US20230212717A1 - Aluminum casting alloy - Google Patents

Aluminum casting alloy Download PDF

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Publication number
US20230212717A1
US20230212717A1 US18/121,825 US202318121825A US2023212717A1 US 20230212717 A1 US20230212717 A1 US 20230212717A1 US 202318121825 A US202318121825 A US 202318121825A US 2023212717 A1 US2023212717 A1 US 2023212717A1
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US
United States
Prior art keywords
casting
aluminum
alloy
calcium
zinc
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Pending
Application number
US18/121,825
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English (en)
Inventor
Viktor Khrist'yanovich MANN
Aleksandr Nikolaevich ALABIN
Aleksandr Yur'evich KROKHIN
Dmitrij Olegovich FOKIN
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Obshchestvo S Ogranichennoj Otvetstvennost'yu "institut Legkikh Materialov I Tekhnologij"
Original Assignee
Obshchestvo S Ogranichennoj Otvetstvennost'yu "institut Legkikh Materialov I Tekhnologij"
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Application filed by Obshchestvo S Ogranichennoj Otvetstvennost'yu "institut Legkikh Materialov I Tekhnologij" filed Critical Obshchestvo S Ogranichennoj Otvetstvennost'yu "institut Legkikh Materialov I Tekhnologij"
Assigned to Obshchestvo s ogranichennoj otvetstvennost'yu "Institut legkikh materialov i tekhnologij" reassignment Obshchestvo s ogranichennoj otvetstvennost'yu "Institut legkikh materialov i tekhnologij" ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ALABIN, Aleksandr Nikolaevich, FOKIN, Dmitrij Olegovich, KROKHIN, Aleksandr Yur'evich, MANN, VIKTOR KRIST'YANOVICH
Publication of US20230212717A1 publication Critical patent/US20230212717A1/en
Pending 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
    • C22C21/003—Alloys based on aluminium containing at least 2.6% of one or more of the elements: tin, lead, antimony, bismuth, cadmium, and titanium
    • 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
    • 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
    • B22D21/02—Casting exceedingly oxidisable non-ferrous metals, e.g. in inert atmosphere
    • B22D21/04—Casting aluminium or magnesium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/02—Making non-ferrous alloys by melting
    • C22C1/026—Alloys based on aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/02—Making non-ferrous alloys by melting
    • C22C1/03—Making non-ferrous alloys by melting using master alloys
    • 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
    • C22C21/10—Alloys based on aluminium with zinc 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

Definitions

  • This technology is directed to the field of metallurgy, in particular, to aluminum-based alloys characterized by high corrosion resistance.
  • the alloy can be used in the manufacture of thin-walled complex-shaped castings by casting in a metal mold.
  • Industrial non-heat-treatable alloys of the A-Si system such as A413.2 or AK12pch (GOST1583) are characterized by high processability when casting and a relatively low level of strength properties; in particular, the yield strength usually does not exceed 60-80 MPa, depending on the thickness of the castings.
  • a higher level of strength properties of castings already in the as-cast condition is provided by the addition of copper; in particular, alloys such as AA383.1 or AK12M2 are known.
  • the increase in mechanical properties in this case is accompanied by a significant decrease in elongation and deterioration of corrosion resistance.
  • Non-heat-treatable and corrosion-resistant alloys include the solid solution alloys based on the Al—Mg system, for example, AMg6L, AMg5K, AMg5Mz (GOST1583), Magsimal®59 (Rheinfelden Alloys) and others characterized by satisfactory processability when casting, good corrosion resistance, a high level of strength properties and elongation.
  • the disadvantages of alloys of this system include high linear shrinkage and insufficient tightness of thin-walled castings.
  • NITU MISIS is disclosed in patent RU2660492 and is known in the art.
  • Material for use in the as-cast condition for NITU MISIS contains (wt. %): 5.4-6.4% calcium, 0.3-0.6% silicon, and 0.8-1.2% iron.
  • the disadvantages of the proposed process in RU2660492 results in low relative elongation, (e.g., elongation which does not exceed 2.6%), which limits the use of the material in critical cast parts.
  • Al—Ni—Mn casting alloy for structural components for automotive and aerospace applications is known as an alternative to branded silumins, developed by Alcoa and disclosed in U.S. Pat. No. 6,783,730B2 (published on 31 Aug. 2004).
  • This alloy can be used to produce castings with a good combination of casting and mechanical properties in the case of (wt. %) 2-6% Ni, 1-3% Mn, 1% Fe, less than 1% silicon, as well as in the case of other unavoidable impurities.
  • 6,783,730B2 include the fact that the high level of casting and mechanical properties is ensured by using high-purity aluminum grades and with a high nickel content, which significantly increases the cost of the castings produced. Besides, the proposed material in U.S. Pat. No. 6,783,730B2 is non-heat-treatable in the entire concentration range, which limits its use. At the same time, the corrosion resistance of the castings disclosed in U.S. Pat. No. 6,783,730B2 decreases significantly in the area of high nickel concentrations.
  • Cast aluminum alloys based on Al—Ni and Al—Ni—Mn systems and a method of producing cast parts from them are known, which are described in Alcoa, U.S. Pat. No. 8,349,462B2 (published on 8 Jan. 2013) and application EP2011055318 of Rheinfelden Alloys GmbH & Co. KG.
  • These references propose alloy compositions for casting applications. For example, these references discuss compositions having a high nickel content of 1-6%, which determines their main disadvantages—a significant decrease in corrosion resistance. With a relatively low nickel and manganese content, cast alloys have a low level of strength characteristics.
  • Other materials include a material containing (wt. %) Al-3.5% Ca-0.9% Mn-0.5% Fe-0.1% Zr-0.1% Sc disclosed in the publication available at https://doi.org/10.1016/j.msea.2019.138410.
  • the authors of the publication consider the material as a deformed alloy, the process chain of which excludes water quenching.
  • the publication shows the non-obviousness of using the alloy mentioned in the publication for castings and use in the as-cast condition.
  • the disadvantages of the process outlined in the publication include the presence of expensive scandium, as well as the need to use heat treatment to achieve the hardening effect of the joint addition of zirconium and scandium.
  • the object of the disclosed technology is to create a new casting aluminum alloy designed to produce thin-walled castings by various methods of casting into a metal mold, in particular, gravity casting, high-pressure casting, low-pressure casting, liquid forging, but not limited to, satisfying the specified requirements for a set of process and corrosion characteristics.
  • the technical result of the disclosed technology is to provide a given combination of process characteristics in casting and corrosion resistance.
  • calcium and zinc are predominantly represented in the structure in the form of eutectic particles.
  • the alloy is made in the form of castings.
  • FIG. 1 shows an exemplary alloy composition, according to some embodiments of this disclosure.
  • FIG. 2 illustrates the use of an exemplary “rod” length indicator to obtain a casting, according to some embodiments of this disclosure.
  • the proposed alloy is characterized by a narrow crystallization interval, which in combination with a large amount of eutectic phase provides a good level of casting characteristics, and because of the elements dissolved in aluminum solid solution—a satisfactory level of strength properties in the as-cast condition.
  • the corrosion resistance within the claimed area is maintained at a good level.
  • the basic criterion for the acceptable choice of alloying elements was the formation of the desired structure, excluding the presence of coarse primary crystals and/or coarsening of the eutectic phase; the justification of the concentration range is given below.
  • Concentrations (wt. %) of calcium in the range 1.5-5.1% and zinc in the range 0.1-1.8% provide good casting properties because calcium and zinc predominantly form a sufficient amount of the eutectic phase.
  • the main effect of the joint introduction of calcium and zinc is the formation of a joint eutectic phase Al4(Ca,Zn), where the zinc atom replaces that of calcium.
  • the level of strength properties is further increased. If the calcium content is less than the declared level, it will lead to a decrease in casting characteristics. If zinc is reduced below the declared level, no significant increase in strength properties will be observed. Calcium and zinc content above the declared level will lead to the formation of a coarse structure and a significant decrease in mechanical properties.
  • iron and silicon content is primarily determined by the purity of the aluminum used to make the alloy.
  • iron and silicon can also be used as alloying elements because silicon in amounts of up to 1.0 wt. % is redistributed between solid solution and eutectics, which, on the one hand, provides an increase in strength properties due to additional solid-solution hardening in the as-cast condition and, on the other hand, positively affects the alloy casting characteristics by increasing the eutectics. With a higher silicon content, the morphology of the eutectic phase deteriorates, which generally reduces the strength characteristics. Iron in amounts of up to 0.5 wt.
  • % predominantly forms phases of eutectic origin, which positively affects the casting characteristics of the alloy by increasing the amount of eutectics.
  • An increase in iron concentration above 0.5 wt. % may lead to coarsening of the eutectic phase and, as a consequence, a decrease in mechanical properties.
  • Manganese in amounts of up to 2.5 wt. % may be required to increase the strength properties, primarily in the as-cast condition, by providing solid-solution hardening. With manganese content above 2.5 wt. %, primary crystals of the Al 6 (Fe,Mn) phase can be formed in the structure, which can lead to a decrease in mechanical characteristics. A manganese content of less than 0.2 wt. % will not result in significant solid-solution hardening and, as a consequence, an increase (e.g., a weak increase) in strength characteristics.
  • Zirconium and chromium in the declared limits (wt. %) of 0.05-0.14% and 0.05-0.15%, respectively, may provide solid-solution hardening. Lower concentrations of these elements do not result in a significant increase in strength characteristics in the as-cast condition. Larger quantities may lead to higher casting temperatures than typical, which would reduce the stability of the casting molds; otherwise, there would be a high probability of forming primary crystals of the Al 7 Cr and Al 3 Zr phase, which would not increase the level of mechanical properties from the introduction of these elements.
  • Titanium in an amount of 0.005-0.1 wt. % may be used to modify the aluminum solid solution.
  • a higher titanium content in the structure may result in the appearance of primary crystals, which will reduce the overall level of mechanical properties, while a lower titanium content will not achieve the positive effect of this element.
  • Titanium can be introduced as a multicomponent ligature, such as Al—Ti—B and/or Al—Ti—C, so that the alloy may contain boron and carbon in compounds with titanium in quantities proportional to the content of the corresponding ligature. Boron and carbon, as independent elements, had no significant effect on the mechanical and casting properties for the range in question. Besides, in the presence of titanium, a decrease in the propensity to form hot cracks during casting may be noted in some cases.
  • the following exemplary charge materials were used to prepare the alloys (wt. %): Aluminum grade A99 and A8, zinc grade CO, calcium as metallic calcium and ligature Al-6Ca, manganese as ligature Al-10% Mn, ligature Al-10% Zr, Al-10% Cr, Al-5% Ti.
  • the content of other elements typically did not exceed 0.05 wt. %.
  • the chemical composition of the alloy was chosen from the condition of obtaining a structure comprising an aluminum solid solution and eutectic component. Specimens were cast gravitationally in a metal mold “Separately Cast Sample”. The mold temperature could vary in the range of 20-60° C. The casting was a tensile specimen 10 mm in diameter with an estimated length of 50 mm, which was tensile tested (with a determination of yield strength, tensile strength, and elongation) immediately after casting without machining. The structure of the specimens was evaluated from the specimen heads.
  • compositions 2, 5, and 12 are preferred because of their good yield strength to elongation ratio for use in the as-cast condition.
  • the corrosion resistance by the example of compositions 2, 5, 8, and 11 of the claimed alloy was evaluated by the method of accelerated corrosion tests conducted by exposure to neutral salt fog under the following program: 1 cycle soaking in a salt fog chamber at spraying of 5% NaCl solution for 8 hours at a temperature of 25 ⁇ 1° C., then soaking at 35 ⁇ 3° C. without spraying the solution for 16 hours, a total of 7 cycles. The result was evaluated by changing the surface appearance of the specimens and the depth of corrosion damage (metallographic method).
  • the ADC6 type alloy was used as a reference, which is characterized by the highest corrosion resistance among cast aluminum alloys.
  • Casting characteristics were evaluated using the hot brittleness (HB) parameter using the “harp casting”, where the best indicator is to obtain a casting with the maximum “rod” length ( FIG. 2 ).
  • the propensity for hot cracks was assessed using alloys 2, 4, and 12 as examples (Table 1).
  • ADC6 type alloy was used as a comparison.
  • the absence of cracks in alloys 2, 4, and 12 was shown (Table 1), which is a good indicator at the level of most Al—Si alloys, in contrast to the ADC6 alloy, the casting from which about 40% of the rods failed starting from the maximum length.

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  • 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)
  • Continuous Casting (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Mold Materials And Core Materials (AREA)
US18/121,825 2020-09-16 2023-03-15 Aluminum casting alloy Pending US20230212717A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
RU2020130578A RU2745595C1 (ru) 2020-09-16 2020-09-16 Литейный алюминиевый сплав
RU2020130578 2020-09-16
PCT/RU2021/050295 WO2022060253A1 (ru) 2020-09-16 2021-09-15 Литейный алюминиевый сплав

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EP (1) EP4215634A4 (ja)
JP (1) JP2023542129A (ja)
KR (1) KR20230069152A (ja)
CN (1) CN116057193A (ja)
CA (1) CA3195581A1 (ja)
MX (1) MX2023003144A (ja)
RU (1) RU2745595C1 (ja)
WO (1) WO2022060253A1 (ja)

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WO2024072262A1 (ru) * 2022-09-28 2024-04-04 Общество с ограниченной ответственностью "Институт легких материалов и технологий" Литейный алюминиевый сплав
DE202023107201U1 (de) 2023-05-30 2024-03-28 Hyundai Mobis Co., Ltd. Fahrzeugbeleuchtungseinrichtung

Family Cites Families (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB546899A (en) * 1941-10-23 1942-08-04 Nat Smelting Co Improvements in or relating to aluminium base alloys
US4126448A (en) * 1977-03-31 1978-11-21 Alcan Research And Development Limited Superplastic aluminum alloy products and method of preparation
GB2055895A (en) * 1979-07-20 1981-03-11 British Aluminium Co Ltd Aluminium-calcium alloys
US5573606A (en) * 1995-02-16 1996-11-12 Gibbs Die Casting Aluminum Corporation Aluminum alloy and method for making die cast products
US6783730B2 (en) 2001-12-21 2004-08-31 Alcoa Inc. Al-Ni-Mn casting alloy for automotive and aerospace structural components
US8349462B2 (en) 2009-01-16 2013-01-08 Alcoa Inc. Aluminum alloys, aluminum alloy products and methods for making the same
RU2478131C2 (ru) 2010-10-29 2013-03-27 Федеральное государственное образовательное учреждение высшего профессионального образования "Национальный исследовательский технологический университет "МИСиС" Термостойкий литейный алюминиевый сплав
KR101402896B1 (ko) * 2011-05-20 2014-06-02 한국생산기술연구원 알루미늄 합금 및 그 제조방법
CN108070746A (zh) * 2016-11-14 2018-05-25 镇江市润州金山金属粉末厂 一种铝合金压铸件
MX2019014060A (es) * 2017-05-30 2020-02-05 Obshchestvo S Ogranichennoy Otvetstvennostyu Obedinennaya Kompaniya Rusal Inzhenerno Tekh Tsentr Aleacion de elevada resistencia a base de aluminio.
JP7229181B2 (ja) * 2017-06-21 2023-02-27 オプシチェストボ エス オグラニチェンノイ オトヴェストヴェンノストユ “オベディネンナヤ カンパニア ルサール インゼネルノ－テクノロギケスキー チェントル” アルミニウム系合金
RU2660492C1 (ru) * 2017-11-03 2018-07-06 Федеральное государственное автономное образовательное учреждение высшего образования "Национальный исследовательский технологический университет "МИСиС" Литейный алюминиево-кальциевый сплав
RU2672653C1 (ru) * 2017-11-16 2018-11-16 Федеральное государственное автономное образовательное учреждение высшего образования "Национальный исследовательский технологический университет "МИСиС" Коррозионностойкий литейный алюминиевый сплав
RU2714564C1 (ru) * 2019-08-15 2020-02-18 Общество с ограниченной ответственностью "Объединенная Компания РУСАЛ Инженерно-технологический центр" Литейный алюминиевый сплав

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RU2745595C1 (ru) 2021-03-29
WO2022060253A1 (ru) 2022-03-24
KR20230069152A (ko) 2023-05-18
JP2023542129A (ja) 2023-10-05
CA3195581A1 (en) 2022-03-24
EP4215634A1 (en) 2023-07-26
CN116057193A (zh) 2023-05-02
MX2023003144A (es) 2023-06-16
EP4215634A4 (en) 2024-10-09

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