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
  • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
  • C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
• • 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
• • 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
  • C22C21/00—Alloys based on aluminium
• • 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
  • C22F1/047—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 magnesium as the next major constituent

Definitions

• the present invention relates to a die casting alloy based on aluminium, iron, magnesium and silicon.
• the aluminium casting industry plays a crucial role in various applications, from the automotive industry to electronic devices.
• the demand for environmentally friendly and cost-efficient casting alloys, especially die casting alloys has increased.
• One of the challenges is to enable the use of low-grade aluminium scrap resp. secondary aluminium, which is obtained from aluminium scrap of various origins, in order to reduce waste and use resources more efficiently.
• wheel scrap is used for the production of AISi9MnMg alloys with a high recycled content, especially because of the low iron content of this type of scrap.
• Other types of scrap with a higher iron content or other impurities are generally not usable.
• a die casting alloy based on aluminium, iron and magnesium is known from EP 3235916 B1 , which is used in particular in the field of vehicle structural components.
• the die casting alloy according to the invention consists of the following elements: Iron (Fe) 0.8 - 2.0 wt.% Magnesium (Mg) 0.3 - 6.0 wt.% Silicon (Si) 0.3 - 1.2 wt.% Calcium (Ca) 0.05 - 2.0 wt.% Zinc (Zn) 0 - 4.0 wt.% Copper (Cu) 0 - 2.5 wt.% Manganese (Mn) 0 - 1.5 wt.% Nickel (Ni) 0 - 0.6 wt.%
• a further embodiment of the die casting alloy according to the invention has a silicon content of 0.5 - 0.8 wt.% silicon.
• a further embodiment of the die casting alloy according to the invention has a magnesium content of 3.5 - 5.0 wt.% magnesium.
• a further embodiment of the die casting alloy according to the invention has a zinc content of 0 - 1.0 wt.% zinc.
• a further embodiment of the die casting alloy according to the invention has a zinc content of 0.1 - 0.5 wt.% zinc.
• a further embodiment of the die casting alloy according to the invention has a manganese content of 0.1 - 1 wt.% manganese.
• a further embodiment of the die casting alloy according to the invention has a copper content of max. 2.0 wt.%, preferably max. 0.1 wt.% copper.
• a further embodiment of the die casting alloy according to the invention has a nickel content of max. 0.1 wt.% nickel.
• the alloy according to the invention is a die casting alloy or, in other words, the alloy composition proposed according to the invention is used for die casting, preferably of structural components for automotive manufacture.
• die casting alloys covers alloy compositions which are processed into a die cast component by means of a die casting process. Die casting alloys must be clearly distinguished from wrought alloys. Die casting alloys are alloy compositions that are further processed in one step by means of a die casting process into the direct end product, the die cast component.
• the alloy composition can be introduced into the casting mould as a liquid melt or as a partially solidified melt.
• this product is subsequently heat-treated or such a heat treatment is to be deliberately avoided, as according to the present invention.
• the die-cast product then already exhibits the desired material properties in the casting state "state F". Examples of products are die-cast structural components of cars.
• the following die casting processes are examples of die casting processes: HPDC (High Pressure Die Casting), Vacuum Die Casting and Rheo Die Casting (so-called Reocasting), Vacural Die Casting.
• the molten alloy is shot into a mould at high speed, the so-called gate speed, of 20-100 m/s and solidifies there at a holding pressure of about 500-1000 bar.
• the gate speed is only 1-10 m/s..
• the gate speed is usually arranged horizontally, in some cases vertically or at an oblique angle.
• the alloy according to the invention is an alloy in which the aluminium comes from a secondary source.
• Can scrap includes so-called UBC material (Used Beverage Cans) according to DIN EN 13920-10.
• the end product shows a slightly increased strength compared to conventional casting alloys, for example AlSi alloys, which are also used for structural components in automotive manufacture.
• the alloy already has mechanical properties in the as-cast state (state F) that make it possible to dispense with heat treatment, which reduces manufacturing costs and energy consumption.
• Magnesium (Mg) serves as a solid solution strengthener to increase strength. Silicon (Si) together with magnesium (Mg) also increases the strength by forming Mg2Si. It was found that despite the presence of silicon (Si) no embrittlement occurs, in particular no brittle AIFeSi phases are formed.
• Calcium (Ca) reduces the oxidation tendency of the melt.
• vandium (V) in addition to calcium, the oxidation tendency of the melt could be reduced even further.
• the reduction of the oxidation tendency of the melt also reduces the magnesium melting loss and thus the magnesium loss during the production of the alloy composition according to the invention.
• the following table shows a composition of a can scrap used for the alloy according to the invention (so-called UBC material, see line “Recycled material”).
• An example of the composition according to the invention is listed in the line “Alloy composition J1".
• the addition of the required alloying elements to the impurities found (see line “Addition of elements”).
• the addition of just under 3.2 % Mg already leads to a yield tensile strength of over 160 MPa. Without the content of 0.23 % Cu and 0.80 % Mn, among others, in the starting alloy, this strength would not have been achieved; the addition of a larger quantity of Mg would have been necessary.
• the melting interval (solidus-liquidus) was calculated to be 571-660 °C with the aid of a phase simulation, and the heat of fusion was calculated to be 485 kJ/kg.
• the heat of fusion is comparable to that of conventional AlSi alloys, which are considered by experts to have good castability.
• the heat of fusion of rotor alloys rated as poor castability is, as an example, approx. 80 kJ/kg lower.
• Table 3 discloses a further embodiment of the alloy composition according to the invention. As an example, the effect addition of Ca and V and the magnesium burn-off will be explained here. Table 3A shows the composition of the alloy at the start of the experiment and Table 3B the composition 7 days later.
• Table 3A, 3B shows the effect on magnesium burn-off. Already an addition of 0.082 Ca and 0.023 V led to a no longer measurable loss of magnesium. In addition, a significantly lower oxide layer on the melt could be visually determined.
• Table 4 compares compositions of examples of alloys according to the invention. The figures are in wt.%. Table 4 test Si Fe Cu Mn Mg Zn A1 0,04 1,59 0,00 0,00 5,18 0,00 A2 0,04 1,60 0,00 0,00 5,39 0,00 A3 0,04 1,57 0,00 0,00 5,96 0,00 B1 0,45 1,13 0,05 0,01 3,74 0,00 B2 0,47 1,19 0,05 0,01 3,79 0,00 B3 0,58 1,15 0,05 0,01 3,66 0,00 C1 0,13 1,20 0,03 0,21 3,41 0,01 C2 0,51 1,21 0,04 0,17 4,51 0,01 C3 0,53 1,35 0,04 0,64 4,61 0,01 D1 0,13 1,19 0,03 0,17 3,41 0,01 D2 0,13 1,24 0,03 0,60 3,40 0,01 D3 0,51 1,28 0,04 0,61 3,38 0,01 D4 0,51 1,28 0,04 0,98 3,30 0,01 E1 0,39 1,20 0,06 0,01 4,32 0,05 E2 0,40 1,16 0,05 0,01 5,15 0,05 E3 0,60 1,21
• the recycling content indicates the approximate secondary aluminium content obtained from consumer scrap, so-called post consumer recycling (PCR). Industrial waste (pre-consumer recycling) was not used.

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• Chemical & Material Sciences (AREA)
• Mechanical Engineering (AREA)
• Engineering & Computer Science (AREA)
• Materials Engineering (AREA)
• Organic Chemistry (AREA)
• Metallurgy (AREA)
• Thermal Sciences (AREA)
• Crystallography & Structural Chemistry (AREA)
• Physics & Mathematics (AREA)
• Molds, Cores, And Manufacturing Methods Thereof (AREA)
• Measuring Fluid Pressure (AREA)
• Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)
• Conductive Materials (AREA)

Priority Applications (7)

Applications Claiming Priority (1)

Publications (1)

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Citations (4)

• 2023
  • 2023-10-13 EP EP23203621.0A patent/EP4538405A1/fr active Pending
• 2024
  • 2024-10-09 CA CA3256111A patent/CA3256111A1/en active Pending
  • 2024-10-10 JP JP2024177932A patent/JP2025069086A/ja active Pending
  • 2024-10-11 KR KR1020240138853A patent/KR20250053758A/ko active Pending
  • 2024-10-11 MX MX2024012645A patent/MX2024012645A/es unknown
  • 2024-10-11 US US18/912,715 patent/US20250122599A1/en active Pending
  • 2024-10-14 CN CN202411429510.0A patent/CN119824280A/zh active Pending

Patent Citations (4)

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