WO2009126347A2 - High-strength aluminum casting alloys resistant to hot tearing - Google Patents
High-strength aluminum casting alloys resistant to hot tearing Download PDFInfo
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- WO2009126347A2 WO2009126347A2 PCT/US2009/031251 US2009031251W WO2009126347A2 WO 2009126347 A2 WO2009126347 A2 WO 2009126347A2 US 2009031251 W US2009031251 W US 2009031251W WO 2009126347 A2 WO2009126347 A2 WO 2009126347A2
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- alloy
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- aluminum casting
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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
- C22C21/10—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
- C22F1/053—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 zinc as the next major constituent
Definitions
- the 7XXX wrought Al-Zn-based alloys are commonly used in structural applications demanding high specific strength. Compared to wrought alloys, castings decrease the fabrication cost and associated logistics lead time, because castings enable near-net-shape products.
- the known 7XXX alloys are susceptible to hot tearing during solidification and therefore not optimal for casting. The hot tearing is caused by a relatively high thermal expansion coefficient and significant volumetric difference between liquid and solid.
- Senkov et al. U.S. Patent 7,060,139 (incorporated by reference herein) disclose a high-strength aluminum alloy with a nominal composition of Al - 6.0-12.0 Zn - 2.0-3.5 Mg - 0.1-0.5 Sc - 0.05-0.20 Zr - 0.5-3.0 Cu - 0.10-0.45 Mg - 0.08-0.35 Fe - 0.07-0.20 Si, in wt%.
- the alloy by Senkov et al. shows high tensile strength while maintaining high elongation in ambient temperatures and cryogenic temperatures. The freezing range of the alloy by Senkov et al.
- the present invention comprises high-strength aluminum casting alloys that are resistant to hot tearing.
- the yield strength of the casting alloys ranges from about 410 MPa to about 540 MPa, at room temperature.
- the invented alloys are Al-Zn-based and comprise the major alloying elements Sc, Zr, Mg, and Cu.
- the amounts of Sc and Zr are optimized to produce primary Ll 2-phase particles which refine the grain size and improve the hot-tearing resistance as well as fatigue resistance and toughness.
- the amounts of Zn, Mg, and Cu are optimized for high resistance to hot-tearing and high strength.
- the amounts of Fe, Mn, and Si are kept low and at a minimum because these elements have a detrimental effect on strength and hot-tearing resistance.
- the solvus temperature of the Ll 2 phase must be above the solvus temperature of the fee phase.
- the solvus temperatures can be computed with thermodynamic database and calculation packages such as Thermo- Calc ® software version N offered by Thermo-Calc Software. Alternatively, in the composition space of the alloys, the solvus temperatures can be approximated by the following equations:
- the amount of Zr is kept below about 0.3 wt% to minimize the formation OfAl 3 Zr which has a DO 23 crystal structure.
- DO 23 particles quickly grow too large [Hyde, K. 2001. The Addition of Scandium to Aerospace Casting Alloys. Ph.D. diss., University of Manchester (incorporated herewith)], and are not very effective for refining the fee grain size.
- small Al 3 (Sc, Zr) particles with an Ll 2 crystal structure are employed instead to inoculate small fee grains during melt cooling.
- the alloys of the invention use as much Zr as possible, about 0.25 ⁇ 0.05 wt%. However, where cost is not a limiting factor, as little as 0.15 wt% Zr can be used in combination with a larger amount of Sc.
- the amounts of Sc and Zr in the casting alloys are optimized for cooling rates up to about 100 0 C per second.
- the Zl 2 -Al 3 (Sc, Zr) particle size distribution depends on the melt cooling rate. Casting into a sand mold results in a cooling rate of about 0.5 0 C per second. Higher cooling rates are accessible through direct-chill casting where the billet is cooled, for example, with water during solidification. Cooling rates above about 100 0 C per second are accessible through casting methods such as the Continuous Rheoconversion Process (CRP).
- CRP Continuous Rheoconversion Process
- Solidification parameters such as the freezing range, the solidus temperature, and the eutectic phase fraction can be computed with thermodynamic database and calculation packages such as Thermo-Calc software.
- Thermo-Calc software To compute solidification parameters of complex alloy systems with Thermo-Calc software, the Gibbs free energy of relevant phases must be assessed following the CALPHAD (CALculation of PHAse Diagrams) approach.
- One such relevant phase is the metastable ⁇ ' phase, because the 7XXX wrought alloys employ ⁇ ' phase precipitates for strengthening.
- the mean radius of ⁇ ' precipitate should be less than about 5 nm.
- the ⁇ ' phase precipitation kinetics can be simulated with PrecipiCalc ® software version 0.9.2 offered by QuesTek Innovations LLC after assessing the thermodynamic description.
- the predicted particle size distribution can be used as input to a mechanistic model of the yield strength, which comprises contributions from precipitation strengthening, grain-size strengthening, solid-solution strengthening, and dislocation strengthening.
- the amounts of Zn, Mg, and Cu of the alloys are chosen to optimize the solidification parameters at various yield strength levels.
- the amounts of Fe, Mn, and Si are kept as low as possible because these elements otherwise form large insoluble constituent particles OfAIi 3 Fe 4 , Al 7 Cu 2 Fe, Mg 2 Si, and Al 6 Mn which negatively affect the toughness, fatigue, and SCC resistance.
- the amount of Fe is preferably kept below about 0.0075 wt%, Mn below about 0.2 wt%, and Si below about 0.03 wt%.
- the homogenization or solution treatment temperature should be below the final solidification temperature, preferably with a safety margin of about 10 to 30 0 C.
- the calculated final solidification temperature is about 493°C.
- the homogenization and solution treatment should be at about 460 to 480 0 C. The time of such treatments should be long enough to eliminate the majority of as-cast segregation.
- Figures IA and IB respectively are graphs depicting the simulated primary Zl 2 particle radius and simulated grain size as a function of the alloy Sc and Zr;
- Figures 2A, 2B, and 2C respectively are graphs depicting strength and solidification parameter contours as a function of Zn, Mg, and Cu content wherein the following legends are utilized:
- Figure 3 is a time-temperature diagram illustrating the processing steps for processing an embodiment of the alloy of the invention.
- Figure 4 is a homogenization simulation of the examples of the invention.
- FIG. 5 is a micrograph of alloy A of the invention.
- the micrograph is typical of the examples of the invention.
- a melt was prepared comprising Al - 6.3 Zn - 3.2 Mg - 1.1 Cu - 0.52 Sc - 0.20
- the exemplary alloy preferably includes a variance in the constituents in the range of plus or minus ten percent of the mean value.
- the alloy was cast through the CRP reactor into a sand-casting mold at measured cooling rates of 50 ⁇ 100°C/second. As shown in Figure 3, the optimum processing condition was to apply hot isostatic pressing, homogenize and solutionize at 460 0 C for 2 hours and 480 0 C for 1 hour, quench with water, hold at room temperature for 24 hours, and age at 120 ⁇ 10°C for 20 hours.
- the ambient yield strength in this condition was 521 ⁇ 12 MPa.
- the grain diameter was about 50 ⁇ m, or an ASTM (American Society for Testing and Materials) grain size number of about 5.7.
- the calculated freezing range is 136°C, solidus temperature 493°C, and the eutectic phase fraction formed at late stages of solidification is 10%.
- a melt was prepared comprising Al - 5.3 Zn - 3.0 Mg - 1.1 Cu - 0.55 Sc - 0.25
- the exemplary alloy preferably includes a variance in the constituents in the range of plus or minus ten percent of the mean value.
- the alloy was cast through the CRP reactor into a sand-casting mold at a measured cooling rate of 100°C/second. As shown in Figure 3, the optimum processing condition was to apply hot isostatic pressing, homogenize and solutionize at 460 0 C for 2 hours and 480 0 C for 1 hour, quench with water, hold at room temperature for 24 hours, and age at 120 ⁇ 10°C for 20 hours.
- the ambient yield strength in this condition was 482 ⁇ 6 MPa.
- the grain diameter was about 54 ⁇ m, or an ASTM grain size number of about 5.5.
- the calculated freezing range is 139°C, solidus temperature 494°C, and the eutectic phase fraction formed at late stages of solidification is 9%.
- a rectangular panel of alloy B was cast successfully without hot tearing in accord and otherwise generally with the protocol of alloy A.
- a melt was prepared comprising Al - 4.5 Zn - 2.3 Mg - 0.62 Cu - 0.42 Sc - 0.25
- the exemplary alloy preferably includes a variance in the constituents in the range of plus or minus ten percent of the mean value.
- the alloy was cast through the CRP reactor into a sand-casting mold. As shown in Figure 3, the optimum processing condition was to apply hot isostatic pressing, homogenize and solutionize at 460 0 C for 2 hours and 480 0 C for 1 hour, quench with water, hold at room temperature for 24 hours, and age at 120 ⁇ 10°C for 15 hours.
- the calculated ambient yield strength in this condition is 410 ⁇ 40 MPa.
- the calculated grain diameter is about 50 ⁇ m or an ASTM grain size number of about 5.7.
- the calculated freezing range is 145°C, solidus temperature 494°C, and the eutectic phase fraction formed at late stages of solidification is 6%.
- Two panels were successfully cast from one heat of alloy C without hot tearing and otherwise generally in accord with the protocol used for alloy A.
- Table 1 summarizes the compositions of the examples set forth above and sets forth the general range of the constituents for the practice of the invention in weight percent:
- Table 2 summarizes the information with respect to the microstructural elements of the examples set forth above and considered relevant to the range of the constituents in the practice of the invention. [40] TABLE 2
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- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Organic Chemistry (AREA)
- Metallurgy (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Crystallography & Structural Chemistry (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Continuous Casting (AREA)
- Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)
- Manufacture Of Metal Powder And Suspensions Thereof (AREA)
- Mold Materials And Core Materials (AREA)
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN2009801026580A CN101952467A (zh) | 2008-01-16 | 2009-01-16 | 抗热裂的高强度铸造铝合金 |
JP2010543275A JP2011510174A (ja) | 2008-01-16 | 2009-01-16 | 熱間割れに耐性のある高強度アルミニウム鋳造合金 |
EP09730142A EP2252716A2 (en) | 2008-01-16 | 2009-01-16 | High-strength aluminum casting alloys resistant to hot tearing |
US12/863,148 US20110044843A1 (en) | 2008-01-16 | 2009-01-16 | High-strength aluminum casting alloys resistant to hot tearing |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US2150308P | 2008-01-16 | 2008-01-16 | |
US61/021,503 | 2008-01-16 |
Publications (2)
Publication Number | Publication Date |
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WO2009126347A2 true WO2009126347A2 (en) | 2009-10-15 |
WO2009126347A3 WO2009126347A3 (en) | 2010-09-30 |
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/US2009/031251 WO2009126347A2 (en) | 2008-01-16 | 2009-01-16 | High-strength aluminum casting alloys resistant to hot tearing |
Country Status (6)
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---|---|
US (1) | US20110044843A1 (ru) |
EP (1) | EP2252716A2 (ru) |
JP (1) | JP2011510174A (ru) |
CN (1) | CN101952467A (ru) |
RU (1) | RU2010133971A (ru) |
WO (1) | WO2009126347A2 (ru) |
Families Citing this family (13)
Publication number | Priority date | Publication date | Assignee | Title |
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KR101526660B1 (ko) | 2013-05-07 | 2015-06-05 | 현대자동차주식회사 | 복합 미세조직을 갖는 내마모성 합금 |
KR101526661B1 (ko) | 2013-05-07 | 2015-06-05 | 현대자동차주식회사 | 복합 미세조직을 갖는 내마모성 합금 |
KR101526656B1 (ko) | 2013-05-07 | 2015-06-05 | 현대자동차주식회사 | 복합 미세조직을 갖는 내마모성 합금 |
WO2015108217A1 (ko) * | 2014-01-17 | 2015-07-23 | 한국생산기술연구원 | 주조방법 및 주조장치 |
JP6385683B2 (ja) * | 2014-02-07 | 2018-09-05 | 本田技研工業株式会社 | Al合金鋳造物及びその製造方法 |
CN104018043B (zh) * | 2014-06-19 | 2016-08-24 | 芜湖市泰美机械设备有限公司 | 一种高强度航空用铸造铝合金及其热处理方法 |
US10941473B2 (en) | 2015-09-03 | 2021-03-09 | Questek Innovations Llc | Aluminum alloys |
RU2610578C1 (ru) * | 2015-09-29 | 2017-02-13 | Общество с ограниченной ответственностью "Объединенная Компания РУСАЛ Инженерно-технологический центр" | Высокопрочный сплав на основе алюминия |
US11603583B2 (en) | 2016-07-05 | 2023-03-14 | NanoAL LLC | Ribbons and powders from high strength corrosion resistant aluminum alloys |
JP6969568B2 (ja) * | 2016-10-31 | 2021-11-24 | 住友電気工業株式会社 | アルミニウム合金線、アルミニウム合金撚線、被覆電線、及び端子付き電線 |
JP7465803B2 (ja) | 2017-11-28 | 2024-04-11 | クエステック イノベーションズ リミテッド ライアビリティ カンパニー | 付加製造等の用途向けのAl-Mg-Si合金 |
CN108467979B (zh) * | 2018-06-25 | 2020-12-29 | 上海交通大学 | 一种金属型重力铸造铝合金材料及其制备方法 |
EP4372114A1 (en) | 2022-11-16 | 2024-05-22 | Fundación Tecnalia Research & Innovation | Multicomponent aluminium alloys with improved hot cracking properties and reduced porosity |
Citations (8)
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US5055257A (en) * | 1986-03-20 | 1991-10-08 | Aluminum Company Of America | Superplastic aluminum products and alloys |
US5597529A (en) * | 1994-05-25 | 1997-01-28 | Ashurst Technology Corporation (Ireland Limited) | Aluminum-scandium alloys |
JPH09279284A (ja) * | 1995-06-14 | 1997-10-28 | Furukawa Electric Co Ltd:The | 耐応力腐食割れ性に優れた溶接用高力アルミニウム合金 |
WO2004090185A1 (en) * | 2003-04-10 | 2004-10-21 | Corus Aluminium Walzprodukte Gmbh | An al-zn-mg-cu alloy |
WO2005049878A2 (en) * | 2003-10-29 | 2005-06-02 | Corus Aluminium Walzprodukte Gmbh | Method for producing a high damage tolerant aluminium alloy |
US20050238528A1 (en) * | 2004-04-22 | 2005-10-27 | Lin Jen C | Heat treatable Al-Zn-Mg-Cu alloy for aerospace and automotive castings |
WO2006127812A2 (en) * | 2005-05-25 | 2006-11-30 | Howmet Corporation | AN Al-Zn-Mg-Cu-Sc HIGH STRENGTH ALLOY FOR AEROSPACE AND AUTOMOTIVE CASTINGS |
RU2293783C1 (ru) * | 2005-08-30 | 2007-02-20 | Федеральное государственное унитарное предприятие "Всероссийский научно-исследовательский институт авиационных материалов" (ФГУП "ВИАМ") | Сплав на основе алюминия и изделие, выполненное из него |
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US6524410B1 (en) * | 2001-08-10 | 2003-02-25 | Tri-Kor Alloys, Llc | Method for producing high strength aluminum alloy welded structures |
-
2009
- 2009-01-16 RU RU2010133971/02A patent/RU2010133971A/ru unknown
- 2009-01-16 EP EP09730142A patent/EP2252716A2/en not_active Withdrawn
- 2009-01-16 JP JP2010543275A patent/JP2011510174A/ja active Pending
- 2009-01-16 CN CN2009801026580A patent/CN101952467A/zh active Pending
- 2009-01-16 US US12/863,148 patent/US20110044843A1/en not_active Abandoned
- 2009-01-16 WO PCT/US2009/031251 patent/WO2009126347A2/en active Application Filing
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US5055257A (en) * | 1986-03-20 | 1991-10-08 | Aluminum Company Of America | Superplastic aluminum products and alloys |
US5597529A (en) * | 1994-05-25 | 1997-01-28 | Ashurst Technology Corporation (Ireland Limited) | Aluminum-scandium alloys |
JPH09279284A (ja) * | 1995-06-14 | 1997-10-28 | Furukawa Electric Co Ltd:The | 耐応力腐食割れ性に優れた溶接用高力アルミニウム合金 |
WO2004090185A1 (en) * | 2003-04-10 | 2004-10-21 | Corus Aluminium Walzprodukte Gmbh | An al-zn-mg-cu alloy |
WO2005049878A2 (en) * | 2003-10-29 | 2005-06-02 | Corus Aluminium Walzprodukte Gmbh | Method for producing a high damage tolerant aluminium alloy |
US20050238528A1 (en) * | 2004-04-22 | 2005-10-27 | Lin Jen C | Heat treatable Al-Zn-Mg-Cu alloy for aerospace and automotive castings |
WO2006127812A2 (en) * | 2005-05-25 | 2006-11-30 | Howmet Corporation | AN Al-Zn-Mg-Cu-Sc HIGH STRENGTH ALLOY FOR AEROSPACE AND AUTOMOTIVE CASTINGS |
RU2293783C1 (ru) * | 2005-08-30 | 2007-02-20 | Федеральное государственное унитарное предприятие "Всероссийский научно-исследовательский институт авиационных материалов" (ФГУП "ВИАМ") | Сплав на основе алюминия и изделие, выполненное из него |
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Also Published As
Publication number | Publication date |
---|---|
JP2011510174A (ja) | 2011-03-31 |
EP2252716A2 (en) | 2010-11-24 |
US20110044843A1 (en) | 2011-02-24 |
RU2010133971A (ru) | 2012-02-27 |
WO2009126347A3 (en) | 2010-09-30 |
CN101952467A (zh) | 2011-01-19 |
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