WO2018103065A1 - Procédé de vieillissement artificiel d'alliages aluminium-silicium pour composants coulés sous pression - Google Patents

Procédé de vieillissement artificiel d'alliages aluminium-silicium pour composants coulés sous pression Download PDF

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WO2018103065A1
WO2018103065A1 PCT/CN2016/109172 CN2016109172W WO2018103065A1 WO 2018103065 A1 WO2018103065 A1 WO 2018103065A1 CN 2016109172 W CN2016109172 W CN 2016109172W WO 2018103065 A1 WO2018103065 A1 WO 2018103065A1
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Prior art keywords
equal
mass
aluminum alloy
less
die cast
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PCT/CN2016/109172
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English (en)
Inventor
Bin Hu
Pan WANG
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GM Global Technology Operations LLC
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Priority to DE112016007434.4T priority Critical patent/DE112016007434T5/de
Priority to PCT/CN2016/109172 priority patent/WO2018103065A1/fr
Priority to US16/348,864 priority patent/US20190276919A1/en
Priority to CN201680091430.6A priority patent/CN110023524A/zh
Publication of WO2018103065A1 publication Critical patent/WO2018103065A1/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
    • C22F1/043—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 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
    • 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

Definitions

  • the present disclosure pertains to processes for artificially ageing aluminum-based alloys, especially aluminum-based alloys used in high-pressure die casting to form lightweight, high strength, high ductility components.
  • Aluminum alloys are commonly used for manufacturing components by die-casting, such as, for example, die cast engine blocks and transmission cases in the automobile industry.
  • aluminum alloys Al alloys
  • Al alloys are often used to die-cast parts with thin walls requiring high strength and high ductility, while also being lightweight.
  • Many common Al alloys used in the automobile industry are die castable and heat treatable. Such die cast aluminum alloys can undergo additional heat treatments to improve strength.
  • a T5 heat treatment process is typically used for certain aluminum alloys, which involves die casting the alloy, cooling it, and then artificial ageing/age hardening that occurs at an elevated temperature for a predetermined period of time, where the main alloying elements form a eutectic phase during slow solidification.
  • a T6 heat treatment may also be used when the alloy is cast, which typically involves solution heat treating to dissolve soluble phases that form after solidification, and then artificial ageing/age hardening that occurs at an elevated temperature for a predetermined period of time, where the main alloying elements form a eutectic phase during slow solidification.
  • T5 is typically used for thin wall castings
  • T6 is typically used for thick wall castings.
  • the present disclosure relates to a method of heat treating a die cast aluminum alloy component.
  • such a method includes die casting an aluminum alloy to form a die cast component having at least one thin walled region with a thickness of less than or equal to about 5 mm.
  • the aluminum alloy has silicon at greater than or equal to about 6.5%by mass to less than or equal to about 15.5%by mass of the aluminum alloy, copper at greater than or equal to about 0.1%by mass to less than or equal to about 3.5%by mass of the aluminum alloy, magnesium at less than or equal to about 0.5%by mass of the aluminum alloy, manganese at less than or equal to about 0.6%by mass of the aluminum alloy, and chromium at less than or equal to about 0.6%by mass of the aluminum alloy.
  • the method further includes quenching the die cast component at a cooling rate of greater than or equal to about 100°C/second to a first temperature of less than 50°C.
  • the method may further include age hardening by heating the die cast component to a second temperature of greater than or equal to about 150°C for a predetermined duration of time to facilitate formation of particles of magnesium silicide (Mg 2 Si) in a matrix of the aluminum alloy.
  • Mg 2 Si magnesium silicide
  • the aluminum alloy further includes iron at less than or equal to about 1.3 %by weight, titanium at less than or equal to about 0.15%by mass of the aluminum alloy, strontium at less than or equal to about 0.08%by mass of the aluminum alloy, phosphorus at less than or equal to about 0.003%by weight, and has a balance of aluminum.
  • the second temperature is greater than or equal to about 155°C to less than or equal to about 220°C.
  • the die cast component has a yield strength of greater than or equal to about 150 MPa.
  • the die cast component has an ultimate tensile strength of greater than or equal to about 280 MPa.
  • the die cast component has a ductility of greater than or equal to about 5%.
  • the particles of magnesium silicide are substantially homogenously distributed in the matrix of the aluminum alloy of the die cast component.
  • the present disclosure includes a method of heat treating a die cast aluminum alloy component.
  • the method includes die casting an aluminum alloy to form a die cast component having at least one thin walled region with a thickness of less than or equal to about 5 mm.
  • the aluminum alloy has silicon at greater than or equal to about 8.5%by mass to less than or equal to about 10.5%by mass of the aluminum alloy, copper at greater than or equal to about 0.8%by mass to less than or equal to about 1.5%by mass of the aluminum alloy, magnesium at greater than or equal to about 0.1%by mass to less than or equal to about 0.5%by mass of the aluminum alloy, manganese may be present at greater than or equal to about 0.4%by mass to less than or equal to about 0.6%by mass of the aluminum alloy, and chromium at greater than or equal to about 0.1%by mass to less than or equal to about 0.6%by mass of the aluminum alloy.
  • the method includes quenching the die cast component at a cooling rate of greater than or equal to about 100°C/second to a first temperature of less than 50°C and age hardening by heating the die cast component to a second temperature of greater than or equal to about 150°C for a predetermined duration of time to facilitate formation of particles of magnesium silicide (Mg 2 Si) in a matrix of the aluminum alloy.
  • a cooling rate of greater than or equal to about 100°C/second to a first temperature of less than 50°C and age hardening by heating the die cast component to a second temperature of greater than or equal to about 150°C for a predetermined duration of time to facilitate formation of particles of magnesium silicide (Mg 2 Si) in a matrix of the aluminum alloy.
  • Mg 2 Si magnesium silicide
  • the aluminum alloy further has iron at less than or equal to about 0.25 %by weight, titanium at greater than or equal to about 0.05%by mass to less than or equal to about 0.1%by mass of the aluminum alloy, strontium at greater than or equal to about 0.01%by mass to less than or equal to about 0.015%by mass of the aluminum alloy, phosphorus at less than or equal to about 0.003%by weight, and a balance of aluminum.
  • the second temperature is greater than or equal to about 155°C to less than or equal to about 220°C.
  • the die cast component has a yield strength of greater than or equal to about 150 MPa.
  • the die cast component has an ultimate tensile strength of greater than or equal to about 280 MPa.
  • the die cast component has a ductility of greater than or equal to about 5%.
  • the particles of magnesium silicide are substantially homogenously distributed in the matrix of the aluminum alloy of the die cast component.
  • the present disclosure provides a method of manufacturing a vehicle component.
  • the method may include die casting the vehicle component with an aluminum alloy to form a die cast component having at least one thin walled region with a thickness of less than or equal to about 5 mm.
  • the aluminum alloy has silicon at greater than or equal to about 8.5%by mass to less than or equal to about 10.5%by mass of the aluminum alloy, copper at greater than or equal to about 0.8%by mass to less than or equal to about 1.5%by mass of the aluminum alloy, magnesium at greater than or equal to about 0.1%by mass to less than or equal to about 0.5%by mass of the aluminum alloy, manganese at greater than or equal to about 0.4%by mass to less than or equal to about 0.6%by mass of the aluminum alloy, chromium at greater than or equal to about 0.1%by mass to less than or equal to about 0.6%by mass of the aluminum alloy, titanium at greater than or equal to about 0.05%by mass to less than or equal to about 0.1%by mass of the aluminum alloy, strontium at greater than or equal to about 0.01%by
  • the method further includes quenching the die cast vehicle component at a cooling rate of greater than or equal to about 100°C/second to a first temperature of less than 50°C and age hardening by heating the die cast vehicle component to a second temperature of greater than or equal to about 150°C for a predetermined duration of time to facilitate formation of particles of magnesium silicide (Mg 2 Si) in a matrix of the aluminum alloy.
  • a cooling rate of greater than or equal to about 100°C/second to a first temperature of less than 50°C and age hardening by heating the die cast vehicle component to a second temperature of greater than or equal to about 150°C for a predetermined duration of time to facilitate formation of particles of magnesium silicide (Mg 2 Si) in a matrix of the aluminum alloy.
  • Mg 2 Si magnesium silicide
  • the die cast vehicle component is selected from the group consisting of: pillars, hinge pillars, panels, door panels, door components, interior floors, floor pans, roofs, exterior surfaces, underbody shields, wheels, storage areas, glove boxes, console boxes, trunks, trunk floors, truck beds, lamp pockets, shock towers, shock tower caps, control arms, suspension components, drive train components, engine mount brackets, transmission mount brackets, alternator brackets, air conditioner compressor brackets, cowl plates, and combinations thereof.
  • the second temperature is greater than or equal to about 155°C to less than or equal to about 220°C.
  • the die cast component has a yield strength of greater than or equal to about 150 MPa.
  • the die cast component has an ultimate tensile strength of greater than or equal to about 280 MPa.
  • the die cast component has a ductility of greater than or equal to about 5%.
  • the particles of magnesium silicide are substantially homogenously distributed in the matrix of the aluminum alloy of the die cast component.
  • FIG. 1 shows a graph comparing a T5 heat treatment process with a heat treatment process according to certain aspects of the present disclosure showing temperature versus time.
  • Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific compositions, components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
  • compositions, materials, components, elements, features, integers, operations, and/or process steps are to be understood as a non-restrictive term used to describe and claim various embodiments set forth herein, in certain aspects, the term may alternatively be understood to instead be a more limiting and restrictive term, such as “consisting of” or “consisting essentially of. ”
  • the present disclosure also specifically includes embodiments consisting of, or consisting essentially of, such recited compositions, materials, components, elements, features, integers, operations, and/or process steps.
  • the alternative embodiment excludes any additional compositions, materials, components, elements, features, integers, operations, and/or process steps, while in the case of “consisting essentially of, ” any additional compositions, materials, components, elements, features, integers, operations, and/or process steps that materially affect the basic and novel characteristics are excluded from such an embodiment, but any compositions, materials, components, elements, features, integers, operations, and/or process steps that do not materially affect the basic and novel characteristics can be included in the embodiment.
  • first, second, third, etc. may be used herein to describe various steps, elements, components, regions, layers and/or sections, these steps, elements, components, regions, layers and/or sections should not be limited by these terms, unless otherwise indicated. These terms may be only used to distinguish one step, element, component, region, layer or section from another step, element, component, region, layer or section. Terms such as “first, ” “second, ” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first step, element, component, region, layer or section discussed below could be termed a second step, element, component, region, layer or section without departing from the teachings of the example embodiments.
  • Spatially or temporally relative terms such as “before, ” “after, ” “inner, ” “outer, ” “beneath, ” “below, ” “lower, ” “above, ” “upper, ” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element (s) or feature (s) as illustrated in the figures.
  • Spatially or temporally relative terms may be intended to encompass different orientations of the device or system in use or operation in addition to the orientation depicted in the figures.
  • composition and “material” are used interchangeably to refer broadly to a substance containing at least the preferred chemical constituents, elements, or compounds, but which may also comprise additional elements, compounds, or substances, including trace amounts of impurities, unless otherwise indicated.
  • the word “substantially, ” when applied to a characteristic of a composition or method of this disclosure, indicates that there may be slight variation in the characteristic without having a substantial effect on the chemical or physical attributes of the composition or method.
  • “about” as used herein indicates at least variations that may arise from ordinary methods of measuring and using such parameters.
  • “about” may comprise a variation of less than or equal to 5%, optionally less than or equal to 4%, optionally less than or equal to 3%, optionally less than or equal to 2%, optionally less than or equal to 1%, optionally less than or equal to 0.5%, and in certain aspects, optionally less than or equal to 0.1%.
  • disclosure of ranges includes disclosure of all values and further divided ranges within the entire range, including endpoints and sub-ranges given for the ranges.
  • Aluminum alloys are widely used in vehicles, such as automobiles, motorcycles, boats, tractors, buses, mobile homes, campers, and tanks, and their utilization will continue with efforts to reduce vehicle mass and save space.
  • Methods of processing aluminum alloys according to the present technology form components with reduced mass relative to components made with traditional alloys, such as steel, while maintaining strength and ductility requirements.
  • Aluminum alloys are particularly suitable for use in components of an automobile or other vehicle (e.g., motorcycles, boats) , but may also be used in a variety of other industries and applications, including aerospace components, industrial equipment and machinery, farm equipment, heavy machinery, by way of non-limiting example.
  • aluminum alloys may be used to form die-cast vehicle or automotive components. While exemplary components are illustrated and described throughout the specification, it is understood that the inventive concepts in the present disclosure may also be applied to any structural component capable of being formed of a lightweight metal, including those used in vehicles, like automotive applications including, but not limited to, pillars, such as hinge pillars, panels, including structural panels, door panels, and door components, interior floors, floor pans, roofs, exterior surfaces, underbody shields, wheels, storage areas, including glove boxes, console boxes, trunks, trunk floors, truck beds, lamp pockets and other components, shock towers, shock tower cap, control arms and other suspension or drive train components, engine mount brackets, transmission mount brackets, alternator brackets, air conditioner compressor brackets, cowl plates, and the like.
  • the present disclosure is particularly suitable for any piece of hardware subject to loads or impact (e.g., load bearing) .
  • the present disclosure provides methods for achieving precipitation hardening of die cast aluminum alloys by an artificial aging process.
  • the strengthened aluminum alloys may thus be used in vehicle or automotive applications, by way of non-limiting example.
  • Strengthened aluminum metal components may be load bearing in certain applications for vehicles, in which case they have good strength, stiffness, and ductility (e.g., elongation) .
  • the methods according to certain aspects of the present disclosure can produce high strength, high stiffness, and high ductility thin-wall casting components or parts.
  • the method of producing the aluminum alloy components may be die casting. In a die-casting process, the molten alloy material passes through a die defining one or more orifices or apertures as it enters a mold cavity during the casting process. After passing through the in-gate, runners and gating in the die, the molten metal enters a mold cavity where it solidifies to complete the casting process.
  • the die cast components formed from aluminum alloys enable significant mass reduction relative to conventional metal components, like steel, while providing high strength and good elongation.
  • the cast solid parts form lightweight metal structural components, which have one or more surfaces that are further machined after casting and solidification.
  • the solidified aluminum alloy forms a solid lightweight metal alloy component having at least one dimension that is considered to be thin, so that thin wall part castings are formed.
  • the at least one dimension may extend across the entire solid lightweight metal alloy component or only in certain regions of particular importance to the structure of the component.
  • a thickness or width of at least one region of the solidified aluminum alloy part may be considered to be thin (e.g., to form a thin wall) .
  • a dimension may be considered to be thin if it is less than or equal to about 5 mm, optionally less than or equal to about 4 mm, optionally less than or equal to about 3 mm, optionally less than or equal to about 2 mm, optionally less than or equal to about 1.75 mm, optionally less than or equal to about 1.5 mm, optionally less than or equal to about 1.25 mm, optionally less than or equal to about 1 mm, optionally less than or equal to about 0.75 mm, and in certain variations, optionally less than or equal to about 0.5 mm.
  • the part may have other dimensions well in excess of 5 mm (such as height and/or length) , although the part may have at least one thin region having the dimensions described above.
  • heat-treatment strengthening mainly occurs by formation of nano-sized precipitation phase/particles within the matrix.
  • Such precipitation particles in heat treatable aluminum alloys may be formed by a process including a solution heat treatment, where the soluble phases dissolve, followed by an artificial aging process, because mainly alloying elements form as eutectic phases during slow solidification rates.
  • temperature 20 versus time 22 is shown.
  • a casting temperature is indicated at 24 and ambient or room temperature at 26.
  • a first heat treatment 30 for strengthening an aluminum alloy in a component having a thin wall is shown as a dotted line.
  • the first heat treatment 30 is representative of a T5 heat treatment temper.
  • the first heat treatment 30 of the aluminum alloy starts at the die casting temperature 24. Then, the aluminum alloy component having a thin wall is slowly cooled until it reaches a second temperature 32 that may be at or slightly above room temperature 26 (shown as above room temperature) . Next, the aluminum alloy component is heated in the first heat treatment 30 for artificial aging and age hardening, which occurs at a third elevated temperature 34 for a first predetermined period of time 36. During the artificial aging and age hardening, the main alloying elements form a eutectic phase during slow solidification in the aluminum alloy component having a thin wall.
  • a second heat treatment 40 for strengthening an aluminum alloy component having a thin wall is shown as a solid line and is one example embodiment of a method according to certain aspects of the present disclosure.
  • the aluminum alloy component having a thin wall is quenched from an initial quench temperature 42 for rapid cooling to a fourth temperature 44 that is less than or equal to about 50°C.
  • the fourth temperature 44 may be at or slightly above room temperature 26.
  • the quenching can avoid or minimize formation of certain precipitation products, such as Mg 2 Si, in certain aluminum alloys.
  • the initial quench temperature 42 can change depending on the alloy composition, in certain variations, it is greater than or equal to about 425°C. All of the temperatures described herein with respect to treatment of the aluminum alloy may vary depending on the composition of the aluminum alloy, as appreciated by those of skill in the art.
  • the quenching may be conducted by contacting the alloy with a cooling medium.
  • the contacting may be achieved by submerging or dipping the aluminum alloy/die cast component into a cooling medium, such as a bath or moving stream of cooling medium, such as water and/or liquid nitrogen.
  • cooling can occur by spraying the aluminum alloy with a cooling medium.
  • the spray may be pressurized and directed via a nozzle.
  • the cooling medium may be in the form of a gas, a vapor or mist, a liquid, and/or a solid. The cooling medium is directed towards or contacted with the surface of the aluminum alloy component to induce cooling and quenching at a desired cooling rate.
  • a cooling rate may greater than or equal to about 100°C/ per second.
  • the quenching process may take the only 3 to 5 seconds, for example, to cool an aluminum alloy from a casting temperature 24 of about 500°C to room temperature 26.
  • the second heat treatment 40 involves artificial aging and age hardening by heating the aluminum alloy component, which occurs at a fifth elevated temperature 46 for a second predetermined period of time 48.
  • the main alloying elements form a eutectic phase during slow solidification to form particles of magnesium silicide (Mg 2 Si) in a matrix of the aluminum alloy.
  • the second predetermined period of time 48 is less than the first predetermined period of time 36.
  • the third temperature 34 is higher than the fifth temperature 46.
  • the artificial aging and age hardening can be conducted at a lower temperature and/or for less time than in a conventional first heat treatment 30 (e.g., T5 heat treatment) .
  • a conventional first heat treatment 30 e.g., T5 heat treatment
  • the second predetermined period 48 may need to be longer.
  • the fifth temperature 46 may be the same as the third temperature 34, but this will result in the second predetermined period 48 advantageously being significantly shorter than the first predetermined period 36.
  • the fifth temperature 46 is greater than or equal to about 150°C, which facilitates formation of particles of magnesium silicide (Mg 2 Si) in a matrix of the aluminum alloy. In certain variations, the fifth temperature 46 may be greater than or equal to about 155°C to less than or equal to about 220°C. The present disclosure thus provides methods of artificial aging for achieving precipitation hardening by in die cast aluminum alloys.
  • the present methods of heat treating select aluminum alloys after casting to form thin wall components can create solid aluminum alloy metal components or parts having a substantially uniform microstructure (e.g., eliminating segregation and bands) . Further, more solute and alloying ingredients can be distributed in the metal matrix. In traditional high pressure die-casting processes, concentration of alloying ingredients with the metal is not necessarily uniform, as inhomogeneity may occur. However, in certain aspects, the aluminum alloy components or parts formed in accordance with the methods of the present disclosure may have a homogenous and substantially uniform composition, where concentration of ingredients is homogenously distributed throughout. In such variations, the aluminum alloy component may have a substantially uniform microstructure, meaning that the microstructure is substantially the same microstructure, composition, grain boundaries, and grain sizes throughout the region or solid phase. Such a microstructure results in higher ductility and higher strength in the cast part. In certain aspects, the magnesium silicide (Mg 2 Si) may be substantially homogeneously distributed throughout the matrix of the aluminum alloy of the die cast component.
  • Mg 2 Si magnesium silicide
  • the selection of alloys in accordance with the principles of the present disclosure can form solid lightweight aluminum alloy metal components or parts having superior strength and ductility (e.g., elongation) .
  • the methods of the present disclosure are particularly suitable for use with high or medium ductility die cast aluminum alloy components.
  • the methods of the present disclosure include artificial aging for achieving precipitation hardening of die cast aluminum alloys to provide about 40 MPa to about 50 MPa of improvement in yield strength, meanwhile not significantly reducing or sacrificing ductility.
  • a cast solid aluminum alloy component formed in accordance with certain aspects of the present disclosure may have a percentage of elongation of greater than or equal about 5%.
  • a percentage of elongation may optionally be greater than or equal to about 6%, and in certain variations, optionally greater than or equal to about 7%.
  • a high strength cast solid aluminum alloy component may have a yield strength of greater than or equal to 150 MPa. In certain variations, a high strength cast aluminum alloy component has a yield strength of greater than or equal to about 175 MPa, optionally greater than or equal to about 200 MPa, and in certain variations, optionally greater than or equal to about 225 MPa.
  • a high strength cast solid aluminum alloy component may have an ultimate tensile strength of greater than or equal to about 175 MPa, optionally greater than or equal to about 200 MPa, optionally greater than or equal to about 225 MPa, optionally greater than or equal to about 250 MPa, optionally greater than or equal to about 275 MPa, and in certain variations optionally greater than or equal to about 280 MPa.
  • the aluminum alloy comprises silicon (Si) at greater than or equal to about 6.5%by mass to less than or equal to about 15.5%by mass of the aluminum alloy, copper (Cu) at greater than or equal to about 0.1%by mass to less than or equal to about 3.5%by mass of the aluminum alloy, magnesium (Mg) at less than or equal to about 0.5%by mass of the aluminum alloy, manganese (Mn) at less than or equal to about 0.6%by mass of the aluminum alloy, and/or chromium (Cr) at less than or equal to about 0.6%by mass of the aluminum alloy.
  • the aluminum alloy may further comprise iron (Fe) at less than or equal to about 1.3 %by weight, titanium (Ti) at less than or equal to about 0.15%by mass of the aluminum alloy, strontium (Sr) at less than or equal to about 0.08%by mass of the aluminum alloy, and/or phosphorus (P) at less than or equal to about 0.003%by weight.
  • Fe iron
  • Ti titanium
  • Sr strontium
  • P phosphorus
  • the aluminum alloy comprises silicon at greater than or equal to about 8.5%by mass to less than or equal to about 10.5%by mass of the aluminum alloy, copper at greater than or equal to about 0.8%by mass to less than or equal to about 1.5%by mass of the aluminum alloy, magnesium at greater than or equal to about 0.1%by mass to less than or equal to about 0.5%by mass of the aluminum alloy, chromium at greater than or equal to about 0.1%by mass to less than or equal to about 0.6%by mass of the aluminum alloy, and/or manganese at greater than or equal to about 0.4%by mass to less than or equal to about 0.6%by mass of the aluminum alloy.
  • the aluminum alloy may further comprise iron (Fe) at less than or equal to about 0.25%by weight, titanium (Ti) at greater than or equal to about 0.05%by mass to less than or equal to about 0.1%by mass of the aluminum alloy, strontium (Sr) at greater than or equal to about 0.01%by mass to less than or equal to about 0.015%by mass of the aluminum alloy, and/or phosphorus (P) at less than or equal to about 0.003%by weight.
  • the balance is aluminum.
  • impurities are cumulatively present at less than or equal to about 0.1 %by mass of the aluminum alloy.
  • Table 2 Such a composition is represented in Table 2.
  • the present disclosure contemplates a method of heat treating a die cast aluminum alloy component.
  • the method includes die casting an aluminum alloy to form a die cast component having at least one thin walled region.
  • the think walled region may have a thickness of less than or equal to about 5 mm.
  • the aluminum alloy may be any of those described above that are heat treatable.
  • the aluminum alloy includes silicon at greater than or equal to about 6.5%by mass to less than or equal to about 15.5%by mass of the aluminum alloy, copper at greater than or equal to about 0.1%by mass to less than or equal to about 3.5%by mass of the aluminum alloy, magnesium at less than or equal to about 0.5%by mass of the aluminum alloy, and manganese at less than or equal to about 0.6%by mass of the aluminum alloy.
  • the method may further include quenching the die cast component at a cooling rate of greater than or equal to about 100°C/second to a first temperature of less than 50°C. Then, the die cast component can be age hardened by heating the die cast component to a second temperature of greater than or equal to about 150°C for a predetermined duration of time to facilitate formation of particles of magnesium silicide (Mg 2 Si) in a matrix of the aluminum alloy.
  • a cooling rate of greater than or equal to about 100°C/second to a first temperature of less than 50°C.
  • the die cast component can be age hardened by heating the die cast component to a second temperature of greater than or equal to about 150°C for a predetermined duration of time to facilitate formation of particles of magnesium silicide (Mg 2 Si) in a matrix of the aluminum alloy.
  • Mg 2 Si magnesium silicide
  • the aluminum alloy further includes iron at less than or equal to about 1.3 %by weight, titanium at less than or equal to about 0.15%by mass of the aluminum alloy, strontium at less than or equal to about 0.08%by mass of the aluminum alloy, phosphorus at less than or equal to about 0.003%by weight, and a balance of aluminum.
  • the second temperature is greater than or equal to about 155°C to less than or equal to about 220°C.
  • the die cast component has a yield strength of greater than or equal to about 150 MPa.
  • the die cast component may have an ultimate tensile strength of greater than or equal to about 280 MPa.
  • the die cast component has a ductility or elongation of greater than or equal to about 5%.
  • the particles of magnesium silicide are substantially homogenously distributed in the matrix of the aluminum alloy of the die cast component.
  • the method includes die casting an aluminum alloy to form a die cast component having at least one thin walled region.
  • the think walled region may have a thickness of less than or equal to about 5 mm.
  • the aluminum alloy may be any of those described above that are heat treatable.
  • the aluminum alloy includes silicon at greater than or equal to about 8.5%by mass to less than or equal to about 10.5%by mass of the aluminum alloy, copper at greater than or equal to about 0.8%by mass to less than or equal to about 1.5%by mass of the aluminum alloy, magnesium at greater than or equal to about 0.1%by mass to less than or equal to about 0.5%by mass of the aluminum alloy, chromium at greater than or equal to about 0.1%by mass to less than or equal to about 0.6%by mass of the aluminum alloy, and manganese at greater than or equal to about 0.4%by mass to less than or equal to about 0.6%by mass of the aluminum alloy.
  • the method may also include quenching the die cast component at a cooling rate of greater than or equal to about 100°C/second to a first temperature of less than 50°C and age hardening by heating the die cast component to a second temperature of greater than or equal to about 150°C for a predetermined duration of time to facilitate formation of particles of magnesium silicide (Mg 2 Si) in a matrix of the aluminum alloy.
  • a cooling rate of greater than or equal to about 100°C/second to a first temperature of less than 50°C and age hardening by heating the die cast component to a second temperature of greater than or equal to about 150°C for a predetermined duration of time to facilitate formation of particles of magnesium silicide (Mg 2 Si) in a matrix of the aluminum alloy.
  • Mg 2 Si magnesium silicide
  • the aluminum alloy further includes iron at less than or equal to about 0.25 %by weight, titanium at greater than or equal to about 0.05%by mass to less than or equal to about 0.1%by mass of the aluminum alloy, strontium at greater than or equal to about 0.01%by mass to less than or equal to about 0.015%by mass of the aluminum alloy, phosphorus at less than or equal to about 0.003%by weight, and a balance of aluminum.
  • the second temperature is greater than or equal to about 155°C to less than or equal to about 220°C.
  • the die cast component has a yield strength of greater than or equal to about 150 MPa.
  • the die cast component may have an ultimate tensile strength of greater than or equal to about 280 MPa.
  • the die cast component has a ductility or elongation of greater than or equal to about 5%.
  • the present disclosure contemplates a method of manufacturing a vehicle component.
  • the method may include die casting the vehicle component with an aluminum alloy to form a die cast component having at least one thin walled region.
  • the thin walled region has a thickness of less than or equal to about 5 mm.
  • the aluminum alloy may be any of those described previously above.
  • the aluminum alloy may include silicon at greater than or equal to about 8.5%by mass to less than or equal to about 10.5%by mass of the aluminum alloy, copper at greater than or equal to about 0.8%by mass to less than or equal to about 1.5%by mass of the aluminum alloy, magnesium at greater than or equal to about 0.1%by mass to less than or equal to about 0.5%by mass of the aluminum alloy, manganese at greater than or equal to about 0.4%by mass to less than or equal to about 0.6%by mass of the aluminum alloy, chromium at greater than or equal to about 0.1%by mass to less than or equal to about 0.6%by mass of the aluminum alloy, titanium at greater than or equal to about 0.05%by mass to less than or equal to about 0.1%by mass of the aluminum alloy, strontium at greater than or equal to about 0.01%by mass to less than or equal to about 0.015%by mass of the aluminum alloy, iron at less than or equal to about 0.25 %by weight, phosphorus at less than or equal to about 0.003%by weight, and a balance aluminum.
  • the die cast vehicle component is selected from the group consisting of pillars, hinge pillars, panels, door panels, door components, interior floors, floor pans, roofs, exterior surfaces, underbody shields, wheels, storage areas, glove boxes, console boxes, trunks, trunk floors, truck beds, lamp pockets, shock towers, shock tower caps, control arms, suspension components, drive train components, engine mount brackets, transmission mount brackets, alternator brackets, air conditioner compressor brackets, cowl plates, and combinations thereof.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Body Structure For Vehicles (AREA)

Abstract

L'invention concerne un procédé de traitement thermique d'un composant de type alliage d'aluminium coulé sous pression. Le composant coulé sous pression comporte au moins une région à paroi mince d'une épaisseur ≤ 5 mm. L'alliage contient du silicium, ≥ 6,5 à ≤ 15,5 % en poids, du cuivre, ≥ 0,1 à ≤ 3,5 % en poids, du magnésium, ≤ 0,5 % en poids, du manganèse, ≤ 0,6 % en poids, et du chrome, ≤ 0,6 % en poids. Le procédé comprend la trempe du composant coulé sous pression à une vitesse de refroidissement ≥ environ 100 °C/seconde jusqu'à une première température inférieure à 50 °C et un durcissement par vieillissement par chauffage du composant coulé sous pression jusqu'à une seconde température ≥ environ 150 °C pendant une durée prédéfinie pour faciliter la formation de particules de Mg2Si dans une matrice d'alliage d'aluminium. L'alliage d'aluminium traité par le procédé selon l'invention permet de former des composants légers, de résistance mécanique et ductilité élevées.
PCT/CN2016/109172 2016-12-09 2016-12-09 Procédé de vieillissement artificiel d'alliages aluminium-silicium pour composants coulés sous pression WO2018103065A1 (fr)

Priority Applications (4)

Application Number Priority Date Filing Date Title
DE112016007434.4T DE112016007434T5 (de) 2016-12-09 2016-12-09 Künstlicher Alterungsprozess für Aluminium-Siliziumlegierungen (AISi) für Druckgussteile
PCT/CN2016/109172 WO2018103065A1 (fr) 2016-12-09 2016-12-09 Procédé de vieillissement artificiel d'alliages aluminium-silicium pour composants coulés sous pression
US16/348,864 US20190276919A1 (en) 2016-12-09 2016-12-09 ARTIFICIAL AGING PROCESS FOR ALUMINUM-SILICON (AlSi) ALLOYS FOR DIE CAST COMPONENTS
CN201680091430.6A CN110023524A (zh) 2016-12-09 2016-12-09 用于压铸件的铝-硅合金的人工时效方法

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PCT/CN2016/109172 WO2018103065A1 (fr) 2016-12-09 2016-12-09 Procédé de vieillissement artificiel d'alliages aluminium-silicium pour composants coulés sous pression

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