WO2025173376A1 - Matériau pour le forgeage d'alliage d'aluminium, produit forgé en alliage d'aluminium et procédé de fabrication associé - Google Patents

Matériau pour le forgeage d'alliage d'aluminium, produit forgé en alliage d'aluminium et procédé de fabrication associé

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Publication number
WO2025173376A1
WO2025173376A1 PCT/JP2024/044047 JP2024044047W WO2025173376A1 WO 2025173376 A1 WO2025173376 A1 WO 2025173376A1 JP 2024044047 W JP2024044047 W JP 2024044047W WO 2025173376 A1 WO2025173376 A1 WO 2025173376A1
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WIPO (PCT)
Prior art keywords
mass
aluminum alloy
less
range
casting
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Pending
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PCT/JP2024/044047
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English (en)
Japanese (ja)
Inventor
卓也 荒山
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Resonac Corp
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Resonac Corp
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Publication date
Application filed by Resonac Corp filed Critical Resonac Corp
Priority to CN202480024717.1A priority Critical patent/CN120936731A/zh
Publication of WO2025173376A1 publication Critical patent/WO2025173376A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

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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
    • C22C21/02—Alloys based on aluminium 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
    • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
    • 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
    • C22F1/05—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 of the Al-Si-Mg type, i.e. containing silicon and magnesium in approximately equal proportions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/04—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
    • 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

Definitions

  • the present invention relates to an aluminum alloy forging material, an aluminum alloy forging, and a method for producing the same.
  • automotive parts especially suspension parts
  • Al-Mg-Si alloys are often used as the aluminum alloy material.
  • these automotive parts are manufactured using forging, a type of plastic processing, with aluminum alloy material as the processing material.
  • the above-mentioned high-strength Al-Mg-Si alloys have the problem that the processed structure recrystallizes during the forging and heat treatment processes, resulting in the formation of coarse crystal grains, making it impossible to achieve sufficient strength. Therefore, some alloys contain zirconium (Zr) to prevent recrystallization and prevent the formation of coarse recrystallized grains (see, for example, Patent Documents 1 and 2 above).
  • Zr zirconium
  • Zr is effective in preventing recrystallization, it has the following problems.
  • Zr forms compounds with Al-Ti-B alloys, and these compounds accumulate at the bottom of the furnace storing the molten alloy, contaminating the furnace. In addition, these compounds also crystallize coarsely in the produced ingot, reducing its strength.
  • the present invention was made in light of this technical background, and aims to provide an aluminum alloy forging material with excellent mechanical properties at room temperature, an aluminum alloy forged product, and a method for manufacturing the same.
  • the present invention provides the following means.
  • Aspect 1 of the present invention is a steel containing Cu in the range of 0.25 mass% or more and 0.55 mass% or less, Mg in the range of 0.85 mass% or more and 1.25 mass% or less, Si in the range of 1.02 mass% or more and 1.4 mass% or less, Mn in the range of 0.55 mass% or more and 1.0 mass% or less, Fe in the range of 0.32 mass% or more and 0.65 mass% or less, Zn in the range of 0.25 mass% or less, Cr in the range of 0.050 mass% or more and 0.30 mass% or less, Ti in the range of 0.01 mass% or more and 0.1 mass% or less, and B in the range of 0.
  • This aluminum alloy forging material contains 0.0010% by mass or more and 0.030% by mass or less of Zr, 0.0010% by mass or more and 0.050% by mass or less of Zr, the ratio of Fe to Mn (Fe/Mn) is 0.3 to 1.1 by mass, and the balance is Al and unavoidable impurities.
  • DSC differential thermal analysis
  • Aspect 2 of the present invention is an aluminum alloy forging containing Cu in the range of 0.25% by mass to 0.55% by mass, Mg in the range of 0.85% by mass to 1.25% by mass, Si in the range of 1.02% by mass to 1.4% by mass, Mn in the range of 0.55% by mass to 1.0% by mass, Fe in the range of 0.32% by mass to 0.65% by mass, Zn in the range of 0.25% by mass or less, Cr in the range of 0.050% by mass to 0.30% by mass, Ti in the range of 0.01% by mass to 0.1% by mass, B in the range of 0.0010% by mass to 0.030% by mass, and Zr in the range of 0.0010% by mass to 0.050% by mass, wherein the ratio of the Fe content to the Mn content (Fe/Mn) is 0.3 to 1.1 in mass ratio, and the balance is Al and inevitable impurities, After a corrosion resistance test according to H8502, 1999, the aluminum alloy forged product has a corrosion rate of 0.045% or less
  • the aluminum alloy forged product of the second aspect is used for a suspension arm.
  • Aspect 4 of the present invention is a method for manufacturing an aluminum alloy forged product according to either aspect 2 or aspect 3, comprising a molten metal forming step for obtaining a molten aluminum alloy; a casting step for obtaining a cast product by casting the obtained molten metal; a forging step for heating the cast product at a temperature of 500°C to the melting point and subjecting it to plastic processing to obtain a forged product; and a heating step for the obtained forged product at a heating rate of 5.0°C/min or more from 20°C to 500°C, and then heating it at 530-560°C for 0.3-3 hours.
  • This method for manufacturing aluminum alloy forged products includes a solution treatment process in which a solution treatment is performed by holding the forged product in a solution bath for no more than 1 minute; a quenching process in which the entire surface of the forged product is brought into contact with quenching water within 5 to 60 seconds after the solution treatment and the product is quenched in a water tank for more than 1 minute but no more than 40 minutes; and an aging process in which the forged product is heated at a temperature of 180°C to 220°C for 0.5 to 8 hours to undergo aging treatment, with the split time between the quenching process and the aging process being no more than 2 hours.
  • This method for manufacturing aluminum alloy forged products includes a solution treatment process in which the forged product is solution-treated and held at a temperature of 650 to 600°C or less; a quenching process in which the entire surface of the forged product is brought into contact with quenching water within 5 to 60 seconds after the solution treatment and quenched in a water tank for more than 1 minute but not more than 40 minutes; and an aging process in which the forged product is heated at a temperature of 180°C to 220°C for 0.5 to 8 hours to undergo aging treatment; and in the casting process, the time spent passing through a temperature range of 650 to 600°C during casting solidification is limited to 20 seconds or less.
  • Aspect 6 of the present invention is a method for producing an aluminum alloy forging material according to Aspect 1, which comprises a molten metal forming step for obtaining a molten aluminum alloy, and a casting step for obtaining a cast product by casting the obtained molten metal, and which does not perform a homogenization treatment after the casting step.
  • FIG. 1 is a perspective view showing an example of an aluminum alloy forged product according to an embodiment of the present invention.
  • FIG. 2 is a plan view showing another example of an aluminum alloy forged product according to an embodiment of the present invention.
  • FIG. 10 is a perspective view showing yet another example of an aluminum alloy forged product according to an embodiment of the present invention.
  • 1 is a cross-sectional view showing an example of the vicinity of a mold of a horizontal continuous casting apparatus for producing an aluminum alloy forged product according to an embodiment of the present invention.
  • FIG. 5 is an enlarged cross-sectional view of a main portion near a cooling water cavity of the horizontal continuous casting machine shown in FIG. 4 .
  • FIG. 2 is an explanatory diagram illustrating the heat flux of a cooling wall portion of the horizontal continuous casting device.
  • FIG. 2 is a plan view showing the position at which the central portion was sampled from the aluminum alloy forging obtained in this example for preparing a test piece for evaluating mechanical properties.
  • FIG. 1 is a plan view showing
  • the aluminum alloy forging material of this embodiment contains Cu in the range of 0.25% by mass or more and 0.55% by mass or less, Mg in the range of 0.85% by mass or more and 1.25% by mass or less, Si in the range of 1.02% by mass or more and 1.4% by mass or less, Mn in the range of 0.55% by mass or more and 1.0% by mass or less, Fe in the range of 0.32% by mass or more and 0.65% by mass or less, Zn in the range of 0.25% by mass or less, Cr in the range of 0.050% by mass or more and 0.30% by mass or less, Ti in the range of 0.01% by mass or more and 0.1% by mass or less,
  • the aluminum alloy forging material contains B in the range of 0.0010% by mass or more and 0.030% by mass or less, Zr in the range of 0.0010% by mass or more and 0.050% by mass or less, the ratio of the
  • Exothermic (precipitation) peak in the thermal analysis curve by differential thermal analysis It is known that an exothermic peak that appears in a thermal analysis curve (DSC curve) obtained by carrying out differential thermal analysis on a metallic material corresponds to the formation of a predetermined precipitate.
  • the DSC curve shows one exothermic peak between 200 and 300° C. and one between 400 and 500° C.
  • the exothermic peak between 200 and 300° C. corresponds to the formation of ⁇ '-Mg 2 Si
  • the exothermic peak in between corresponds to the formation of ⁇ -Mg 2 Si.
  • FIG. 1 is a perspective view of an aluminum alloy forging according to one embodiment of the present invention.
  • an aluminum alloy forging 1a has a long portion 2 and connecting portions 4a, 4b connected to both ends of the long portion 2 in the longitudinal direction.
  • the long portion has a rectangular cross section.
  • Each of the two connecting portions 4 may have a through hole.
  • An aluminum alloy forging 1a having this shape can be used as, for example, an I-type suspension arm.
  • the aluminum alloy forged product of this embodiment contains Cu in the range of 0.25 mass% or more and 0.55 mass% or less, Mg in the range of 0.85 mass% or more and 1.25 mass% or less, Si in the range of 1.02 mass% or more and 1.4 mass% or less, Mn in the range of 0.55 mass% or more and 1.0 mass% or less, Fe in the range of 0.32 mass% or more and 0.65 mass% or less, Zn in the range of 0.25 mass% or less, Cr in the range of 0.050 mass% or more and 0.30 mass% or less, and % by mass or less, Ti in the range of 0.01% by mass or more and 0.1% by mass or less, B in the range of 0.0010% by mass or more and 0.030% by mass or less, Zr in the range of 0.0010% by mass or more and 0.050% by mass or less, a ratio of the Fe content to the Mn content Fe/Mn in mass ratio of 0.3 or more and 1.1 or less, and the balance consisting of Al and unavoid
  • the aluminum alloy forging materials and aluminum alloy forgings in the above embodiments correspond to 6000 series aluminum alloys in that they contain Mg and Si.
  • Cu has the effect of finely dispersing Mg-Si compounds in the aluminum alloy and improving the tensile strength of the aluminum alloy by precipitating as Al-Cu-Mg-Si compounds such as the Q phase.
  • the mechanical properties of the aluminum alloy forging 1a at room temperature can be improved.
  • Mg has the effect of improving the tensile strength of aluminum alloys. Mg contributes to strengthening the aluminum alloy by dissolving in the aluminum matrix or by precipitating as Mg-Si compounds (Mg 2 Si) such as the ⁇ " phase, or Al-Cu-Mg-Si compounds (AlCuMgSi) such as the Q phase. Mg 2 Si also has the effect of suppressing the formation of CuAl 2 phase in the aluminum alloy. Suppressing the formation of CuAl 2 phase improves the corrosion resistance of aluminum alloy forging materials and aluminum alloy forgings made therefrom. When the Mg content is within the above range, it is possible to improve the corrosion resistance as well as the mechanical properties at room temperature of aluminum alloy forging materials and aluminum alloy forgings made therefrom.
  • Si 1.02 mass% or more, 1.4 mass% or less
  • Si has the effect of improving the mechanical properties and corrosion resistance of aluminum alloy forging materials at room temperature.
  • coarse primary Si grains may crystallize, potentially reducing the tensile strength of the aluminum alloy.
  • Mn 0.55 mass% or more, 1.0 mass% or less
  • Mn has the effect of improving the tensile strength of the aluminum alloy by forming fine granular precipitates containing intermetallic compounds such as Al-Mn-Fe-Si and Al-Mn-Cr-Fe-Si in the aluminum alloy.
  • Fe 0.32 mass% or more, 0.65 mass% or less
  • Fe has the effect of improving the tensile strength of the aluminum alloy by crystallizing in the aluminum alloy as fine crystallized particles including intermetallic compounds such as Al-Mn-Fe-Si, Al-Mn-Cr-Fe-Si, Al-Fe-Si, Al-Cu-Fe, and Al-Mn-Fe.
  • the Fe/Mn relationship is 0.3 or more and 1.1 or less.
  • Fe/Mn relationship By having the Fe/Mn relationship be 0.3 or more and 1.1 or less, it is possible to suppress the crystallization of AlFeSi-based compounds having a size of 2.0 ⁇ m or more, and to improve the number density of AlMn-based compounds in the crystal grains.
  • Cr 0.050 mass% or more, 0.30 mass% or less
  • Cr has the effect of improving the tensile strength of the aluminum alloy by forming fine granular crystallized products containing intermetallic compounds such as Al-Mn-Cr-Fe-Si and Al-Fe-Cr in the aluminum alloy.
  • the Cr content is within the above range, the mechanical properties at room temperature of the aluminum alloy forging material and aluminum alloy forgings made therefrom can be improved.
  • Ti 0.01% by mass or more, 0.1% by mass or less
  • Ti has the effect of refining the crystal grains of aluminum alloys and improving their wrought workability. If the Ti content is less than 0.01% by mass, the effect of refining the crystal grains may not be sufficient. On the other hand, if the Ti content exceeds 0.1% by mass, coarse crystals may be formed, which may reduce the wrought workability. Furthermore, if a large amount of coarse crystals containing Ti are mixed into aluminum alloy forging materials and aluminum alloy forgings made therefrom, the toughness may be reduced. Therefore, the Ti content is set to 0.01% by mass or more and 0.1% by mass or less. The Ti content is preferably 0.015% by mass or more and 0.050% by mass or less.
  • B has the effect of refining the crystal grains of an aluminum alloy and improving its wrought workability. Adding B to an aluminum alloy together with the above-mentioned Ti improves the effect of refining the crystal grains. If the B content is less than 0.0010% by mass, the effect of refining the crystal grains may not be sufficient. On the other hand, if the B content exceeds 0.030% by mass, coarse crystals may form and be mixed as inclusions in the aluminum alloy forging material and the aluminum alloy forged product using the same. Furthermore, if a large amount of coarse crystals containing B are mixed into the final aluminum alloy product, the toughness may be reduced. Therefore, the B content is set to 0.0010% by mass or more and 0.030% by mass or less. The B content is preferably 0.0050% by mass or more and 0.025% by mass or more.
  • the Zn content should be 0.250% by mass or less. If the Zn content exceeds 0.250% by mass, MgZn2 is generated and precipitates from the Al matrix at grain boundaries, causing intergranular corrosion and leading to a decrease in the corrosion resistance of the aluminum alloy forging material and aluminum alloy forgings made therefrom. Therefore, it is preferable that the Zn content be 0.250% by mass or less, or that no Zn be included at all.
  • Inevitable impurities are impurities that are inevitably mixed into the aluminum alloy from raw materials or the manufacturing process.
  • Examples of inevitable impurities include Ni, Sn, and Be.
  • the content of these inevitable impurities preferably does not exceed 0.1% by mass.
  • the longitudinal central portion 2a of the long portion 2 of the aluminum alloy forging 1a of this embodiment is the portion to which the maximum principal stress is applied when the aluminum alloy forging 1a is used, for example, as a suspension arm for a vehicle.
  • the central portion 2a is, for example, a region that is in the range of 1% to 80% of the entire long portion 2, including the longitudinal center of the long portion 2.
  • the aspect ratio of the long portion 2 (longitudinal length/length of the short side perpendicular to the longitudinal direction) is, for example, in the range of 2 to 100.
  • the cross section of the central portion 2a of the long portion 2 is a cross section (hereinafter sometimes referred to as the central cross section) taken along the direction in which pressure was applied when manufacturing the aluminum alloy forging 1a by forging.
  • the corrosion resistance test was carried out in accordance with the method based on JIS H8502,1999.
  • the aluminum alloy forging material of this embodiment and the aluminum alloy forged product using the same have a corrosion rate of 0.045% or less after a corrosion resistance test according to JIS H8502, 1999.
  • the corrosion rate is preferably 0.040% or less.
  • the aluminum alloy forging material of this embodiment and the aluminum alloy forgings using the same have a corrosion depth of 300 ⁇ m or less after a corrosion resistance test according to JIS H8502, 1999.
  • the corrosion depth is preferably 250 ⁇ m or less, and more preferably 210 ⁇ m or less.
  • the corrosion depth can be measured, for example, with a one-shot 3D shape measuring instrument (Keyence Corporation, VR6000).
  • the one-shot 3D shape measuring instrument irradiates a striped pattern of light onto the object, and by taking advantage of the fact that the striped pattern distorts depending on the unevenness of the object, the reflected light is received by a CMOS and the shape of the object is measured from the distortion of the striped pattern using triangulation. If the corrosion depth exceeds 300 ⁇ m, the corrosion resistance is low, making it difficult to apply the material to automobile undercarriage parts, such as suspension arms.
  • the size of the Mg 2 Si compound is 2.5 ⁇ m or less
  • the size of the Mg 2 Si compounds is 2.5 ⁇ m or less. If this size exceeds 2.5 ⁇ m, corrosion pits are likely to form and corrosion resistance may decrease.
  • the aluminum alloy forging material and aluminum alloy forging product of this embodiment, configured as described above, are made of an aluminum alloy having the above alloy composition and manufactured using the method described below.
  • the size of the Mg2Si compounds is controlled to 2.5 ⁇ m or less. Therefore, after a corrosion resistance test according to JIS H8502, 1999, the corrosion rate is 0.045% or less, the corrosion area rate is 3 [%/1.05E+09 ⁇ m2 ] or less, and the corrosion depth is 300 ⁇ m or less, resulting in good corrosion resistance.
  • the aluminum alloy forging material and aluminum alloy forgings of this embodiment have high strength and durability, good corrosion resistance, and are lightweight, making them advantageous for use in suspension arms for automobiles and other vehicles.
  • one connecting portion 4a is cylindrical and has a relatively small diameter
  • one connecting portion 4b is cylindrical and has a relatively large diameter
  • the long portion 2 has a shape that widens in width from the end edge on the side of one connecting portion 4a toward the end edge on the side of the other connecting portion 4b, but the shape of the aluminum alloy forging 1a is not limited to this.
  • one connecting portion 4a and the other connecting portion 4b of the aluminum alloy forging 1a may have the same shape.
  • the width of the long portion 2 may be constant.
  • the long portion 2 may have a curved shape. Three or more connecting portions 4 may be formed.
  • FIG. 2 is a plan view of another example of an aluminum alloy forged product according to an embodiment of the present invention.
  • the aluminum alloy forging 1b shown in Fig. 2 has three connecting portions 4c, 4d, and 4e.
  • the connecting portions 4c and 4d are connected by a long portion 2, and the connecting portions 4d and 4e are connected by a short portion 5 that is relatively shorter than the long portion 2.
  • a through hole is provided in the connecting portion 4c.
  • This aluminum alloy forging 1b can be used, for example, as an L-shaped suspension arm.
  • FIG. 3 is a plan view of yet another example of an aluminum alloy forged product according to an embodiment of the present invention.
  • the aluminum alloy forging 1c shown in Fig. 3 has three connecting portions 4f, 4g, and 4h.
  • the connecting portions 4f and 4g are connected to each other by the long portion 2, and the connecting portions 4f and 4h are connected to each other by the long portion 2.
  • a through hole is provided in the connecting portion 4f.
  • This aluminum alloy forging 1b can be used, for example, as an A-type suspension arm.
  • the method for producing an aluminum alloy forging material and the method for producing an aluminum alloy forged product of this embodiment include, for example, a molten metal forming step, a casting step, a forging step, a solution treatment step, a quenching treatment step, and an aging treatment step.
  • the molten metal forming step is a step of melting raw materials to obtain a molten aluminum alloy having a composition adjusted to include Cu in a range of 0.25% by mass to 0.55% by mass, Mg in a range of 0.85% by mass to 1.25% by mass, Si in a range of 1.02% by mass to 1.4% by mass, Mn in a range of 0.55% by mass to 1.0% by mass, Fe in a range of 0.32% by mass to 0.65% by mass, Zn in a range of 0.25% by mass, and Cr in a range of 0.050% by mass to 0.30% by mass.
  • a molten 6000 series aluminum alloy is obtained by adjusting the alloy composition to have an alloy composition comprising: Ti in the range of 0.01% by mass or more and 0.1% by mass or less; B in the range of 0.0010% by mass or more and 0.030% by mass or less; Zr in the range of 0.0010% by mass or more and 0.050% by mass or less; a ratio of the Fe content to the Mn content, Fe/Mn, in mass ratio, of 0.3 or more and 1.1 or less, with the balance being Al and unavoidable impurities.
  • Aluminum alloy molten metal can be obtained by heating and melting an aluminum alloy. Alternatively, it can be formed by melting a mixture containing the elements or compounds containing two or more elements that are the raw materials for the aluminum alloy, in the ratio required to produce the desired aluminum alloy. For example, to control the grain size of the aluminum alloy produced in the casting process, Ti or B can be mixed in as a grain refiner, such as an Al-Ti-B rod.
  • the raw materials for the molten aluminum alloy may be 10% or more of scrap material from 1000, 2000, 3000, 4000, 5000, 6000, or 7000 series aluminum alloys, with the remainder being virgin aluminum ingots and the above-mentioned additive elements. These may be melted to obtain a molten aluminum alloy with an adjusted composition. In this case, it is possible to obtain Al-Mg-Si aluminum alloy forgings that are less prone to recrystallization and have excellent mechanical properties at room temperature.
  • virgin aluminum ingots are aluminum with a purity of, for example, 99% or more, obtained by subjecting alumina produced from minerals to electrolysis, a process known as electrolytic refining.
  • a molten aluminum alloy (liquid phase) is cooled and solidified into a solid (solid phase) to obtain an aluminum alloy cast product.
  • the casting process can be performed by, for example, a vertical continuous casting method or a horizontal continuous casting method.
  • the time required to pass through the temperature range of 650 to 600°C is controlled to within 20 seconds.
  • FIG. 4 and 5 show a horizontal continuous casting apparatus that can be used to manufacture the aluminum alloy cast product of this embodiment.
  • 4 is a cross-sectional view showing an example of the vicinity of the mold 12 of the horizontal continuous casting apparatus 10.
  • FIG. 5 is an enlarged cross-sectional view of a main portion of the horizontal continuous casting apparatus 10 near the cooling water cavity 24.
  • the horizontal continuous casting apparatus 10 shown in Figures 4 and 5 has a molten metal receiving portion (tundish) 11, a hollow cylindrical mold 12, and a refractory plate-like body (insulating member) 13 arranged between one end side 12a of the mold 12 and the molten metal receiving portion 11.
  • the molten metal receiving portion 11 is composed of a molten metal inlet portion 11a that receives the molten aluminum alloy M obtained in the molten metal forming process described above, a molten metal holding portion 11b, and an outlet portion 11c that flows into the hollow portion 21 of the mold 12.
  • a withdrawal drive device that withdraws the cast aluminum alloy rod B at a constant speed may be installed at the other end 12b of the mold 12. It is also preferable to install a synchronized cutting machine (not shown) that cuts the continuously withdrawn aluminum alloy rod B to any desired length.
  • the refractory plate 13 is a member that blocks heat transfer between the molten metal receptacle 11 and the mold 12, and may be made of materials such as calcium silicate, alumina, silica, a mixture of alumina and silica, silicon nitride, silicon carbide, graphite, etc. Such a refractory plate 13 can also be made up of multiple layers made of different materials.
  • the hollow portion 21 of the mold 12 is formed with a circular cross section to cast the aluminum alloy rod B into a cylindrical rod shape, and the mold 12 is held so that the mold central axis (central axis) C, which passes through the center of this hollow portion 21, is aligned approximately horizontally.
  • the inner peripheral surface 21a of the hollow portion 21 of the mold 12 is formed at an elevation angle of 0° to 3° (more preferably 0° to 1°) relative to the mold center axis C toward the casting direction of the aluminum alloy rod B (see Figure 1).
  • the inner peripheral surface 21a is configured in a tapered shape that opens out like a cone toward the casting direction. The angle of this taper is the elevation angle.
  • the aluminum alloy rod B may encounter resistance at the other end 12b, which is the mold outlet, when it is pulled out of the mold 12, making casting difficult.
  • the elevation angle exceeds 3°, the inner surface 21a will not make sufficient contact with the molten aluminum alloy M, reducing the heat transfer effect from the molten aluminum alloy M and its solidified shell to the mold 12, which may result in insufficient solidification. This is undesirable as it may result in casting problems such as the formation of a re-melted skin on the surface of the aluminum alloy rod B or the ejection of unsolidified molten aluminum alloy M from the end of the aluminum alloy rod B.
  • the cross-sectional shape of the hollow portion 21 of the mold 12 may be selected to match the shape of the aluminum alloy rod to be cast, such as a triangular or rectangular cross-sectional shape, a polygonal, semicircular, elliptical, or an irregular cross-sectional shape that does not have an axis or plane of symmetry, in addition to the circular shape of this embodiment.
  • the pressurized lubricating fluid is supplied from the lubricant supply port 22a to the inner circumferential surface 21a of the mold 12.
  • the liquid lubricant may be heated to decompose into a gas, which is then supplied to the inner circumferential surface 21a of the mold 12.
  • a porous material may be placed in the lubricant supply port 22a, and the lubricating fluid may be allowed to seep out onto the inner circumferential surface 21a of the mold 12 through this porous material.
  • a cooling device 23 which is a cooling means for cooling and solidifying the molten aluminum alloy M, is formed inside the mold 12.
  • the cooling device 23 has a cooling water cavity 24 that contains cooling water W for cooling the inner surface 21a of the hollow portion 21 of the mold 12, and a cooling water injection passage 25 that connects this cooling water cavity 24 with the hollow portion 21 of the mold 12.
  • the cooling water cavity 24 is formed in a ring shape surrounding the hollow portion 21, outside the inner surface 21a of the hollow portion 21 inside the mold 12, and cooling water W is supplied via a cooling water supply pipe 26.
  • the inner surface 21a of the mold 12 is cooled by the cooling water W contained in the cooling water cavity 24, which removes heat from the molten aluminum alloy M filling the hollow portion 21 of the mold 12 through the surface that comes into contact with the inner surface 21a of the mold 12, forming a solidified shell on the surface of the molten aluminum alloy M.
  • cooling water injection passage 25 sprays cooling water W directly from the shower opening 25a facing the hollow portion 21 toward the aluminum alloy rod B at the other end 12b of the mold 12, thereby cooling the aluminum alloy rod B.
  • the vertical cross-sectional shape of such cooling water injection passage 25 may be, in addition to the circular shape of this embodiment, semicircular, pear-shaped, or horseshoe-shaped, for example.
  • the length from the position where the extension of the central axis of the shower opening 25a of the cooling water injection passage 25 hits the surface of the cast aluminum alloy rod B to the contact surface between the mold 12 and the refractory plate 13 is called the effective mold length L, and this effective mold length L is preferably, for example, 10 mm or more and 40 mm or less. If this effective mold length L is less than 10 mm, a good coating will not form, making casting impossible. If it exceeds 40 mm, the effect of forced cooling will be reduced, solidification by the mold wall will become dominant, and contact resistance between the mold 12 and the molten aluminum alloy M or aluminum alloy rod B will increase, which may lead to unstable casting, such as cracks on the casting surface or tearing inside the mold, and this is undesirable.
  • the supply of cooling water W to the cooling water cavity 24 and the spray of cooling water W from the shower opening 25a of the cooling water spray passage 25 can each be controlled by a control signal from a control device (not shown).
  • the cooling wall portion 27 of the mold 12 which is the portion where the inner bottom surface 24a of the cooling water cavity 24 faces the inner surface 21a of the hollow portion 21 of the mold 12, is formed so that the heat flux value per unit area from the molten aluminum alloy M in the hollow portion 21 toward the cooling water W in the cooling water cavity 24 is in the range of 10 x 105 W/ m2 or more and 50 x 105 W/ m2 or less.
  • the mold 12 should be formed so that the thickness t of the cooling wall portion 27 of the mold 12, i.e., the distance between the inner bottom surface 24a of the cooling water cavity 24 and the inner peripheral surface 21a of the hollow portion 21 of the mold 12, is within the range of, for example, 0.5 mm to 3.0 mm, preferably 0.5 mm to 2.5 mm. Furthermore, the material from which the mold 12 is formed should be selected so that the thermal conductivity of at least the cooling wall portion 27 of the mold 12 is within the range of 100 W/m ⁇ K to 400 W/m ⁇ K.
  • the molten aluminum alloy M in the molten metal receiving portion 11 is supplied through a refractory plate 13 to one end 12a of a mold 12, which is held so that the mold center axis C is approximately horizontal, and is forcibly cooled at the other end 12b of the mold 12 to form an aluminum alloy rod B.
  • the aluminum alloy rod B is drawn out at a constant speed by a drawing drive device (not shown) installed near the other end 12b of the mold 12, so that it is continuously cast to form a long aluminum alloy rod B.
  • the drawn aluminum alloy rod B is then cut to the desired length, for example, by a synchronized cutting machine (not shown).
  • composition ratio of the cast aluminum alloy rod B can be confirmed, for example, using a photoelectric emission spectrophotometer (e.g., PDA-5500 manufactured by Shimadzu Corporation, Japan) as described in JIS H 1305.
  • a photoelectric emission spectrophotometer e.g., PDA-5500 manufactured by Shimadzu Corporation, Japan
  • the difference in height between the liquid level of the molten aluminum alloy M stored in the molten metal receiver 11 and the upper inner circumferential surface 21a of the mold 12 is preferably 0 mm to 250 mm (more preferably 50 mm to 170 mm). By keeping it within this range, the pressure of the molten aluminum alloy M supplied into the mold 12 is optimally balanced with the lubricating oil and the gas produced by vaporizing the lubricating oil, resulting in stable castability.
  • the liquid lubricant can be a vegetable oil, which is a lubricating oil. Examples include rapeseed oil, castor oil, and salad oil.
  • the lubricating oil supply rate is preferably 0.05 mL/min to 5 mL/min (more preferably 0.1 mL/min to 1 mL/min). If the supply rate is too low, the molten aluminum alloy M in the aluminum alloy rod B may not solidify and leak from the mold 12 due to insufficient lubrication. If the amount of supply is excessive, the excess may be mixed into the aluminum alloy rod B, causing internal defects.
  • the casting speed which is the speed at which the aluminum alloy rod B is withdrawn from the mold 12, is preferably 200 mm/min or more and 1500 mm/min or less (more preferably 400 mm/min or more and 1000 mm/min or less). This is because a casting speed within this range results in a uniform and fine network structure of the crystals formed during casting, which increases the resistance of the aluminum matrix to deformation at high temperatures and improves its high-temperature mechanical strength.
  • the amount of cooling water sprayed from the shower opening 25a of the cooling water spray passage 25 is preferably 10 L/min or more and 50 L/min or less (more preferably 25 L/min or more and 40 L/min or less) per mold. If the amount of cooling water is less than this, the molten aluminum alloy M may not solidify and leak from the mold 12. In addition, the surface of the cast aluminum alloy rod B may remelt, forming an uneven structure that may remain as an internal defect. On the other hand, if the amount of cooling water is greater than this range, the mold 12 may lose too much heat, causing it to solidify prematurely.
  • the average temperature of the molten aluminum alloy M flowing from the molten metal receiver 11 into the mold 12 is preferably, for example, 650°C or higher and 750°C or lower (more preferably 680°C or higher and 720°C or lower). If the temperature of the molten aluminum alloy M is too low, there is a risk that coarse crystals will form in the mold 12 or before that, and be incorporated into the aluminum alloy rod B as internal defects. On the other hand, if the temperature of the molten aluminum alloy M is too high, large amounts of hydrogen gas will be easily incorporated into the molten aluminum alloy M, which will be incorporated into the aluminum alloy rod B as porosity, potentially causing internal cavities.
  • the heat flux value per unit area from the molten aluminum alloy M in the hollow portion 21 to the cooling water W in the cooling water cavity 24 in the cooling wall portion 27 of the mold 12 is set to a range of 10 x 10 5 W/m 2 or more and 50 x 10 5 W/m 2 or less, it is possible to prevent the aluminum alloy rod B from sticking.
  • the cooling wall 27 of the mold 12 receives heat from the molten aluminum alloy M and performs heat exchange by cooling this heat with the cooling water W contained in the cooling water cavity 24.
  • the heat flux per unit area is expressed by the following equation (1) using Fourier's law.
  • the cooling wall portion 27 of the mold 12 is configured so that the heat flux value per unit area is 10 ⁇ 10 5 W/m 2 or more, thereby preventing seizure of the cast aluminum alloy bar B. It is also preferable that the heat flux value per unit area is 50 ⁇ 10 5 W/m 2 or less.
  • the mold 12 can be formed so that the thickness t of the cooling wall portion 27 of the mold 12 is, for example, in the range of 0.5 mm or more and 3.0 mm or less. Furthermore, the thermal conductivity of at least the cooling wall portion 27 of the mold 12 can be set in the range of 100 W/m ⁇ K or more and 400 W/m ⁇ K or less.
  • the horizontal continuous casting apparatus 10 described above is used to continuously supply the molten aluminum alloy M stored in the molten metal receiving portion 11 from one end side 12a of the mold 12 into the hollow portion 21.
  • Cooling water W is also supplied to the cooling water cavity 24, and a lubricating fluid, such as lubricating oil, is supplied from the fluid supply pipe 22.
  • the molten aluminum alloy M supplied into the hollow portion 21 is then cooled and solidified under conditions where the heat flux value per unit area at the cooling wall portion 27 is 10 ⁇ 10 W/ m2 or more, thereby casting the aluminum alloy rod B. Furthermore, when casting the aluminum alloy rod B, it is preferable to set the wall surface temperature of the cooling wall portion 27 of the mold 12, which is cooled by cooling water W, to 100°C or less.
  • the aluminum alloy rod B thus obtained is cooled and solidified under conditions where the heat flux value per unit area in the cooling wall portion 27 is 10 ⁇ 10 5 W/m 2 or more, thereby suppressing the adhesion of reaction products, such as carbides, caused by contact between the lubricating oil gas and the molten aluminum alloy M. This eliminates the need to cut and remove carbides and the like from the surface of the aluminum alloy rod B, and allows the aluminum alloy rod B to be produced with a high yield.
  • the casting process for obtaining a cast product from the molten aluminum alloy M is not limited to the horizontal continuous casting method described above, and known continuous casting methods such as vertical continuous casting can also be used.
  • Vertical continuous casting methods are classified into the float method and the hot top method depending on the method by which the molten aluminum alloy M is supplied to the mold (casting die 12); however, the following will briefly explain the case where the hot top method is used.
  • the casting equipment used in the hot top method is equipped with a mold, a molten metal receiving vessel (header), etc.
  • the molten metal supplied to the molten metal receiving vessel passes through a tapping port and then through the header, where the flow rate is adjusted, before entering a cylindrical mold installed almost horizontally, where it is forcibly cooled and a solidified shell is formed on the outer surface of the molten metal.
  • Molds generally use metal components with good thermal conductivity and have a hollow structure to allow the introduction of refrigerant inside.
  • the refrigerant used can be selected from those that are industrially available, but water is recommended from the standpoint of ease of use.
  • the mold used in this embodiment is made of a metal such as copper or aluminum, or graphite, selected from the viewpoint of heat transfer performance and durability at the contact point with the molten metal.
  • the header is generally made of refractory material and is installed above the mold. There are no particular restrictions on the material and size of the header, and it can be selected appropriately depending on the composition range of the alloy being cast and the dimensions of the cast product.
  • the average cooling rate during casting may be selected appropriately from a generally recommended range, such as 10 to 300°C/sec.
  • the casting speed may be selected appropriately from a range generally used in horizontal continuous casting, such as 200 to 600 mm/min.
  • the casting method described above allows for the production of uniform metal structures even in medium to large castings. There are no particular restrictions on the diameter of the castings, and it is suitable for use with rods with diameters of 30 to 100 mm.
  • the forging process involves cutting the cast aluminum alloy casting to a predetermined size, heating the resulting forging material to a predetermined temperature, and then applying pressure in a press to mold it into a die.
  • forging is performed without the homogenization treatment that was conventionally performed after casting to remove segregation. Therefore, the segregation removal that was previously performed in the homogenization treatment must be performed by heating the material during forging, so heating must be performed at a temperature above 500°C and below the melting point. Forging is then performed to obtain a forged product (e.g., an automobile suspension arm part, etc.).
  • the material heating temperature during forging is below 500°C, compounds such as AlFeSi and Mg 2 Si in the alloy structure remain in a segregated state, increasing deformation resistance and preventing sufficient processing, and cracks will occur. Furthermore, if the temperature exceeds the melting point, defects such as eutectic melting are likely to occur.
  • the solution treatment step is a step in which the forged product obtained in the forging step is heated to bring about a solution, thereby alleviating the strain introduced in the forging step and causing the solute elements to dissolve.
  • the forged product is solution-treated by holding it at a treatment temperature of 530°C or higher and 560°C or lower for a period of 0.3 to 3 hours.
  • the heating rate from room temperature to the above-mentioned treatment temperature is preferably 5.0°C/min or higher. If the treatment temperature is lower than 530°C, the solute elements may not be dissolved sufficiently. On the other hand, if the treatment temperature exceeds 560°C, the solute elements are more dissolved, but eutectic melting and recrystallization may occur easily. Furthermore, if the heating rate is lower than 5.0°C/min, coarse precipitation of Mg2Si may occur. On the other hand, if the treatment temperature is lower than 530°C, the solution treatment may not progress, making it difficult to achieve high strength by aging precipitation.
  • the forged product is placed in a water tank containing water (quenching water) and quenched by submerging the forged product.
  • the water temperature in the tank is preferably 20°C or higher and 60°C or lower.
  • the forged product is preferably placed in the water tank for 5 seconds or higher and 60 seconds or lower after solution treatment so that all surfaces of the forged product come into contact with water.
  • the submersion time of the forged product varies depending on the size of the casting, but is, for example, between 1 minute and 30 minutes.
  • the split time between the hardening process and the subsequent aging process must be within two hours.
  • the aging treatment process is a process in which the forged product is heated and held at a relatively low temperature to precipitate supersaturated solid-solution elements, thereby imparting an appropriate hardness.
  • the forged product after the quenching process is heated to a temperature of 170°C or higher and 210°C or lower and held at that temperature for 0.5 hours or longer and 7 hours or shorter to perform aging treatment. If the treatment temperature is lower than 170°C or the holding time is shorter than 0.5 hours, the Mg2Si -based precipitates that improve tensile strength may not grow sufficiently. On the other hand, if the treatment temperature exceeds 190°C or the holding time exceeds 7 hours, the Mg2Si -based precipitates may become too coarse to sufficiently improve tensile strength.
  • the split time between the quenching treatment step and the subsequent aging treatment step is set to within 2 hours.
  • the split time is the time from the solution treatment and water quenching to the artificial aging treatment.
  • the size of the Mg 2 Si compound can be controlled to 2.5 ⁇ m or less.
  • the method for producing an aluminum alloy material for forging of this embodiment includes a molten metal forming step for obtaining a molten aluminum alloy, and a casting step for obtaining a cast product by casting the obtained molten metal, and does not perform a homogenization treatment after the casting step.
  • the manufacturing method for aluminum alloy forging materials of this embodiment makes it possible to manufacture aluminum alloy forging materials with a Rockwell hardness [HRF] of 60 or more and 78 or less, and with a chip count of 200 or more chips per 1 g when machined.
  • HRF Rockwell hardness
  • Example 1 to 8 and Comparative Examples 1 to 4 (Production of continuous cast products) First, an aluminum alloy was prepared having the alloy composition (the balance being aluminum) shown in Table 1 below. Using the prepared aluminum alloy, a continuous cast product having a circular cross section and a diameter of 82 mm was produced.
  • Fe/Mn The Fe/Mn ratio was adjusted to 0.3 or more and 1.1 or less in the examples, and less than 0.3 and more than 1.1 in the comparative examples. (Judgment criteria) "Good”: 0.3 or more and 1.1 or less. "X”: Less than 0.3, more than 1.1.
  • ⁇ Corroded area ratio is 3 [%/1.05E+09 ⁇ m 2 ] or less> After a corrosion resistance test according to JIS H8502, 1999, the corrosion area ratio is 3 [%/1.05E+09 ⁇ m 2 ] or less. (Judgment criteria) "Good”: 3 [%/1.05E+09 ⁇ m 2 ] or less. " ⁇ ”: More than 3 [%/1.05E+09 ⁇ m 2 ]. ⁇ Corrosion depth of 300 ⁇ m or less> After a corrosion resistance test according to JIS H8502, 1999, the corrosion depth is 300 ⁇ m or less. (Judgment criteria) "Good”: 300 ⁇ m or less. "X”: More than 300 ⁇ m.
  • ⁇ Size of Mg 2 Si Compound is 2.5 ⁇ m or Less> (Judgment criteria) "Good”: All Mg 2 Si compounds are 2.5 ⁇ m or less. "x”: Mg 2 Si compounds larger than 2.5 ⁇ m are present.

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  • Organic Chemistry (AREA)
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Abstract

Ce matériau pour le forgeage d'alliage d'aluminium présente une composition d'alliage qui contient du Cu dans une plage de 0,25 à 0,55 % en masse, du Mg dans une plage de 0,85 à 1,25 % en masse, du Si dans une plage de 1,02 à 1,4 % en masse, du Mn dans une plage de 0,55 à 1,0 % en masse, du Fe dans une plage de 0,32 à 0,65 % en masse, du Zn dans une plage de 0,25 % en masse ou moins, du Cr dans une plage de 0 050 à 0,30 % en masse, du Ti dans une plage de 0,01 à 0,1 % en masse, du B dans une plage de 0,0010 à 0,030 % en masse et du Zr dans une plage de 0,0010 à 0,050 % en masse, et dans laquelle le rapport Fe/Mn de la teneur en Fe par rapport à la teneur en Mn est de 0,3 à 1,1, la partie restante étant de l'Al et des impuretés inévitables. Dans une courbe d'analyse thermique obtenue en effectuant une analyse thermique différentielle (DSC) sur le matériau pour le forgeage d'alliage d'aluminium, des pics exothermiques émergent entre 200 et 300 °C et entre 400 à 500 °C.
PCT/JP2024/044047 2024-02-16 2024-12-12 Matériau pour le forgeage d'alliage d'aluminium, produit forgé en alliage d'aluminium et procédé de fabrication associé Pending WO2025173376A1 (fr)

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2011006736A (ja) * 2009-06-25 2011-01-13 Sumikei Techno Co Ltd 高強度フロントフォークアウターチューブ用管材の製造方法および該製造方法により得られる管材
JP2011017063A (ja) * 2009-07-10 2011-01-27 Furukawa-Sky Aluminum Corp 冷間プレス成形用アルミニウム合金板ブランクの製造方法、およびそれによる冷間プレス成形方法および成形品
JP2023094446A (ja) * 2021-12-23 2023-07-05 株式会社レゾナック アルミニウム合金鍛造品
JP2023104587A (ja) * 2022-01-18 2023-07-28 株式会社レゾナック アルミニウム合金鍛造品及びその製造方法
JP2024086609A (ja) * 2022-12-15 2024-06-27 株式会社レゾナック アルミニウム合金鍛造用素材、アルミニウム合金製鍛造品及びその製造方法
JP2024086612A (ja) * 2022-12-15 2024-06-27 株式会社レゾナック アルミニウム合金鍛造用素材、アルミニウム合金製鍛造品及びその製造方法

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2011006736A (ja) * 2009-06-25 2011-01-13 Sumikei Techno Co Ltd 高強度フロントフォークアウターチューブ用管材の製造方法および該製造方法により得られる管材
JP2011017063A (ja) * 2009-07-10 2011-01-27 Furukawa-Sky Aluminum Corp 冷間プレス成形用アルミニウム合金板ブランクの製造方法、およびそれによる冷間プレス成形方法および成形品
JP2023094446A (ja) * 2021-12-23 2023-07-05 株式会社レゾナック アルミニウム合金鍛造品
JP2023104587A (ja) * 2022-01-18 2023-07-28 株式会社レゾナック アルミニウム合金鍛造品及びその製造方法
JP2024086609A (ja) * 2022-12-15 2024-06-27 株式会社レゾナック アルミニウム合金鍛造用素材、アルミニウム合金製鍛造品及びその製造方法
JP2024086612A (ja) * 2022-12-15 2024-06-27 株式会社レゾナック アルミニウム合金鍛造用素材、アルミニウム合金製鍛造品及びその製造方法

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