US20180340243A1 - Aluminum alloy material - Google Patents

Aluminum alloy material Download PDF

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US20180340243A1
US20180340243A1 US15/985,880 US201815985880A US2018340243A1 US 20180340243 A1 US20180340243 A1 US 20180340243A1 US 201815985880 A US201815985880 A US 201815985880A US 2018340243 A1 US2018340243 A1 US 2018340243A1
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mass
aluminum alloy
alloy material
producing
recited
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Takumi Maruyama
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Honda Motor Co Ltd
Resonac Holdings Corp
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Showa Denko KK
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Assigned to SHOWA DENKO K.K. reassignment SHOWA DENKO K.K. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MARUYAMA, TAKUMI
Publication of US20180340243A1 publication Critical patent/US20180340243A1/en
Assigned to SHOWA DENKO K.K., HONDA GIKEN KOGYO KABUSHIKI KAISHA reassignment SHOWA DENKO K.K. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MOTANI, RYUTA, MARUYAMA, TAKUMI, KAWAKAMI, MASASHI, KOJIMA, TAKAHIRO
Assigned to SHOWA DENKO K.K., HONDA MOTOR CO., LTD. reassignment SHOWA DENKO K.K. CORRECTIVE ASSIGNMENT TO CORRECT THE THE SECOND ASSIGNEE NAME PREVIOUSLY RECORDED AT REEL: 048848 FRAME: 0436. ASSIGNOR(S) HEREBY CONFIRMS THE ASSIGNMENT. Assignors: MOTANI, RYUTA, MARUYAMA, TAKUMI, KAWAKAMI, MASASHI, KOJIMA, TAKAHIRO
Priority to US17/111,881 priority Critical patent/US20210087654A1/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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/043—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with silicon as the next major constituent
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C7/00—Connecting-rods or like links pivoted at both ends; Construction of connecting-rod heads
    • F16C7/02—Constructions of connecting-rods with constant length
    • F16C7/023—Constructions of connecting-rods with constant length for piston engines, pumps or the like
    • 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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C2204/00—Metallic materials; Alloys
    • F16C2204/20—Alloys based on aluminium

Definitions

  • the present disclosure relates to an aluminum alloy material suitably used as, for example, a connecting rod (hereinafter also referred to as “conrod”) which is a rod for connecting a piston and a crank representing automobile engine parts, and also relates to a related technique thereof.
  • a connecting rod hereinafter also referred to as “conrod”
  • an aluminum alloy material with high specific strength which is the ratio of strength to weight.
  • a forged material made of an aluminum alloy such as, e.g., an Al—Si based alloy, having high strength at high temperature has been drawing attention.
  • the disclosed embodiments of this disclosure have been developed in view of the above-mentioned and/or other problems in the related art.
  • the disclosed embodiments of this disclosure can significantly improve upon existing methods and/or apparatuses.
  • Some embodiments of this disclosure have been made in view of the aforementioned problems, and aim to provide an aluminum alloy material having desired properties such as high strength and low thermal expansion coefficient even under severe usage environments such as high temperature environments without using an atomized powder extruded material, and also aim to provide its related technology.
  • some embodiments of the present invention have the following structure.
  • An aluminum alloy material having a composition consisting of: Si: 13 mass % to 15 mass %, Cu: 2.0 mass % to 6.0 mass %, Mg: 0.2 mass % to 1.5 mass %, Fe: 0.4 mass % to 0.8 mass %, Ni: 0.2 mass % to 0.8 mass %, P: 0.005 mass % to 0.015 mass %, and the balance being Al and inevitable impurities.
  • composition further includes at least one component selected from the group consisting of Mn: 0.01 mass % to 0.50 mass %, Ti: 0.01 mass % to 0.30 mass %, and Zr: 0.01 mass % to 0.30 mass %.
  • a connecting rod for vehicles the connecting rod being constituted by the aluminum alloy material as recited in any one of the aforementioned Items [ 1 ] to [ 3 ].
  • a method for producing an aluminum material comprising:
  • the aluminum alloy material as recited in the aforementioned Items [1] to [3], since it has a specific alloy composition, it has sufficient strength and low thermal expansion coefficient even under high temperature environment.
  • FIG. 1 is a flowchart showing an example of a production process of a connecting rod for automobiles according to an embodiment of the present invention.
  • FIG. 2 is a perspective view showing a cast material based on a method for producing an aluminum alloy material according to the embodiment.
  • FIG. 3 is a perspective view showing a forged material based on a method for producing an aluminum alloy material according to the embodiment.
  • the conrod for automobiles which is an embodiment of the present invention is constituted by a predetermined aluminum alloy material. It should be noted that in this embodiment, “%” as an additive amount (content) is used in the sense of “mass %”.
  • the aluminum alloy material as a conrod in this embodiment has a composition consisting of Si: 13% to 15%, Cu: 4.2% to 4.8%, Mg: 0.4% to 0.6%, Fe: 0.4% to 0.6%, Ni: 0.2% to 0.8%, P: 0.005% to 0.015%, and the balance being Al and inevitable impurities.
  • the additive amount (content) of each composition component (additive element) of the aluminum alloy material and its effects are as follows.
  • the additive amount of Si is 13% to 15%.
  • Si has an effect of improving high temperature strength and an effect of lowering thermal expansion. This effect is hard to appear when the additive amount of Si is less than 13%, and particularly noticeably appears at 13% or more.
  • the additive amount of Si exceeds 15%, the forging processability deteriorates, and further the crystallization of the primary crystal Si increases and elongation at room temperature decreases, and the cutting blade for use in a cutting process is likely to be chipped due to the existence of the primary crystal Si which is harder than aluminum. For this reason, the additive amount of Si needs to be set to 13% to 15%, preferably 13.5% to 14.5%.
  • the additive amount of Cu is 4.2% to 4.8%.
  • Cu has an effect of improving the high temperature strength, particularly the strength at 150° C. which is a practical temperature range of a conrod. This effect is due to the precipitation of Cu, and the aforementioned effect can be obtained by performing artificial aging.
  • Ni By adding simultaneously with Ni, it is crystallized as an Al—Ni—Cu based compound and dispersion-strengthened, and therefore there is an effect of further improving the high temperature strength. Both effects are difficult to appear when the additive amount of Cu is less than 4.2%, and remarkably appear at 4.2% or more. When it exceeds 4.8%, the aforementioned effect becomes difficult to remarkably appear, and the specific strength may not be improved due to an increase in specific gravity. Therefore, the additive amount of Cu needs to be set to 4.2% to 4.8%, more preferably 4.4% to 4.6%.
  • the additive amount of Mg is 0.4% to 0.6%.
  • Mg has an effect of improving high temperature strength.
  • Mg is solid-soluted during continuous casting and forms a compound with Si and Cu during artificial aging to be precipitated, and therefore there is an effect of improving the strength at 150° C. which is a practical temperature range of a conrod.
  • This effect is hard to appear when the additive amount of Mg is less than 0.4%, and remarkably appears at 0.4% or more. When it exceeds 0.6%, the aforementioned effect will not appear noticeably. For this reason, the additive amount of Mg needs to be set to 0.4% to 0.6%, more preferably 0.45% to 0.55%.
  • the additive amount of Fe is 0.4% to 0.6%.
  • an Al—Fe—Si compound is crystallized, which contributes to dispersion-strengthening and causes an effect of improving the strength in a practical temperature range of a conrod.
  • This effect is hard to appear when the additive amount of Fe is less than 0.4%, and remarkably appears at 0.4% or more.
  • the additive amount of Fe needs to be set to 0.4% to 0.6%, more preferably 0.45% to 0.55%.
  • the additive amount of Ni is 0.2% to 0.8%.
  • Ni has an effect of improving high temperature strength and an effect of lowering thermal conductivity.
  • an Al—Cu—Ni compound is crystallized, contributing to dispersion-strengthening, which causes an effect of improving the strength in a target temperature range.
  • This effect is hard to appear when the additive amount of Ni is less than 0.2%, and remarkably appears at 0.2% or more.
  • the additive amount of Ni is 0.2% to 0.8%, more preferably 0.3% to 0.7%.
  • the additive amount of P is 0.005% to 0.015%.
  • P forms an AlP compound to become a nucleus of a primary crystal Si and has an effect of contributing to miniaturization and uniform dispersion of the primary crystal Si. This effect is hard to appear when the additive amount of P is less than 0.005%, and appears remarkably at 0.005% or more.
  • the additive amount of P needs to be set to 0.005% to 0.015%, more preferably 0.007% to 0.013%.
  • Mn is preferably added in the range of 0.01 to 0.5%. That is, when Mn is added simultaneously with Si, an Al—Mn—Si based compound is crystallized to contribute to dispersion-strengthening, and some of them solid-solutes in the Al mother phase at the time of a solution treatment to precipitate as a fine precipitate during the artificial aging treatment, which contributes to fatigue strength improvement in a practical temperature range of a conrod. This effect is hard to appear when the additive amount of Mn is less than 0.01%, and remarkably appears at 0.01% or more. When it exceeds 0.5%, it is crystallized earlier than the Al mother phase into a coarse crystallized substance, possibly causing ductility deterioration. Therefore, in the case of adding Mn, it is preferable to add by 0.01% to 0.5%, more preferably 0.1 to 0.3%.
  • Ti is preferably added in the range of 0.01% to 0.3%. That is, by adding fine Ti, it solid-solutes in the Al mother phase during casting, and is concentrated at the time of the artificial aging treatment, leading to matrix reinforcement, which contributes to fatigue strength improvement in a practical temperature range of a conrod. This effect is hard to appear when the additive amount of Ti is less than 0.01%, and remarkably appears at 0.01% or more. On the other hand, when it exceeds 0.3%, the compound containing Ti may be coarsely crystallized, which may cause ductility decrease. For this reason, in the case of adding Ti, it is preferable to add by 0.01% to 0.3%, more preferably 0.05% to 0.10%.
  • Zr is preferably added in the range of 0.01% to 0.3%. That is, by slightly adding Zr, it solid-solutes in the Al mother phase during casting and thickens during artificial aging treatment, leading to matrix strengthening. By simultaneously adding Ti, nanoscale precipitates with an L12 structure is generated as an Al—(Ti, Zr) based alloy during artificial aging treatment, which contributes to fatigue strength improvement in a practical temperature range of a conrod. This effect is hard to appear when the additive amount of Zr is less than 0.01%, and remarkably appears at 0.01% or more. On the other hand, when it exceeds 0.3%, the compound containing Zr may be coarsely crystallized, which may cause ductility decrease. For this reason, the additive amount of Zr needs to be set to 0.01% to 0.3%, more preferably 0.05% to 0.10%.
  • an aluminum alloy molten metal having the aforementioned alloy composition is prepared, and a continuously cast material (billet) is produced by continuous casting using the molten metal. Furthermore, the continuously cast material is subjected to a heat treatment and then subjected to plastic working, such as, e.g., a forging process. Thus, a low thermal expansion aluminum alloy material for a conrod according to this embodiment is obtained.
  • an aluminum alloy molten metal in which ingredients have been adjusted as described above is prepared by melting.
  • Continuous casting is carried out using this molten metal as shown in FIG. 1 to produce a continuously cast material (Step S 1 ).
  • this continuously cast material is configured as a billet for a forging material, and is formed into a round bar shape with a diameter of, for example, 30 mm to 40 mm.
  • an extrusion billet may be produced by continuous casting and extruded to form an extruded material to be used as a forging material.
  • the production cost increases since the extrusion processing is carried out. Therefore, it is advantageous to produce a billet for a forging material by continuous casting (casting step).
  • Step S 2 a homogenization treatment is carried out as shown in Step S 2 .
  • the heating temperature be set to 480° C. to 505° C. and the processing time be set to 0.5 hours to 6 hours.
  • the continuously cast material is cut into a predetermined length to obtain a forging material as shown in Step S 3 .
  • the forging material obtained in this manner is subjected to a forging process as shown in Step S 4 to form a forged material.
  • a forging process as shown in Step S 4 to form a forged material.
  • the die temperature it is preferable to set the die temperature at 100° C. to 250° C. and the material temperature at 370° C. to 450° C.
  • this forged material is subjected to a solution treatment as shown in Step S 5 .
  • the heating temperature be set to 485° C. to 510° C. and the processing time be set to 1.0 hour to 5.0 hours.
  • the forged material subjected to the solution treatment is subjected to a water quenching treatment to be quickly cooled as shown in Step S 6 .
  • the water temperature is preferably set to 10° C. to 80° C.
  • the forged material to which the water quenching treatment was performed is subjected to an artificial aging treatment as shown in Step S 7 .
  • this artificial aging treatment it is preferable to set the heat treatment temperature to 160° C. to 220° C. and the processing time to 1 hour to 18 hours.
  • the surface of the forged material (forged T6 treated product) to which the artificial aging treatment was performed is cut by machining.
  • perform shot blasting shot peening
  • This shot blasting is a treatment for improving the fatigue strength by peening shots to the surface of the forged material to give a compressive stress to cause plastic deformation of the surface of the forged material.
  • the size of the shot media abrasive grain size
  • the abrasive grain type be SUS304 (JIS material symbol), alumina, etc.
  • the pressure of peening gas be 1 MPa or less.
  • an aluminum alloy material (forged material) for a conrod according to this embodiment is produced.
  • the conrod produced using the aluminum alloy material obtained as described above in the conrod produced using the aluminum alloy material thus obtained, it is excellent in normal temperature strength and high temperature strength, especially high in thermal fatigue strength under high temperature against low thermal expansion property by joining with iron part and repeated loading, which is possible to obtain high performance as a conrod.
  • Table 1 is a table showing composition components of the aluminum alloy materials (samples) of Examples 1 to 7 and Comparative Examples 8 to 20. Except for Example 7, each aluminum alloy molten metal having the composition shown in Table 1 was melted. Using each aluminum alloy molten metal, continuous casting was carried out with a casting diameter of 38 mm to obtain continuously cast materials of Examples other than Example 7 and Comparative Examples having a diameter of 38 mm. The obtained continuous cast materials were each subjected to a homogenization treatment at 470° C. ⁇ 7 hours and air-cooled.
  • Example 7 an aluminum alloy molten metal having the composition shown in Example 7 in Table 1 was melted. Using the aluminum alloy molten metal, continuous casting was carried out with a casting diameter of 210 mm to obtain an extruding billet having a diameter of 210 mm of Example 7. The billet 2 was heated to 350° C. and extruded to obtain an extruded material having a diameter of 38 mm of Example 7. The obtained extruded material was subjected to a homogenization treatment at 470° C. ⁇ 7 hours and air-cooled.
  • the obtained forging material W 1 was subjected to hot forging at a material temperature of 420° C. and a die temperature of 180° C.
  • 50% of upsetting was performed in the direction (LT direction) perpendicular to the axial direction of the continuous cast material) to obtain a forged material (upset material) W 2 for investigating material properties of Examples and Comparative Examples as shown in FIG. 3 .
  • the forged material was heated at 500° C. ⁇ 3 hours to perform a solution treatment, and then subjected to water quenching with water at 25° C. Then, it was subjected to an artificial aging treatment at 170° C. ⁇ 8 hours to obtain a solution treated forged material (forged T6 treated product) Examples and Comparative Examples.
  • the forged T6 treated products of Examples and Comparative Examples were preheated at 150° C. ⁇ 100 hours, then partly cut out by cutting and high temperature tensile test pieces of Examples and Comparative Examples (sample) was obtained.
  • the shape of this test piece the shape of the JIS No. 4 test piece was adopted, and a tensile test was performed on each test piece according to the regulation of JISZ2241, and the tensile strength was measured.
  • the forged T6 treated products of Examples and Comparative Examples were preheated at 150° C. ⁇ 100 hours, then partly cut out by cutting process and prescribed shaped test pieces (samples) of Examples and Comparative Examples were obtained. And a fatigue test was performed on each test piece. Using the Ono type rotating bending test machine, the fatigue test was performed to measure 8 times for each test piece (alloy) to obtain an S-N curve. From the obtained S-N curve, the strength at the number of repetitions of 10 7 times was obtained and was taken as fatigue strength.
  • thermo expansion test a part of the forged T6 treated products of the Examples and Comparative Examples was cut out by a cutting process to obtain test pieces (samples) of predetermined shapes of Examples and Comparative Examples. Then, a thermal expansion measurement was performed on each test piece. The thermal expansion measurement was measured in the range of 30° C. to 150° C. using a Rigaku's linear expansion measurement device (Thermo plus EVO) for each test piece.
  • the results of the room temperature tensile strength, the 150° C. tensile strength, the 150° C. fatigue strength, and the thermal expansion coefficient measured as described above are shown in Table 2. Also in Table 2, the room temperature tensile strength, the 150° C. tensile strength, the 150° C. fatigue strength, and the thermal expansion coefficient were evaluated as “ ⁇ ” (Excellent)”, “ ⁇ ” (Good), “X” (Poor)” in three stages. In this evaluation, in the room temperature tensile strength, it was evaluated as “ ⁇ ” for 431 MPa or more, “ ⁇ ” for 400 MPa to 430 MPa, and “X” for 399 MPa or less; in the 150° C.
  • tensile strength it was evaluated as “ ⁇ ” for 381 MPa or more, “ ⁇ ” for 350 MPa to 380 MPa, and “X” for 349 MPa or less; in the 150° C. fatigue strength, it was evaluated as “ ⁇ ” for 156 MPa or more, “ ⁇ ” for 150 MPa to 155 MPa, and “X” for 149 MPa or less; and in the thermal expansion coefficient, it was evaluated as “ ⁇ ” for 19.4 ⁇ 10 ⁇ 6 /K or less, “ ⁇ ” for more than 19.4 ⁇ 10 ⁇ 6 /K to 19.9 ⁇ 10 ⁇ 6 /K or less, 20 ⁇ 10 ⁇ 6 /K or more for “X”.
  • the room temperature tensile strength, the 150° C. tensile strength, the 150° C. fatigue strength, and the thermal expansion coefficient are excellent, and even under severe usage environments such as high temperature environment, since it has sufficient fatigue strength and low thermal expansion coefficient, it can be particularly suitably used as a vehicle conrod.
  • the aluminum alloy material which deviates from the gist of the present invention like the samples of Comparative Examples 8 to 20, the 150° C. tensile strength, the 150° C. fatigue strength, and the thermal expansion coefficient are inferior to the present invention. Therefore, the aluminum alloy material of the present invention is considered to be suitable for use in under high temperature environments.
  • the aluminum alloy material of the present invention can be suitably used, for example, as a connecting rod which is a connecting rod between a piston and a crank in an automobile internal combustion engine.

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  • Chemical & Material Sciences (AREA)
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  • Mechanical Engineering (AREA)
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  • Metallurgy (AREA)
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  • General Engineering & Computer Science (AREA)
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  • Shafts, Cranks, Connecting Bars, And Related Bearings (AREA)
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