US20230043878A1 - Cast Alloy - Google Patents
Cast Alloy Download PDFInfo
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- US20230043878A1 US20230043878A1 US17/876,661 US202217876661A US2023043878A1 US 20230043878 A1 US20230043878 A1 US 20230043878A1 US 202217876661 A US202217876661 A US 202217876661A US 2023043878 A1 US2023043878 A1 US 2023043878A1
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- 229910045601 alloy Inorganic materials 0.000 title claims abstract description 60
- 239000000956 alloy Substances 0.000 title claims abstract description 60
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 27
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims abstract description 23
- 239000011777 magnesium Substances 0.000 claims abstract description 16
- 239000011701 zinc Substances 0.000 claims abstract description 13
- 239000010949 copper Substances 0.000 claims abstract description 12
- 229910052742 iron Inorganic materials 0.000 claims abstract description 12
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 12
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims abstract description 11
- 229910052796 boron Inorganic materials 0.000 claims abstract description 11
- 229910052749 magnesium Inorganic materials 0.000 claims abstract description 10
- 229910052725 zinc Inorganic materials 0.000 claims abstract description 10
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 9
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims abstract description 9
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims abstract description 9
- 229910052802 copper Inorganic materials 0.000 claims abstract description 9
- 229910052718 tin Inorganic materials 0.000 claims abstract description 9
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims abstract description 8
- 239000011572 manganese Substances 0.000 claims abstract description 8
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims abstract description 7
- 229910052748 manganese Inorganic materials 0.000 claims abstract description 7
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 7
- 239000010703 silicon Substances 0.000 claims abstract description 7
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 claims abstract description 6
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 claims abstract description 4
- 239000011574 phosphorus Substances 0.000 claims abstract description 4
- 229910052698 phosphorus Inorganic materials 0.000 claims abstract description 4
- -1 aluminum-iron-nickel Chemical compound 0.000 claims abstract 3
- 238000004512 die casting Methods 0.000 claims description 11
- 229910052782 aluminium Inorganic materials 0.000 claims description 10
- 238000010438 heat treatment Methods 0.000 claims description 10
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 6
- 239000011575 calcium Substances 0.000 claims description 5
- 239000011651 chromium Substances 0.000 claims description 5
- 238000001816 cooling Methods 0.000 claims description 5
- 239000012535 impurity Substances 0.000 claims description 5
- 239000010936 titanium Substances 0.000 claims description 5
- 229910052791 calcium Inorganic materials 0.000 claims description 4
- 229910052804 chromium Inorganic materials 0.000 claims description 4
- 229910052750 molybdenum Inorganic materials 0.000 claims description 4
- 229910052719 titanium Inorganic materials 0.000 claims description 4
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 claims description 3
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 3
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 claims description 3
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 3
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 3
- 229910052744 lithium Inorganic materials 0.000 claims description 3
- 239000011733 molybdenum Substances 0.000 claims description 3
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 claims description 3
- 229910052726 zirconium Inorganic materials 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 claims description 2
- 238000000034 method Methods 0.000 claims description 2
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims 2
- 229910052720 vanadium Inorganic materials 0.000 claims 2
- 238000005266 casting Methods 0.000 abstract description 9
- 239000000203 mixture Substances 0.000 description 7
- 230000005496 eutectics Effects 0.000 description 6
- 230000000694 effects Effects 0.000 description 5
- 238000010276 construction Methods 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 3
- 230000005484 gravity Effects 0.000 description 3
- 101100352919 Caenorhabditis elegans ppm-2 gene Proteins 0.000 description 2
- 238000005054 agglomeration Methods 0.000 description 2
- 230000002776 aggregation Effects 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 238000001000 micrograph Methods 0.000 description 2
- 239000006104 solid solution Substances 0.000 description 2
- 238000005728 strengthening Methods 0.000 description 2
- 238000009864 tensile test Methods 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 229910000789 Aluminium-silicon alloy Inorganic materials 0.000 description 1
- 229910017518 Cu Zn Inorganic materials 0.000 description 1
- 229910019752 Mg2Si Inorganic materials 0.000 description 1
- 229910017961 MgNi Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 238000005275 alloying Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 238000007872 degassing Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000008092 positive effect Effects 0.000 description 1
- VSZWPYCFIRKVQL-UHFFFAOYSA-N selanylidenegallium;selenium Chemical compound [Se].[Se]=[Ga].[Se]=[Ga] VSZWPYCFIRKVQL-UHFFFAOYSA-N 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 230000007847 structural defect Effects 0.000 description 1
- JBQYATWDVHIOAR-UHFFFAOYSA-N tellanylidenegermanium Chemical compound [Te]=[Ge] JBQYATWDVHIOAR-UHFFFAOYSA-N 0.000 description 1
- 239000011135 tin Substances 0.000 description 1
Classifications
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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
-
- 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
- C22C21/003—Alloys based on aluminium containing at least 2.6% of one or more of the elements: tin, lead, antimony, bismuth, cadmium, and titanium
-
- 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
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
-
- 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
Definitions
- the present invention relates to a casting alloy based on aluminum, iron and nickel with the addition of boron. Further the invention relates to the use of the alloy for high pressure die casting or gravity die casting.
- the alloy according to the invention is used for the production of rotors and stators for electric motors and heat ex-changers, cooling and heating elements in the electronics sector or in vehicle construction.
- Rotor-Aluminum e.g. in qualities of 99.7% Al
- a metallic body is placed in the die-casting mold and the aluminum rotor or stator is cast into this metallic body.
- difficulties that arise when casting such an alloy are avoided, above all the high tendency to stick to steel, which otherwise leads to rapid wear of the casting mold.
- Other typical disadvantages are high shrinkage, very high casting temperatures, poor mechanical machinability and particularly low strength (e.g. Rpo.2 of 20-40 MPa for the alloy A199.7E).
- alloys of the AlSi type are often used, e.g., the alloy AlSigSr (Castasil-21). Compared to Rotor-Aluminum, these alloy type is better castable. The tendency to stick to the casting mold, shrinkage, mold fillability and casting temperatures are more advantageous. However, the lower electric and thermal conductivity compared to Rotor-Aluminum are disadvantageous. With the help of a heat treatment, an electric conductivity of up to 28 MS/m can be achieved, the thermal conductivity is then 190 (W/K m). The yield strength of such an alloy (Rpo.2) is 80-100 MPa.
- the applicant's patent EP 3 235 916 B1 discloses an alloy of the AlMg4Fe2 (Castaduct-42) type, which is preferably used for crash-relevant structural components in automobile construction.
- the metallurgical basis of this alloy is the Al3Fe eutectic.
- the electric conductivity is 16-17 MS/m.
- One object of the invention is, that at least one disadvantage of the alloys known from the prior art is solved.
- the alloy has an electric conductivity, preferably of least 23 MS/m, more preferred over 30 MS/m.
- the alloy should provide a high strength, preferably a Rpo.2 of at least 74 MPa, more preferred over 95 MPa. Further object is providing an alloy composition with a good castability.
- an alloy comprising, consisting essentially of, or consisting of:
- the alloy according to the inventions comprises, consists essentially of, or consists of:
- the iron content ranges from or lies between 1.0-2.5% by weight.
- the iron content ranges from or lies between 1.2-2.0% by weight.
- the iron content ranges from or lies between 1.4-1.9% by weight.
- the nickel content ranges from or lies between 0.3-3.0% by weight.
- the nickel content ranges from or lies between 0.8-2.0% by weight.
- the boron content ranges from or lies between 70-200 ppm.
- the boron content ranges from or lies between 100-160 ppm.
- the boron content ranges from or lies between 80-150 ppm.
- the silicon content ranges from or lies between 0-0.3% by weight silicon.
- the copper content ranges from or lies between 0.2-3% by weight.
- the copper content ranges from or lies between 1.0-3.0%.
- the zinc content ranges from or lies between 0-3% by weight zinc.
- the zinc content ranges from or lies between 0.5% to 4.0 by weight of zinc.
- the magnesium content ranges from or lies between 0-0.4% by weight of magnesium.
- the magnesium content ranges from or lies between of 0.2-0.4%.
- the manganese content ranges from or lies between 0-0.1% by weight.
- the tin content ranges from or lies between 0-2.5% by weight.
- the tin content ranges from or lies between 0.2-2.5% by weight.
- the cast alloy is used for high pressure die-casting, preferably for high pressure die casting of rotors and stators for electric motors and heat ex-changers, cooling and heating elements in the electronics sector or in vehicle construction.
- a high pressure die casted product preferably rotors and stators for electric motors and heat exchangers, cooling and heating elements in the electronics sector or in vehicle construction are manufactured from a cast alloy according to the invention.
- the castability of the alloy according to the invention is achieved by adding the alloying elements iron and nickel, whereby eutectic phases are formed (eutectic phases improve the castability of an alloy).
- an AlgFeNi phase should be achieved which is, according to the literature, created in the ideal ternary system with a composition of 1.75 wt % Fe and 1.25 wt % Ni.
- an Al3Fe or Al3Ni phase may also exist.
- the Al3Ni phase occurs with a high Ni and at the same time a low Fe content.
- the Fe content should be high and promote the formation of AlgFeNi together with a smaller amount of Al3Fe eutectic. In this way, the tendency of the alloy to stick is reduced and the castability is improved.
- the alloy according to the invention hardly reacts to heat treatments.
- Heat treatment can have a positive effect on electric conductivity and thermal conductivity.
- the metallurgical background is mostly an agglomeration of additional elements and a coarsening of the phases, which leads to a better conductivity of the Alpha-Al.
- the Si content should not exceed 0.4% in order to ensure Si-free eutectics. Up to this level, only an enrichment in the alpha-Al phase is to be expected, which can slightly increase the strength.
- the addition of boron of around 40-300 ppm leads to a slight increase in conductivity.
- the metallurgical background is the formation of borides, which can reduce the negative effects of impurities. On one hand such borides can be put out during a degassing and the other hand they lead to an agglomeration of impurities and thus lead to higher conductivity (electric and thermal conductivity).
- Mg An element for increasing strength is Mg. It does not form phases with Fe, has a high solubility in Alpha-Al and however, has a negative effect on conductivity (electric and thermal conductivity). In addition, MgNi-containing phases can be formed, which interfere with the formation of an AlgFeNi phase.
- the alloy according to the invention should therefore either be Mg-free or contain only a small proportion of Mg, preferably maximum 0.6%.
- Further elements which may have a strength-increasing effect are Sn, Mn, Cr, Li, V, Ti, Ca, Ga, Bi, Mo and Zr.
- Variants I and J both alloys known from the prior art named Castaduct-42 and Castasil-21 respectively, are shown.
- Variant T is a further known alloy named Rotors-Al99.7.
- Variants K to O refer to gravity die casting (GDC).
- GDC gravity die casting
Abstract
Description
- This application claims priority to European Patent Application No. 21188809.4, filed on Jul. 30, 2021, the disclosure of which is hereby incorporated by reference in its entirety.
- The present invention relates to a casting alloy based on aluminum, iron and nickel with the addition of boron. Further the invention relates to the use of the alloy for high pressure die casting or gravity die casting. The alloy according to the invention is used for the production of rotors and stators for electric motors and heat ex-changers, cooling and heating elements in the electronics sector or in vehicle construction.
- The use of Rotor-Aluminum (e.g. in qualities of 99.7% Al) in high pressure die casting has been known for a long time. Typically, a metallic body is placed in the die-casting mold and the aluminum rotor or stator is cast into this metallic body. In this way, difficulties that arise when casting such an alloy are avoided, above all the high tendency to stick to steel, which otherwise leads to rapid wear of the casting mold. Other typical disadvantages are high shrinkage, very high casting temperatures, poor mechanical machinability and particularly low strength (e.g. Rpo.2 of 20-40 MPa for the alloy A199.7E).
- For heat exchangers produced via high pressure die casting, alloys of the AlSi type are often used, e.g., the alloy AlSigSr (Castasil-21). Compared to Rotor-Aluminum, these alloy type is better castable. The tendency to stick to the casting mold, shrinkage, mold fillability and casting temperatures are more advantageous. However, the lower electric and thermal conductivity compared to Rotor-Aluminum are disadvantageous. With the help of a heat treatment, an electric conductivity of up to 28 MS/m can be achieved, the thermal conductivity is then 190 (W/K m). The yield strength of such an alloy (Rpo.2) is 80-100 MPa.
- The applicant's patent EP 3 235 916 B1 discloses an alloy of the AlMg4Fe2 (Castaduct-42) type, which is preferably used for crash-relevant structural components in automobile construction. The metallurgical basis of this alloy is the Al3Fe eutectic. The electric conductivity is 16-17 MS/m.
- In the prior art there are aluminum alloys with high conductivity and low strength or there exist alloys with high strength and low conductivity.
- One object of the invention is, that at least one disadvantage of the alloys known from the prior art is solved.
- It is an object of the alloy according to the invention that the alloy has an electric conductivity, preferably of least 23 MS/m, more preferred over 30 MS/m. At the same time the alloy should provide a high strength, preferably a Rpo.2 of at least 74 MPa, more preferred over 95 MPa. Further object is providing an alloy composition with a good castability.
- Further object is, to provide an alloy composition that does not require heat treatment, while still maintaining the desired strength and conductivity.
- Further object is providing an alloy composition which is suitable for mechanical machining, joining or which is corrosion resistant.
- At least one of the objects, mentioned above is solved by an alloy comprising, consisting essentially of, or consisting of:
- The alloy according to the inventions comprises, consists essentially of, or consists of:
-
Iron (Fe) 0.8 to 3.0% by weight Nickel (Ni) 0.1 to 3.5% by weight Boron (B) 40 to 300 ppm Zinc (Zn) 0-5% by weight Tin (Sn) 0-5% by weight Copper (Cu) 0-3% by weight Manganese (Mn) 0-1% by weight Magnesium (Mg) 0-0.6% by weight Phosphorus(P) 0-500 ppm Silicon (Si) 0- 0.4%
and 0-0.8% by weight of an element or a group of elements selected from chromium (Cr), lithium (Li), vanadium (V), titanium (Ti), calcium(Ca), molybdenum (Mo) and zirconium (Zr) and the remainder aluminum and inevitable impurities. - In a preferred embodiment, the iron content ranges from or lies between 1.0-2.5% by weight.
- In a further preferred embodiment, the iron content ranges from or lies between 1.2-2.0% by weight.
- In a further preferred embodiment, the iron content ranges from or lies between 1.4-1.9% by weight.
- In a further preferred embodiment, the nickel content ranges from or lies between 0.3-3.0% by weight.
- In a further preferred embodiment, the nickel content ranges from or lies between 0.8-2.0% by weight.
- In a further preferred embodiment, the boron content ranges from or lies between 70-200 ppm.
- In a further preferred embodiment, the boron content ranges from or lies between 100-160 ppm.
- In a further preferred embodiment, the boron content ranges from or lies between 80-150 ppm.
- In a further preferred embodiment, the silicon content ranges from or lies between 0-0.3% by weight silicon.
- In a further preferred embodiment, the copper content ranges from or lies between 0.2-3% by weight.
- In a further preferred embodiment, the copper content ranges from or lies between 1.0-3.0%.
- In a further preferred embodiment, the zinc content ranges from or lies between 0-3% by weight zinc.
- In a further preferred embodiment, the zinc content ranges from or lies between 0.5% to 4.0 by weight of zinc.
- In a further preferred embodiment, the magnesium content ranges from or lies between 0-0.4% by weight of magnesium.
- In a further preferred embodiment, the magnesium content ranges from or lies between of 0.2-0.4%.
- In a further preferred embodiment, the manganese content ranges from or lies between 0-0.1% by weight.
- In a further preferred embodiment, the tin content ranges from or lies between 0-2.5% by weight.
- In a further preferred embodiment, the tin content ranges from or lies between 0.2-2.5% by weight.
- According to a further aspect of the invention, the cast alloy is used for high pressure die-casting, preferably for high pressure die casting of rotors and stators for electric motors and heat ex-changers, cooling and heating elements in the electronics sector or in vehicle construction.
- A high pressure die casted product, preferably rotors and stators for electric motors and heat exchangers, cooling and heating elements in the electronics sector or in vehicle construction are manufactured from a cast alloy according to the invention.
- The castability of the alloy according to the invention is achieved by adding the alloying elements iron and nickel, whereby eutectic phases are formed (eutectic phases improve the castability of an alloy). In particular, an AlgFeNi phase should be achieved which is, according to the literature, created in the ideal ternary system with a composition of 1.75 wt % Fe and 1.25 wt % Ni. In the case of alloy variants, an Al3Fe or Al3Ni phase may also exist. The Al3Ni phase occurs with a high Ni and at the same time a low Fe content.
- According to the invention, the Fe content should be high and promote the formation of AlgFeNi together with a smaller amount of Al3Fe eutectic. In this way, the tendency of the alloy to stick is reduced and the castability is improved.
- All three phases AlgFeNi, Al3Fe and Al3Ni show very fine, long fibers in the micrograph and have a similar eutectic temperature (640, 650 and 655° C.). As a result, they are created almost at the same time and in almost the same place in the casting process, which can lead to a mixing of these phases. Industrially produced die-cast parts also show numerous structural defects. As a result, these three phases (AlgFeNi, Al3Fe and Al3Ni) are often difficult to distinguish in the micrograph.
- As long as no further element is added, the alloy according to the invention hardly reacts to heat treatments. Heat treatment can have a positive effect on electric conductivity and thermal conductivity. The metallurgical background is mostly an agglomeration of additional elements and a coarsening of the phases, which leads to a better conductivity of the Alpha-Al.
- It is possible to increase the strength of the alloy by adding further alloy elements.
- Basically a solid solution strengthening of the alpha-Al-phase should be achieved. In general, however, such solid solution strengthening usually leads to a reduction in conductivity, which is why only certain elements are even considered.
- The Si content should not exceed 0.4% in order to ensure Si-free eutectics. Up to this level, only an enrichment in the alpha-Al phase is to be expected, which can slightly increase the strength. The addition of boron of around 40-300 ppm leads to a slight increase in conductivity. The metallurgical background is the formation of borides, which can reduce the negative effects of impurities. On one hand such borides can be put out during a degassing and the other hand they lead to an agglomeration of impurities and thus lead to higher conductivity (electric and thermal conductivity).
- An element for increasing strength is Mg. It does not form phases with Fe, has a high solubility in Alpha-Al and however, has a negative effect on conductivity (electric and thermal conductivity). In addition, MgNi-containing phases can be formed, which interfere with the formation of an AlgFeNi phase. The alloy according to the invention should therefore either be Mg-free or contain only a small proportion of Mg, preferably maximum 0.6%.
- If Si is present in the alloy, a Mg2Si phase (or one of its metastable variants) is formed, which increases strength. Further a heat treatment becomes possible.
- It is known that Zn increases the strength of the alloy according to the invention and its negative effect on conductivity (electric and thermal) is limited. Without the addition of Mg, however, no significant increase in strength could be achieved. If both Mg and Zn are added, the material hardens and the strength increases.
- Another element in aluminum which increases strength is the element Cu. Its negative effect on conductivity is less than that of Mg. However, a significant increase in strength could only be achieved with Cu by adding a small amount of Mg.
- Further elements which may have a strength-increasing effect are Sn, Mn, Cr, Li, V, Ti, Ca, Ga, Bi, Mo and Zr.
- In the following tables, different compositions of the alloy according to the invention and three prior art alloys, AlMg4Fe2, AlSigSr and Rotor Al 99.7 are shown. The data are in % by weight (or ppm). Values for Zn of 0.01 or 0.02% or even below can be considered as composition free of Zn. Values for Si of 0.03 or 0.04% or even below can be considered as a composition fee of Si.
- For the high pressure die-cast samples (C to E, I and J, P, R to T, V to Z), the mechanical parameters (Rm, Rpo.2, A5) and the electric conductivity were measured on high pressure die casted plates with a thickness of 3 mm plates The average value from at least 6 tensile tests or 5 electric conductivity measurements is shown in Table 2.
- As comparative samples, Variants I and J, both alloys known from the prior art named Castaduct-42 and Castasil-21 respectively, are shown. Variant T is a further known alloy named Rotors-Al99.7.
- Variants K to O refer to gravity die casting (GDC). The measuring results with respect to mechanical parameters UTS (ultimate tensile strength), YS (yield strength) and E (A5 elongation at break) have been measured by using a Diez molds with a diameter of 16 mm. The electric conductivity was measured on separately cast and machined samples. The average value from at least 5 tensile tests or 2 conductivity measurements is shown in Table 3.
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TABLE i Casting method Fe Ni Si Mg Cu Zn Variant C HP-DC 1.29 0.56 0.03 0.00 0.00 0.02 Variant D HP-DC 1.67 1.54 0.04 0.00 0.00 0.00 Variant E HP-DC 1.11 1.90 0.03 0.00 0.00 0.01 Variant I: State of the art HP-DC 1.63 0.00 0.04 4.24 0.00 0.00 Variant J: State of the art HP-DC 0.50 0.01 9.24 0.00 0.00 0.02 Variant K G-DC 0.93 0.97 0.03 0.00 0.00 0.01 Variant L G-DC 1.69 0.96 0.03 0.00 0.00 0.01 Variant M G-DC 1.70 1.21 0.03 0.00 0.00 0.00 Variant N G-DC 1.68 1.26 0.03 0.00 0.00 0.97 Variant O G-DC 1.77 1.49 0.03 0.29 0.00 3.39 Variant P HP-DC 1.67 1.55 0.04 0.00 0.00 0.00 Variant R HP-DC 1.73 1.18 0.03 0.00 0.00 0.01 Variant S HP-DC 1.80 1.43 0.03 0.31 0.00 3.50 Variant T: State of the art HP-DC 0.25 0.00 0.20 0.00 0.00 0.00 Variant V HP-DC 1.80 1.40 0.03 0.00 0.00 0.00 Variant W HP-DC 1.80 1.45 0.03 0.35 1.00 0.00 Variant X HP-DC 1.80 1.45 0.03 o.35 2.00 0.00 Variant Y HP-DC 1.80 1.47 0.03 0.00 1.00 3.47 Variant Z HP-DC 1.78 1.41 0.03 0.00 0.00 0.01 Mn Sn B Ti P Variant C 0.01 0.00 60 ppm 20 ppm 2 ppm Variant D 0.01 0.00 20 ppm 170 ppm 6 ppm Variant E 0.00 0.00 50 ppm 100 ppm 1 ppm Variant F: State of the art 0.01 0.00 2 ppm 40 ppm 3 ppm Variant J: State of the art 0.00 0.00 100 ppm 2 ppm 4 ppm Sr 0.013 Variant K 0.00 0.45 100 ppm 27 ppm 1 ppm Variant L 0.00 0.99 95 ppm 28 ppm 1 ppm Variant M 0.00 0.00 118 ppm 44 ppm 1 ppm Variant N 0.00 0.00 99 ppm 28 ppm 1 ppm Variant O 0.00 0.00 104 ppm 32 ppm 1 ppm Variant P 0.01 0.00 20 ppm 170 ppm 6 ppm Variant R 0.00 0.00 52 ppm 3 ppm 0 ppm Variant S 0.00 0.00 50 ppm 10 ppm 0 ppm Variant T: State of the art 0.00 0.00 1 ppm 100 ppm 1 ppm Variant V 0.00 0.00 71 ppm 40 ppm 1 ppm Variant W 0.00 0.00 84 ppm 50 ppm 0 ppm Variant X 0.00 0.00 84 ppm 50 ppm 0 ppm Variant Y 0.00 0.00 72 ppm 40 ppm 0 ppm Variant Z 0.00 0.00 80 ppm 40 ppm 0 ppm - Results Achieved
- High Pressure Die Casting (HPC), Status F
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TABLE 2 Electric Conductivity UTS [MPa] YS [MPa] E [%] [MS/m] Variant C 135 74 22,4 30,8 Variant D 161 83 15,0 28,5 Variant E 156 79 17,9 30,1 State of the art 251 122 14,4 16,3 State of the art 204 80 10,5 24,5 Variant P 161 83 15,0 29,1 Variant R 158 82 18,0 29,9 Variant S 201 94 11,9 24,5 State of the art (Ro- 100 30 20,0 35,5 Variant V 165 86 15,5 29,4 Variant W 227 103 11,9 25,4 Variant X 253 123 9,3 23,6 Variant Y 199 85 13,9 27,1 Variant Z 162 78 16,8 26,5 - Gravity Die Casting (GDC), Status F
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TABLE 3 Electric UTS [MPa] YS [MPa] E [%] Conductivity Variant K 100 55 26,0 33,2 Variant L 110 57 21,5 31,7 Variant M 129 63 18,4 32,4 Variant N 129 62 21,9 30,8 Variant 0 169 72 7,8 25,4
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