WO2017185321A1 - Alliages d'aluminium coulés sous pression pour composants de coulée à paroi mince - Google Patents

Alliages d'aluminium coulés sous pression pour composants de coulée à paroi mince Download PDF

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Publication number
WO2017185321A1
WO2017185321A1 PCT/CN2016/080629 CN2016080629W WO2017185321A1 WO 2017185321 A1 WO2017185321 A1 WO 2017185321A1 CN 2016080629 W CN2016080629 W CN 2016080629W WO 2017185321 A1 WO2017185321 A1 WO 2017185321A1
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Prior art keywords
equal
alloy composition
weight
less
concentration
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PCT/CN2016/080629
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English (en)
Inventor
Bin Hu
Michael C. RIZZO
Liming Peng
Wenjiang Ding
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Shanghai Jiao Tong University
GM Global Technology Operations LLC
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Shanghai Jiao Tong University
GM Global Technology Operations LLC
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Priority to PCT/CN2016/080629 priority Critical patent/WO2017185321A1/fr
Publication of WO2017185321A1 publication Critical patent/WO2017185321A1/fr
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    • 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

Definitions

  • the present disclosure relates to alloy compositions for high strength and high ductility components made by casting.
  • Aluminum alloys are commonly used in manufacturing industries for die-casting components, such as, for example, 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 that require high strength and high ductility and that are lightweight.
  • a common Al alloy used in the automobile industry is known as A380.
  • A380 has a silicon content of 7.5% (wt. /wt. ) to 9.5% (wt. /wt. ) , an iron content of 0.6% (wt. /wt. ) to 1.3% (wt. /wt. ) , a copper content of 3.0% (wt. /wt. ) to 4.0% (wt. /wt. ) , a zinc content of 3.0% (wt. /wt. ) , other components, and a balance being aluminum.
  • A380 may require an additional heat treatment (T5) to improve strength. Accordingly, the development of new alloys that are strong and ductile, and do not require expensive heat treatments or manufacturing processes are desirable.
  • the present technology provides an alloy composition.
  • the alloy composition comprises silicon at a concentration of from greater than or equal to about 9.5%by weight per total alloy composition weight to less than or equal to about 11.5%by weight/total alloy composition weight (or wt. /wt. ) ; manganese at a concentration of greater than or equal to about 0.5% (wt. /wt. ) to less than or equal to about 0.8%(wt. /wt. ) ; copper at a concentration of less than or equal to about 2% (wt. /wt. ) ; and a balance of the alloy composition being aluminum.
  • the alloy composition has a higher strength and ductility relative to traditional alloys.
  • the present technology also provides an alloy composition that comprises silicon at a concentration of from greater than or equal to about 9.5%by weight per total alloy composition weight (or wt. /wt. ) to less than or equal to about 11.5% (wt. /wt. ) ; copper at a concentration of greater than or equal to about 0.5% (wt. /wt. ) to less than or equal to about 1.5% (wt. /wt. ) ; manganese at a concentration of greater than or equal to about 0.5%(wt. /wt. ) to less than or equal to about 0.8% (wt. /wt. ) ; magnesium at a concentration of greater than or equal to about 0.1% (wt. /wt.
  • the alloy composition may form, without any artificial heat treatment, a cast part in an as-cast condition that has a yield strength of from greater than or equal to about 150 MPa to less than or equal to about 210 MPa, an ultimate tensile strength of from greater than or equal to about 270 MPa to less than or equal to about 330 MPa, and a ductility (elongation) of from greater than or equal to about 5%to less than or equal to about 8%.
  • the present technology provides a method of manufacturing an automobile or vehicle part.
  • the method includes die casting the vehicle part with an alloy composition.
  • the alloy composition comprises silicon at a concentration of from greater than or equal to about 9.5%by weight per total alloy composition weight (or wt. /wt. ) to less than or equal to about 11.5% (wt. /wt. ) ; at last one element selected from the group consisting of copper at a concentration of greater than or equal to about 0.5% (wt. /wt. ) to less than or equal to about 1.5% (wt. /wt.
  • the die casting is either high-pressure die casting or low-pressure die casting.
  • An as-cast vehicle part made by this method has a yield strength offrom greater than or equal to about 150 MPa to less than or equal to about 210 MPa, an ultimate tensile strength of from greater than or equal to about 270 MPa to less than or equal to about 330 MPa, and a ductility (elongation) of from greater than or equal to about 5%to less than or equal to about 8%. Accordingly, a heat treatment after casting is not necessary.
  • Fig. 1 is a graph that shows the effect of copper (Cu) content on tensile strength and ductility, wherein the left y-axis is tensile strength (MPa) , the right y-axis is ductility (%elongation) , and the x-axis is Cu content (%wt. /wt. ) and square points refer to yield strength, hexagonal points refer to ultimate tensile strength, and triangles refer to ductility.
  • Cu copper
  • 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.
  • 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.
  • 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.
  • composition and “material” are used interchangeably to refer broadly to a substance containing at least the preferred elements, but which may also comprise additional elements, substances or compounds, including impurities.
  • the present technology pertains to improved aluminum alloys, which may be used in vehicle applications.
  • the aluminum alloys include low-cost alloying elements and minimal impurities that result in high strength and high ductility thin-wall casting components or parts. Not only are the alloying elements low-cost, but the components or parts cast from the alloy do not require expensive heat treatments as with existing alloys, including A380, to achieve high strength and the desired stiffness and ductility requirements. Additionally, the high strength of the aluminum alloys enables significant mass reduction in completed components relative to conventional aluminum alloys, while meeting ductility requirements for the components.
  • Aluminum alloys are widely used in vehicles, such as automobiles, motorcycles, boats, tractors, buses, mobile homes, campers, and tanks, and their utilization will continue alongside efforts to reduce vehicle mass and save space.
  • the aluminum alloy according to the present technology results in components with reduced mass relative to components made with traditional alloys, while maintaining strength and ductility requirements. Therefore, relative to components made with traditional alloys, compact components can be made with the current aluminum alloys that have lower mass and take less space.
  • 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. Non-limiting examples include engine mount brackets, transmission mount brackets, shock towers, alternator brackets, air conditioner compressor brackets, cowl plates, and the like.
  • the aluminum alloy provided by the present technology includes greater than or equal to about 9.5%by weight to less than or equal to about 11.5%by weight of the alloy composition (wt. /wt. ) silicon (Si) .
  • “castability” refers to an alloys ability to be cast without formation of defects, such as cracks, segregations, pores, or misruns.
  • the aluminum alloy can be used in high-pressure die casting or low-pressure die casting applications, without additional heat treatments or machining. Nonetheless, the aluminum alloy may be used in other casting applications that include much lower cooling rates relative to high-pressure die casting or low-pressure die casting, such as, for example, gravity casting, sand casting, and investment casting, with heat treatment.
  • the current aluminum alloy includes copper (Cu) at a concentration of less than or equal to about 2% (wt. /wt. ) or optionally less than or equal to about 1.5% (wt. /wt. ) .
  • the Cu concentration is greater than or equal to about 0.5% (wt. /wt. ) to less than or equal to about 1.5% (wt. /wt. ) . Having this low Cu concentration prevents or deters the formation of an Al 2 Cu phase and does not negatively influence corrosion. Simultaneously, the addition of Cu increases yield strength.
  • Fig. 1 is a graph that shows the effect of Cu content on tensile strength and ductility.
  • the left y-axis is tensile strength (MPa)
  • the right y-axis is ductility (%elongation)
  • the x-axis is Cu content (%wt. /wt. ) .
  • Square points refer to yield strength
  • hexagonal points refer to ultimate tensile strength
  • triangles refer to ductility.
  • acopper concentration between 0 and about 1.5%(wt. /wt. ) provides results that are positive in regard to yield strength, ultimate tensile strength, and ductility.
  • the aluminum alloy also includes a low iron (Fe) concentration of less than or equal to about 0.20% (wt. /wt. ) or less than or equal to about 0.15% (wt. /wt. ) .
  • This low concentration ofFe results in less brittle Al-Si-Fe intermetallic phase relative to traditional alloys.
  • the presence of an intermetallic phase generally decreases ductility. Therefore, having a minimal amount of Fe contributes to the aluminum alloy’s high ductility by preventing or minimizing the formation of a brittle intermetallic phase.
  • the aluminum alloy also may include a Mn concentration of greater than nor equal to about 0.5% (wt. /wt. ) to less than or equal to about 0.8% (wt. /wt. ) .
  • Mg magnesium
  • Mg is included in the present aluminum alloy relative to traditional alloys.
  • Mg is included at a concentration of greater than or equal to about 0.10% (wt. /wt. ) to less than or equal to about 0.50% (wt. /wt. ) .
  • the Mg increases the strength of the aluminum and does not have a negative impact on ductility.
  • a high phosphorous (P) content in Al-Si alloys results in a fibrous eutectic Si phase, which may have a negative impact on strength as well as ductility. Due to this effect, P may be considered an impurity. Consequently, strontium (Sr) is commonly added to Al-Si alloys to modify this phase.
  • Sr strontium
  • Using Sr as a modifier of eutectic Si phase has a tendency to increase the risk of hydrogen absorption into molten Al-Si alloys so as to increase the formation of pore-type defects in castings.
  • a low P content in Al-Si alloys results in a finer morphology of particle-like eutectic Si phases associated with increased ductility without the addition of Sr.
  • the current aluminum alloy includes phosphorous at a concentration of less than or equal to about 0.003% (wt. /wt. ) to promote fine particle-like eutectic Si morphology and to improve ductility.
  • Sr in the current aluminum alloy is optional.
  • the aluminum alloy composition may optionally include Sr at a concentration of greater than or equal to 0.0% (wt. /wt. ) (or a positive concentration greater than 0.0% (wt. /wt. ) ) to less than or equal to about 0.05% (wt. /wt. ) .
  • the present aluminum alloy also contains low levels of the impurities zinc (Zn) and tin (Sn) relative to traditional alloys.
  • the Zn and Sn concentrations are individually less than or equal to about 0.01% (wt. /wt. ) .
  • the low Zn and Sn concentrations relative to traditional alloys provide increased ductility and improved machinability, which refers to the ease in which the alloy can be worked with a cutting tool.
  • the aluminum alloy includes a lowtitanium (Ti; another impurity) concentration of greater than or equal to about 0.05% (wt. /wt. ) to less than or equal to about 0.1% (wt. /wt. ) .
  • the aluminum alloy may contain small concentrations of other impurities, the balance of the aluminum alloy is aluminum. Therefore, the aluminum concentration is greater than or equal to about 84% (wt. /wt. ) to less than or equal to about 90%.
  • the current aluminum alloy contains Al, Si, Fe, Cu, Mn, Mg, Zn, Ti, P, Sn, and optionally Sr with varying concentrations.
  • the current aluminum alloy comprises Al and Si and at least one or at least two elements selected from the group consisting of Fe, Cu, Mn, and Mg.
  • the current aluminum alloy may also comprise Zn, Ti, P, and/or Sn.
  • the foregoing elements and their corresponding concentrations are provided in Table 1. Nonetheless, it is understood that the aluminum alloy may include trace amounts of impurities (other than the impurities described herein) that do not materially affect the strength, ductility, and stiffness of the aluminum alloy at a concentration of less than or equal to about 0.15% (wt. /wt. ) .
  • the current aluminum alloy composition comprises Al and Si and at least one or at least two elements selected from the group consisting of Cu, Mn, Mg, Fe, Zn, Ti, P, Sn, and Sr at the concentrations provided herein.
  • the aluminum alloy composition comprises Al, Fe, Si, Cu, Mn, Fe, Mg, Zn, Ti, P, Sn, and optionally Sr at the concentrations provided herein.
  • the aluminum alloy consists essentially of the components described herein.
  • the aluminum alloy can include Al, Si, Fe, Cu, Mn, Mg, Zn, Ti, P, Sn, and optionally Sr at the concentrations provided herein and other impurities that do not materially affect the strength, ductility, and stiffness of the aluminum alloy.
  • the aluminum alloy consists essential of Al and Si and at last one or at least two other elements selected from the group consisting of Fe, Cu, Mn, Mg, Zn, Ti, P, Sn, and Sr.
  • the aluminum alloy consists of the components described herein.
  • the aluminum alloy can include Al, Si, Fe, Cu, Mn, Mg, Zn, Ti, P, Sn, and optionally Sr at the concentrations provided herein and no other impurities.
  • the aluminum alloy consists of Al and Si and at last one or at least two other elements selected from the group consisting of Fe, Cu, Mn, Mg, Zn, Ti, P, Sn, and Sr.
  • the aluminum alloy provided herein has a yield strength (YS) of from greater than or equal to about 150 MPa, or from greater than or equal to about 150 MPa to less than or equal to about 210 MPa, such as a YS of about 150 MPa, 160 MPa, 170 MPa, 180 MPa, 190 MPa, 200 MPa, or 200 MPa.
  • YS yield strength
  • the aluminum alloy has an ultimate tensile strength (UTS) of greater than or equal to about 270 MPa, or from greater than or equal to about 270 MPa to less than or equal to about 330 MPa, such as a UTS of about 270 MPa, 280 MPa, 290 MPa, 300 MPa, 310 MPa, 320 MPa, or 330 MPa.
  • UTS ultimate tensile strength
  • the aluminum alloy has a ductility (elongation) of greater than or equal to about 5%(elongation) to less than or equal to about 8% (elongation) , such as a ductility of about 5% (elongation) , about 6% (elongation) , about 7% (elongation) , or about 8% (elongation) in the as-cast condition without heat treatment.
  • the current aluminum alloy enables the design of lighter weight components relative to traditional alloys.
  • the mass of a casting made from the current aluminum alloy is about 26%less than the mass of an equivalent casting composed of A380.
  • the casting made from the current aluminum alloy maintains all stiffness and strength requirements. Therefore, the current aluminum alloy has improved strength and ductility relative to traditional alloys and maintains an acceptable stiffness.
  • the current technology also provides a method of manufacturing a component, such as an automobile part.
  • the method comprises die casting the component with an aluminum alloy described herein.
  • the die casting is either high-pressure die casting or low-pressure die casting and optionally includes heat treating the component after casting and machining the casting.
  • the method omits any heat treatment and/or machining after the die casting.
  • the component can be, for example, an engine mount bracket, a transmission mount bracket, a shock tower, an alternator bracket, an air conditioner compressor bracket, or a cowl plate.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Body Structure For Vehicles (AREA)

Abstract

L'invention concerne une composition d'alliage d'aluminium. La composition d'alliage d'aluminium comprend du silicium à une concentration supérieure ou égale à environ 9,5 % (poids/poids) à une valeur inférieure ou égale à environ 11,5 % (poids/poids); du manganèse à une concentration supérieure ou égale à environ 0,5 % en poids à inférieure ou égale à environ 0,8 % en poids de la composition d'alliage; du cuivre à une concentration inférieure ou égale à environ 2 % (poids/poids); et un équilibre de la composition d'alliage étant de l'aluminium. La composition d'alliage d'aluminium présente une résistance et une ductilité supérieures par rapport aux alliages d'aluminium classiques.
PCT/CN2016/080629 2016-04-29 2016-04-29 Alliages d'aluminium coulés sous pression pour composants de coulée à paroi mince Ceased WO2017185321A1 (fr)

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10927436B2 (en) 2017-03-09 2021-02-23 GM Global Technology Operations LLC Aluminum alloys
CN115003832A (zh) * 2020-01-22 2022-09-02 特斯拉公司 用于结构部件的压铸铝合金
CN116970823A (zh) * 2023-08-04 2023-10-31 昆明冶金研究院有限公司 一种低铸造缺陷免热处理压铸铝硅合金制备方法

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4336076A (en) * 1977-03-17 1982-06-22 Kawasaki Jukogyo Kabushiki Kaisha Method for manufacturing engine cylinder block
EP0577062A1 (fr) * 1992-06-29 1994-01-05 Sumitomo Electric Industries, Limited Pompe à huile en alliages d'aluminium
DE19524564A1 (de) * 1995-06-28 1997-01-02 Vaw Alucast Gmbh Aluminiumguß-Legierung
US6364970B1 (en) * 1994-06-16 2002-04-02 Aluminium Rheinfelden Gmbh Diecasting alloy
CN101709415A (zh) * 2009-12-16 2010-05-19 中国科学院苏州纳米技术与纳米仿生研究所 压铸铝合金材料及其制备方法
CN102703774A (zh) * 2012-06-27 2012-10-03 贵阳华烽有色铸造有限公司 一种铸造铝合金
CN104498781A (zh) * 2014-12-22 2015-04-08 贵阳广航铸造有限公司 用于制造压铸气缸盖罩的铝合金及压铸气缸盖罩
CN105039799A (zh) * 2015-07-12 2015-11-11 张小龙 一种硅铝合金材料及其制备方法
CN105112740A (zh) * 2015-07-16 2015-12-02 陈巨根 一种压铸铝合金材料及其制备方法

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4336076A (en) * 1977-03-17 1982-06-22 Kawasaki Jukogyo Kabushiki Kaisha Method for manufacturing engine cylinder block
EP0577062A1 (fr) * 1992-06-29 1994-01-05 Sumitomo Electric Industries, Limited Pompe à huile en alliages d'aluminium
US6364970B1 (en) * 1994-06-16 2002-04-02 Aluminium Rheinfelden Gmbh Diecasting alloy
DE19524564A1 (de) * 1995-06-28 1997-01-02 Vaw Alucast Gmbh Aluminiumguß-Legierung
CN101709415A (zh) * 2009-12-16 2010-05-19 中国科学院苏州纳米技术与纳米仿生研究所 压铸铝合金材料及其制备方法
CN102703774A (zh) * 2012-06-27 2012-10-03 贵阳华烽有色铸造有限公司 一种铸造铝合金
CN104498781A (zh) * 2014-12-22 2015-04-08 贵阳广航铸造有限公司 用于制造压铸气缸盖罩的铝合金及压铸气缸盖罩
CN105039799A (zh) * 2015-07-12 2015-11-11 张小龙 一种硅铝合金材料及其制备方法
CN105112740A (zh) * 2015-07-16 2015-12-02 陈巨根 一种压铸铝合金材料及其制备方法

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10927436B2 (en) 2017-03-09 2021-02-23 GM Global Technology Operations LLC Aluminum alloys
CN115003832A (zh) * 2020-01-22 2022-09-02 特斯拉公司 用于结构部件的压铸铝合金
CN116970823A (zh) * 2023-08-04 2023-10-31 昆明冶金研究院有限公司 一种低铸造缺陷免热处理压铸铝硅合金制备方法

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