US20170121793A1 - Aluminum alloy for die casting, and aluminum alloy die cast produced using same - Google Patents

Aluminum alloy for die casting, and aluminum alloy die cast produced using same Download PDF

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Publication number
US20170121793A1
US20170121793A1 US15/104,439 US201515104439A US2017121793A1 US 20170121793 A1 US20170121793 A1 US 20170121793A1 US 201515104439 A US201515104439 A US 201515104439A US 2017121793 A1 US2017121793 A1 US 2017121793A1
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Prior art keywords
aluminum alloy
alloy
die
casting
content ratio
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Abandoned
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US15/104,439
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Atsuo KABURAGI
Satoshi MIYAJIRI
Naoto Oshiro
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Daiki Aluminium Industry Co Ltd
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Daiki Aluminium Industry Co Ltd
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Assigned to DAIKI ALUMINIUM INDUSTRY CO., LTD. reassignment DAIKI ALUMINIUM INDUSTRY CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KABURAGI, Atsuo, MIYAJIRI, Satoshi, OSHIRO, NAOTO
Publication of US20170121793A1 publication Critical patent/US20170121793A1/en
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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

Definitions

  • the present invention relates to an aluminum alloy for die casting, having excellent mechanical properties and corrosion resistance, and an aluminum alloy die cast produced using the alloy.
  • aluminum alloys are lightweight and superior in moldability and mass producibility, aluminum alloys are widely used as a material for components in various fields such as automobiles, industrial machines, aircrafts, and electrical home appliances.
  • Patent Literature 1 An aluminum alloy for die cast containing silicon by 9.5 to 11.5 wt %, magnesium by 0.1 to 0.5 wt %, manganese by 0.5 to 0.8 wt %, iron by 0.15 wt % at maximum, copper by 0.03 wt % at maximum, zinc by 0.10 wt % at maximum, titanium by 0.15 wt % at maximum, and, as the remaining portion, aluminum and 30 to 300 ppm of strontium as a permanent atomization agent.
  • the main objective of the invention is to provide an aluminum alloy for die casting, suitable for important safety-related components in automobiles without significantly worsening corrosion resistance even though containing Cu at a ratio capable of providing an effect of improving mechanical characteristics, and an aluminum alloy die cast obtained through die-casting the alloy.
  • a first aspect of the present invention is an aluminum alloy for die casting “containing, in wt %, 0.03% ⁇ Cu ⁇ 0.7%, 6.0% ⁇ Si ⁇ 11.0%, 0.15% ⁇ Mg ⁇ 0.50%, 0.05% ⁇ Fe ⁇ 0.6%, 0.05% ⁇ Ti ⁇ 0.25%, Mn ⁇ 0.8%, 0.10% ⁇ Cr ⁇ 0.40%, and, for the remaining portion, Al and unavoidable impurities”.
  • Cu can be contained within a range higher than 0.03 wt % but not higher than 0.7 wt %, usage of a recycled material becomes possible, and mechanical characteristics such as tensile strength and 0.2%-proof strength can be improved in particular.
  • Cr is contained by not lower than 0.10 wt % but not higher than 0.40 wt %, deterioration of corrosion resistance can be prevented.
  • an ingot of an aluminum alloy for die casting having not only excellent castability and mechanical characteristics but also excellent corrosion resistance can be produced safety and easily.
  • At least one selected from Na, Sr, and Ca is added by 30 to 200 ppm, and Sb is added by 0.05 to 0.20 wt %. By doing so, it is possible to reduce the size of particles of eutectic Si and further improve strength and toughness of the aluminum alloy.
  • adding B by 1 to 50 ppm is also preferable. By doing so, crystal grains of the aluminum alloy can be miniaturized even when the amount of Si is particularly small and when a casting method having a low cooling rate is used, and, as a result, elongation of the aluminum alloy can be improved.
  • a second aspect of the present invention is an aluminum alloy die cast obtained through die-casting the aluminum alloy for die casting according to the first aspect.
  • the aluminum alloy die cast obtained through die-casting the aluminum alloy for die casting of the present invention can be mass produced with fine castability and is superior in not only mechanical properties such as tensile strength and hardness but also in corrosion resistance; the aluminum alloy die cast is most suitable in use applications such as, for example, important safety-related components for automobiles.
  • an aluminum alloy for die casting suitable for such as important safety-related components in automobiles without significantly worsening corrosion resistance even though containing Cu at a ratio capable of providing an effect of improving mechanical characteristics, and an aluminum alloy die cast obtained through die-casting the alloy can be provided.
  • FIG. 1 includes graphs each showing the relationship between content ratio of Cu and a mechanical characteristic in an aluminum alloy for die casting.
  • FIG. 2 includes graphs showing the relationship between corrosion resistance and the content ratios of Cu and Cr in an aluminum alloy for die casting.
  • FIG. 3 includes graphs each showing the relationship between content ratio of Ti and a mechanical characteristic in an aluminum alloy for die casting.
  • An aluminum alloy for die casting of the present invention (hereinafter, also simply referred to as “aluminium alloy”) contains, in wt %, 0.03% ⁇ Cu (copper) ⁇ 0.7%, 6.0% ⁇ Si (silicon) ⁇ 11.0%, 0.15% ⁇ Mg (magnesium) ⁇ 0.50%, 0.05% ⁇ Fe (iron) ⁇ 0.6%, 0.05% ⁇ Ti (titanium) ⁇ 0.25%, Mn (manganese) ⁇ 0.8%, 0.1% ⁇ Cr (chromium) ⁇ 0.4%, and, for the remaining portion, Al (aluminum) and unavoidable impurities as approximately.
  • aluminum alloy contains, in wt %, 0.03% ⁇ Cu (copper) ⁇ 0.7%, 6.0% ⁇ Si (silicon) ⁇ 11.0%, 0.15% ⁇ Mg (magnesium) ⁇ 0.50%, 0.05% ⁇ Fe (iron) ⁇ 0.6%, 0.05% ⁇ Ti (titanium) ⁇ 0.25%, Mn (manganese
  • Cu copper is an important element for improving abrasion resistance, mechanical strength, and hardness of an aluminum alloy.
  • the content ratio of Cu with respect to the whole weight of the aluminum alloy is preferably within a range of higher than 0.03 wt % but not higher than 0.7 wt % as described above.
  • the content ratio of Cu is not higher than 0.03 wt %, the effect of improving the mechanical characteristics described above cannot be obtained, whereas, when the content ratio of Cu is higher than 0.7 wt %, problems occur such as a significant reduction in corrosion resistance, reduction in elongation, increase in specific gravity, and increase in raw-material cost.
  • the content ratio of Cu is preferably set within a range of higher than 0.03 wt % but not higher than 0.2 wt %.
  • Si silicon is an important element for improving castability and ensuring fluidity when the aluminum alloy is molten.
  • the content ratio of Si with respect to the whole weight of the aluminum alloy is preferably within a range of not lower than 6.0 wt % but not higher than 11.0 wt % as described above.
  • the content ratio of Si is lower than 6.0 wt %, ensuring fluidity of a molten metal becomes difficult, and, when cases regarding molding with an ordinary die casting that is used frequently in general are considered, application to large-sized components is hampered.
  • the content ratio of Si is higher than 11.0 wt %, elongation of the alloy is reduced.
  • Mg manganesium
  • Mg 2 Si mainly exists as Mg 2 Si or in a solid-solution state in an Al base metal, and is a component that provides proof strength and tensile strength to the aluminum alloy but, when being contained by an excessive amount, has an adverse effect on castability and corrosion resistance.
  • the content ratio of Mg with respect to the whole weight of the aluminum alloy is preferably within a range of not lower than 0.15 wt % but not higher than 0.5 wt % as described above.
  • the content ratio of Mg is lower than 0.15 wt %, the advantageous effect described above cannot be sufficiently obtained, whereas when the content ratio of Mg is higher than 0.5 wt %, elongation and corrosion resistance of the alloy are reduced.
  • Fe iron
  • Fe is known to have a soldering prevention effect during die-casting.
  • Fe causes crystallization of a needle shape crystal in the form of Al—Si—Fe, reduces the toughness of the aluminum alloy, and, when being added in a large quantity, causes melting to be difficult at a suitable temperature.
  • the content ratio of Fe with respect to the whole weight of the aluminum alloy is preferably within a range from 0.05 to 0.6 wt % as described above.
  • the content ratio of Fe is lower than 0.05 wt %, the soldering prevention effect during die-casting becomes insufficient, whereas when the content ratio of Fe is higher than 0.6 wt %, although the soldering prevention effect becomes sufficient, toughness of the alloy reduces and the melting temperature rises to cause deterioration of castability.
  • Ti titanium
  • Ti has an effect of miniaturizing crystal grains, and is generally said to be an element capable of reducing casting cracks and particularly improving elongation among the mechanical characteristics.
  • the content ratio of Ti with respect to the whole weight of the aluminum alloy is preferably within a range of not lower than 0.05 wt % but not higher than 0.25 wt % as described above.
  • the content ratio of Ti is lower than 0.05 wt %, miniaturizing crystal grains in the aluminum alloy becomes difficult, whereas when the content ratio of Ti is higher than 0.25 wt %, melting of the aluminum alloy becomes difficult, and the aluminum alloy may partially remain not melted.
  • Mn manganese
  • Fe manganese
  • Mn also causes melting to be difficult at a suitable temperature when being contained in a large quantity.
  • the content ratio of Mn with respect to the whole weight of the aluminum alloy is limited to not higher than 0.8 wt %.
  • Mn is preferably contained by not lower than 0.2 wt % in order to significantly exert the soldering prevention effect.
  • Cr chromium
  • the content ratio of Cr with respect to the whole weight of the aluminum alloy is preferably within a range of not lower than 0.1 wt % but not higher than 0.4 wt % as described above.
  • the content ratio of Cr is lower than 0.1 wt %, the advantageous effect described above cannot be sufficiently obtained, whereas when the content ratio of Cr is higher than 0.4 wt %, no further addition effect can be obtained even when the added amount is increased.
  • At least one element selected from the group consisting of Na (sodium), Sr (strontium), Ca (calcium), and Sb (antimony) may be added as a modification material.
  • a modification material it is possible to reduce the size of eutectic Si particles, and further improve strength and toughness of the aluminum alloy.
  • the added ratio of the modification material with respect to the whole weight of the aluminum alloy is preferably within a range of 30 to 200 ppm when the modification material is Na, Sr, and Ca, and within a range of 0.05 to 0.20 wt % when the modification material is Sb.
  • the added ratio of the modification material is lower than 30 ppm (0.05 wt % in the case with Sb)
  • miniaturizing eutectic Si particles in the aluminum alloy becomes difficult
  • the added ratio of the modification material is higher than 200 ppm (0.20 wt % in the case with Sb)
  • eutectic Si particles in the aluminum alloy are sufficiently miniaturized, and no further addition effect can be obtained even when the added amount is increased.
  • B boron
  • the crystal grains of the aluminum alloy are miniaturized, and elongation of the alloy can be improved. It should be noted that such an advantageous effect becomes significant when the amount of Si is small and when a casting method having a low cooling rate is used.
  • the added ratio of B with respect to the whole weight of the aluminum alloy is preferably within a range from 1 to 50 ppm.
  • the added ratio of B is lower than 1 ppm, miniaturizing crystal grains in the aluminum alloy becomes difficult, whereas when the added ratio of B is higher than 50 ppm, crystal grains in the aluminum alloy are sufficiently miniaturized, and no further addition effect can be obtained even when the added amount is increased.
  • the aluminum alloy for die casting of the present invention When the aluminum alloy for die casting of the present invention is to be produced, first, a raw material designed to contain, at the predetermined ratio described above, each of the elemental components of Al, Cu, Si, Mg, Fe, Ti, Mn, and Cr is prepared (if necessary, the modification material, etc., described above may be added). Next, the raw material is placed in a melting furnace such as a sealed melting furnace or a melting furnace with a fore hearth to melt the elemental components. With respect to the melted raw material, i.e., molten metal of the aluminum alloy, refinement treatments such as an inclusion removal treatment and a dehydrogenation treatment are performed if necessary. Then, the refined molten metal is casted in a predetermined mold and solidified in order to form the molten metal of the aluminum alloy into an alloy base metal ingot and the like.
  • a melting furnace such as a sealed melting furnace or a melting furnace with a fore hearth to melt the elemental components.
  • a solution treatment and an aging treatment, etc. are performed if necessary.
  • a solution treatment and an aging treatment, etc. are performed if necessary.
  • alloy components of each type of alloys were measured by using a solid emission spectrophotometer (Thermo Scientific ARL 4460 manufactured by Thermo Fisher Scientific Inc.).
  • corrosion resistance was evaluated with a (neutral) salt spray test compliant with Japanese Industrial Standards JIS Z2371.
  • the test was performed by using CASS Test Instrument CASSER-ISO-3 manufactured by Suga Test Instruments Co., Ltd.
  • Table 1 shows the component compositions and each of the mechanical properties (tensile strength, elongation, and 0.2%-proof strength) of aluminum alloys for die cast produced by changing the content ratio of Cu as well as making adjustments such that alloy components other than Cu were set at a certain ratio within the range of the present invention.
  • alloys 3 to 11 in Table 1 are alloy compositions within a range of the present invention, i.e., alloys of Examples.
  • Table 2 is a table showing the relationship between corrosion resistance and each aluminum alloy composition depending on the casting method.
  • alloys 15 to 20, 26, and 27 in Table 2 are alloy compositions within a range of the present invention, i.e., alloys of Examples.
  • Table 3 shows the component compositions and each of the mechanical properties (tensile strength, elongation, and 0.2%-proof strength) of aluminum alloys for die cast produced by changing the content ratio of Ti as well as making adjustments such that alloy components other than Ti were set at a certain ratio within the range of the present invention.
  • alloys 30 to 32 in Table 3 are alloy compositions within a range of the present invention, i.e., alloys of Examples.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Extrusion Of Metal (AREA)
  • Forging (AREA)
US15/104,439 2015-04-15 2015-04-15 Aluminum alloy for die casting, and aluminum alloy die cast produced using same Abandoned US20170121793A1 (en)

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PCT/JP2015/002086 WO2016166779A1 (ja) 2015-04-15 2015-04-15 ダイカスト用アルミニウム合金およびこれを用いたアルミニウム合金ダイカスト

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US (1) US20170121793A1 (ko)
EP (1) EP3121302B1 (ko)
JP (1) JP5898819B1 (ko)
KR (1) KR20170138916A (ko)
CN (1) CN106255770A (ko)
MX (1) MX2016010352A (ko)
MY (1) MY183152A (ko)
PH (1) PH12017500237B1 (ko)
PL (1) PL3121302T3 (ko)
WO (1) WO2016166779A1 (ko)

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WO2021247373A1 (en) * 2020-06-01 2021-12-09 Alcoa Usa Corp. Al-si-fe casting alloys

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ES2753164T3 (es) * 2016-12-28 2020-04-07 Befesa Aluminio S L Aleación de aluminio para fundición
CN110402295A (zh) * 2017-03-09 2019-11-01 通用汽车环球科技运作有限责任公司 铝合金
WO2018189869A1 (ja) * 2017-04-13 2018-10-18 株式会社大紀アルミニウム工業所 ダイカスト用アルミニウム合金およびこれを用いたアルミニウム合金ダイカスト
WO2018235272A1 (ja) * 2017-06-23 2018-12-27 株式会社大紀アルミニウム工業所 アルミニウム合金およびアルミニウム合金鋳物品
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
CN107604219A (zh) * 2017-09-26 2018-01-19 辽宁忠旺集团有限公司 一种高强铝合金车体部件的配方及其生产工艺
CN107881379A (zh) * 2017-11-01 2018-04-06 道然精密智造无锡有限公司 一种高强度无链条自行车壳体制造方法
CN107858565A (zh) * 2017-12-13 2018-03-30 浙江诺达信汽车配件有限公司 一种高强高韧性的压铸用铝合金材料
JP7147647B2 (ja) * 2019-03-20 2022-10-05 日本軽金属株式会社 アルミニウム合金及びアルミニウム合金ダイカスト材
CN110629079A (zh) * 2019-10-25 2019-12-31 江苏铭利达科技有限公司 用于新能源汽车的铝合金材料
CN112795820A (zh) * 2019-10-28 2021-05-14 晟通科技集团有限公司 建筑用铝合金模板压铸材料
CN113549791A (zh) * 2020-08-24 2021-10-26 山东弗泽瑞金属科技有限公司 压铸用高导热铝合金制造装置
JP2022072574A (ja) * 2020-10-30 2022-05-17 昭和電工株式会社 自動車のホイール用アルミニウム合金及び自動車のホイール
WO2023167312A1 (ja) * 2022-03-03 2023-09-07 日本軽金属株式会社 鋳物用Ａｌ－Ｓｉ合金及びＡｌ－Ｓｉ合金鋳物並びにＡｌ－Ｓｉ合金鋳物接合体
CN116657005B (zh) * 2023-06-01 2023-12-12 保定市立中车轮制造有限公司 一种再生铝合金材料及其制备方法
JP7401080B1 (ja) 2023-08-31 2023-12-19 新陽株式会社 鋳造用Ａｌ合金の製造方法

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CN106255770A (zh) 2016-12-21
PH12017500237A1 (en) 2017-07-03
EP3121302A1 (en) 2017-01-25
WO2016166779A1 (ja) 2016-10-20
EP3121302B1 (en) 2018-09-19
MX2016010352A (es) 2018-02-09
MY183152A (en) 2021-02-16
KR20170138916A (ko) 2017-12-18
JPWO2016166779A1 (ja) 2017-04-27
EP3121302A4 (en) 2017-05-31
JP5898819B1 (ja) 2016-04-06
PL3121302T3 (pl) 2019-03-29
PH12017500237B1 (en) 2017-07-03

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