US3899820A - Method of producing a dispersion-strengthened aluminum alloy article - Google Patents

Method of producing a dispersion-strengthened aluminum alloy article Download PDF

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Publication number
US3899820A
US3899820A US372204A US37220473A US3899820A US 3899820 A US3899820 A US 3899820A US 372204 A US372204 A US 372204A US 37220473 A US37220473 A US 37220473A US 3899820 A US3899820 A US 3899820A
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Prior art keywords
droplets
alloy
substrate
aluminium
alloying constituent
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Expired - Lifetime
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US372204A
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English (en)
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Peter John Read
Keith Graham Latimer
Terence David Warren Reynolds
David Munson
Administrator By George Munson
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Alcan Research and Development Ltd
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Alcan Research and Development Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • 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
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0408—Light metal alloys
    • C22C1/0416—Aluminium-based alloys
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S29/00—Metal working
    • Y10S29/039—Spraying with other step
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/4998—Combined manufacture including applying or shaping of fluent material
    • Y10T29/49988—Metal casting

Definitions

  • ABSTRACT Aluminium alloy articles of high strength and high resistance to temperature softening are produced by spraying droplets of selected aluminium alloy en trained in a stream of gas onto a substrate under such Conditions that the metal droplets strike the substrate in a highly undercoolcd (supercooled) condition. On striking the substrate the undercooled liquid droplets flatten and are very rapidly chilled so that the alloying constituent is either maintained in supersaturated solid solution or is precipitated as a very fine precipitate. The deposit is consolidated by warm working.
  • the selected aluminium alloy contains up to 25 percent of alloying constituent, which is in excess of the equilibr um solid solubility and has a low diffusion rate in aluminium.
  • the preferred alloying constituents are one or more ofTi, V, Cr, Mn, Fe, Co, Ni, Zr, Nb and Mo.
  • Si may be added but is unsuitable by itself. Particularly satisfactory results are obtained with eutectic ternary alloys containing Ni or Si.
  • the present invention relates to the production of high hot strength aluminium alloy articles.
  • these articles are produced by employing a spray casting process which is operated to produce a deposit of aluminium alloy droplets in which the alloying constituent. which may be one or more metals, is maintained either in supersatu rated solid solution or in the form of a precipitate of exceptionally fine particles.
  • the mass of solidified droplets produced by the spray casting operation is then compacted to produce an article which may have high mechanical strength and resistance to temperature softening.
  • the spray-casting operation entails the atomisation and subsequent cooling of a stream of the molten alloy by high velocity jets of nitrogen or other suitable gas.
  • the atomised metal droplets are carried to a moving substrate where, upon impact. they become flattened and solidify almost instantaneously as a result of the initial gas cooling and secondary cooling from the substrate.
  • the conditions for obtaining a supersaturated deposit or one containing a dispersion of fine lam) particles are:
  • each droplet solidifies individually on deposition and the alloying additions. to be described. are largely retained in supersaturated solid solution or are dispersed as very fine lam) particles.
  • the deposit that results from this operation is porous and of low strength and requires consolidation by hot working.
  • the object of the hot working (which may take the form of hot rolling. hot extrusion, hot pressing, hot forging or explosive forming) is as follows:
  • the effect of both (a) and (b) is to improve homogeneity and hence to improve ductility and strength.
  • the effect of (c) is to produce a structure containing a very fine dispersion of very small intcrmetallic compound particles and it is this structure that determines the exceptional combination of properties. viz. high mechanical strength. high resistance to temperature softening and high elastic modulus.
  • alloying elements The choice of alloying elements is determined by the need to achieve (a) maximum properties as previously defined. and (b) ease of spray-casting and consolidation.
  • a method of producing an aluminium alloy article having a high hot strength comprising establishing a substantially homogeneous body of molten metal comprising aluminium and 0.05 to 25 percent of alloying constitutent. the amount of said alloying constituent being in excess of the equilibrium solid solubility, the maximum value of the equilibrium solid solubility being 2 percent. said alloying constituent having a low diffusion rate in aluminium, establishing a stream of droplets of said molten metal in a stream of gas, preferably nitrogen or argon, or in some cases air, said droplets having an average diameter in the range of 50 am to l mm.
  • the projection of the droplets is performed under such conditions that the droplets are undercooled by about 200C. Under these conditions it is estimated that the individual droplets are chilled at a rate of at least 10 C/sec. and indeed up to or even beyond 10 C/sec. in their transition from the liquid state to the solid state on striking the substrate.
  • the droplets are projected against a substrate. which presents a surface moving relatively to the source of said droplets so as to form a strip of cohered solidified droplets on the substrate.
  • the strip is then preferably separated from the substrate for compaction.
  • the alloying constituent is preferably constituted by one or more of the following elements Ti. V, Cr. Mn. Fe, Co. Ni. Zr. Nb and Mo. It is preferred that at least one element should be present in approximately the amount required to form a eutectic with aluminium.
  • the alloying additions are chosen so as to have l very little solid solubility in aluminium and (2) very slow rates of diffusion in aluminium. up to at least 400C. These requirements ensure that the precipitates. when formed, are stable and resistant to change at elevated temperatures.
  • the alloying elements of interest are principally the transition metals Ti. V. Cr. Mn. Fe. Co. Ni. Zr. Nb and M0.
  • the total addition of one or more of these metals is preferably 3-15 percent.
  • the liquidus temperature of the resulting alloy should not exceed approximately l.500C; otherwise the amount of heat required to be extracted by the gas be comes excessive to ensure rapid solidification of the droplets on impact on the substrate.
  • Aluminium alloys of near eutectic composition such as alloys containing 1271 Si or 6% Ni are especially favourable alloys for spray-casting. Because the liquidus temperature is relatively low. An alloy containing 5-7% Ni. preferably 5.5 6.5% Ni. with additions of one or more of the previously mentioned transition elements is particularly favourable. 1n consequence, the amount of heat needed to be extracted from the droplets by the gas to achieve undercooling is kept to a minimum. ln addition. the contraction stresses during solidification appear to be low. since deposits of these a1- loys have less tendency to curl-up from the substrate during spray casting.
  • the method of the present invention allows the formation of a relatively thick deposit. for example up to 2 cms thickness.
  • a relatively thick deposit for example up to 2 cms thickness.
  • this can only be achieved by correct adjustment of the relation between the gas supply and the supply of molten metal to the spray jet so as to ensure that the metal droplets impinge on the substrate in a suitable undercooled (but still liquid) condition. If the metal droplet temperature is too high or striking the substrate. the droplets will not instantly solidify on impact and solidification will be delayed. This will be evidenced by a relatively coarse structure in the deposit.
  • droplets are subjected to excessive cooling by the gas a large number of generally spherical solidified droplets will be present in the deposit, indicating solidification before impact with the substrate.
  • Such droplets exhibit a coarse structure as they have not undergone very rapid chilling at the transition from the liquid to the solid state.
  • droplets deposited under correct conditions appear flattened as a rsult of their impact with the substrate and are relatively free from coarse second phase particles and indeed may exhibit a virtually featureless structure.
  • ternary alloys have been shown in the main to be preferable to binary alloys, it may be that small additions of many elements would be preferable to larger additions of a few, as in this way a larger total fraction of alloying elements can be added before the liquidus temperature becomes too high for successful spraycasting.
  • spray-cast alloys of the present invention are suitable for being based on relatively impure aluminium metal. Any socalled impurities will be taken into solid solution during spray-casting and will add to the general strength of the fabricated material. This is demonstrated by the good properties of the spray cast alloys containing iron and silicon, which are the two most common elements to be found in low purity aluminium.
  • FIGS. 1 and 2 the hardness and ultimate tensile stress of test pieces at room tempera ture. after being held at the indicated temperature for one week. is recorded.
  • the test pieces were made by the spray-casting procedure as detailed above and are contrasted with the DlJS alloy in the fully aged (T6) condition. The are also contrasted with a spray-cast. roll-consolidated Al-l 2' Si alloy (which does not fall within the scope of the in ⁇ cntion I. It is to be seen that the binary and ternary spray-cast. roll-consolidated alloys. based on the transition elements.
  • the molten alloy which is to be spray-deposited, is fed continuously to a crucible I, having a delivery tube 2.
  • the delivery tube 2 has a bore of 3 mms and is surrounded by an array of twelve gas nozzles 3, each 2 mms in diameter. Nitrogen is delivered to the nozzles 3 from a supply pipe 4 at a pressure of about 80 p.s.i. (about 5.6 atmospheres).
  • the substrate in the form of a steel strip was positioned at a distance of about 14 ins. (350 mms) from the delivery tube 2 and advanced at such a rate as to build up a deposit about 20 mms thickness.
  • the droplet size of the metal (considered as a spherical droplet in flight) was about l8() microns and it is estimated to have been cooled from an initial temperature of 850C by between 300 and 360C before striking the substrate so as to result in undercooling by l l()l7()C.
  • the chilling of the molten droplets by the nitrogen gas is mostly effected in the immediate vicinity of the delivery tube nozzle 2, where the gas is coolest and the difference in velocity between the gas and the molten metal is highest.
  • the particle size of the metal droplets and the extent of the undercooling can be varied by increase or decrease of the gas delivery pressure.
  • the correctness of the undercooling of the droplets can be judged by visual inspection of the deposit and appropriate corrections may be made as necessary to im prove the deposit.
  • the alloy Al-Ni-(r'-FeAJ was sprayed under two different conditions 1 a I under the same conditions as in the foregoing examples. employing it cu.ft. of nitrogen per lb. of metal sprtncd l.l m /kg] and (h) -lll cuft. of nitrogcn per lb. of metal sprayed (0.5 Hi ni /Kg).
  • a method of producing an aluminium alloy article having a high hot strength comprising establishing a substantially homogeneous body of molten metal comprising aluminium and 0.05 to 25 percent of alloying constituent, the amount of said alloying constituent being in excess of the equilibrium solid solubility, the maximum value of the equilibrium solid solubility being 2 percent, said alloying constituent having a low diffusion rate in aluminium, establishing a stream of droplets of said molten metal in a stream of unheated gas, said droplets having an average diameter in the range of pm to 1 mm, projecting said droplets against a substrate, undercooling said droplets of molten metal by at least 50C during flight so that on striking the substrate they are very rapidly solidified to maintain said alloying constituent in supersaturated solid solution or in the form of particles of a size not greater than 1 pm in said aluminium, and compacting the mass of droplets by hot working at a temperature in the range of 200 to 500C.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture Of Metal Powder And Suspensions Thereof (AREA)
  • Coating By Spraying Or Casting (AREA)
US372204A 1972-06-30 1973-06-21 Method of producing a dispersion-strengthened aluminum alloy article Expired - Lifetime US3899820A (en)

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GB3087672A GB1431895A (en) 1972-06-30 1972-06-30 Production of aluminium alloy products

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US (1) US3899820A (cs)
CA (1) CA986720A (cs)
DE (1) DE2333198A1 (cs)
FR (1) FR2190553B1 (cs)
GB (1) GB1431895A (cs)
IT (1) IT989488B (cs)
SE (1) SE397543B (cs)

Cited By (23)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4114251A (en) * 1975-09-22 1978-09-19 Allegheny Ludlum Industries, Inc. Process for producing elongated metal articles
US4389258A (en) * 1981-12-28 1983-06-21 Allied Corporation Method for homogenizing the structure of rapidly solidified microcrystalline metal powders
US4592781A (en) * 1983-01-24 1986-06-03 Gte Products Corporation Method for making ultrafine metal powder
US4613371A (en) * 1983-01-24 1986-09-23 Gte Products Corporation Method for making ultrafine metal powder
US4629505A (en) * 1985-04-02 1986-12-16 Aluminum Company Of America Aluminum base alloy powder metallurgy process and product
US4647321A (en) * 1980-11-24 1987-03-03 United Technologies Corporation Dispersion strengthened aluminum alloys
US4715893A (en) * 1984-04-04 1987-12-29 Allied Corporation Aluminum-iron-vanadium alloys having high strength at elevated temperatures
US4743317A (en) * 1983-10-03 1988-05-10 Allied Corporation Aluminum-transition metal alloys having high strength at elevated temperatures
US4799978A (en) * 1986-06-05 1989-01-24 Lockheed Corporation Aluminum alloy
US4805686A (en) * 1983-10-03 1989-02-21 Allied-Signal Inc. An apparatus for forming aluminum-transition metal alloys having high strength at elevated temperatures
US4838936A (en) * 1987-05-23 1989-06-13 Sumitomo Electric Industries, Ltd. Forged aluminum alloy spiral parts and method of fabrication thereof
US4889582A (en) * 1986-10-27 1989-12-26 United Technologies Corporation Age hardenable dispersion strengthened high temperature aluminum alloy
US4961457A (en) * 1989-04-03 1990-10-09 Olin Corporation Method to reduce porosity in a spray cast deposit
US4963322A (en) * 1988-09-26 1990-10-16 Pechiney Recherche Groupement D'interet Economique Process for the production of good fatigue strength aluminum alloy components
US5022455A (en) * 1989-07-31 1991-06-11 Sumitomo Electric Industries, Ltd. Method of producing aluminum base alloy containing silicon
US5102620A (en) * 1989-04-03 1992-04-07 Olin Corporation Copper alloys with dispersed metal nitrides and method of manufacture
WO1992006797A1 (en) * 1990-10-18 1992-04-30 United States Department Of Energy A low temperature process of applying high strength metal coatings to a substrate and article produced thereby
WO1992010307A1 (en) * 1990-12-07 1992-06-25 United States Department Of Energy Process of spraying controlled porosity metal structures against a substrate and articles produced thereby
US5366691A (en) * 1990-10-31 1994-11-22 Sumitomo Electric Industries, Ltd. Hyper-eutectic aluminum-silicon alloy powder and method of preparing the same
US6551551B1 (en) 2001-11-16 2003-04-22 Caterpillar Inc Sinter bonding using a bonding agent
US6746225B1 (en) * 1992-11-30 2004-06-08 Bechtel Bwtx Idaho, Llc Rapid solidification processing system for producing molds, dies and related tooling
US11047024B2 (en) * 2017-04-12 2021-06-29 Purdue Research Foundation High-strength aluminum alloy coatings, deformation layers and methods of making the same
CN120138453A (zh) * 2025-03-19 2025-06-13 天津大学 一种增材制造Al-Cu-X共晶相强化铝合金材料

Families Citing this family (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2541884C2 (de) * 1975-09-19 1987-04-16 The Secretary Of State For Defence In Her Britannic Majesty's Government Of The United Kingdom Of Great Britain And Northern Ireland, London Anwendung des Verfahrens zur Herstellung einer Chrom und Eisen enthaltenden Aluminiumlegierung
US4135922A (en) * 1976-12-17 1979-01-23 Aluminum Company Of America Metal article and powder alloy and method for producing metal article from aluminum base powder alloy containing silicon and manganese
CA1230761A (en) * 1982-07-12 1987-12-29 Fumio Kiyota Heat-resistant, wear-resistant, and high-strength aluminum alloy powder and body shaped therefrom
IL74267A (en) * 1984-02-29 1988-01-31 Gen Electric Method of atomization of melt from a closely coupled nozzle,apparatus and product formed
GB2172900A (en) * 1985-03-25 1986-10-01 Osprey Metals Ltd Making thixotropic metal by spray casting
DE3921709A1 (de) * 1989-07-01 1991-01-10 Deutsche Forsch Luft Raumfahrt Leichtmetallegierung, ihre herstellung und verwendung
DE4328619C2 (de) * 1993-08-26 1995-08-10 Peak Werkstoff Gmbh Partiell verstärktes Al-Gußbauteil und Verfahren zu dessen Herstellung
DE19532252C2 (de) * 1995-09-01 1999-12-02 Erbsloeh Ag Verfahren zur Herstellung von Laufbuchsen
DE19643029A1 (de) * 1996-10-18 1998-04-23 Bayerische Motoren Werke Ag Verfahren zum Beschichten eines aus einer Aluminium-Legierung bestehenden Bauteils einer Brennkraftmaschine mit Silicium

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1128058A (en) * 1910-04-01 1915-02-09 Metals Coating Company Of America Metallic coating and process of making same.
US2171599A (en) * 1937-09-07 1939-09-05 Metallizing Engineering Compan Process of making negatives in metal of metal objects of substantially smooth surface
US2967351A (en) * 1956-12-14 1961-01-10 Kaiser Aluminium Chem Corp Method of making an aluminum base alloy article
US3670400A (en) * 1969-05-09 1972-06-20 Nat Res Dev Process and apparatus for fabricating a hot worked metal layer from atomized metal particles
US3689987A (en) * 1968-04-05 1972-09-12 Johnson Matthey Co Ltd Method of making metal articles
US3696502A (en) * 1968-07-12 1972-10-10 Johnson Matthey Co Ltd Method of making a dispersion strengthened metal
US3711310A (en) * 1971-07-26 1973-01-16 United Aircraft Corp Repair process for aluminum and magnesium articles
US3742585A (en) * 1970-12-28 1973-07-03 Homogeneous Metals Method of manufacturing strip from metal powder

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1128058A (en) * 1910-04-01 1915-02-09 Metals Coating Company Of America Metallic coating and process of making same.
US2171599A (en) * 1937-09-07 1939-09-05 Metallizing Engineering Compan Process of making negatives in metal of metal objects of substantially smooth surface
US2967351A (en) * 1956-12-14 1961-01-10 Kaiser Aluminium Chem Corp Method of making an aluminum base alloy article
US3689987A (en) * 1968-04-05 1972-09-12 Johnson Matthey Co Ltd Method of making metal articles
US3696502A (en) * 1968-07-12 1972-10-10 Johnson Matthey Co Ltd Method of making a dispersion strengthened metal
US3670400A (en) * 1969-05-09 1972-06-20 Nat Res Dev Process and apparatus for fabricating a hot worked metal layer from atomized metal particles
US3742585A (en) * 1970-12-28 1973-07-03 Homogeneous Metals Method of manufacturing strip from metal powder
US3711310A (en) * 1971-07-26 1973-01-16 United Aircraft Corp Repair process for aluminum and magnesium articles

Cited By (23)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4114251A (en) * 1975-09-22 1978-09-19 Allegheny Ludlum Industries, Inc. Process for producing elongated metal articles
US4647321A (en) * 1980-11-24 1987-03-03 United Technologies Corporation Dispersion strengthened aluminum alloys
US4389258A (en) * 1981-12-28 1983-06-21 Allied Corporation Method for homogenizing the structure of rapidly solidified microcrystalline metal powders
US4592781A (en) * 1983-01-24 1986-06-03 Gte Products Corporation Method for making ultrafine metal powder
US4613371A (en) * 1983-01-24 1986-09-23 Gte Products Corporation Method for making ultrafine metal powder
US4743317A (en) * 1983-10-03 1988-05-10 Allied Corporation Aluminum-transition metal alloys having high strength at elevated temperatures
US4805686A (en) * 1983-10-03 1989-02-21 Allied-Signal Inc. An apparatus for forming aluminum-transition metal alloys having high strength at elevated temperatures
US4715893A (en) * 1984-04-04 1987-12-29 Allied Corporation Aluminum-iron-vanadium alloys having high strength at elevated temperatures
US4629505A (en) * 1985-04-02 1986-12-16 Aluminum Company Of America Aluminum base alloy powder metallurgy process and product
US4799978A (en) * 1986-06-05 1989-01-24 Lockheed Corporation Aluminum alloy
US4889582A (en) * 1986-10-27 1989-12-26 United Technologies Corporation Age hardenable dispersion strengthened high temperature aluminum alloy
US4838936A (en) * 1987-05-23 1989-06-13 Sumitomo Electric Industries, Ltd. Forged aluminum alloy spiral parts and method of fabrication thereof
US4963322A (en) * 1988-09-26 1990-10-16 Pechiney Recherche Groupement D'interet Economique Process for the production of good fatigue strength aluminum alloy components
US4961457A (en) * 1989-04-03 1990-10-09 Olin Corporation Method to reduce porosity in a spray cast deposit
US5102620A (en) * 1989-04-03 1992-04-07 Olin Corporation Copper alloys with dispersed metal nitrides and method of manufacture
US5022455A (en) * 1989-07-31 1991-06-11 Sumitomo Electric Industries, Ltd. Method of producing aluminum base alloy containing silicon
WO1992006797A1 (en) * 1990-10-18 1992-04-30 United States Department Of Energy A low temperature process of applying high strength metal coatings to a substrate and article produced thereby
US5366691A (en) * 1990-10-31 1994-11-22 Sumitomo Electric Industries, Ltd. Hyper-eutectic aluminum-silicon alloy powder and method of preparing the same
WO1992010307A1 (en) * 1990-12-07 1992-06-25 United States Department Of Energy Process of spraying controlled porosity metal structures against a substrate and articles produced thereby
US6746225B1 (en) * 1992-11-30 2004-06-08 Bechtel Bwtx Idaho, Llc Rapid solidification processing system for producing molds, dies and related tooling
US6551551B1 (en) 2001-11-16 2003-04-22 Caterpillar Inc Sinter bonding using a bonding agent
US11047024B2 (en) * 2017-04-12 2021-06-29 Purdue Research Foundation High-strength aluminum alloy coatings, deformation layers and methods of making the same
CN120138453A (zh) * 2025-03-19 2025-06-13 天津大学 一种增材制造Al-Cu-X共晶相强化铝合金材料

Also Published As

Publication number Publication date
CA986720A (en) 1976-04-06
IT989488B (it) 1975-05-20
GB1431895A (en) 1976-04-14
SE397543B (sv) 1977-11-07
FR2190553A1 (cs) 1974-02-01
DE2333198A1 (de) 1974-01-31
FR2190553B1 (cs) 1980-04-04

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