Classifications

• • 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
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
  • B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
• • 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
  • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
• • 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
  • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
  • C22C21/04—Modified aluminium-silicon alloys
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
  • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
  • F02F3/00—Pistons 
  • F02F3/0084—Pistons  the pistons being constructed from specific materials

Definitions

• the present invention relates to a method for
• Aluminum alloy is cast by gravity die casting, an engine component, which consists at least partially of an aluminum alloy, and the use of an aluminum alloy for producing such
• Combustion temperatures and combustion pressures can be used, which is essentially by always
• a piston for an internal combustion engine must have a high heat resistance and at the same time be as light and strong as possible. It is of particular importance how the microstructural distribution, morphology, composition and thermal stability of highly heat-resistant phases are formed. An optimization in this regard usually takes into account a minimum content of pores and oxide inclusions.
• the material sought must be both in terms of isothermal fatigue strength (HCF) and in terms of
• thermomechanical fatigue strength (TMF) optimized become.
• TMF thermomechanical fatigue strength
• the described aluminum alloy comprises 8.0 to 10.0% by weight of silicon, 0.8 to 2.0% by weight of magnesium, 4.0 to 5.9% by weight of copper, 1.0 to 3.0 Wt% nickel, 0.2-0.4 wt% manganese, less than 0.5 wt% iron, and at least one element selected from antimony, zirconium, titanium, strontium, cobalt, chromium, and vanadium wherein at least one of these elements is present in an amount of> 0.3% by weight, the sum of these elements being ⁇ 0.8% by weight.
• EP 0 924 310 Bl describes an aluminum-silicon alloy which has its application in the production of pistons, in particular for pistons in internal combustion engines.
• the aluminum alloy has the following composition: 10.5 to 13.5% by weight of silicon, 2.0 to less than 4.0% by weight of copper 0.8 to 1.5% by weight of magnesium, 0, 5 to 2.0% by weight of nickel, 0.3 to 0.9% by weight of cobalt, at least 20 ppm
• Phosphorus and either 0.05 to 0.2% by weight of titanium or up to 0.2% by weight of zirconium and / or up to 0.2% by weight of vanadium and balance aluminum and unavoidable impurities.
• WO 00/71767 A1 describes an aluminum alloy suitable for high temperature applications, e.g.
• the aluminum alloy is composed of the following elements: 6.0 to 14.0% by weight
• Silicon 3.0 to 8.0% by weight of copper, 0.01 to 0.8% by weight of iron, 0.5 to 1.5% by weight of magnesium, 0.05 to 1.2% by weight.
• % Nickel 0.01 to 1.0% by weight manganese, 0.05 to 1.2% by weight
• Titanium 0.05 to 1.2% by weight zirconium, 0.05 to 1.2% by weight vanadium, 0.001 to 0.10% by weight strontium and the remainder
• Cast aluminum alloy contains: 0.2 or less wt%
• Phosphorus from 0.02 to 0.3% by weight of zirconium and balance
• the size of a non-metallic inclusion present within the bulb is less than 100 ⁇ , ⁇ .
• EP 1 975 262 B1 describes an aluminum casting alloy consisting of: 6 to 9% silicon, 1.2 to 2.5% copper, 0.2 to 0.6% magnesium, 0.2 to 3% nickel, 0.1 to 0.7% iron, 0.1 to 0.3% titanium, 0.03 to 0.5% zirconium, 0.1 to 0.7% manganese, 0.01 to 0.5% vanadium and one or more of the following elements: strontium 0.003 to 0.05%, antimony 0.02-0.2% and sodium 0.001-0.03%, the total amount of titanium and zirconium being less than 0.5% and
• Aluminum and unavoidable impurities make up the remainder when the total amount is taken as 100 mass percent.
• WO 2010/025919 A2 describes a method for
• the invention provides that the copper content is at most 5.5% of the aluminum-silicon alloy and that the aluminum-silicon alloy portions of titanium (Ti), zirconium (Zr), chromium (Cr) or vanadium (V) are admixed and the sum of all ingredients is 100%.
• the application DE 102011083969 relates to a method for producing an engine component, in particular a piston for an internal combustion engine, in which an aluminum alloy is poured by gravity die casting method, an engine component, at least partially from a
• the aluminum alloy for producing an engine component.
• the aluminum alloy has the following alloying elements: 6 to 10 wt .-% silicon, 1.2 to 2 wt .-% nickel, 8 to 10 wt .-% copper, 0.5 to 1.5 wt .-% magnesium , 0.1 to 0.7% by weight of iron, 0.1 to 0.4% by weight of manganese, 0.2 to 0.4% by weight of zirconium, 0.1 to 0.3% by weight Vanadium, 0.1 to 0.5 wt -.% Titanium and aluminum and avoidable impurities as the remainder.
• this alloy has a phosphorus content of less than 30 ppm. Presentation of the invention
• An object of the present invention is to provide a method for producing an engine component, in particular a piston for an internal combustion engine, in which an aluminum alloy in
• Gravity die casting process is poured off, so that a highly heat resistant engine component in the
• Another object of the invention is a
• Engine component in particular a piston for a
• Combustion engine to provide, which is the highest heat resistant and at least partially from a
• Nickel > 2.0% by weight - -% to ⁇ 3.5% by weight -%
• Cobalt up to ⁇ 1% by weight
• Magnesium 0, 5 Gew. -% to 1, 5 Gew. -%,
• Zirconium > 0.1% by weight - -% to ⁇ 0.2% by weight
• Vanadium > 0.1% by weight to ⁇ 0.2% by weight
• Titanium 0.05% by weight to ⁇ 0.2% by weight
• the aluminum alloy has from> about 9 to about 10.5, more preferably ⁇ about 10, more preferably ⁇ about 9.5, or even more preferably from about 9.5 to about 10.5 weight percent silicon; from> about 2.3, more preferably> about 3 to ⁇ about 3.5 or more preferably from about 2.5, more preferably from about 2.9 to about 3 weight percent nickel; from> about 3.8, more preferably> about 4 and especially preferably> about 4.8 to about 5.2 or more preferably from> about 3.7 to about ⁇ 5, more preferably ⁇ 4 or even more preferably about 4, especially preferably about 4.1 to about 4.6% by weight copper; from> about 0.5 and more preferably> about 0.9 to ⁇ about 1 wt% cobalt; from about 0.5 and more preferably> about 0.6 and especially about 0.7 to ⁇ about 1.5, more preferably ⁇ about 0.8 or more preferably from> about 1, more preferably> about 1.3 to about 1, 5% by weight of magnesium; from> about 0.5, more preferably> about 0.6 to about 0.7, or
• the selected aluminum alloy it is possible in the gravity die casting process, an engine component
• the alloy according to the invention in particular the
• Gravity die casting process can be produced.
• Zirconium, vanadium and titanium provide an advantageous proportion of strength enhancing precipitates without, however, causing large plate-shaped intermetallic phases. Furthermore, the proportions of cobalt and nickel according to the invention are advantageous for increasing the
• the aluminum alloy preferably comprises from 0.6% to 0.8% by weight of magnesium, which in the preferred
• the alloy has alternatively or additionally
• Adhesive tendency of the alloy in the casting mold advantageously reduced, wherein in the said concentration range, the formation of plate-shaped phases remains limited.
• Manganese in the aluminum alloy is at most about 5: 1, preferably about 2.5: 1. In this embodiment, the
• Aluminum alloy so at most five parts of iron to one part of manganese, preferably about 2.5 parts of iron over a part of manganese. By this ratio particularly advantageous strength properties of the engine component can be achieved.
• the sum of nickel and cobalt is> 2.0 wt% and ⁇ 3.8 wt%.
• the lower limit ensures an advantageous strength of the alloy and the upper limit advantageously ensures a fine microstructure and avoids the formation of coarse, plate-shaped phases which would reduce the strength.
• the aluminum alloy has a fine
• a low content of pores is preferably to be understood as meaning a porosity of ⁇ 0.01% and less than a few primary silicon ⁇ 1%.
• the fine microstructure advantageously characterized in that the average length of the primary silicon about ⁇ 5 ⁇ and whose maximum length is about ⁇ 10 ⁇ and the intermetallic phases and / or primary precipitates have lengths of on average about ⁇ 30 ⁇ and a maximum ⁇ 50 ⁇ ,
• the aluminum alloy in particular in the trough edge region, has an average value of an area of silicon precipitates ⁇ about 100 ⁇ m 2 and / or an average value of an area of the intermetallic phases ⁇ about 200 ⁇ m 2 .
• Aluminum alloy is preferably carried out by quantitative microstructure analysis. For this purpose, first a metallographic cut is made and micrographically corresponding micrographs are recorded, in particular for the technologically particularly important bowl rim area. By way of example, an inverted reflected-light microscope can be used for this purpose. Thus, at a defined magnification, individual images are taken, compiled by computer into a surface (for example 5.5 mm ⁇ 4.1 mm) and the areas and surface portions of specific phases determined by means of image processing software.
• the fine microstructure contributes in particular to the improvement of the thermomechanical fatigue strength.
• An engine component according to the invention exists at least
• Another independent aspect of the invention resides in the use of the above-described aluminum alloy for the manufacture of an engine component, in particular a piston of an internal combustion engine.
• the found Aluminum alloy processed by gravity die casting process.
• vanadium 0.12% by weight of titanium and 0.006% by weight of phosphorus and an alloy 3 containing 9.5% by weight of silicon; 2.5% by weight nickel; 4.6% by weight of copper; 0.7% by weight of magnesium; 0.45% by weight of iron; 0.2% by weight of manganese; 0.19 wt% zirconium; 0.14% by weight
• vanadium 0.11 wt .-% titanium and 0.005 wt .-% phosphorus and in each case as the balance aluminum and unavoidable

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Materials Engineering (AREA)
• Metallurgy (AREA)
• Organic Chemistry (AREA)
• General Engineering & Computer Science (AREA)
• Combustion & Propulsion (AREA)
• Pistons, Piston Rings, And Cylinders (AREA)
• Molds, Cores, And Manufacturing Methods Thereof (AREA)

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• 2012
  • 2012-11-14 DE DE102012220765.1A patent/DE102012220765A1/de not_active Ceased
• 2013
  • 2013-11-14 EP EP13798957.0A patent/EP2920334B1/de active Active
  • 2013-11-14 US US14/442,615 patent/US10022788B2/en active Active
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