US20160355908A1 - Aluminum alloy and die casting method - Google Patents

Aluminum alloy and die casting method Download PDF

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Publication number
US20160355908A1
US20160355908A1 US15/222,176 US201615222176A US2016355908A1 US 20160355908 A1 US20160355908 A1 US 20160355908A1 US 201615222176 A US201615222176 A US 201615222176A US 2016355908 A1 US2016355908 A1 US 2016355908A1
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United States
Prior art keywords
mass
aluminum alloy
die
less
die casting
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Abandoned
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US15/222,176
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English (en)
Inventor
Tomoo Yoshida
Shinichi Asai
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Aisin Keikinzoku Co Ltd
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Aisin Keikinzoku Co Ltd
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Assigned to AISIN KEIKINZOKU CO., LTD. reassignment AISIN KEIKINZOKU CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ASAI, SHINICHI, YOSHIDA, TOMOO
Publication of US20160355908A1 publication Critical patent/US20160355908A1/en
Priority to US16/841,794 priority Critical patent/US11359264B2/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
    • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
    • 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
    • B22D17/02—Hot chamber machines, i.e. with heated press chamber in which metal is melted
    • 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
    • B22D17/08—Cold chamber machines, i.e. with unheated press chamber into which molten metal is ladled
    • 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
    • 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
    • B22D17/2007—Methods or apparatus for cleaning or lubricating moulds
    • 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
    • B22D17/2015—Means for forcing the molten metal into the die
    • B22D17/2023—Nozzles or shot sleeves
    • 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
    • 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
    • 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

Definitions

  • the present invention relates to an aluminum alloy that is used for a die casting process (aluminum die casting process), and a casting method.
  • a die casting process has high productivity, and is used in a wide variety of fields in which aluminum parts (e.g., automotive parts and mechanical parts) are used.
  • aluminum parts e.g., automotive parts and mechanical parts
  • JIS Japanese Industrial Standards
  • the JIS ADC12 alloy exhibits excellent castability. However, since a product obtained by subjecting the JIS ADC12 alloy to the die casting process has a coarse needle-like metal microstructure, fracture easily occurs from the precipitates, and it is difficult to obtain sufficient strength.
  • Japanese Patent No. 4970709 discloses an aluminum alloy that is used for a die casting process and exhibits high elongation in an as-cast state. In Japanese Patent No. 4970709, it is indispensable to add molybdenum to the aluminum alloy.
  • An object of the invention is to provide an aluminum alloy that is used for a die casting process, and exhibits excellent internal quality, high elongation, and high strength, and a method for casting the same.
  • An aluminum alloy according to one aspect of the invention includes 6.0 to 9.0 mass % of Si, 0.4 to 0.8 mass % of Mg, 0.25 to 1.0 mass % of Cu, 0.08 to 0.25 mass % of Fe, 0.6 mass % or less of Mn, 0.2 mass % or less of Ti, and 0.01 mass % or less of one element selected from the group consisting of Sr, Sb, Ca, and Na with the balance being Al and unavoidable impurities.
  • a casting method includes pouring molten metal of an Al—Si—Cu—Mg-based aluminum alloy into a shot sleeve of a die casting machine, and filling a mold cavity of a center-gate die with the molten metal at a gate speed of 1 m/sec or less so as to produce a laminar flow.
  • a release agent is normally applied to the inside of the mold cavity or the like when implementing a die casting process.
  • a solution-type release agent e.g., oily release agent or water-soluble release agent
  • a powdery release agent suppresses a decrease in die temperature.
  • the above alloy composition is selected for the reasons described below.
  • the Si content must be 6 mass % or more in order to obtain fluidity during casting.
  • the Si content is set to achieve a hypo-eutectic region.
  • the Si content is preferably set to 6.0 to 9.0 mass %.
  • Mg and Cu are required to provide the aluminum alloy with high strength.
  • the Mg content is preferably set to 0.4 to 0.8 mass %, and the Cu content is preferably set to 0.25 to 1.0 mass %.
  • Fe improves toughness when the Fe content is low. If the Fe content exceeds 0.25 mass %, a decrease in ductility may occur.
  • Fe is easily mixed as impurities. It is necessary to increase the purity of the master alloy (i.e., an increase in cost occurs) in order to reduce the Fe content.
  • the Fe content is preferably set to 0.08 to 0.25 mass %.
  • the Mn content is preferably set to 0.6 mass % or less.
  • Ti is effective for achieving the refinement of crystal grains during casting. Ti may be added in a ratio of 0.2 mass % or less.
  • a small amount of B is included in the aluminum alloy when Ti is added to the master alloy.
  • an F material obtained by air-cooling the product obtained by the die casting process, or a T5 material obtained by tempering the F material exhibits improved strength, and it is unnecessary to use a T6 treatment that increases cost.
  • molten metal of an Al—Si—Cu—Mg-based aluminum alloy into a shot sleeve of a die casting machine, and fill the mold cavity of a center-gate die with the molten metal at a gate speed of 1 m/sec or less so as to produce a laminar flow.
  • the type of the die casting machine is not particularly limited as long as the center gate can be provided to the die.
  • Zn, Ni, Sn, Cr, and the like are considered to be unavoidable impurities. These elements may be included in the aluminum alloy each in a ratio of 0.03 mass % or less.
  • the aluminum alloy having the chemical composition according to the invention exhibits fluidity due to Si, exhibits improved strength due to Mg and Cu, has a lower Fe content as compared with a known aluminum alloy, and exhibits improved elongation through modification with Sr and the like. Therefore, the aluminum alloy exhibits high strength without the need for a T6 treatment.
  • FIGS. 1A and 1B illustrate the chemical components of aluminum alloys subjected to evaluation, and the evaluation results.
  • FIGS. 2A and 2B illustrate a photograph of the structure of the aluminum alloy obtained in Example 1.
  • FIG. 3A illustrates a photograph of the structure of the aluminum alloy obtained in Comparative Example 1
  • FIG. 3B illustrates a photograph of the structure of the aluminum alloy obtained in Comparative Example 6
  • FIG. 3C illustrates a photograph of the structure of the aluminum alloy obtained in Comparative Example 10.
  • FIGS. 4A to 4D illustrate an example of the shape of a cast product.
  • FIG. 5 schematically illustrates the principle of a die casting process.
  • FIG. 6 illustrates an example of a die structure in which an intermediate die is provided between a stationary die and a movable die.
  • Molten metal of each aluminum alloy including the chemical components listed in FIG. 1A (having the composition listed in FIG. 1A ) was prepared, and subjected to a die casting process to produce a product. It may be possible to add one element among Sb, Ca, and Na in ratio of 0.01 mass % or less instead of Sr in FIG. 1A , since Sb, Ca, or Na has the same effect as Sr.
  • a JIS No. 14 proportional test piece was cut from the product, and the mechanical properties were evaluated using the test piece.
  • the die casting process was performed at a gate speed as low as 1 m/sec or less so as to produce a laminar flow.
  • a heat treatment (T5) was then performed at 180° C. for 180 minutes.
  • FIG. 6 illustrates an example of the die structure.
  • the target values are specified for the mechanical properties (tensile strength, yield strength (0.2%), and elongation).
  • Comparative Example 2 good strength was obtained by a T6 treatment, but the elongation was lower than the target value, and an increase in cost occurs due to the T6 treatment.
  • FIGS. 2A and 2B illustrate a photograph of the metal structure obtained in Example 1
  • FIG. 3A illustrates a photograph of the metal structure obtained in Comparative Example 1
  • FIG. 3B illustrates a photograph of the metal structure obtained in Comparative Example 6
  • FIG. 3C illustrates a photograph of the metal structure obtained in Comparative Example 10.
  • the die structure is described below.
  • a cavity 13 is formed by a stationary die 11 and a movable die 12 .
  • molten metal is poured into a sleeve 14 , and injected into the cavity 13 .
  • Die casting machines are classified into a horizontal die casting machine and a vertical die casting machine.
  • a horizontal die casting machine is mainly used at present from the viewpoint of productivity and the like.
  • Horizontal die casting machines are classified into an under-gate die casting machine (in which the gate is provided on the lower side) (see FIG. 5 ) and a center-gate die casting machine (in which the gate is provided at the center).
  • FIGS. 4A to 4D cross-sectional views
  • a center-gate die it is preferable to use a center-gate die, and fill the cavity with the molten metal at a gate speed (i.e., the speed at which the molten metal passes through the runner gate of the die) of 1 m/sec or less so as to produce a laminar flow.
  • a gate speed i.e., the speed at which the molten metal passes through the runner gate of the die
  • a center-gate die casting machine in which the gate is provided at the center may also be used (not illustrated in the drawings).
  • a die structure is formed so that an intermediate die 15 is provided between the stationary die 11 and the movable die 12 (see FIG. 6 )
  • the aluminum alloy according to the invention exhibits high strength without the need for a T6 treatment and can be applied to various automotive parts and various mechanical parts.
  • the aluminum alloy according to the invention exhibits excellent die castability, and achieves high productivity.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
US15/222,176 2014-03-31 2016-07-28 Aluminum alloy and die casting method Abandoned US20160355908A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US16/841,794 US11359264B2 (en) 2014-03-31 2020-04-07 Aluminum alloy and die casting method

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JP2014071281 2014-03-31
JP2014-071281 2014-03-31
PCT/JP2014/084505 WO2015151369A1 (fr) 2014-03-31 2014-12-26 Alliage d'aluminium et procédé de coulée sous pression

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Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108655365A (zh) * 2017-03-28 2018-10-16 布伦斯威克公司 用于不含涂层的低压永久模的方法和合金
US20190136349A1 (en) * 2016-03-31 2019-05-09 Rio Tinto Alcan International Limited Aluminum Alloys Having Improved Tensile Properties
CN110669965A (zh) * 2019-11-29 2020-01-10 礼德新能源江苏有限公司 一种太阳能铝合金型材的制备工艺
CN110709526A (zh) * 2017-06-23 2020-01-17 株式会社大纪铝工业所 铝合金及铝合金铸造品
CN111108224A (zh) * 2017-09-20 2020-05-05 爱信轻金属株式会社 压铸铸造用铝合金及使用其的功能性部件
CN113111540A (zh) * 2021-05-06 2021-07-13 浙江大学 面向铝压铸的熔化、配送和保温参数集成的节能优化方法
US11584977B2 (en) * 2015-08-13 2023-02-21 Alcoa Usa Corp. 3XX aluminum casting alloys, and methods for making the same
EP4365323A1 (fr) * 2022-10-31 2024-05-08 Xiaomi EV Technology Co., Ltd. Alliage d'aluminium coulé sous pression sans traitement thermique et son procédé de préparation et son application

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JP2016102246A (ja) * 2014-11-28 2016-06-02 アイシン軽金属株式会社 延性に優れたダイカスト鋳造用アルミニウム合金及びそれを用いた鋳造製品
CN108103330A (zh) * 2017-12-18 2018-06-01 广州致远新材料科技有限公司 一种压铸铝合金材料的制备方法
WO2023228390A1 (fr) * 2022-05-26 2023-11-30 株式会社ダイレクト２１ Procédé et appareil de fabrication par coulée sous pression

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Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11584977B2 (en) * 2015-08-13 2023-02-21 Alcoa Usa Corp. 3XX aluminum casting alloys, and methods for making the same
US20230068164A1 (en) * 2015-08-13 2023-03-02 Alcoa Usa Corp. 3xx aluminum casting alloys, and methods for making the same
US20190136349A1 (en) * 2016-03-31 2019-05-09 Rio Tinto Alcan International Limited Aluminum Alloys Having Improved Tensile Properties
US11198925B2 (en) * 2016-03-31 2021-12-14 Rio Tinto Alcan International Limited Aluminum alloys having improved tensile properties
CN108655365A (zh) * 2017-03-28 2018-10-16 布伦斯威克公司 用于不含涂层的低压永久模的方法和合金
CN110709526A (zh) * 2017-06-23 2020-01-17 株式会社大纪铝工业所 铝合金及铝合金铸造品
CN111108224A (zh) * 2017-09-20 2020-05-05 爱信轻金属株式会社 压铸铸造用铝合金及使用其的功能性部件
US11286542B2 (en) 2017-09-20 2022-03-29 Aisin Keikinzoku Co., Ltd. Aluminum alloy for die casting and functional component using the same
CN110669965A (zh) * 2019-11-29 2020-01-10 礼德新能源江苏有限公司 一种太阳能铝合金型材的制备工艺
CN113111540A (zh) * 2021-05-06 2021-07-13 浙江大学 面向铝压铸的熔化、配送和保温参数集成的节能优化方法
EP4365323A1 (fr) * 2022-10-31 2024-05-08 Xiaomi EV Technology Co., Ltd. Alliage d'aluminium coulé sous pression sans traitement thermique et son procédé de préparation et son application

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JPWO2015151369A1 (ja) 2017-04-13
US11359264B2 (en) 2022-06-14
JP6495246B2 (ja) 2019-04-03
US20200232069A1 (en) 2020-07-23
WO2015151369A1 (fr) 2015-10-08

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