WO2024251532A1 - Alliage d'aluminium - Google Patents

Alliage d'aluminium Download PDF

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Publication number
WO2024251532A1
WO2024251532A1 PCT/EP2024/064254 EP2024064254W WO2024251532A1 WO 2024251532 A1 WO2024251532 A1 WO 2024251532A1 EP 2024064254 W EP2024064254 W EP 2024064254W WO 2024251532 A1 WO2024251532 A1 WO 2024251532A1
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WO
WIPO (PCT)
Prior art keywords
aluminium alloy
friedrichshafen
component
alloy according
alloy
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/EP2024/064254
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German (de)
English (en)
Inventor
Thomas Kurt Stürzel
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ZF Friedrichshafen AG
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ZF Friedrichshafen AG
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Filing date
Publication date
Application filed by ZF Friedrichshafen AG filed Critical ZF Friedrichshafen AG
Priority to CN202480034608.8A priority Critical patent/CN121175442A/zh
Publication of WO2024251532A1 publication Critical patent/WO2024251532A1/fr
Anticipated expiration legal-status Critical
Pending legal-status Critical Current

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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
    • 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
    • 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 invention relates to an aluminum alloy consisting of 0.50 - 1.50 wt.% Fe, 0.45 - 2.00 wt.% Ni, 0 - 0.20 wt.% Si, 0 - 0.20 wt.% Mg, 0 - 0.20 wt.% Cu, 0 - 0.20 wt.% Mn, 0 - 0.20 wt.% Zn, 0 - 0.20 wt.% Ti, 0 - 0.20 wt.% V, 0 - 0.20 wt.% Cr, 0 - 0.20 wt.% Zr, 0 - 0.20 wt.% Ce, 0 - 0.05 wt.% P, 0 - 0.05 wt.% Mo, 0 - 0.05 wt.% Sr, 0 - 0.004 % by weight B; and the remainder AI and unavoidable impur
  • the present invention also relates to a method for producing a component from the aluminum alloy according to the invention, a corresponding component, and the use of the aluminum alloy according to the invention for producing a component.
  • the present invention further relates to an asynchronous machine (ASM) with a corresponding component made from the aluminum alloy according to the invention and an electrically driven vehicle with a corresponding asynchronous machine as a drive unit.
  • ASM asynchronous machine
  • the rotor In an electric drive, the rotor is a main component in addition to the stator.
  • ASM asynchronous machines
  • the rotor has a cage winding incorporated into a rotor base body, which is usually made of aluminum or aluminum-based alloys and is cast or embedded in slots in the rotor base body.
  • the cage winding comprises a plurality of bars that run essentially axially to a rotor axis of rotation, which are mechanically and electrically connected to one another at the front with short-circuit rings that are usually manufactured at the same time, in particular cast on.
  • the requirements for the material for the cage winding of an ASM rotor are very high. The material must withstand the large mechanical forces that occur at the high speeds of the electric machine rotor.
  • the material must therefore ZF Friedrichshafen AG File 300777 Friedrichshafen 2023-06-05 good mechanical properties, in particular a high yield strength even at high temperatures and the associated heat resistance. Furthermore, the material must also have good conductivity for its use in an ASM rotor. Finally, the metal or metal alloy must have good castability so that a satisfactory casting quality can be achieved and more complicated rotor shapes can also be cast. If there is insufficient castability, numerous defects can occur during the complex casting process, such as porosity trapped in the casting, which reduces the quality of the cast body and thus worsens its mechanical properties and electrical conductivity. Originally, technical-pure aluminum was intended as the material for ASM rotors.
  • Al99.7 Technical-pure aluminum
  • Al99.7 does have good electrical conductivity and high elongation at break. However, it has a very low 0.2% yield strength (Rp0.2) at higher temperatures and inadequate castability.
  • Rp0.2 0.2% yield strength
  • Al99.7 efforts were therefore made to develop an aluminum-based alloy that has a higher yield strength compared to Al99.7 while still having good electrical conductivity.
  • the commercially available aluminum alloy Anticorodal ® -04 also known as Ac-04 or [AlSi0.5Mg] and sold by Rheinfelden
  • This alloy which is low in terms of Si content, shows a significant increase in yield strength and tensile strength compared to Al99.7 while still having a very high elongation at break and sufficient conductivity.
  • Anticorodal ® -04 does not have good castability and is therefore only of limited use in a die-casting process, for example.
  • a (final) heat treatment step is usually required (for example in the form of a T5 heat treatment) in order to obtain optimal mechanical properties for the component.
  • the present invention is based on the object of providing an aluminum alloy which, compared to conventional alloys, has an improved yield strength even at high temperatures and thus ZF Friedrichshafen AG File 300777 Friedrichshafen 2023-06-05 associated heat resistance, high electrical conductivity and at the same time improved castability.
  • an aluminum alloy is to be provided that can be produced more easily than conventional alloys. This object is achieved by the embodiments characterized in the patent claims.
  • an aluminum alloy which consists of 0.50 - 1.50 wt.% Fe, 0.45 - 2.00 wt.% Ni, 0 - 0.20 wt.% Si, 0 - 0.20 wt.% Mg, 0 - 0.20 wt.% Cu, 0 - 0.20 wt.% Mn, 0 - 0.20 wt.% Zn, 0 - 0.20 wt.% Ti, 0 - 0.20 wt.% V, 0 - 0.20 wt.% Cr, 0 - 0.20 wt.% Zr, 0 - 0.20 wt.% Ce, 0 - 0.05 wt.% P, 0 - 0.05 wt.% Mo, 0 - 0.05 wt.% Sr, 0 - 0.004 wt.% B; and the remainder AI and unavoidable impurities, the wt.
  • the aluminum alloy according to the invention contains 0.50 - 1.50 wt.% Fe, preferably 0.60 - 1.30 wt.% Fe and particularly preferably 0.70 - 0.85 wt.% Fe.
  • the aluminum alloy according to the invention also contains 0.45 - 2.00 wt.% Ni, preferably 0.50 - 1.60 wt.% Ni and particularly preferably 0.95 - 1.10 wt.% Ni.
  • Iron is used in the alloy according to the invention to reduce the tendency of the alloy to stick to the mold during the casting process and to ZF Friedrichshafen AG File 300777 Friedrichshafen 2023-06-05 ductility. Nickel forms intermetallic phases with Al and so-called ternary intermetallic phases with Fe and Al, which increase the strength of the alloy.
  • the combination of Al, Fe and Ni according to the invention leads to the formation of a eutectic phase diagram and thus to a reduction in the melting temperature, although the structure then shows a typical eutectic structure.
  • the other elements Si, Mg, Cu, Mn, Zn, Ti, V, Cr, Zr, Ce, P and Sr can optionally be present in the amounts mentioned above.
  • the total proportion of Mn, Ti, Cr, V and Zr together is not more than 0.50 wt.%, preferably not more than 0.10 wt.% and particularly preferably not more than 0.03 wt.%.
  • the total proportion of Ti, Cr, V and Zr in the aluminum alloy together is not more than 0.02 wt.%.
  • the aluminum alloy according to the invention contains not more than 0.004 wt.% B, preferably not more than 0.002 wt.% B.
  • the rest of the alloy is made up of Al and unavoidable impurities, the wt.% adding up to 100 wt.% in the alloy.
  • the unavoidable impurities make up a total of not more than 0.25 wt.%, preferably not more than 0.15 wt.%, particularly preferably not more than 0.10 wt.%.
  • Each individual impurity makes up not more than 0.05 wt.%, preferably not more than 0.02 wt.%, particularly preferably not more than 0.01 wt.%.
  • the aluminum alloy according to the invention consists of 0.50 - 1.50 wt.% Fe, 0.45 - 2.00 wt.% Ni, 0 - 0.10 wt.% Si, 0 - 0.02 wt.% Mg, 0 - 0.01 wt.% Cu, 0 - 0.01 wt.% Mn, 0 - 0.07 wt.% Zn, 0 - 0.01 wt.% Ti, 0 - 0.01 wt.% V, 0 - 0.01 wt.% Cr, 0 - 0.01 wt.% Zr, 0 - 0.01 wt.% Ce, 0 - 0.01 wt.% P, 0 - 0.01 wt.% Mo, 0 - 0.001 wt.% Sr, 0 - 0.004 wt.% B, the unavoidable impurities in total not exceeding 0.10 % by weight and no single im
  • an aluminum alloy can be obtained which nevertheless has high electrical conductivity, an increased yield strength and tensile strength compared to Al99.7 while still having high elongation >20% and a reduced tendency to hot cracking, for example compared to Anticorodal-04.
  • components made from the aluminum alloy according to the invention are also easier to manufacture, as will be explained in more detail below.
  • the present invention relates to the use of the aluminum alloy according to the invention for producing a component, preferably an ASM rotor.
  • the present invention further relates to a method for producing a component from the aluminum alloy according to the invention, the method comprising the following steps: (a) melting the aluminum alloy from at least one master alloy and/or the chemical elements in the corresponding weight ratios, (b) pouring the melted aluminum alloy into a mold and (c) allowing it to cool or cooling the aluminum alloy poured into the mold.
  • step (a) of the method the aluminum alloy according to the invention is melted from at least one master alloy and/or the chemical elements in the corresponding weight ratios.
  • the aluminum alloy can be melted from any suitable master alloys or elements.
  • the aluminum alloy is preferably melted from the pure elements or the elements with technical purity (for example Al99.7).
  • Nitrogen impeller treatment is a common melt treatment in the field of Al casting.
  • An impeller usually made of graphite, is introduced into the melt and then rotated in the Al melt at speeds of around 500 rpm for 4 to 15 minutes.
  • the impeller introduces nitrogen into the melt, which is finely distributed by the impeller head.
  • the fine nitrogen bubbles in the melt collect oxides and hydrogen and lead them to the bath surface. There they can then be removed as dross. This process can also be combined with a salt treatment.
  • the molten (i.e. liquid) aluminum alloy is poured into a mold.
  • All mold casting processes known to the person skilled in the art can be used for this purpose, for example the die casting process, the low-pressure casting process or the centrifugal casting process.
  • the temperature at which the casting takes place can be selected by the person skilled in the art in a suitable manner depending on the mold casting process used, although if the casting temperature is too low there is a risk of insufficient mold filling and cold runs.
  • the die casting process is preferably carried out at a temperature in the range from 650 °C to 750 °C, particularly preferably at a temperature of 680 °C to 700 °C.
  • the pressure is usually up to 1000 bar.
  • the casting step is carried out in the form of a die casting process at a temperature in the range from 650 °C to 750 °C or in the form of a centrifugal casting process.
  • step (c) the aluminum alloy cast into the mold is cooled or allowed to cool.
  • the aluminum alloy is poured, for example, into a tempered and/or forced or vacuum-vented mold, particularly preferably into a tempered and/or forced or vacuum-vented permanent mold.
  • the tempering of the mold has the advantage that the ZF Friedrichshafen AG File 300777 Friedrichshafen 2023-06-05 Tempering the aluminum alloy can be cooled in a targeted and controlled manner and thus the service life of the casting tool is increased by its cooling.
  • the cooled aluminum alloy is usually heat treated, for example, at a temperature in the range of 200 ° C to 260 ° C for a period of 1 to 6 hours.
  • components with advantageous mechanical properties are also obtained with the aluminum alloys according to the invention if they are not subjected to a heat treatment step.
  • no heat treatment of the cooled aluminum alloy takes place after step (c), in particular no T5 heat treatment, for example at a temperature in the range of 160 ° C to 250 ° C.
  • the method according to the invention is thus significantly simplified compared to conventional methods.
  • the aluminum alloys according to the invention are particularly advantageous when processed in die casting, since they have a low tendency to stick to the tool, so that a standard spray process is sufficient to prevent the alloy from sticking in the die casting tool.
  • the present invention also relates to a component which comprises the alloy according to the invention or is obtainable by the inventive method described above.
  • the component is preferably a component for vehicle or engine construction.
  • the component is particularly preferably an ASM rotor.
  • the ASM rotor together with a stator, forms an asynchronous machine, which can be used, for example, as a drive unit for driving an electric or hybrid vehicle.
  • the invention also relates to an asynchronous machine and a vehicle with an asynchronous machine.
  • the invention relates to an asynchronous machine (ASM) with a corresponding component made of the aluminum alloy according to the invention, wherein the asynchronous machine is preferably used or installed in a drive unit.
  • the invention also relates to electrically powered vehicles with a corresponding asynchronous machine as a drive unit.
  • the component according to the invention has improved mechanical properties and improved electrical conductivity and can be produced using a simplified process. Accordingly, the component can have an electrical conductivity of at least 30 MS/m.
  • the electrical conductivity is particularly preferably in the range from 30 MS/m to 33.5 MS/m, even more preferably in the range from 31 MS/m to 32.5 MS/m.
  • the electrical conductivity can be determined using the eddy current principle, for example with a FISCHER SIGMASCOPE SMP350, at a 60 kHz test frequency on the samples at room temperature.
  • the component according to the invention has a 0.2% yield strength Rp0.2 of at least 40 MPa.
  • the 0.2% yield strength Rp0.2 is particularly preferably in the range from 43 MPa to 62 MPa, even more preferably in the range from 50 MPa to 60 MPa.
  • the 0.2% yield strength Rp0.2 is to be determined according to the invention at room temperature.
  • the component according to the invention also preferably has an elongation at break A of at least 15%, preferably in the range from 17 to 30% and particularly preferably in the range from 22 to 28%.
  • the component according to the invention preferably has a tensile strength Rm of at least 100 MPa, preferably in the range from 120 to 150 MPa and particularly preferably in the range from 130 to 146 MPa.
  • the component according to the invention has a 0.2% proof stress Rp0.2 in the range from 50 MPa to 58 MPa and an electrical conductivity in the range from 31 MS/m to 32.5 MS/m.
  • the component according to the invention preferably has an HBW hardness (“Brinell tungsten carbide hardness) 2.5/16.625 of at least 25, preferably in the range from 30 to 45 and particularly preferably in the range from 32 to 41 (determined according to standard DIN EN ISO 6506-1).
  • Example 1 The following Al alloys # 01 to # 14 were produced with the compositions given in Table 1 (data in % by weight): Table 1 Alloy Fe Ni Cu Mn Mg Cr # 01 0.543 0.4760 0.0024 0.0023 0.0035 0.0020 # 02 0.526 0.7300 0.0024 0.0024 0.0033 0.0020 # 03 0.724 0.4840 0.0024 0.0041 0.0015 0.0020 # 04 0.981 0.4870 0.0026 0.0049 0.0050 0.0020 #05 1.234 0.4860 0.0024 0.0070 0.0023 0.0023 #06 0.512 0.9940 0.0023 0.0023 0.0010 0.0021 #07 0.730 1.0280 0.0024 0.0037 0.0110 0.0020 #08 1.047 0.9570 0.0024 0.0055 0.0017 0.0020 #09 1.234
  • This tool geometry has a comparatively large cross-section for die casting and is representative of thick short-circuit rings of ASM rotors.
  • a final heat treatment was not carried out.
  • the master alloys AlFe25 and AlNi20 were dissolved using the impeller process (melt bath movement). No burn-off of the alloy elements was observed.
  • a standard spray process was sufficient to prevent the samples from sticking in the die casting tool. The alloys therefore had a low tendency to stick to the tool.
  • Example 2 The alloys obtained from example 1 were characterized in the as-manufactured state. The conductivity was determined using the eddy current principle and measured with a Fischer Sigmascope SMP350 at a test frequency of 60 kHz.
  • the yield strength (Rp0.2), the tensile strength (Rm) and the elongation at break (A) were determined in a quasi-elastic tensile test according to DIN EN ISO 6892-1.
  • the hardness was determined according to DIN EN ISO 6506-1 using balls made of tungsten carbide (HBW).
  • Example 3 The properties of alloy #7 were investigated in more detail: ZF Friedrichshafen AG File 300777 Friedrichshafen 2023-06-05 - Yield strength (Rp0.2): 51 mPa (see Table 2) - Tensile strength (Rm): 129 MPa (see Table 2) - Elongation at break (A): 29 % (see Table 2) - Hardness: 37 HBW (see Table 2) - Electrical conductivity: 32 MS/m (see Table 2) - Density: approx. 2.74 g/cm 3 - Linear thermal expansion: approx. 22 * 10 -6 1/K - Thermal conductivity: approx.
  • Figure 1 shows the structure of the alloy, a corresponding diagram is shown in Figure 2.
  • the structure of the alloys consists of Al solid solution (very light grey) and Al9(Fe,Ni)2 intermetallic phases (medium grey), as well as Al3Ni or Al3Fe intermetallic phases (if the respective element is present in large excess).
  • the morphology of the phases resembles a eutectic solidification of Al-Al9(Fe,Ni)2.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Conductive Materials (AREA)
  • Induction Machinery (AREA)

Abstract

La présente invention concerne un alliage d'aluminium, constitué de 0,50 à 1,50 % en poids de Fe, de 0,45 à 2,00 % en poids de Ni, de 0 à 0,20 % en poids de Si, de 0 à 0,20 % en poids de Mg, de 0 à 0,20 % en poids de Cu, de 0 à 0,20% en poids de Mn, de 0 à 0,20 % en poids de Zn, de 0 à 0,20 % en poids de Ti, de 0 à 0,20 % en poids de V, de 0 à 0,20 % en poids de Cr, de 0 à 0,20 % en poids de Zr, de 0 à 0,20 % en poids de Ce, de 0 à 0,05 % en poids de P, de 0 à 0,05 % en poids de Mo, de 0 à 0,05 % en poids de Sr, de 0 à 0,004 % en poids de B ; et, en tant que reste de l'Al et des impuretés inévitables, le % en poids s'ajoutant à 100 % en poids dans l'alliage, les impuretés inévitables ne constituant pas plus de 0,25 % en poids au total et aucune impureté unique constituant plus de 0,05 % en poids, et la quantité totale de Mn, Ti, Cr, V et Zr ensemble n'étant pas supérieure à 0,50 % en poids. La présente invention concerne également un procédé de production d'un composant à partir de l'alliage d'aluminium selon l'invention, un composant correspondant et l'utilisation de l'alliage d'aluminium selon l'invention pour la production d'un composant. La présente invention concerne en outre une machine asynchrone (ASM) équipé" d'un composant correspondant constitué de l'alliage d'aluminium selon l'invention, et un véhicule à entraînement électrique équipé d'une machine asynchrone correspondante en tant qu'unité d'entraînement.
PCT/EP2024/064254 2023-06-05 2024-05-23 Alliage d'aluminium Pending WO2024251532A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CN202480034608.8A CN121175442A (zh) 2023-06-05 2024-05-23 铝合金

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102023205214.8 2023-06-05
DE102023205214.8A DE102023205214A1 (de) 2023-06-05 2023-06-05 Aluminiumlegierung

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DE (1) DE102023205214A1 (fr)
WO (1) WO2024251532A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN120924841A (zh) * 2025-09-30 2025-11-11 小米汽车科技有限公司 一种铸造铝合金及其制备方法和应用

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4080223A (en) * 1975-06-23 1978-03-21 Southwire Company Aluminum-nickel-iron alloy electrical conductor
US20220127699A1 (en) * 2020-10-27 2022-04-28 Hyundai Motor Company High thermal conductive casting aluminum alloy and manufacturing method thereof
US20230043878A1 (en) * 2021-07-30 2023-02-09 Aluminium Rheinfelden Alloys Gmbh Cast Alloy

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP4328927B2 (ja) 2000-03-13 2009-09-09 三菱樹脂株式会社 電気伝導性および熱伝導性に優れたアルミニウム合金材
JP4562296B2 (ja) 2001-01-31 2010-10-13 三菱樹脂株式会社 熱伝導性に優れたヒートシンク用アルミニウム合金材
CN114015912A (zh) 2021-10-18 2022-02-08 柳州市智甲金属科技有限公司 一种高导热高延伸率压铸铝合金及其制备方法

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4080223A (en) * 1975-06-23 1978-03-21 Southwire Company Aluminum-nickel-iron alloy electrical conductor
US20220127699A1 (en) * 2020-10-27 2022-04-28 Hyundai Motor Company High thermal conductive casting aluminum alloy and manufacturing method thereof
US20230043878A1 (en) * 2021-07-30 2023-02-09 Aluminium Rheinfelden Alloys Gmbh Cast Alloy

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN120924841A (zh) * 2025-09-30 2025-11-11 小米汽车科技有限公司 一种铸造铝合金及其制备方法和应用

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CN121175442A (zh) 2025-12-19

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