WO2015141191A1 - Hélice de compresseur coulée à partir d'un alliage d'al et son procédé de production - Google Patents

Hélice de compresseur coulée à partir d'un alliage d'al et son procédé de production Download PDF

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Publication number
WO2015141191A1
WO2015141191A1 PCT/JP2015/001340 JP2015001340W WO2015141191A1 WO 2015141191 A1 WO2015141191 A1 WO 2015141191A1 JP 2015001340 W JP2015001340 W JP 2015001340W WO 2015141191 A1 WO2015141191 A1 WO 2015141191A1
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Prior art keywords
alloy
mass
casting
molten metal
compressor impeller
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PCT/JP2015/001340
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English (en)
Japanese (ja)
Inventor
貴司 久保
高橋　功一
俊男 牛山
石川　宣仁
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株式会社Uacj
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Priority to EP15764543.3A priority Critical patent/EP3121303B1/fr
Priority to CN201580014056.5A priority patent/CN106170572A/zh
Priority to US15/125,185 priority patent/US20170107600A1/en
Priority to JP2016508521A priority patent/JPWO2015141191A1/ja
Publication of WO2015141191A1 publication Critical patent/WO2015141191A1/fr

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    • 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
    • C22F1/057—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 copper as the next major constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/22—Moulds for peculiarly-shaped castings
    • B22C9/28—Moulds for peculiarly-shaped castings for wheels, rolls, or rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
    • B22D15/005—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor of rolls, wheels or the like
    • 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
    • B22D17/20—Accessories: Details
    • B22D17/2015—Means for forcing the molten metal into the die
    • B22D17/203—Injection pistons
    • 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
    • B22D18/00—Pressure casting; Vacuum casting
    • B22D18/06—Vacuum casting, i.e. making use of vacuum 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
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product
    • B22D25/02—Special casting characterised by the nature of the product by its peculiarity of shape; of works of art
    • 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
    • C22C21/12—Alloys based on aluminium with copper as the next major constituent
    • C22C21/16—Alloys based on aluminium with copper as the next major constituent with magnesium
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/02—Selection of particular materials
    • F04D29/023—Selection of particular materials especially adapted for elastic fluid pumps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/26—Rotors specially for elastic fluids
    • F04D29/28—Rotors specially for elastic fluids for centrifugal or helico-centrifugal pumps for radial-flow or helico-centrifugal pumps
    • F04D29/284—Rotors specially for elastic fluids for centrifugal or helico-centrifugal pumps for radial-flow or helico-centrifugal pumps for compressors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/10—Metals, alloys or intermetallic compounds
    • F05D2300/17—Alloys
    • F05D2300/173—Aluminium alloys, e.g. AlCuMgPb

Definitions

  • the present invention relates to a compressor impeller made of an aluminum alloy casting used for a turbocharger for an internal combustion engine of an automobile or a ship, and a manufacturing method thereof.
  • Turbochargers used in internal combustion engines for automobiles and ships are provided with a compressor impeller for compressing air by high speed rotation and supplying the compressed air to the internal combustion engine.
  • This compressor impeller reaches a high temperature of about 150 ° C. during high-speed rotation, and high stress is generated in the vicinity of the rotation center, particularly in the disk portion due to torsional stress or centrifugal force from the rotating shaft.
  • Compressor impellers are made of various materials according to the required performance of the turbocharger. For large-scale applications such as for ships, an aluminum alloy hot forging material cut into an impeller shape is usually used. For relatively small vehicles such as passenger cars and trucks, and small ships, mass productivity and cost are important.
  • JIS-AC4CH Al-7% Si-0.3% Mg alloy
  • ASTM-354.0 Al-9% Si-1.8% Cu-0.5% Mg alloy
  • ASTM-C355.0 Al-5% Si-1.3% Cu-0.5% Mg alloy
  • a gypsum mold plaster mold
  • the composition of the aluminum alloy to, for example, JIS-AC1B (Al-5% Cu-0.3% Mg alloy) having superior high-temperature strength.
  • JIS-AC1B Al-5% Cu-0.3% Mg alloy
  • Patent Document 2 in the case of a complicated shape such as a compressor impeller and a thin blade portion, an alloy such as JIS-AC1B lacks good fluidity of the molten metal, There was a problem in that poor hot water filling (filling failure) was likely to occur in the thin wall portion.
  • Patent Document 2 in order to solve the above-mentioned problem, an Al—Si based easily castable alloy such as AC4CH is used for the blade portion regarded as having a hot water property, and is coupled to a rotating shaft that requires strength.
  • a method has been proposed in which a high-strength alloy such as AC1B, such as AC1B, is used from the boss portion to the disk portion, and these are poured in two portions and combined to form a compressor impeller.
  • Patent Document 3 an alloy having good castability is used for the blade part, and aluminum is impregnated with a reinforcing material such as an aluminum whisker containing 25% B from the boss part to which stress is applied to the center part of the disk part.
  • a reinforcing material such as an aluminum whisker containing 25% B from the boss part to which stress is applied to the center part of the disk part.
  • Patent Document 4 proposes a method of joining a blade part and a boss part (and a disk part) by friction welding.
  • the method in which different materials are used in combination with each part still has the problem that the productivity is inferior and the cost increases, and industrialization has not yet been achieved.
  • Patent Document 5 discloses that a single alloy can be cast by optimizing the range of elements contained in an Al—Cu—Mg based alloy and the combination thereof.
  • a compressor impeller having a proof stress at 250 ° C. of 250 MPa or more has been proposed.
  • Patent Document 6 discloses that the yield of casting at 200 ° C. is improved to 260 MPa or more by further improving the range of elements contained in the Al—Cu—Mg based alloy and the combination thereof to control the crystal grain size to improve the casting yield. Compressor impellers have been proposed.
  • the present invention has been made in view of the above-mentioned problems, and an aluminum alloy (hereinafter referred to as “Al alloy”) that has a stable strength over a long period of time even at a use temperature of about 200 ° C. and has excellent productivity. It is an object of the present invention to provide a cast compressor impeller and a manufacturing method thereof.
  • the present inventors have focused on the disk portion of the compressor impeller to which high stress is applied, and found that the strength of the disk portion is dramatically improved when the intermetallic compound at the end of the disk portion is finely dispersed. It was.
  • the manufacturing method for finely dispersing the intermetallic compound is intensively studied, and it is important for the fine dispersion of the intermetallic compound to refine the primary crystal grains. For this purpose, the cooling rate of the molten Al alloy is controlled.
  • the inventors have obtained the knowledge that it is important to control the distribution of fine particles in the compressor impeller and have completed the present invention.
  • the disk portion excluding the boss portion, the plurality of blade portions, and the end portion is Cu: 1.4.
  • Mg 1.0 to 2.0 mass%
  • Ni 0.5 to 2.0 mass%
  • Fe 0.5 to 2.0 mass%
  • Ti 0.01 to 0.35 mass%
  • B 0.002 to 0.070 mass%
  • the end of the disk portion has Cu: 1.4 to 3.2 mass%, Mg: 1.
  • the compressor impeller made of an Al alloy casting according to the first aspect of the present invention is used for a large-sized ship application, and the height of the boss portion, the diameter of the disk portion, and the height of the blade portion are 200 to 80 mm, 300 to 100 mm, and 180 to 60 mm, the blade tip thickness was 4.0 to 0.4 mm, and the number of blades was 30 to 10.
  • the compressor impeller made of an Al alloy casting according to the first aspect of the present invention is used for small applications such as automobiles, and the height of the boss portion, the diameter of the disk portion, and the height of the blade portion are 100 It is assumed that the blade tip thickness is 3.0 to 0.1 mm, and the number of blades is 20 to 4 mm.
  • Cu 1.4-3.2 mass%
  • Mg 1.0-2.0 mass%
  • Ni 0.5-2.0 mass%
  • Fe 0.5-2.0 mass 720 to 780 ° C.
  • a melt preparation step further containing 0.01 to 0.35 mass%
  • B 0.002 to 0.070 mass%; cooling at 100 to 250 ° C.
  • the prepared Al is passed through the molten metal inflow hole.
  • a casting process for casting an Al alloy casting by a pressure casting method for press-fitting wherein a casting flow rate of the molten metal in the molten metal inflow hole into the space is 0.12 to 1.00 m / second;
  • the cooling rate of the end of the disk portion is 0.1 to 200 ° C./second in the casting step.
  • the present invention is that in claim 6 or claim 4 or 5, in the solution treatment step, the Al alloy casting is heat-treated at a temperature lower by 5 to 25 ° C. than the solidus temperature of the Al alloy for 2 hours or more. In the aging treatment step, the solution-treated Al alloy casting was heat treated at 180 to 230 ° C. for 3 to 30 hours.
  • an aluminum alloy cast compressor impeller that exhibits stable heat resistance over a long period of time even in a high temperature region around 200 ° C. and is excellent in productivity such as casting yield.
  • the heat resistance strength is stable and excellent over a long period of time means that deformation and fatigue failure do not occur over a long period of time even at a use temperature of about 200 ° C. Specifically, it is assumed that there is no damage due to a turbo assembling durability test at 200 ° C. and 150,000 rpm ⁇ 200 hours.
  • FIG. 1 shows an example of the shape of an aluminum alloy cast compressor impeller (hereinafter simply referred to as “compressor impeller”) according to the present embodiment.
  • the compressor impeller 1 includes a rotation center shaft (boss part) 2, a disk part 3 integrally connected to the rotation center shaft 2, and a plurality of thin blades 4 protruding from the disk part 3.
  • the temperature of the compressor impeller 1 reaches a high temperature of about 200 ° C. during high speed rotation, and a large repetitive stress is generated in the vertical direction particularly at the end of the disk portion.
  • Cu, Mg Cu and Mg are dissolved in the Al matrix and have the effect of improving mechanical strength by solid solution strengthening. Further, the coexistence of Cu and Mg contributes to an improvement in strength by precipitation strengthening of Al 2 Cu, Al 2 CuMg and the like. However, since these two elements are elements that expand the solidification temperature range, excessive inclusion deteriorates the castability.
  • the Cu content is less than 1.4 mass% (hereinafter simply referred to as “%”) and / or when the Mg content is less than 1.0%, the machine required at a high temperature of 200 ° C. Strength cannot be obtained.
  • the Cu content exceeds 3.2% and / or when the Mg content exceeds 2.0%, the castability as a compressor impeller is inferior, and particularly, the hot water around the blade tip is reduced. Insufficient thickness is likely to occur.
  • the Cu content is set to 1.4 to 3.2%, and the Mg content is set to 1.0 to 2.0%.
  • the Cu content is set to 1.7. It is preferable that the content is 2.8% and the Mg content is 1.3-1.8%.
  • Ni, Fe Ni and Fe form an intermetallic compound together with Al, which is dispersed in the Al matrix, and has the effect of improving the high temperature strength of the Al alloy.
  • the Ni content is 0.5% or more
  • the Fe content is also 0.5% or more.
  • both elements are contained excessively, not only the intermetallic compound becomes coarse, but also Cu 2 FeAl 7 and Cu 3 NiAl 6 are formed at a high temperature to reduce the amount of solid solution Cu in the Al matrix. Will reduce the strength.
  • these intermetallic compounds are coarse at the end of the disk portion, the compressor impeller is damaged starting from these intermetallic compounds due to repeated stress applied to the end of the disk portion.
  • the Ni content is 2.0% or less and the Fe content is 2.0% or less.
  • the Ni content is 0.5 to 2.0% and the Fe content is 0.5 to 2.0%. It is preferable that the Ni content is 0.5 to 1.4% and the Fe content is 0.7 to 1.5%.
  • the lower limit value of the above preferred range is a guide value for industrially stable mass production by reducing variation during production, and the upper limit value is a content that is saturated and the content beyond this is wasted This is a guideline for the amount.
  • Ti, B Ti and B are added to exert the effect of suppressing the growth of primary aluminum crystal grains during casting, so that the solidification structure during casting is refined to improve the replenishability of the molten metal and the effect of improving the meltability.
  • the Ti content is less than 0.01% and / or B content is less than 0.002% in the disk part excluding the boss part, the plurality of blade parts, and the end part, and Ti content in the end part of the disk part. Is less than 0.005% and / or when the B content is less than 0.001%, the above effects cannot be obtained sufficiently.
  • the Ti content exceeds 0.35% and / or the B content exceeds 0.070% in the disk part excluding the boss part, the plurality of blade parts, and the end part, and the end of the disk part
  • the Ti content exceeds 0.175% and / or the B content exceeds 0.035% in the part
  • aggregates of finer particles are generated, and fatigue cracks start from the aggregates. Will occur.
  • the Ti content in each part exceeds 0.35%, a coarse intermetallic compound with a size of several tens to several hundreds of ⁇ m is formed together with Al, which becomes a starting point of fatigue cracks during rotation, and reliability as a compressor impeller Reduce.
  • the Ti content is 0.01 to 0.35% and the B content is 0.002 to 0.070%, preferably Has a Ti content of 0.15 to 0.30% and a B content of 0.003 to 0.060%. Further, at the end of the disk portion, the Ti content is 0.005 to 0.175% and the B content is 0.001 to 0.035%, preferably the Ti content is 0.010 to 0%. 165% and B content is 0.002 to 0.033%.
  • the aluminum alloy used in the present invention is a pressure casting method (low pressure casting method, reduced pressure casting method or differential pressure method) using a gypsum mold (plaster mold) in accordance with a conventional method for producing an Al—Si aluminum alloy casting. By casting method) into a compressor impeller shape.
  • the pressure casting method using a gypsum mold relates the distribution of the intermetallic compounds within each casting, at the end of the disk portion, there was intermetallic compounds with a circle equivalent diameter of 1 ⁇ 6 [mu] m is 10000 / mm 2 or more and, it is necessary to control the production conditions so that the intermetallic compound having a circle equivalent diameter of greater than 6 ⁇ m exists 500 / mm 2 or less.
  • the present inventors have applied a high repetitive vertical stress generated by the acceleration / deceleration of the rotation of the compressor impeller to the end of the disk part, and the circle exceeding 6 ⁇ m existing at the end of the disk part. It was found that a coarse intermetallic compound having an equivalent diameter becomes a starting point of cracks and breaks as these cracks progress. Further, when the surface density of the intermetallic compound having a circle-equivalent diameter exceeding 6 ⁇ m is 500 pieces / mm 2 or less at the end of the disk portion by further study, cracks originating from these intermetallic compounds It has been found that the occurrence is suppressed and that the propagation is suppressed even if a crack occurs.
  • any intermetallic compounds with a circle equivalent diameter of 1 ⁇ 6 [mu] m is 10000 / mm 2 or more, it has also been found that the generation of the coarse intermetallic compound is suppressed.
  • the amount of intermetallic compound produced is determined by the composition under general casting conditions.
  • “General casting conditions” refers to a cooling rate by low-pressure casting, specifically 0.1 to 200 ° C./second.
  • generated at the time of casting is not influenced greatly by subsequent heat processing. Therefore, by producing a large amount of fine intermetallic compounds at the time of casting, it is possible to suppress the formation of coarse intermetallic compounds by subsequent heat treatment.
  • the reason why the surface density of the intermetallic compound having a circle-equivalent diameter of 1 to 6 ⁇ m is 10,000 pieces / mm 2 or more is as follows. An intermetallic compound having an equivalent circle diameter of less than 1 ⁇ m does not affect the compressor impeller strength. In addition, when the surface density of the intermetallic compound having an equivalent circle diameter of 1 to 6 ⁇ m is less than 10,000 / mm 2 , the production of the intermetallic compound having an equivalent circle diameter exceeding 6 ⁇ m is promoted and exceeds 6 ⁇ m to be generated. Cracks start from an intermetallic compound having an equivalent circle diameter.
  • the upper limit value of the surface density is not particularly limited, but is determined by the composition of Al alloy and manufacturing conditions. In the present invention, the upper limit value is 30000 pieces / mm 2 .
  • the reason why the surface density of the intermetallic compound having a circle-equivalent diameter exceeding 6 ⁇ m is 500 pieces / mm 2 or less is as follows. As described above, an intermetallic compound having an equivalent circle diameter exceeding 6 ⁇ m is targeted. Moreover, when this areal density exceeds 500 piece / mm ⁇ 2 >, the separation distance of these intermetallic compounds becomes close, and propagation of a crack advances.
  • the lower limit value of the surface density is not particularly limited, and is determined by the composition and production conditions of the Al alloy. In the present invention, 100 pieces / mm 2 is preferable, and 0 pieces / mm 2 is most preferable. .
  • intermetallic compound produced in the present invention examples include Al—Fe—Ni—Cu, Al—Fe—Cu—Ni—Mg, Al—Cu—Mg, Al—Cu, and Al—Cu—Mg—Si. And intermetallic compounds such as Al—Cu—Fe, Al—Ni, Al—Mg, and Mg—Si.
  • the equivalent circle diameter of the intermetallic compound to be generated varies in the range of 0.1 to 20.0 ⁇ m, although it varies depending on the composition of Al alloy and the manufacturing conditions.
  • the equivalent circle diameter means the equivalent circle diameter.
  • Control of the component amount of the micronizing agent at the end of the disk part In controlling the distribution of the intermetallic compound, it is important to control the size of the primary aluminum crystal grains. This is because the intermetallic compound is generated at the grain boundary of primary aluminum crystal grains. In order to control the size of primary aluminum crystal grains, the component amount of the micronizing agent and the cooling rate described later are important control factors.
  • Appropriate component amounts of Ti and B at the end of the disk portion are Ti: 0.005 to 0.175% and B: 0.001 to 0.035%.
  • a refiner composed of Al, Ti and B is added during the melt preparation step, and the Ti and B component amounts in the molten aluminum alloy after the melt preparation step are set to Ti: 0. 0.01 to 0.35%, B: 0.002 to 0.070%.
  • the product-shaped space composed of the gypsum mold and the cooling metal is configured such that the gypsum mold with the molten metal inflow hole provided in the lower part is disposed below and the cooling metal is disposed above.
  • the prepared Al alloy molten metal is press-fitted into the space through the molten metal inflow hole. Furthermore, the inflow speed of the molten metal in the molten metal inflow hole into this space is set to 0.12 to 1.00 m / sec.
  • a casting process for casting an Al alloy casting by a pressure casting method in which the adjusted molten metal is press-fitted into the space so as to satisfy the above requirements is employed.
  • a refiner composed of Al, Ti, and B is added as a refiner during the melt preparation step, but the Ti component amount in the molten aluminum alloy after the melt adjustment step is less than 0.01% and / or the B component amount is 0. If it is less than 0.002%, the primary aluminum crystal grains become coarse, and the intermetallic compounds at the grain boundaries also become coarse, thereby reducing the strength of the Al alloy material. Further, when the Ti component amount in the molten aluminum alloy after the molten metal adjustment step exceeds 0.35% and / or the B component amount exceeds 0.070%, coarse TiB 2 aggregates are generated, which It becomes the starting point of destruction. Therefore, the component amounts of Ti and B in the molten aluminum alloy after the step of adjusting the molten metal by adding the micronizing agent are set to Ti: 0.01 to 0.35% and B: 0.002 to 0.070%.
  • a product-shaped space composed of a plaster mold and a chiller will be described.
  • the plaster mold 7 is cooled downward, and the metal 6 is placed upward to form a product-shaped space 10 constituted by these.
  • the molten metal inflow hole 8 for making a molten metal flow in into the space 10 is provided in the lower part by the side of the gypsum mold 7.
  • the molten metal flows into the space 10 from the molten metal inflow hole 8 along the molten metal inflow direction 9 from the lower side to the upper side in the figure and is filled in the space 10.
  • the molten metal flowing into the space 10 is solidified while being filled from the lower side to the upper side of the space 10. Therefore, in the circumferential direction of the compressor impeller, the circumferential portion below the space 10 is solidified early, and the circumferential portion located above is solidified later, and a uniform solidification state in the circumferential direction is obtained. I can't get it. In a compressor impeller, uneven solidification in the circumferential direction causes bending of the shaft portion, resulting in poor balance when rotated at high speed.
  • the flow rate of the molten metal in the molten metal inflow hole is an important factor in controlling the content of the micronizing agent at the end of the disk portion.
  • the content of the finer particles composed of Ti and B reaching the end of the disk portion is reduced as compared with the content of the finer particles in the melt preparation step. This is because the movement of the finer particles does not follow the molten metal that moves during pressure casting in accordance with the law of inertia.
  • the molten metal inflow speed in the molten metal inflow hole exceeds 1.00 m / sec, the molten metal inflow speed is too high, and the degree of movement of the finer particles that move by inertia cannot follow the molten metal inflow speed increases.
  • the inflow speed of the melt in the melt inflow hole is less than 0.12 m / sec, the inflow speed of the melt is too slow, and the time until the melt reaches the gypsum mold through the stalk becomes longer. Lowers and causes poor coagulation.
  • the molten metal inflow rate in the molten metal inflow hole is preferably 0.20 to 0.85 m / sec.
  • the cooling rate at the end of the disk part is adjusted to a suitable range of 0.1 to 200 ° C./second.
  • cooling rate When the cooling rate is less than 0.1 ° C./second, primary aluminum crystal grains become coarse, and intermetallic compounds generated at the grain boundaries become coarse. Further, shrinkage nests are generated due to a decrease in cooling rate, and productivity is reduced. On the other hand, when the cooling rate exceeds 200 ° C./sec, the product shape cannot be ensured because a hot water defect occurs due to early solidification in the product shape space.
  • a more preferable range of the cooling rate at the end of the disk portion is 3 to 150 ° C./second.
  • the temperature of the molten metal is less than 720 ° C., the molten metal that has been injected solidifies in the product shape space at an early stage, resulting in poor hot water production and the product shape cannot be secured.
  • the temperature of the molten metal exceeds 780 ° C., the oxidation of the molten metal progresses, the increase in the number of generated porosity due to the absorption of hydrogen gas and the increase in the oxide deteriorate the molten metal quality, and it is difficult to ensure the product strength. Become.
  • the temperature of the cooling metal is less than 100 ° C.
  • the progress of solidification is too fast, resulting in poor hot water.
  • the temperature of the chilled metal exceeds 250 ° C.
  • solidification from the chilled metal is delayed, and the primary aluminum crystal grains become coarse due to a decrease in the cooling rate, resulting in coarse intermetallic compounds generated at the grain boundaries.
  • a so-called burr defect occurs in which hot water is inserted between the gypsum mold and the cooling metal.
  • the preheating temperature of the gypsum mold is not particularly limited, but it is preferably controlled to 200 to 350 ° C. If the preheating temperature of the gypsum mold is less than 200 ° C., solidification proceeds before the molten metal is filled at the tip of the mold, resulting in poor hot water and a product shape cannot be secured. On the other hand, when the preheating temperature of the gypsum mold exceeds 350 ° C., solidification in the gypsum mold is delayed and a shrinkage defect is generated.
  • the material of the cooling metal is preferably copper or copper alloy having high thermal conductivity, but iron, stainless steel, etc. can also be used.
  • a mechanism that suppresses overheating during casting through a cooling medium such as water inside the cooling metal.
  • This manufacturing method includes a melt preparation process, a casting process, and a heat treatment process.
  • each component element is added and melted by heating so as to achieve the above-described Al alloy composition, and molten metal treatment such as dehydrogenation gas treatment and inclusion removal treatment is performed. Then, the temperature is adjusted so that the final molten metal temperature is 720 to 780 ° C. Also, the amount of hydrogen gas in the molten metal is adjusted. As a method for adjusting the amount of hydrogen gas in the molten metal, a rotary gas blowing device is used, but is not limited thereto.
  • Casting process In the casting process, the molten metal whose temperature is adjusted to 720 to 780 ° C. is cast into a compressor impeller shape by a pressure casting method using a gypsum mold. As described above, the temperature of the cooling metal disposed on the surface in contact with the disk surface is adjusted to 100 ° C. to 250 ° C. As shown in FIG. 3, the product-shaped space composed of the gypsum mold and the cooling metal is arranged with the gypsum mold downward and the cooling metal disposed upward to form a product-shaped space composed of these. To do.
  • the molten metal inflow hole for making a molten metal flow in into a space along a molten metal inflow direction is provided in the lower part by the side of the gypsum mold 7.
  • the inflow speed of the molten metal in the molten metal inflow hole to the space is adjusted to 0.12 to 1.00 m / sec.
  • an Al alloy casting is cast by the pressure casting method in which the prepared molten Al alloy is press-fitted into the space.
  • Heat treatment process The cast Al alloy casting is subjected to a heat treatment process.
  • the heat treatment step includes a solution treatment step and an aging treatment step.
  • solid solution strengthening by Cu; precipitation strengthening by Cu and Mg; dispersion strengthening by an intermetallic compound formed by Al and Fe and by Al and Ni can be effectively utilized.
  • the solution treatment is preferably performed in a temperature range 5 to 25 ° C. lower than the solidus temperature.
  • the temperature range 5 to 25 ° C. lower than the solidus temperature is 510 to 530 ° C. If the temperature exceeds a temperature range lower by 5 to 25 ° C. than the solidus temperature, the risk of melting the second phase of the crystal grain boundary increases, and it becomes difficult to ensure the strength. On the other hand, at temperatures below this temperature range, element diffusion does not proceed sufficiently and sufficient solution is not achieved.
  • the solution treatment time is preferably 2 hours or longer. If it is less than 2 hours, element diffusion does not proceed sufficiently and sufficient solution is not achieved.
  • the solution time by element diffusion is not particularly limited as long as it is 2 hours or longer, but is preferably 30 hours or less in consideration of mass production.
  • the aging treatment is preferably heat treatment at 180 to 230 ° C. for 3 to 30 hours, more preferably heat treatment at 190 to 210 ° C. for 5 to 20 hours.
  • the treatment temperature is less than 180 ° C. or when the treatment time is less than 3 hours, precipitation strengthening for improving the strength may be insufficient.
  • the processing temperature exceeds 230 ° C. or when the processing time exceeds 30 hours, the formed precipitated phase becomes coarse (over-aged) and a sufficient strengthening action cannot be obtained. The solution strengthening ability decreases.
  • the shape and dimensions of the compressor impeller according to the present invention and the number of blades are not particularly limited, and can be applied to many uses such as large ships for ships and small applications such as automobiles. it can.
  • the height of the boss part, the diameter of the disk part and the height of the blade part are 200 to 80 mm, 300 to 100 mm, 180 to 60 mm, preferably 180 to 100 mm, respectively.
  • the blade tip thickness is 4.0 to 0.4 mm, preferably 3.0 to 0.6 mm.
  • the number of blades is 30 to 10, preferably 26 to 12.
  • the height of the boss, the diameter of the disk and the height of the blades are 100 to 20 mm, 120 to 25 mm, 90 to 5 mm, preferably 90 to 25 mm, respectively.
  • the blade tip thickness is 3.0 to 0.1 mm, preferably 2.0 to 0.2 mm.
  • the number of blades is 20 to 4, preferably 18 to 6.
  • the Al alloy molten metal prepared in the molten metal preparing step is a predetermined structure constituted by a gypsum mold adjusted to 250 ° C. and a copper cooling metal that is arranged on the surface in contact with the impeller disk surface and adjusted to the temperature shown in Table 1.
  • Low pressure that is injected into the space through a molten metal inflow hole provided in the lower part of the lower plaster mold (FIG. 3), the lateral part of the lateral plaster mold (FIG. 4) or the upper part of the upper plaster mold (FIG. 5).
  • An Al alloy casting was produced by a casting method.
  • This Al alloy cast compressor impeller is a compressor impeller for a passenger car turbocharger having a disk part diameter of 40 mm, a boss part height of 40 mm, 12 blades, a blade part height of 35 mm, and a blade tip thickness of 0.3 mm.
  • the direction of the molten metal flowing into the space composed of the plaster mold and the cooling metal is shown in Table 1, and the molten metal inflow rate into the space is shown in Table 1.
  • the molten metal is injected into the space under pressure. The pressure was maintained until solidification of the entire Al alloy casting was completed.
  • Density, amount of component of finer (Ti, B) at the end of the disk part, amount of component of finer (Ti, B) at a part other than the end of the disk part, high temperature characteristics (durability test evaluation), and The productivity (casting yield evaluation) was evaluated as follows.
  • FIG. 2 shows a cross section of one side of the central shaft 5 of the compressor impeller.
  • the end 31 of the disk portion was cut out and then polished, and imaged with an optical microscope at a magnification of 100 times.
  • the end portion 31 of the disk portion refers to a disk portion that is 20% from the outer periphery in the length from the outer periphery of the disk portion of the compressor impeller to the central axis 5 along the radial direction.
  • the surface density of an intermetallic compound having an equivalent circle diameter of 1 to 6 ⁇ m and the surface density of an intermetallic compound having an equivalent circle diameter exceeding 6 ⁇ m were measured.
  • 10 measurement locations were arbitrarily selected, and the arithmetic average value was used as the surface density.
  • the measurement field area of each measurement point was 1 mm 2. The results are shown in Table 2.
  • High-temperature fatigue strength was evaluated by an endurance test (turbo assembly, 150,000 rpm ⁇ 200 hours, outlet temperature 200 ° C.). The results are shown in Table 2.
  • “ ⁇ ” indicates that the sample was broken during the test, “ ⁇ ” indicates that the sample was not broken but cracked, and the sample was not broken or cracked and remained in a healthy state. In this case, “ ⁇ ” was assigned.
  • Comparative Example 1 the surface density of the intermetallic compound having a high temperature of the cooling metal, the surface density of the intermetallic compound having an equivalent circle diameter of 1 to 6 ⁇ m at the end of the disk portion is small, and the surface density of the intermetallic compound having an equivalent circle diameter exceeding 6 ⁇ m was big. As a result, the disk portion was broken at the end portion and inferior in the high temperature characteristics. Further, the shrinkage defect in the boss portion was frequently generated, and the casting yield was greatly reduced.
  • Comparative Example 5 there were few Cu components and the high temperature characteristics were good, but poor hot water in the blades occurred frequently, resulting in a decrease in casting yield.
  • Comparative Example 11 there were many Mg components and the high temperature characteristics were good, but poor hot water in the blades occurred frequently, resulting in a decrease in casting yield.
  • Comparative Example 12 the surface density of the intermetallic compound having a large amount of Fe component and having a circle-equivalent diameter exceeding 6 ⁇ m was large. As a result, cracks occurred in the disk portion and the high temperature characteristics were inferior.
  • Comparative Example 13 the surface density of the intermetallic compound having a large Ni component and having an equivalent circle diameter exceeding 6 ⁇ m was large. As a result, the disk portion cracked and the high temperature characteristics were inferior.
  • Second Example (Invention Examples 8 to 18 and Comparative Examples 21 to 26)
  • the Al alloy having the composition shown in the component column of Table 3 was melted by performing a normal molten metal treatment, and subjected to a molten metal preparation step in which the molten metal was adjusted to the temperature shown in Table 3.
  • a molten metal preparation step 150 kg of an Al alloy having the composition shown in the component column of Table 3 was melted to obtain a molten metal.
  • degassing was performed by blowing argon gas into the molten metal for 20 minutes under the conditions of a rotor rotation speed of 400 rpm and a gas flow rate of 2.5 Nm 3 / h using a rotating gas blowing device. Thereafter, the entire molten metal was sedated for 1 hour and removed.
  • a refiner composed of Ti and B shown in the component amount column of the refiner after preparation of the melt in Table 3 was added to the melt.
  • the Al alloy molten metal prepared in the molten metal preparing step is a predetermined structure composed of a gypsum mold adjusted to 220 ° C. and a copper chiller arranged on the surface in contact with the impeller disk surface and adjusted to the temperature shown in Table 3.
  • An Al alloy casting was produced by a low pressure casting method in which pressure was injected into the space.
  • This Al alloy casting compressor impeller is a compressor impeller for a truck turbocharger having a disk portion diameter of 80 mm, a boss portion height of 70 mm, a blade number of 14 pieces, a blade portion height of 60 mm, and a blade tip thickness of 0.4 mm. As shown in FIG.
  • the space constituted by the gypsum mold and the cooling metal is configured such that the gypsum mold in which the molten metal inflow hole is provided in the lower part is disposed below and the cooling metal is disposed above,
  • the direction of the molten metal flowing into the space was upward.
  • the molten metal inflow rate into the space was set to 0.75 m / second, and the molten metal was pressurized and injected into the space, and the pressure was maintained until solidification of the entire Al alloy casting was completed.
  • Comparative Example 25 no solution treatment step was performed, and in Comparative Example 26, an aging treatment step was not performed. As a result, all of them were broken at the disk portion and inferior in high temperature characteristics.
  • the Al alloy molten metal prepared in the molten metal preparing step is a predetermined structure composed of a gypsum mold adjusted to 220 ° C. and a copper chiller arranged on the surface in contact with the impeller disk surface and adjusted to the temperature shown in Table 5.
  • An Al alloy casting was produced by a low pressure casting method in which pressure was injected into the space.
  • This Al alloy casting compressor impeller is a compressor impeller for a marine turbocharger having a disk portion diameter of 150 mm, a boss portion height of 160 mm, a blade number of 16 pieces, a blade portion height of 120 mm, and a blade tip thickness of 0.6 mm. As shown in FIG.
  • the space constituted by the gypsum mold and the cooling metal is configured such that the gypsum mold in which the molten metal inflow hole is provided in the lower part is disposed below and the cooling metal is disposed above,
  • the direction of the molten metal flowing into the space was upward.
  • the molten metal inflow rate into the space was 0.95 m / second, and the molten metal was pressurized and injected into the space, and the pressure was maintained until solidification of the entire Al alloy casting was completed.
  • Density, amount of component of finer (Ti, B) at the end of the disk part, amount of component of finer (Ti, B) at a part other than the end of the disk part, high temperature characteristics (durability test evaluation), and The productivity (casting yield evaluation) was evaluated in the same manner as in the first example. The results are shown in Table 6.
  • Comparative Example 27 the melt temperature was high and the cooling rate was lowered, so that the surface density of the intermetallic compound having an equivalent circle diameter of 1 to 6 ⁇ m at the end of the disk portion was small, and the equivalent circle diameter exceeding 6 ⁇ m.
  • the surface density of the intermetallic compound was large. As a result, the appearance defect of the shrinkage cavity in the boss part frequently occurred, the casting yield was greatly reduced, and the disk part was broken and inferior in high temperature characteristics.
  • Comparative Example 28 the molten metal temperature was low, the appearance of hot water around the blade portion was frequent, the casting yield was lowered, and cracks were generated in the blade portion, resulting in poor high temperature characteristics.
  • Comparative Example 31 the solution treatment process was not performed, and in Comparative Example 32, the aging process was not performed. As a result, all of them were broken at the disk portion and inferior in high temperature characteristics.
  • the present invention it is possible to supply at low cost an Al alloy compressor impeller having excellent heat resistance and capable of stably withstanding an increase in temperature accompanying an increase in the rotational speed over a long period of time.
  • the present invention has an industrially significant effect that it can contribute to improving the output of the internal combustion engine by increasing the charging capability of the turbocharger.

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  • Engineering & Computer Science (AREA)
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  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Organic Chemistry (AREA)
  • Metallurgy (AREA)
  • Physics & Mathematics (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Thermal Sciences (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
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Abstract

L'invention concerne : une hélice de compresseur qui est coulée à partir d'un alliage d'aluminium, présente d'excellentes caractéristiques de production et présente une résistance à haute température stable lorsqu'elle est utilisée à des températures autour de 200° ; et son procédé de fabrication. L'hélice de compresseur qui est coulée à partir d'un alliage d'Al est pourvue d'une section de bossage, d'une pluralité de sections d'aube et d'une section de disque ; la section de bossage, la pluralité de sections d'aube, et la section de disque à l'exclusion de la section d'extrémité comprennent un alliage d'Al comprenant une composition de métal prédéterminée ; et au niveau de la section d'extrémité de la section de disque, il y a au moins 10 000/mm2 de composés intermétalliques ayant un diamètre équivalent au cercle de 1 à 6 μm, et il n'y a pas plus de 500/mm2 de composés intermétalliques ayant un diamètre équivalent au cercle dépassant 6 µm.
PCT/JP2015/001340 2014-03-15 2015-03-11 Hélice de compresseur coulée à partir d'un alliage d'al et son procédé de production WO2015141191A1 (fr)

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EP15764543.3A EP3121303B1 (fr) 2014-03-15 2015-03-11 Hélice de compresseur coulée à partir d'un alliage d'al et son procédé de production
CN201580014056.5A CN106170572A (zh) 2014-03-15 2015-03-11 Al合金铸件制压缩机叶轮及其制造方法
US15/125,185 US20170107600A1 (en) 2014-03-15 2015-03-11 Compressor impeller cast from al alloy and method for producing same
JP2016508521A JPWO2015141191A1 (ja) 2014-03-15 2015-03-11 Ａｌ合金鋳物製コンプレッサーインペラー及びその製造方法

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US10253782B2 (en) * 2013-12-13 2019-04-09 Showa Denko K.K. Shaped component for aluminum alloy turbo compressor wheel and method of manufacturing turbo compressor wheel
JP7020031B2 (ja) * 2017-09-28 2022-02-16 日本電産株式会社 インペラ、羽根車、送風装置、及び、送風装置の製造方法
JP2019065359A (ja) * 2017-10-03 2019-04-25 株式会社豊田自動織機 高温における機械的特性に優れたアルミニウム粉末合金製輸送機用圧縮機部品及びその製造方法
CN108730229B (zh) * 2018-05-22 2020-07-28 江苏昊科汽车空调有限公司 高强度压缩机叶轮
CN112743044A (zh) * 2020-12-29 2021-05-04 上海蓝铸特种合金材料有限公司 一种超细晶粒度高温合金叶轮的精密铸造方法
CN114309455B (zh) * 2021-12-17 2023-04-18 山东豪迈机械科技股份有限公司 一种消除石膏型铸造局部热节的方法

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US20170107600A1 (en) 2017-04-20
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