WO2022162245A1 - Aluminium alloy, component made of an aluminium alloy, and method for producing a component made of an aluminium alloy - Google Patents
Aluminium alloy, component made of an aluminium alloy, and method for producing a component made of an aluminium alloy Download PDFInfo
- Publication number
- WO2022162245A1 WO2022162245A1 PCT/EP2022/052358 EP2022052358W WO2022162245A1 WO 2022162245 A1 WO2022162245 A1 WO 2022162245A1 EP 2022052358 W EP2022052358 W EP 2022052358W WO 2022162245 A1 WO2022162245 A1 WO 2022162245A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- weight
- silicon
- casting
- aluminum
- cast
- Prior art date
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 11
- 229910000838 Al alloy Inorganic materials 0.000 title description 11
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 65
- 239000000956 alloy Substances 0.000 claims abstract description 65
- 238000005266 casting Methods 0.000 claims abstract description 26
- KMWBBMXGHHLDKL-UHFFFAOYSA-N [AlH3].[Si] Chemical compound [AlH3].[Si] KMWBBMXGHHLDKL-UHFFFAOYSA-N 0.000 claims abstract description 16
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 7
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 7
- 229910052748 manganese Inorganic materials 0.000 claims abstract description 7
- 239000011572 manganese Substances 0.000 claims abstract description 7
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims abstract description 6
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 claims abstract description 6
- 239000011651 chromium Substances 0.000 claims abstract description 6
- 229910052749 magnesium Inorganic materials 0.000 claims abstract description 6
- 239000011777 magnesium Substances 0.000 claims abstract description 6
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 6
- 239000010703 silicon Substances 0.000 claims abstract description 6
- 239000011701 zinc Substances 0.000 claims abstract description 6
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims abstract description 5
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 5
- 229910052725 zinc Inorganic materials 0.000 claims abstract description 5
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims abstract description 4
- 239000012535 impurity Substances 0.000 claims abstract 2
- 238000004512 die casting Methods 0.000 claims description 34
- CSDREXVUYHZDNP-UHFFFAOYSA-N alumanylidynesilicon Chemical compound [Al].[Si] CSDREXVUYHZDNP-UHFFFAOYSA-N 0.000 claims description 25
- 238000000034 method Methods 0.000 claims description 15
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 11
- 238000000137 annealing Methods 0.000 claims description 10
- 239000010936 titanium Substances 0.000 claims description 7
- 229910052742 iron Inorganic materials 0.000 claims description 6
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 5
- 229910052750 molybdenum Inorganic materials 0.000 claims description 5
- 229910052719 titanium Inorganic materials 0.000 claims description 5
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 4
- 239000011733 molybdenum Substances 0.000 claims description 4
- 239000000155 melt Substances 0.000 claims description 3
- 229910052684 Cerium Inorganic materials 0.000 claims description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 2
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims description 2
- GWXLDORMOJMVQZ-UHFFFAOYSA-N cerium Chemical compound [Ce] GWXLDORMOJMVQZ-UHFFFAOYSA-N 0.000 claims description 2
- 229910052802 copper Inorganic materials 0.000 claims description 2
- 239000010949 copper Substances 0.000 claims description 2
- 229910052735 hafnium Inorganic materials 0.000 claims description 2
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 claims description 2
- 229910052761 rare earth metal Inorganic materials 0.000 claims description 2
- 229910052712 strontium Inorganic materials 0.000 claims description 2
- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 claims description 2
- 229910052726 zirconium Inorganic materials 0.000 claims description 2
- 229910000789 Aluminium-silicon alloy Inorganic materials 0.000 claims 1
- 239000004411 aluminium Substances 0.000 abstract 1
- 239000000470 constituent Substances 0.000 abstract 1
- 239000000463 material Substances 0.000 description 14
- 239000000243 solution Substances 0.000 description 11
- 238000010521 absorption reaction Methods 0.000 description 7
- 238000010438 heat treatment Methods 0.000 description 7
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 4
- 238000005452 bending Methods 0.000 description 3
- 208000002352 blister Diseases 0.000 description 2
- 238000005728 strengthening Methods 0.000 description 2
- 229910018125 Al-Si Inorganic materials 0.000 description 1
- 229910018520 Al—Si Inorganic materials 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 229910052746 lanthanum Inorganic materials 0.000 description 1
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000012805 post-processing Methods 0.000 description 1
- 239000006104 solid solution Substances 0.000 description 1
- 239000010421 standard material Substances 0.000 description 1
- JBQYATWDVHIOAR-UHFFFAOYSA-N tellanylidenegermanium Chemical compound [Te]=[Ge] JBQYATWDVHIOAR-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- 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
-
- 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
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/02—Making non-ferrous alloys by melting
- C22C1/026—Alloys based on aluminium
Definitions
- Aluminum alloy aluminum alloy component and method of manufacturing an aluminum alloy component
- the present invention relates to an aluminum alloy for die casting, an aluminum alloy die cast component and a die casting method for producing an aluminum alloy component.
- Die-casting is an economical process for the series production of components, for example for motor vehicles.
- structural components for motor vehicles on the one hand low weight and low unit costs are desired, on the other hand there are high demands on the ductility of the material and the energy absorption capacity of the finished component.
- the energy absorption capacity of the finished component is particularly important for components that are intended to deform in the event of a crash.
- the aluminum alloys suitable for this are also referred to as crash alloys.
- the material should be able to be processed reliably and allow a high series quality with as little mold wear as possible and as little post-processing of the cast structural components as possible.
- Structural components for the automotive industry are becoming ever larger and more complex due to the integration of components and functions.
- a waiver of the heat treatment and possible straightening processes of these thin-walled but large-area components results in considerable costs.
- advantage for automobile production This advantage applies in particular to battery housings in hybrid and electric vehicles. Battery boxes are integrated into the vehicle's support structure and have to carry the loads in the event of a crash.
- an aluminum cast alloy is sought that is suitable for the production of structural components for the automotive industry, which should have good crash properties, using the die-casting process.
- an aluminum-silicon cast alloy according to claim 1 which has the following alloy components in addition to at least 88% by weight aluminum:
- Zinc between 0.2 and 0.8% by weight
- Chromium between 0.1 and 0.3% by weight
- Magnesium with up to 0.05% by weight Magnesium with up to 0.05% by weight.
- the silicon content of the aluminum-silicon cast alloy is preferably between 7.0 and 8.5% by weight and particularly preferably between 7.5 and 8.5% by weight.
- the alloy preferably has one or more of the following alloy components:
- Titanium between 0.04 and 0.15% by weight
- iron with up to 0.2% by weight, Copper with up to 0.5% by weight, preferably up to 0.2
- Molybdenum and/or zirconium together up to 0.25% by weight.
- the magnesium content is preferably at most 0.01% by weight.
- the aluminium-silicon cast alloy can contain up to 0.15% by weight of hafnium, cerium, lanthanum and/or another rare earth element.
- the aluminium-silicon cast alloy AISi8ZnMn according to the invention is suitable for producing structural components with good crash properties, for example for the automotive industry in the die-casting process.
- the components produced with the aluminum-silicon cast alloy according to the invention do not require any heat treatment after the die-casting process in order to achieve high ductility and high energy absorption capacity.
- Die-cast components made from the aluminum-silicon cast alloy according to the invention exhibit good folding behavior and can therefore be used as crash-relevant components.
- Previously known cast alloys for components with good crash properties either require heat treatment, e.g. solution annealing (see DIN EN 1706 EN-AC-43500,) or are difficult to cast in die casting (see DIN EN 1706 EN-AC-51500, AIMg5Si2Mn ).
- the aluminium-silicon casting alloy AISi8ZnMn according to the invention can be easily cast in pressure die-casting due to its silicon content.
- the flowability, mold filling and demoulding is comparable to the standard materials EN-AC-43500 and AISiOMn.
- Die-casting alloys that require solution annealing after casting are usually cast using vacural casting - ie using a vacuum pressure die-casting process - because with classic die-casting machines there is a risk of blistering (risk of blistering), so that they are not suitable for solution annealing.
- the standard crash alloys are alloys that require solution annealing and are therefore not cast on "classic" die casting machines.
- the aluminium-silicon cast alloy according to the invention achieves the desired properties in terms of ductility of the material and energy absorption capacity of the finished component even without solution annealing, so that structural components produced using the aluminium-silicon cast alloy according to the invention can be used for their final purpose, e.g. as part of a vehicle without the component having to be solution annealed between die casting and installation in the vehicle.
- the aluminum-silicon cast alloy according to the invention is very ductile and exhibits a bending angle of greater than 60°.
- the yield point R p0.2 and the elongation at break A are due to the mixed-crystal strengthening of zinc, titanium and molybdenum in the aluminium-silicon system increased.
- Manganese and chromium are used to ensure that the components can be removed from the die casting mold despite the low silicon and iron content.
- a method for producing a structural component in particular for a motor vehicle, is also proposed, which is characterized in that the structural component is cast using the aluminum-silicon cast alloy according to the invention, preferably in a die-casting process.
- the die casting mold is preferably heated to a temperature between 105° C. and 290° C. before casting and the melt of the aluminum-silicon casting alloy according to the invention preferably has a temperature between 690° C. and 725° C. immediately before casting .
- the melt is around 10°C to 20°C hotter than in conventional die-casting processes, for example with the aluminium-silicon casting alloy AISi10MnMg.
- the mold is somewhat colder than was usual up until then. There is preferably no solution annealing between die casting and final use of the component.
- solution annealing is necessary for conventional components that deform in the event of a crash in order to improve the energy absorption capacity
- a component made from the aluminum-silicon cast alloy according to the invention does not require solution annealing - on the contrary, solution annealing could actually worsen the properties.
- the production of components from the aluminium-silicon cast alloy according to the invention is therefore more economical and the properties achieved are better.
- a component in particular a structural component, preferably for a motor vehicle, made from the aluminum-silicon cast alloy according to the invention is also proposed.
- the structural component is preferably a battery housing for a hybrid vehicle or a purely electric vehicle.
- the component is preferably not solution annealed.
- the aluminium-silicon cast alloy according to the invention is a die-cast alloy with good castability, mold filling and flowability.
- the aluminum-silicon cast alloy according to the invention has a high ductility without heat treatment of the cast parts.
- the aluminum-silicon casting alloy according to the invention is suitable for the pressure-casting production of structural components.
- the very high ductility of the aluminum-silicon cast alloy according to the invention and a high energy absorption capacity enable it to be used for crash-relevant components.
- the aluminum-silicon casting alloy according to the invention is suitable for die-casting structural components, in particular battery housings for electric and hybrid vehicles.
- the aluminum-silicon casting alloy according to the invention is suitable for the die-casting of large components with shot weights >25 kg due to its high flowability and low tendency to stick in die-casting.
- the aluminum-silicon casting alloy according to the invention can be applied directly to existing die-casting processes as an AISi alloy system.
- Due to the combination of Mn, Cr and Mo in the Al-Si system, the aluminum-silicon casting alloy according to the invention has a low tendency to stick in die-casting molds.
- the die-cast components made from the aluminum-silicon cast alloy according to the invention are suitable for industrial joining processes, in particular also for punch riveting, also with sheet metal, profiles and other materials.
- Table 1 Main alloy range of an alloy AISi8ZnMn according to the invention
- Table 2 (in the appendix) lists various materials and their properties.
- the materials were manufactured and cast into permanent mold specimens for round tensile bars.
- the tensile bars were used to determine the mechanical (mecha.) properties and the bending angle. All results apply to separately cast permanent mold specimens in condition F (as-cast condition, without heat treatment).
- condition F as-cast condition, without heat treatment
- the elements of the alloys in round brackets were varied in the tests in order to quantify their influence.
- Table 2 shows that the bending angle of the newly developed materials could be almost doubled compared to the existing materials.
- the two materials with a gray background were used for further die-casting tests and crash tests. For die-casting tests, 240 kg each of the two materials shown in italics in Table 2 (see appendix) were produced and cast into structural components in the form of a profile.
- the die-casting tests show very good castability with low iron and manganese content of the alloys and good mechanical properties.
- a crash test that was passed on the drop tower test stand, it was determined that the first fold of the profile remained free of cracks for 5 ms. It is required that the structural component remains free of cracks for at least 3.5 ms.
- the die casting tests were accompanied by chill casting tests to determine the notched impact strength as a measure of the energy absorption behavior of the component. It is noticeable that the notched impact strength of the test alloys could be increased by more than four times compared to conventional aluminum die-casting alloys in condition F. The components made of these materials do not require any heat treatment.
- Table 3 Comparison of the impact strength with mechanical properties of the two test alloys (see Table 2) above and a conventional aluminum die-cast alloy below:
- FIG. 1 shows the yield strength R p0.2 and the elongation at break A of eight alloys tested with different zinc and titanium contents with two newly developed variants called Milestone 4.
- Milestone 4 had the goal of increasing the yield strength, keeping the elongation at break to > 14% and at the same time limiting the use of peritectic elements to avoid the formation of undesired intermetallic phases.
- the results of "Milestone 4" in Figure 2 surprisingly showed that these goals could be achieved with two materials.
- the analyzes of the materials "Milestone 4" in Figure 1 are listed in Table 4 (in the appendix) and designated AISi8Zn0.6Mn0.35Zr and AISi8Zn0.4Mn0.35Cr according to the order.
- the alloys are already very ductile in chill casting without heat treatment. Experience has shown that the strength in die casting increases significantly, with the elongation at break remaining about the same, which means that it is suitable as a naturally ductile cast alloy for structural components, in particular battery boxes for electric vehicles with crash properties.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Body Structure For Vehicles (AREA)
- Arrangement Or Mounting Of Propulsion Units For Vehicles (AREA)
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP22709599.9A EP4284954A1 (en) | 2021-02-01 | 2022-02-01 | Aluminium alloy, component made of an aluminium alloy, and method for producing a component made of an aluminium alloy |
CN202280012637.5A CN117062926A (en) | 2021-02-01 | 2022-02-01 | Aluminum alloy, component made of aluminum alloy, and method for manufacturing component made of aluminum alloy |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102021102268.1A DE102021102268A1 (en) | 2021-02-01 | 2021-02-01 | Aluminum alloy, aluminum alloy component and method of manufacturing an aluminum alloy component |
DE102021102268.1 | 2021-02-01 |
Publications (1)
Publication Number | Publication Date |
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WO2022162245A1 true WO2022162245A1 (en) | 2022-08-04 |
Family
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/EP2022/052358 WO2022162245A1 (en) | 2021-02-01 | 2022-02-01 | Aluminium alloy, component made of an aluminium alloy, and method for producing a component made of an aluminium alloy |
Country Status (4)
Country | Link |
---|---|
EP (1) | EP4284954A1 (en) |
CN (1) | CN117062926A (en) |
DE (1) | DE102021102268A1 (en) |
WO (1) | WO2022162245A1 (en) |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
KR20040088857A (en) * | 2003-04-14 | 2004-10-20 | 현대자동차주식회사 | Composition of aluminum alloy for cylinder head with improved fatigue/intensity property |
CN106244864A (en) * | 2016-08-30 | 2016-12-21 | 苏州梅克卡斯汽车科技有限公司 | A kind of automobile turbocharger housing and preparation method thereof |
US20200131605A1 (en) * | 2018-10-29 | 2020-04-30 | Fna Group, Inc. | Aluminum alloy |
CN112048645A (en) * | 2020-08-24 | 2020-12-08 | 山东弗泽瑞金属科技有限公司 | Preparation method and equipment of die-casting aluminum alloy material |
Family Cites Families (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE1246256B (en) | 1957-11-26 | 1967-08-03 | North American Aviation Inc | Process to improve the strength and ductility of aluminum-silicon cast alloys |
AT14019U1 (en) | 2014-02-14 | 2015-02-15 | Amag Casting Gmbh | cast alloy |
KR101641170B1 (en) | 2014-09-02 | 2016-07-20 | 삼성전자주식회사 | Aluminum alloy for diecasting and manufacturing method thereof |
DE102016004216A1 (en) | 2016-04-07 | 2016-09-29 | Daimler Ag | Aluminum alloy, in particular for a casting method, and method for producing a component from such an aluminum alloy |
WO2018113838A1 (en) | 2016-12-22 | 2018-06-28 | Ksm Castings Group Gmbh | Al casting alloy |
-
2021
- 2021-02-01 DE DE102021102268.1A patent/DE102021102268A1/en active Pending
-
2022
- 2022-02-01 WO PCT/EP2022/052358 patent/WO2022162245A1/en active Application Filing
- 2022-02-01 CN CN202280012637.5A patent/CN117062926A/en active Pending
- 2022-02-01 EP EP22709599.9A patent/EP4284954A1/en active Pending
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
KR20040088857A (en) * | 2003-04-14 | 2004-10-20 | 현대자동차주식회사 | Composition of aluminum alloy for cylinder head with improved fatigue/intensity property |
CN106244864A (en) * | 2016-08-30 | 2016-12-21 | 苏州梅克卡斯汽车科技有限公司 | A kind of automobile turbocharger housing and preparation method thereof |
US20200131605A1 (en) * | 2018-10-29 | 2020-04-30 | Fna Group, Inc. | Aluminum alloy |
CN112048645A (en) * | 2020-08-24 | 2020-12-08 | 山东弗泽瑞金属科技有限公司 | Preparation method and equipment of die-casting aluminum alloy material |
Also Published As
Publication number | Publication date |
---|---|
EP4284954A1 (en) | 2023-12-06 |
CN117062926A (en) | 2023-11-14 |
DE102021102268A1 (en) | 2022-08-04 |
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