound, and may include, for example, scandium oxide (Sc 2 O 3 ), cesium oxide (CeO 2 ), and the like.
  • a rare earth metal supplied from the rare earth compound may bond to magnesium or aluminum.
  • cesium (Cs) may be boned to aluminum to form an aluminum-cesium compound, such as Al 2 Ce or the like
  • scandium (Sc) may be boned to aluminum to form an aluminum-scandium compound, such as Al 2 Sc.
  • the second compound may be added in at least two portions that are different in kind from each other.
  • calcium oxide and silicon oxide may be added in the magnesium molten metal at the same time.
  • calcium supplied from calcium oxide and silicon supplied from silicon oxide may be bonded to each other in the magnesium molten metal to form a calcium-silicon compound, such as CaSi, or the like.
  • oxidation resistance of the magnesium molten metal can be improved by the second compound added to the magnesium molten metal.
  • oxidation resistance of the magnesium molten metal is improved and thus ignition resistance is increased, so that introduction of oxide or other inclusions into the magnesium molten metal is suppressed. Therefore, the amount of the protection gas necessary for melting magnesium can be remarkably reduced or may not be used at all.
  • the first compound included in the magnesium mother alloy may have a higher melting point than a casting metal.
  • Mg 2 Si, Al 2 Ca, Al 4 Sr, Al 2 Sc, and Al 2 Se have melting points of 1085° C., 1078° C., 1040° C., 1420° C., and 1480° C., respectively
  • casting metals for example, tin, zinc, magnesium, and aluminum have melting points of 231.9° C., 419.5° C., 649° C., and 660.1° C., respectively.
  • the first compound may be distributed in the matrix of the casting metal after cast. That is, since the molten metal of the casting metal is maintained in liquid phase at a lower temperature than the melting point of the first compound, the first compound added together with the magnesium mother alloy is not melted in the molten metal of the casting metal but exists in solid phase, and after cast and solidified, is distributed on the matrix of the casting metal.
  • a compound can be formed on the matrix of the metal without a separate treatment, such as a heat treatment or a mechanical processing.
  • aluminum alloy 6063 that is a commercial alloy allows a large amount of Mg 2 Si to be distributed on an aluminum matrix, thus greatly improving the mechanical strength.
  • Mg 2 Si magnesium and silicon are added to aluminum and a heat treatment is performed to precipitate Mg 2 Si on the aluminum matrix.
  • an aluminum mother alloy containing Mg 2 Si as the first compound may be added to an aluminum molten metal and then cast to easily produce an aluminum alloy in which Mg 2 Si is formed in the aluminum matrix.
  • a remaining component that is not bonded to a metal component within the molten metal is discharged in the state of gas to the atmosphere through a portion over the surface of the magnesium molten metal or may be floated on the molten metal in the form of dross or sludge.
  • the second compound is advantageous for enhancement of reactivity when the surface area thereof is as wide as possible, and thus is added in the form of powder.
  • the present disclosure is not limited thereto, and the silicon-based additive may be added in the form of pellet or bulk in which powder particles are agglomerated so as to prevent powder from scattering.
  • the size of the second compound may be in a range of 0.1 ⁇ m to 500 ⁇ m, and more strictly in a range of 0.1 ⁇ m to 200 ⁇ m.
  • the size of the second compound is less than 0.1 ⁇ m, the size is so fine that the second compound is scattered by sublimated magnesium or hot wind and thus have a difficulty in introducing the same in the crucible. Also, since the second compounds are agglomerated to form an agglomerate, they are not easily mixed with the liquid phase molten metal. Such an agglomerate is not preferred in that it decreases the surface area for reaction.
  • the surface area for a reaction decreases, and further the second compound may not react with the magnesium molten metal.
  • the second compound may be added in a range of 0.001 wt % to 30 wt %, and more strictly, in a range of 0.01 wt % to 15 wt %.
  • the total added amount of the second compound is less than 0.001 wt %, an effect by addition of the second compound is slight or is almost not generated.
  • the total added amount of the second compound exceeds 30 wt %, the fluidity of the molten metal may be degraded.
  • the second compounds may be added to the molten metal at the same time, or with a time difference.
  • the second compound may be added at one time by a necessary amount, or may be added in multi-stage with a constant time difference by dividing the necessary amount into proper amounts.
  • the added second compound is a powder having fine particles, the agglomeration possibility of the powder may be lowered and the reaction of the second compound may be promoted by adding the second compound in multi-stage with a constant time difference.
  • FIG. 3 is a schematic view exemplarily illustrating a decomposition process of calcium oxide 20 in an upper layer portion of a magnesium molten metal 10 when calcium oxide 20 is added to the magnesium molten metal 10 in a melting furnace 1 .
  • calcium oxide 20 is decomposed into oxygen (O 2 ) and calcium (Ca) in the upper layer portion of the magnesium molten metal 10 .
  • the decomposed oxygen is a gas (O 2 ), is discharged to the outside from the melting furnace or is floated on the magnesium molten metal in the form of dross or sludge.
  • the decomposed calcium may react with another element, for example, magnesium (Mg) or aluminum (Al) in the molten metal to form various compounds.
  • the added second compound may be maintained such that it stays on the surface of the molten metal for a long time and is exposed to the atmosphere.
  • stirring (S 3 ) of the magnesium molten metal may be performed.
  • the stirring may start at the same time with the adding of the second compound or after the added second compound is heated to a predetermined temperature in the molten metal.
  • the molten metal and an alloy element are positively stirred such that a reaction occurs in the molten metal through convection or stirring.
  • the reaction of the second compound is not effective and thus the frequency that the second compound remains in the final molten metal in a non-decomposed state increases.
  • the remaining second compound may be incorporated into the cast magnesium alloy to degrade the mechanical characteristics of the magnesium alloy.
  • Table 1 shows a measurement result of the amount of calcium oxide remaining according to a stirring method when calcium oxide (CaO) is added to AM60B molten metal.
  • the size of the added calcium oxide is 70 ⁇ m, and the calcium oxide is added by 5 wt %, 10 wt %, and 15 wt %.
  • Stirring of an upper layer portion of the magnesium molten metal, inner stirring, and no stirring are selected as a way for confirming a stirring effect. It can be known from Table 1 that when the stirring of the upper layer portion of the magnesium molten metal is performed, most of the added calcium oxide is reduced into calcium, unlike other cases.
  • the stirring may be performed in an upper layer portion from the surface of the magnesium molten metal to a point which is not more than 20% of a total depth of the magnesium molten metal, and more strictly, in an upper layer portion to a point which is not more than 10% of the total depth of the magnesium molten metal. At the depth exceeding 20%, decomposition of the second compound in the surface does not easily occur.
  • the stirring time may be different depending on the temperature of the molten metal and the state of added powder, and the stirring may be sufficiently performed until the added second compound is completely exhausted in the molten metal.
  • exhaust indicates that the decomposition of the second compound is substantially completed.
  • Such stirring can more promote the decomposition of the second compound in the magnesium molten metal and a process in which a component supplied by such decomposition reacts with a metal component in the magnesium molten metal to form various first compounds.
  • casting (S 24 ) in which the magnesium molten metal is injected into a mold to solidify the injected molten metal is performed to produce a magnesium mother alloy.
  • calcium (Ca) or strontium (Sr) element instead of a calcium-based compound or strontium-based compound may be added as the second compound to produce a magnesium mother alloy.
  • the added calcium or strontium may be melted in the magnesium molten metal to form a first compound.
  • FIG. 4 is a flow diagram showing an exemplary embodiment of a method of producing an aluminum mother alloy.
  • the method of producing the aluminum alloy includes forming (S 31 ) of an aluminum molten metal, adding (S 32 ) of a magnesium mother alloy, stirring (S 33 ), and casting (S 34 ).
  • the aluminum in the forming (S 31 ) of the aluminum molten metal may be any one selected from the group consisting of pure aluminum, an aluminum alloy, and equivalents thereof.
  • the aluminum alloy may be any one selected from the group consisting of 1000 series, 2000 series, 3000 series, 4000 series, 5000 series, 6000 series, 7000 series and 8000 series plastic working aluminum alloys, or 100 series, 200 series, 300 series, 400 series, 500 series, and 700 series casting aluminum alloys.
  • the magnesium alloy may be added in a range of 0.0001 parts by weight to 30 parts by weight based on 100 parts by weight of aluminum.
  • the added amount of the magnesium mother alloy is less than 0.0001 parts by weight, an effect according to the adding of the magnesium alloy may be small. Also, when the added amount of the magnesium mother alloy exceeds 30 parts by weight, the original characteristics of the aluminum alloy do not appear.
  • the magnesium alloy may be added in the form of an ingot, but the present disclosure is not limited thereto, and the magnesium alloy may have other forms such as powder form, granule form, and the like. Also, the size of the magnesium mother alloy is not limited.
  • the first compound included in the magnesium alloy is also provided to the aluminum molten metal.
  • the magnesium alloy may have therein the first compound having a higher melting point than aluminum, and when the magnesium mother alloy including the first compound is added to the aluminum molten metal, the first compound may be included in an aluminum alloy.
  • the aluminum molten metal is stirred for a predetermined time (S 33 ), and then the casting (S 34 ) in which the aluminum molten metal is injected into a mold and is solidified is performed to produce an aluminum alloy.
  • the produced aluminum alloy may be any one selected from the group consisting of 1000 series, 2000 series, 3000 series, 4000 series, 5000 series, 6000 series, 7000 series and 8000 series plastic working aluminum alloys, or 100 series, 200 series, 300 series, 400 series, 500 series, and 700 series casting aluminum alloys.
  • magnesium mother alloy or aluminum mother alloy including the first compound when added as an alloy element to the molten metal of the casting metal, oxidation resistance of the molten metal of the casting metal can be improved.
  • the magnesium mother alloy to which a calcium-based compound is added may contain a magnesium-calcium compound, an aluminum-calcium compound, a magnesium-aluminum-calcium compound, and the like as the first compound, and the aluminum mother alloy produced by adding such a mother alloy also contains the first compound described above.
  • the inclusion of impurities such as oxide in the molten metal of the casting metal remarkably decreases, compared to a case in which magnesium or aluminum no containing the first compound is added. Therefore, in the case where the mother alloy according to an exemplary embodiment is added as an alloy element, although a protection gas is not used, cleanness of the molten metal of the casting metal can be greatly enhanced to remarkably improve the quality of the molten metal. Due to the improvement of the quality of the molten metal, the physical properties, such as the mechanical and chemical characteristics of the cast alloy are greatly improved.
  • the magnesium mother alloy may be produced by adding calcium (Ca) or strontium (Sr) in the form of element, instead of adding the magnesium alloy including the first compound. While being melted in the aluminum molten metal, such calcium or strontium may react with aluminum to form a first compound, such as Al 2 Ca, Al 4 Ca, Al 4 Sr, or the like.
  • the present disclosure is not limited thereto, and in another exemplary embodiment, it will be also possible to directly add the first compound to the mother alloy molten metal.
  • the first compound may be one produced by various methods in the outside.
  • aluminum powder and calcium powder are put in an apparatus such as a ball-mill to produce Al 2 Ca powder through a mechanical alloying, and the produced Al 2 Ca powder may be added as a first compound to the aluminum molten metal.
  • Al 2 Ca is included as the first compound in the cast magnesium alloy or aluminum alloy.
  • the Al 2 Ca powder produced as above is added to a magnesium molten metal to produce a magnesium alloy containing Al 2 Ca, and then the produced magnesium alloy may be again added to an aluminum molten metal to produce an aluminum mother alloy containing Al 2 Ca.
  • the mechanical alloying has been suggested as a method for forming the first compound, the present disclosure is not limited thereto, and any method will be allowable if it is a method of capable of forming the first compound.
  • the mother alloy including the first compound may be further subject to diluting thereof.
  • the magnesium mother alloy (for convenience, referred to as a first magnesium mother alloy) produced by the above-described method may be added to a magnesium molten metal and diluted to form a second magnesium mother alloy including a first compound having a decreased concentration.
  • a second aluminum mother alloy may be formed by diluting the first aluminum mother alloy.
  • FIGS. 5A through 5D show analysis results of a magnesium mother alloy according to an exemplary embodiment by electron probe micro analyzer (EPMA), in which the magnesium mother alloy is one produced by adding calcium oxide (CaO) as a second compound to a magnesium alloy containing aluminum as an alloy element.
  • EPMA electron probe micro analyzer
  • FIG. 5A shows a microstructure of the magnesium mother alloy observed using a back scattering electron.
  • the magnesium mother alloy shows a microstructure having a plurality of crystal grains surrounded by compounds (white portions). The compounds (white portions) are formed along grain boundaries.
  • FIGS. 5B through 5D show distribution regions of aluminum, calcium, and oxygen that are mapping results of components in the compound regions (white portions) by EPMA. As shown in FIGS. 5B and 5C , aluminum and calcium were detected from the compounds (white portion of FIG. 5A ) but oxygen was not detected ( FIG. 5D ).
  • an aluminum-calcium compound that is produced as calcium separated from calcium oxide reacts with aluminum included in the mother material is distributed.
  • Such an aluminum-calcium compound may be Al 2 Ca or Al 4 Ca that is an intermetallic compound.
  • FIGS. 6A through 6E show EPMA analysis results of an aluminum mother alloy produced according to an exemplary embodiment.
  • the magnesium mother alloy added to the aluminum molten metal was one which is produced by adding calcium oxide to a magnesium molten metal including aluminum.
  • FIG. 6A shows a microstructure of an aluminum mother alloy observed by EPMA
  • FIG. 6B through 6E show mapping results of aluminum, calcium, magnesium, and oxygen that are mapping results of components by EPMA.
  • FIGS. 6B through 6D calcium and magnesium were detected at the same locations of the aluminum matrix, but oxygen was not detected as shown in FIG. 6E . From this result, it can be known that the magnesium-aluminum-calcium compound which is included as the first compound in the magnesium mother alloy also exists as the first compound in the aluminum mother alloy.
  • FIG. 7A shows a state of an aluminum molten metal which is produced by adding a magnesium mother alloy
  • FIG. 7B shows a state of an aluminum molten metal which is produced by adding pure magnesium.
  • Table 2 shows results obtained by observing and comparing states of a magnesium molten metal according to the added amount of protection gas, SF 6 in a case where beryllium (Be) is added in a magnesium molten metal and in a case where calcium oxide is added.
  • the magnesium molten metal was produced from a magnesium-aluminum alloy (Mg-0.45Al) in which 0.45 wt % of aluminum is added.
  • FIG. 8 shows an oxidation resistance measurement result according to the amount of calcium oxide in the magnesium mother alloy.
  • the oxidation of the magnesium mother alloy was performed in an oxygen atmosphere at 550° C. for 40 hours. Referring to FIG. 8 , it can be seen that as the amount of calcium oxide increases, oxidation resistance is remarkably improved.
  • FIG. 9 is a graph for comparison of oxidation resistance in an aluminum alloy produced according to an exemplary embodiment and an aluminum alloy produced by a method different from an exemplary embodiment, both having the same magnesium composition.
  • x-axis represents isothermal oxidation time (minute)
  • y-axis represents weight gain (%), respectively.
  • red line, green line, and blue line represent 2.5 wt %, 5 wt %, and 10 wt % of aluminum alloys, respectively
  • dotted line having the same color indicates an aluminum alloy which has the same magnesium composition, and is produced from a magnesium mother alloy produced by adding calcium oxide as a second compound.
  • FIG. 9 it can be known that the aluminum alloys according to an exemplary embodiment have superior oxidation resistance.
  • an alloy element having a high oxidation property such as magnesium or aluminum
  • cleanness of the molten metal can be maintained at a high level, and thus characteristics of the cast alloy can be remarkably improved.
  • a mother alloy including a compound as an alloy element the compound can be formed in the matrix of the alloy without a separate treatment.

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US20170266721A1 (en) 2017-09-21
KR20120129719A (ko) 2012-11-28
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EP2712941A4 (en) 2014-12-17
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KR101402897B1 (ko) 2014-06-02
US9901981B2 (en) 2018-02-27

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