US20150152526A1 - Aluminum member - Google Patents

Aluminum member Download PDF

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Publication number
US20150152526A1
US20150152526A1 US14/557,673 US201414557673A US2015152526A1 US 20150152526 A1 US20150152526 A1 US 20150152526A1 US 201414557673 A US201414557673 A US 201414557673A US 2015152526 A1 US2015152526 A1 US 2015152526A1
Authority
US
United States
Prior art keywords
die
aluminum
cast
subframe
sand core
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
Application number
US14/557,673
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English (en)
Inventor
Akihiko ASAMI
Tsunehisa Hata
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Honda Motor Co Ltd
Original Assignee
Honda Motor Co Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Honda Motor Co Ltd filed Critical Honda Motor Co Ltd
Assigned to HONDA MOTOR CO., LTD. reassignment HONDA MOTOR CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ASAMI, AKIHIKO, HATA, TSUNEHISA
Publication of US20150152526A1 publication Critical patent/US20150152526A1/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
    • C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C3/00—Selection of compositions for coating the surfaces of moulds, cores, or patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
    • B22D17/2218—Cooling or heating equipment for dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
    • B22D17/24—Accessories for locating and holding cores or inserts
    • 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
    • B22D21/002—Castings of light metals
    • B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C

Definitions

  • the present invention relates to an aluminum member, particularly, to a large aluminum cast part.
  • Aluminum cast parts are widely used in practical fields for the object to reduce weight. Further, aluminum members produced by die casting are widely provided to achieve fine grain size (for example, see JP 2541412 B1).
  • JP 2541412 B1 provides an aluminum alloy for die casting including magnesium (Mg), silicon (Si), iron (Fe), and manganese (Mn) within certain ranges.
  • the alloy is used for the material of electronic devices such as computers.
  • JP 2541412 B1 The technique discussed in JP 2541412 B1 is useful for small thin parts such as electronic devices. For parts with a large difference in thickness such as vehicle parts, there occurs a difference in cooling rate between a thick portion and a thin portion.
  • Aluminum-manganese (Al-Mg) materials generally have low fluidity and is difficult to cast. When such material having low fluidity is used for a large part with a large difference in thickness, a misrun or insufficient supply of molten metal during solidification might cause cracks.
  • Al-silicon (Al-Si) based materials are used, although the Al-Si based material requires heat treatment to obtain strength, which may results in high production cost.
  • an aluminum member composed of ingredients of, by weight percentage, 1.0% to 3.0% of Si, 4.0% to 6.0% of Mg, 1.0% or less Fe, 1.0% or less Mn, 0.5% or less Cu, 0.5% or less Zn, at least either of 0.10% to 0.20% of titanium (Ti) or 0.0015% to 0.0030% of beryllium (Be) added to obtain a fine grain size in a metal structure, and a residual of Al and inevitable impurities is provided.
  • the aluminum member is produced using a cast die and a sand core disposed in the cast die by casting a molten metal composed of the aforementioned ingredients in a space between the cast die and the sand core.
  • Si is included in the aluminum cast part within a range from 1.0% to 3.0%. If the included Si is less than 1.0%, the 0.2% proof strength and the tensile strength are reduced, and if the included Si is more than 3.0%, elongation is reduced. If the included Si is within 1.0% to 3.0%, predetermined degrees of 0.2% proof strength, tensile strength and elongation can be secured. Further, fluidity of Al-Mg based alloys, which is the negative aspect, can be improved by adding Si.
  • the molten aluminum alloy has a disadvantage in fluidity, and when high pressure casting (die casting) is applied for a large part with a large difference in thickness, a misrun at a portion to be filled in the final stage of casting or a crack at a thick portion and a thin portion may occur.
  • a sand core having a low heat conductivity is disposed in a die to suppress the dropping of temperature of a molten metal and also to reduce the difference in thickness of the part.
  • the hollow structure produced by using the sand core can provide a thin light structure having high rigidity.
  • the present invention provides a technique that can produce an aluminum cast part also for a large part with a large difference in thickness, that is, a part that should have a large difference in thickness if a core is not used when producing the part.
  • the aluminum member is preferably a hollow die cast member produced by high pressure casting.
  • a thin aluminum member can be provided, and moreover, since a high pressure casting is used, a fine grain sized aluminum member having high strength can be provided.
  • the hollow die cast member is desirably used for a subframe for a vehicle.
  • the hollow die cast member can be made thin and has superior mechanical property without treatment, and therefore is preferable for a subframe requiring strength and reliability.
  • a light and low cost subframe can be provided.
  • the subframe supporting a power plant such as engines receives rotational forces and vibration generated by the power plant and loads from a suspension, and therefore requires high strength and high rigidity.
  • a cross-member unit and a suspension supporting unit are integrated in the subframe for a vehicle and both the members have a hollow structure.
  • the subframe for a vehicle preferably includes an inclined portion.
  • FIGS. 1A and 1B illustrate a general concept of die casting apparatuses
  • FIG. 2 is a perspective view illustrating a vehicle front structure
  • FIG. 3 is a bottom view of a subframe
  • FIG. 4 is a sectional view of the subframe
  • FIGS. 5A to 5C illustrate a relationship between the added amount of Si and tensile strength, 0.2% proof strength, and elongation.
  • FIG. 6 illustrates a relationship between the existence of a sand core and a flow length.
  • a conventional die casting apparatus 100 is described as a comparative example in FIG. 1A .
  • a molten metal 105 is injected through a sleeve 104 into a cavity 103 formed by a fixed die 101 and a movable die 102 .
  • the cavity 103 is made large to produce a large thick part. Note that, although the general concept and the cavity 103 with a constant thickness is illustrated in FIG. 1A , an actual part may have a large difference in thickness. In a case where a molten metal 105 having poor fluidity is injected, when the difference in thickness is large, the difference in cooling rate between the thick portion and the thin portion may cause casting defects.
  • a die casting apparatus 10 includes, for example, a base plate 11 , a fixed plate 12 fixed on the base plate 11 , a fixed die 13 attached on the fixed plate 12 , a movable plate 14 arranged to oppose the fixed plate 12 , a die-closing cylinder 15 that moves the movable plate 14 , a movable die 16 attached on the movable plate 14 , a sand core 17 disposed between the movable die 16 and the fixed die 13 , a cylindrical sleeve 18 attached to the fixed plate 12 , and a plunger 19 that moves the sleeve 18 along the axial direction.
  • the sand core 17 is coated with an alumina coating applied by sintering a mixture of natural sand and artificial sand so that the sand core 17 can be used for high pressure injection.
  • the fixed die 13 and the movable die 16 constitute a cast die 20 .
  • a runner 22 and a plurality of gates 23 are provided in the fixed die 13 . These gates 23 are opened to the cavity 24 located between the sand core 17 and the fixed die 13 . By providing the sand core 17 , the thickness T of the cavity 24 is made thin.
  • a molten aluminum alloy 26 (hereinafter abbreviated as molten metal 26 ) is injected into the sleeve 18 through a pouring gate 25 provided on the sleeve 18 .
  • the molten metal 26 is kept in the sleeve 18 .
  • the plunger 19 By moving the plunger 19 forward, the molten metal 26 is injected into the runner 22 with high pressure, and then through a plurality of gates 23 , the molten metal 26 is injected into the cavity 24 with high pressure.
  • the outer surface of the molten metal 26 is cooled by the fixed die 13 and the movable die 16 , and the inner surface of the molten metal 26 is cooled by the sand core 17 . Because the sand core 17 has very poor property to work as a coolant than a metal core, the molten metal 26 is cooled moderately. Since the cooling is moderately performed, the fluidity of the molten metal 26 is kept for a relatively long period of time, allowing the molten metal 26 to reach the far end of the cavity 24 without solidifying.
  • the die-closing cylinder 15 moves the movable plate 14 and the movable die 16 to open the die.
  • the aluminum casting is taken out from the opened cast die 20 .
  • the sand core 17 is taken out of the aluminum casting and a hollow die cast member composed of an aluminum member is obtained.
  • FIG. 1B merely illustrates an example.
  • the cast die 20 can be rotated by 90 degrees so that the sand core 17 can be horizontally positioned. Further, the runner 22 may be provided inside the fixed die 13 .
  • the arrow Fr indicates the front side and the arrow Rr indicates the rear side.
  • the vehicle front structure 30 includes right-and-left side frames 31 R and 31 L (R is appended to indicate the right side, and L is appended to indicate the left side, as will be similarly used hereinafter) arranged along the front-and-rear direction of the vehicle body, a subframe for a vehicle 40 (hereinafter referred to as subframe 40 ) attached below the right-and-left side frames 31 R and 31 L, right-and-left suspension arms 32 R and 32 L provided on the right-and-left end portions of the subframe 40 , and right-and-left suspensions 33 R and 33 L connected to the right-and-left suspension arms 32 R and 32 L, respectively.
  • subframe 40 a subframe for a vehicle 40
  • the vehicle front structure 30 further includes a steering gear box 34 attached to the upper portion of the subframe 40 and a torque rod 36 that connects the subframe 40 and the power plant 35 .
  • a steering wheel 39 is attached to the steering shaft 38 extending from the steering gear box 34 .
  • the power plant 35 is configured by integrating an engine and a transmission, that is, as an engine/transmission unit, and is arranged along the right-and-left direction between the right-and-left side frames 31 R and 31 L.
  • the subframe 40 is configured with right-and-left suspension supporting units 41 R and 41 L supporting the suspension arms 32 R and 32 L and a cross-member unit 42 that extends between the suspension supporting unit 41 R and the suspension supporting unit 41 L.
  • the suspension supporting units 41 R and 41 L and the cross-member unit 42 are integrally formed and each has a hollow structure.
  • the subframe 40 has an inclined portion 43 that inclines from the rear side to the front side of the vehicle so as to avoid interference with the power plant (see reference sign 35 in FIG. 3 ). Since the inclined portion 43 gradually changes the shape, the fluidity is preferably maintained.
  • the whole structure of the subframe 40 is formed in a hollow die cast member produced by high pressure casting using the sand core (see reference sign 17 in FIG. 1B ).
  • the sand core contributes to moderate the cooling to produce a thin structure.
  • the reference sign 45 indicates a large hollow space formed by the sand core.
  • the sand core is located inside each of the suspension supporting units 41 R and 41 L and the cross-member unit 42 . In this manner, larger portion can be cooled moderately and thereby a thin structure can be produced.
  • the ingredients of the molten metal 26 shown in FIG. 1B are, by weight percentage, 1.0% to 3.0% of Si, 4.0% to 6.0% of Mg, 1.0% or less Fe, 1.0% or less Mn, 0.5% or less Cu, 0.5% or less Zn, at least either of 0.10% to 0.20% of Ti or 0.0015% to 0.0030% of Be added to obtain a fine grain size in a metal structure, and a residual of Al and inevitable impurities
  • the included Si of 2.0% by weight percentage gives the highest tensile strength and the included Si of 3.0% gives the second highest tensile strength, followed by the included Si of 1.0%.
  • the 0.2% proof strength increases proportional to the added amount of Si.
  • the included Si of 1.0% gives the highest elongation and the included Si of 2.0% gives the second highest elongation, followed by the included Si of 3.0%.
  • the included Si is less than 1.0%, the tensile strength is small, and if the included Si is more than 3.0%, the elongation is small. If the included Si is within 1.0% to 3.0%, the predetermined degrees of tensile strength, proof strength, and elongation can be maintained.
  • the apparatus using the sand core has a far longer flow length than the apparatus that does not use the sand core.
  • the aluminum member according to the embodiment of the present invention is applicable for any hollow casting and can be produced by die casting, sand mold casting, low pressure casting, and other casting methods.
  • the aforementioned embodiment is applied to the subframe for a vehicle, the embodiment may be applied to other vehicle structural members such as suspension arms, frame members of motorcycles, and components of structures other than those for vehicles.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Body Structure For Vehicles (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
US14/557,673 2013-12-03 2014-12-02 Aluminum member Abandoned US20150152526A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2013-250015 2013-12-03
JP2013250015A JP6090793B2 (ja) 2013-12-03 2013-12-03 アルミニウム部材

Publications (1)

Publication Number Publication Date
US20150152526A1 true US20150152526A1 (en) 2015-06-04

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ID=53058674

Family Applications (1)

Application Number Title Priority Date Filing Date
US14/557,673 Abandoned US20150152526A1 (en) 2013-12-03 2014-12-02 Aluminum member

Country Status (4)

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US (1) US20150152526A1 (ja)
JP (1) JP6090793B2 (ja)
CN (1) CN104694799B (ja)
DE (1) DE102014224744A1 (ja)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20160068189A1 (en) * 2013-04-26 2016-03-10 Honda Motor Co., Ltd. Vehicle subframe
US20160075379A1 (en) * 2013-04-26 2016-03-17 Honda Motor Co., Ltd. Vehicle subframe

Families Citing this family (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105734365A (zh) * 2016-03-29 2016-07-06 南通超达装备股份有限公司 一种铸造铝材料
CN106040995A (zh) * 2016-08-04 2016-10-26 苏州利达铸造有限公司 一种汽车振动器模具
JP6975572B2 (ja) * 2017-07-28 2021-12-01 ハイリマレリジャパン株式会社 鋳型及び鋳造部品の製造方法
CN110093541B (zh) * 2018-07-27 2020-03-31 比亚迪股份有限公司 压铸铝合金及其制备方法和应用以及压铸铝合金复合塑料产品
EP3878991A4 (en) * 2018-11-07 2021-12-15 Nippon Light Metal Co., Ltd. ALUMINUM ALLOY FOR DIE CASTING AND DIE CASTING ALUMINUM ALLOY MATERIAL
CN109593995A (zh) * 2018-12-28 2019-04-09 哈尔滨工业大学 一种复杂构件仪表级复合材料基体铝合金及其制备方法
JP7238545B2 (ja) * 2019-03-29 2023-03-14 株式会社アイシン アルミニウム合金及び鋳造部品の製造方法
CN114226687B (zh) * 2021-12-23 2024-04-26 江苏文灿压铸有限公司 一种分体式砂芯成型的新能源汽车副车架制备方法

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0853133A1 (de) * 1994-11-15 1998-07-15 ALUMINIUM RHEINFELDEN GmbH Verwendung einer Aluminiumlegierung zum Druckgiessen
JP2007118071A (ja) * 2005-10-31 2007-05-17 Honda Motor Co Ltd 鋳造製品の製造方法及び鋳型

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JPS61261466A (ja) * 1985-05-14 1986-11-19 Sumitomo Light Metal Ind Ltd 成形性の優れたアルミニウム合金の硬質圧延板の製造方法
JPH01247548A (ja) * 1988-03-29 1989-10-03 Ryobi Ltd 高靭性アルミニウム合金
JP2541412B2 (ja) * 1991-12-13 1996-10-09 日本軽金属株式会社 ダイカスト用アルミニウム合金
FR2833616B1 (fr) * 2001-12-17 2004-07-30 Pechiney Aluminium Piece coulee sous pression en alliage d'aluminium a haute ductilite et resilience
JP4248195B2 (ja) * 2002-07-03 2009-04-02 本田技研工業株式会社 中空部を有する鋳造品の製造方法
JP5613453B2 (ja) * 2010-05-19 2014-10-22 本田技研工業株式会社 軽合金高圧鋳造方法
JP5444198B2 (ja) * 2010-12-06 2014-03-19 本田技研工業株式会社 サブフレーム構造体
CN102248150B (zh) * 2011-07-04 2013-04-17 宁波炜兴特种铝制品有限公司 一种铝压铸模具嵌入砂芯模型成型工艺

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0853133A1 (de) * 1994-11-15 1998-07-15 ALUMINIUM RHEINFELDEN GmbH Verwendung einer Aluminiumlegierung zum Druckgiessen
JP2007118071A (ja) * 2005-10-31 2007-05-17 Honda Motor Co Ltd 鋳造製品の製造方法及び鋳型

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20160068189A1 (en) * 2013-04-26 2016-03-10 Honda Motor Co., Ltd. Vehicle subframe
US20160075379A1 (en) * 2013-04-26 2016-03-17 Honda Motor Co., Ltd. Vehicle subframe
US9399488B2 (en) * 2013-04-26 2016-07-26 Honda Motor Co., Ltd. Vehicle subframe
US9776660B2 (en) * 2013-04-26 2017-10-03 Honda Motor Co., Ltd. Vehicle subframe

Also Published As

Publication number Publication date
DE102014224744A1 (de) 2015-06-03
JP2015107492A (ja) 2015-06-11
CN104694799A (zh) 2015-06-10
JP6090793B2 (ja) 2017-03-08
CN104694799B (zh) 2017-09-22

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AS Assignment

Owner name: HONDA MOTOR CO., LTD., JAPAN

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:ASAMI, AKIHIKO;HATA, TSUNEHISA;REEL/FRAME:034308/0600

Effective date: 20141201

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION