US20230043878A1 - Cast Alloy - Google Patents

Cast Alloy Download PDF

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Publication number
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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US
United States
Prior art keywords
weight
ppm
cast alloy
alloy according
variant
Prior art date
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Pending
Application number
US17/876,661
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English (en)
Inventor
Stuart Wiesner
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.)
Aluminium Rheinfelden Alloys GmbH
Original Assignee
Aluminium Rheinfelden Alloys GmbH
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 Aluminium Rheinfelden Alloys GmbH filed Critical Aluminium Rheinfelden Alloys GmbH
Assigned to ALUMINIUM RHEINFELDEN ALLOYS GMBH reassignment ALUMINIUM RHEINFELDEN ALLOYS GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: WIESNER, STUART
Publication of US20230043878A1 publication Critical patent/US20230043878A1/en
Pending legal-status Critical Current

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Classifications

    • 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

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Induction Machinery (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Sealing Battery Cases Or Jackets (AREA)
  • Conductive Materials (AREA)
US17/876,661 2021-07-30 2022-07-29 Cast Alloy Pending US20230043878A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP21188809.4 2021-07-30
EP21188809.4A EP4124668A1 (fr) 2021-07-30 2021-07-30 Alliage moulé

Publications (1)

Publication Number Publication Date
US20230043878A1 true US20230043878A1 (en) 2023-02-09

Family

ID=77155681

Family Applications (1)

Application Number Title Priority Date Filing Date
US17/876,661 Pending US20230043878A1 (en) 2021-07-30 2022-07-29 Cast Alloy

Country Status (5)

Country Link
US (1) US20230043878A1 (fr)
EP (1) EP4124668A1 (fr)
JP (1) JP2023021070A (fr)
KR (1) KR20230019055A (fr)
CN (1) CN115679158A (fr)

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4080222A (en) * 1974-03-01 1978-03-21 Southwire Company Aluminum-iron-nickel alloy electrical conductor
JP4328927B2 (ja) * 2000-03-13 2009-09-09 三菱樹脂株式会社 電気伝導性および熱伝導性に優れたアルミニウム合金材
US10822675B2 (en) * 2015-03-06 2020-11-03 NanoAL LLC High temperature creep resistant aluminum superalloys
EP3235916B1 (fr) 2016-04-19 2018-08-15 Rheinfelden Alloys GmbH & Co. KG Alliage de moulage
CN108130456B (zh) * 2017-12-22 2020-12-15 广州致远新材料科技有限公司 一种高导热压铸铝合金材料及其制备方法

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
NPL: on-line translation of JP 2001254135, 09-2001 (Year: 2001) *

Also Published As

Publication number Publication date
EP4124668A1 (fr) 2023-02-01
JP2023021070A (ja) 2023-02-09
KR20230019055A (ko) 2023-02-07
CN115679158A (zh) 2023-02-03

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