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US20050173032A1 - Casting of an aluminium alloy - Google Patents

Casting of an aluminium alloy Download PDF

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Publication number
US20050173032A1
US20050173032A1 US11/029,130 US2913005A US2005173032A1 US 20050173032 A1 US20050173032 A1 US 20050173032A1 US 2913005 A US2913005 A US 2913005A US 2005173032 A1 US2005173032 A1 US 2005173032A1
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Prior art keywords
max
alloy
process according
alloy contains
casting
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Abandoned
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US11/029,130
Inventor
Hubert Koch
Rudiger Franke
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Aluminium Rheinfelden GmbH
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Aluminium Rheinfelden GmbH
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Assigned to ALUMINIUM RHEINFELDEN GMBH reassignment ALUMINIUM RHEINFELDEN GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KOCH, HUBERT, FRANKE, RUDIGER
Publication of US20050173032A1 publication Critical patent/US20050173032A1/en
Abandoned legal-status Critical Current

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    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47K—SANITARY EQUIPMENT NOT OTHERWISE PROVIDED FOR; TOILET ACCESSORIES
    • A47K10/00—Body-drying implements; Toilet paper; Holders therefor
    • A47K10/24—Towel dispensers, e.g. for piled-up or folded textile towels; Toilet paper dispensers; Dispensers for piled-up or folded textile towels provided or not with devices for taking-up soiled towels as far as not mechanically driven
    • A47K10/32—Dispensers for paper towels or toilet paper
    • A47K10/34—Dispensers for paper towels or toilet paper dispensing from a web, e.g. with mechanical dispensing means
    • A47K10/38—Dispensers for paper towels or toilet paper dispensing from a web, e.g. with mechanical dispensing means the web being rolled up with or without tearing edge
    • A47K10/3809—Dispensers for paper towels or toilet paper dispensing from a web, e.g. with mechanical dispensing means the web being rolled up with or without tearing edge with roll spindles which are not directly supported
    • A47K10/3827—Dispensers for paper towels or toilet paper dispensing from a web, e.g. with mechanical dispensing means the web being rolled up with or without tearing edge with roll spindles which are not directly supported with a distribution opening which is parallel to the rotation axis
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
    • C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon

Definitions

  • the invention concerns a casting of an aluminium alloy with good heat resistance.
  • WO-A-0043560 discloses an aluminium alloy with 2.5-7.0 w. % Mg, 1.0-3.0 w. % Si, 0.3-0.49 w. % Mn, 0.1-0.3 w. % Cr, max. 0.15 w. % Ti, max. 0.15 w. % Fe, max. 0.00005 w. % Ca, max. 0.00005 w. % Na, max. 0.0002 w. % P, other contaminants individually max. 0.02 w. % and aluminium as the remainder, for the production of safety components in diecasting, squeeze casting, thixoforming and thixoforging processes.
  • the invention is based on the object of preparing an aluminium alloy with good heat resistance suitable for the production of thermally stressed components.
  • the alloy is particularly suitable for gravity diecasting, low pressure chilled casting and sand casting.
  • Components cast from the alloy should have a high strength in connection with high ductility.
  • the desired mechanical properties of the component are defined as follows: Yield strength Rp0.2 > 170 MPa Tensile strength Rm > 230 MPa Elongation at fracture A5 > 6%
  • the corrosion tendency of the alloys should be kept as low as possible and the alloy must have a correspondingly good fatigue strength.
  • the castability of the alloy should be better than that of the AlSiCu casting alloys which are currently used, and the alloy should have no tendency to heat cracks.
  • casting includes, as well as the pure components produced solely by casting, those cast as a premould and subsequently formed to the final dimensions by hot or cold shaping.
  • pure castings are those which are produced exclusively by sand casting, gravity diecasting, low pressure chilled casting, diecasting, thixocasting or squeeze casting.
  • Forming operations performed on a cast premould by shaping are for example forging and thixoforging.
  • the object according to the invention is achieved by an aluminium alloy with
  • the following content ranges are preferred for the individual alloy elements: Mg 2.5 to 3.5 w. %, in particular 2.7 to 3.3 w. % Si 0.9 to 1.3 w. % Mn 0.15 to 0.3 w. % Cr 0.15 to 0.3 w. % Ti 0.05 to 0.15 w. % Fe max. 0.15 w. % Cu max. 0.05 w. % Be 0.002 to 0.005 w. % V 0.01 to 0.1 w. % Zr 0.1 to 0.2 w. %
  • Silicon in conjunction with magnesium leads to a corresponding hardening where in particular thermal hardening is of interest.
  • Preferred is heat treatment to a state T6 e.g. solution annealing at 550° C. for 12 hours with subsequent artificial ageing at 160-170° C. for 8 to 10 hours.
  • the combination of manganese and chromium leads to good heat resistance at a sustained temperature of up to 180° C.
  • Titanium and zirconium are used for grain refining. Good grain refining makes a substantial contribution to an improvement in casting properties.
  • a preferred area of application of the castings according to the invention is thermally stressed components, in particular pressure vessels, compressor housings and engine components such as cylinder heads in automobile construction.
  • the components are preferably produced in the sand casting or chilled casting process.
  • FIGS. 1-3 tensile strength, yield strength and elongation at fracture as a function of temperature after 500 hours sustained temperature load for an alloy according to the invention and a comparison alloy according to the prior art.
  • the alloy according to the invention was cast in a trial rod mould according to Diez for round rods 16 mm diameter.
  • the mechanical properties of yield strength (Rp0.2), tensile strength (Rm) and elongation at fracture (A5) were determined on the trial rods in state T6 (165° C./6 hours) after a sustained temperature load of 500 hours at various temperatures.
  • the corresponding values for the comparison alloy were taken from the above article by F. J. Feikus. The results are shown in FIG. 1 in diagram form.
  • the alloy AlMg3Si1MnCr according to the invention admittedly does not reach the peak values of the comparison alloy AlSi7MgCu1 with regard to yield strength and tensile strength, but in its temperature behaviour is “less changeable”. This changeability has a disruptive effect in operation insofar as slight changes in temperature can cause great changes in mechanical properties.
  • the yield strength of the alloy according to the invention remains at around the same level up to around 180° C., gradually falls away up to 200° C., and only above around 200° C. begins to decrease continuously. The continuous decrease takes place with a lesser gradient than the alloy AlSi7MgCu1.
  • the alloy according to the invention is characterised by an almost constant value up to 180° C.
  • High elongation values give a favourable fracture/failure behaviour. A visible deformation precedes the break of the component. Above 180° C. the elongation rises continuously.
  • the comparison alloy AlSi7MgCu1 the clear hardening effect can be seen.
  • Low elongation values cause an unfavourable failure behaviour i.e. the component only deforms slightly or not at all. Under load peaks the component breaks without warning.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Public Health (AREA)
  • Health & Medical Sciences (AREA)
  • Body Structure For Vehicles (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
  • Continuous Casting (AREA)
  • Compressor (AREA)
  • Conductive Materials (AREA)
  • Secondary Cells (AREA)
  • Cookers (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Superconductors And Manufacturing Methods Therefor (AREA)
  • Casings For Electric Apparatus (AREA)
  • Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)

Abstract

A casting with good heat resistance comprises an alloy with 2 to 4 w. % magnesium 0.9 to 1.5 w. % silicon 0.1 to 0.4 w. % manganese 0.1 to 0.4 w. % chromium max. 0.2 w. % iron max. 0.1 w. % copper max. 0.2 w. % zinc max. 0.2 w. % titanium max. 0.3 w. % zirconium max. 0.008 w. % beryllium max. 0.5 w. % vanadium with aluminium as the remainder, with further elements and production-induced contaminants individually max. 0.02 w. %, total max. 0.2 w. %.

Description

  • The invention concerns a casting of an aluminium alloy with good heat resistance.
  • For thermally stressed components today normally AlSi alloys are used, where the heat resistance is achieved by the addition of Cu to the alloy. Copper, however, also increases the heat crack tendency and has a negative effect on the castability. Applications in which particular heat resistance is required normally occur in the field of cylinder heads in automobile construction, see e.g. F. J. Feikus, “Optimisation of Aluminium Silicon Casting Alloys for Cylinder Heads”, Giesserei-Praxis 1999, Vol. 2, pages 50-57.
  • WO-A-0043560 discloses an aluminium alloy with 2.5-7.0 w. % Mg, 1.0-3.0 w. % Si, 0.3-0.49 w. % Mn, 0.1-0.3 w. % Cr, max. 0.15 w. % Ti, max. 0.15 w. % Fe, max. 0.00005 w. % Ca, max. 0.00005 w. % Na, max. 0.0002 w. % P, other contaminants individually max. 0.02 w. % and aluminium as the remainder, for the production of safety components in diecasting, squeeze casting, thixoforming and thixoforging processes.
  • The invention is based on the object of preparing an aluminium alloy with good heat resistance suitable for the production of thermally stressed components. The alloy is particularly suitable for gravity diecasting, low pressure chilled casting and sand casting.
  • Components cast from the alloy should have a high strength in connection with high ductility. The desired mechanical properties of the component are defined as follows:
    Yield strength Rp0.2 > 170 MPa
    Tensile strength Rm > 230 MPa
    Elongation at fracture A5 > 6%
  • Because of the applications, the corrosion tendency of the alloys should be kept as low as possible and the alloy must have a correspondingly good fatigue strength. The castability of the alloy should be better than that of the AlSiCu casting alloys which are currently used, and the alloy should have no tendency to heat cracks.
  • The term “casting” includes, as well as the pure components produced solely by casting, those cast as a premould and subsequently formed to the final dimensions by hot or cold shaping.
  • Examples of pure castings are those which are produced exclusively by sand casting, gravity diecasting, low pressure chilled casting, diecasting, thixocasting or squeeze casting.
  • Forming operations performed on a cast premould by shaping are for example forging and thixoforging.
  • The object according to the invention is achieved by an aluminium alloy with
    • 2 to 4 w. % magnesium
    • 0.9 to 1.5 w. % silicon
    • 0.1 to 0.4 w. % manganese
    • 0.1 to 0.4 w. % chromium
    • max. 0.2 w. % iron
    • max. 0.1 w. % copper
    • max. 0.2 w. % zinc
    • max. 0.2 w. % titanium
    • max. 0.3 w. % zirconium
    • max. 0.008 w. % beryllium
    • max. 0.5 w. % vanadium
    • with aluminium as the remainder, with further elements and production-induced contaminants individually max. 0.02 w. %, total max. 0.2 w. %.
  • The following content ranges are preferred for the individual alloy elements:
    Mg 2.5 to 3.5 w. %, in particular 2.7 to 3.3 w. %
    Si 0.9 to 1.3 w. %
    Mn 0.15 to 0.3 w. %
    Cr 0.15 to 0.3 w. %
    Ti 0.05 to 0.15 w. %
    Fe max. 0.15 w. %
    Cu max. 0.05 w. %
    Be 0.002 to 0.005 w. %
    V 0.01 to 0.1 w. %
    Zr 0.1 to 0.2 w. %
  • The effect of the alloy elements can be characterised approximately as follows:
  • Silicon in conjunction with magnesium leads to a corresponding hardening where in particular thermal hardening is of interest. Preferred is heat treatment to a state T6 e.g. solution annealing at 550° C. for 12 hours with subsequent artificial ageing at 160-170° C. for 8 to 10 hours.
  • The combination of manganese and chromium leads to good heat resistance at a sustained temperature of up to 180° C.
  • Titanium and zirconium are used for grain refining. Good grain refining makes a substantial contribution to an improvement in casting properties.
  • Beryllium in conjunction with vanadium reduces the dross formation.
  • A preferred area of application of the castings according to the invention is thermally stressed components, in particular pressure vessels, compressor housings and engine components such as cylinder heads in automobile construction. The components are preferably produced in the sand casting or chilled casting process.
  • Further advantages, features and details of the invention arise from the description below of preferred embodiment examples and the drawing which shows:
  • FIGS. 1-3 tensile strength, yield strength and elongation at fracture as a function of temperature after 500 hours sustained temperature load for an alloy according to the invention and a comparison alloy according to the prior art.
  • An alloy according to the invention reference AlMg3SilMnCr and a comparison alloy reference AlSi7MgCu1 by F. J. Feikus, “Optimisation of Aluminium Silicon Casting Alloys for Cylinder Heads”, Giesserei-Praxis 1999, Vol. 2, pages 50-57, with the compositions given in table 1, were compared with regard to long-term behaviour under sustained temperature load.
    TABLE 1
    Chemical Composition of Alloys (in w. %)
    Alloy Si Fe Cu Mn Mg Cr Zn Ti Be V Zr
    AlSi7MgCu1 6.97 0.11 0.94 0.005 0.38 0.008 0.03
    AlMg3Si1MnCr 1.10 0.07 0.001 0.20 3.2 0.21 0.002 0.12 0.003 0.03 0.0005
  • The alloy according to the invention was cast in a trial rod mould according to Diez for round rods 16 mm diameter. The mechanical properties of yield strength (Rp0.2), tensile strength (Rm) and elongation at fracture (A5) were determined on the trial rods in state T6 (165° C./6 hours) after a sustained temperature load of 500 hours at various temperatures. The corresponding values for the comparison alloy were taken from the above article by F. J. Feikus. The results are shown in FIG. 1 in diagram form.
  • The alloy AlMg3Si1MnCr according to the invention admittedly does not reach the peak values of the comparison alloy AlSi7MgCu1 with regard to yield strength and tensile strength, but in its temperature behaviour is “less changeable”. This changeability has a disruptive effect in operation insofar as slight changes in temperature can cause great changes in mechanical properties. The yield strength of the alloy according to the invention remains at around the same level up to around 180° C., gradually falls away up to 200° C., and only above around 200° C. begins to decrease continuously. The continuous decrease takes place with a lesser gradient than the alloy AlSi7MgCu1.
  • With regard to the elongation at fracture, the alloy according to the invention is characterised by an almost constant value up to 180° C. High elongation values give a favourable fracture/failure behaviour. A visible deformation precedes the break of the component. Above 180° C. the elongation rises continuously. In the comparison alloy AlSi7MgCu1, the clear hardening effect can be seen. Low elongation values cause an unfavourable failure behaviour i.e. the component only deforms slightly or not at all. Under load peaks the component breaks without warning.

Claims (20)

1: A casting process for producing a cast product comprising:
(a) providing an aluminum alloy comprising:
2 to 4 w. % magnesium
0.9 to 1.5 w. % silicon
0.1 to 0.4 w. % manganese
0.1 to 0.4 w. % chromium
max. 0.2 w. % iron
max. 0.1 w. % copper
max. 0.2 w. % zinc
max. 0.2 w. % titanium
max. 0.3 w. % zirconium
max. 0.008 w. % beryllium
max. 0.5 w. % vanadium
with aluminium as the remainder, with further elements and production-induced contaminants individually max. 0.02 w. %, total max. 0.2 w. %; and
(b) casting the aluminum alloy to produce a cast product.
2: A process according to claim 1, wherein the alloy contains 2.5 to 3.5 w. % Mg.
3: A process according to claim 1, wherein the alloy contains 0.9 to 1.3 w. % Si.
4: A process according to claim 1, wherein the alloy contains 0.15 to 0.3 w. % Mn.
5: A process according to claim 1, wherein the alloy contains 0.15 to 0.3 w. % Cr.
6: A process according to claim 1, wherein the alloy contains 0.05 to 0.15 w. % Ti.
7: A process according to claim 1, wherein the alloy contains max. 0.15 w. % Fe.
8: A process according to claim 1, wherein the alloy contains max. 0.05 w. % Cu.
9: A process according to claim 1, wherein the alloy contains 0.002 to 0.005 w. % Be.
10: A process according to claim 1, wherein the alloy contains 0.01 to 0.1 w. % V.
11: A process according to claim 1, wherein the alloy contains 0.1 to 0.2 w. % Zr.
12: A process according to claim 1, wherein the alloy is sandcast or chilled casting process.
13: A process according to claim 11 wherein the alloy is chillcast or chilled casting process.
14: An aluminium alloy with good heat resistance comprising:
2 to 4 w. % magnesium
0.9 to 1.5 w. % silicon
0.1 to 0.4 w. % manganese
0.1 to 0.4 w. % chromium
max. 0.2 w. % iron
max. 0.1 w. % copper
max. 0.2 w. % zinc
max. 0.2 w. % titanium
max. 0.3 w. % zirconium
max. 0.008 w. % beryllium
max. 0.5 w. % vanadium
with aluminium as the remainder, with further elements and production-induced contaminants individually max. 0.02 w. %, total max. 0.2 w. %.
15: The alloy of claim 14, wherein the alloy contains 2.7 to 3.3 w. % Mg.
16: The alloy of claim 14, wherein the alloy contains 0.05 to 0.15 w. % Ti.
17: The alloy of claim 14, wherein the alloy contains max. 0.15 w. % Fe.
18: The alloy of claim 14, wherein the alloy contains max. 0.05 w. % Cu.
19: The alloy of claim 14, wherein the alloy contains 0.002 to 0.005 w. % Be.
20: The alloy of claim 14, wherein the alloy contains 0.01 to 0.1 w. % V.
US11/029,130 2004-02-11 2005-01-04 Casting of an aluminium alloy Abandoned US20050173032A1 (en)

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CH00195/04 2004-02-11
CH1952004 2004-02-11

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EP (1) EP1564308B1 (en)
JP (1) JP2005226161A (en)
KR (1) KR20050081168A (en)
CN (1) CN1654694A (en)
AT (1) ATE338149T1 (en)
BR (1) BRPI0500277A (en)
CA (1) CA2496140A1 (en)
DE (1) DE502005000072D1 (en)
ES (1) ES2270403T3 (en)
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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR100691328B1 (en) 2006-02-07 2007-03-12 (주)새서울경금속 Die-cast aluminum alloy
WO2011031183A1 (en) * 2009-09-14 2011-03-17 Anisimov Oleg Vladimirovich Method for producing a construction material from an aluminium-based alloy
WO2013144343A1 (en) 2012-03-30 2013-10-03 Jaguar Land Rover Limited Alloy and method of production thereof
US9617623B2 (en) 2011-07-28 2017-04-11 Korea Automotive Technology Institute Aluminum alloy including iron-manganese complete solid solution and method of manufacturing the same
US11203801B2 (en) 2019-03-13 2021-12-21 Novelis Inc. Age-hardenable and highly formable aluminum alloys and methods of making the same

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ATE376075T1 (en) * 2005-08-22 2007-11-15 Rheinfelden Aluminium Gmbh HEAT-RESISTANT ALUMINUM ALLOY
US9518312B2 (en) * 2009-03-31 2016-12-13 Hitachi Metals, Ltd. Al—Mg—Si-based, casting aluminum alloy with excellent yield strength and cast member made thereof
US20150030496A1 (en) * 2013-07-26 2015-01-29 M&C Corporation Aluminum alloy wire and wire assembly parts
CN103436755B (en) * 2013-08-23 2015-09-23 北京艾路浦科技发展有限公司 A kind of rust-preventing aluminum alloy material
CN103469024B (en) * 2013-09-24 2015-06-24 天津那诺机械制造有限公司 Special aluminum-alloy material for liquid die-forging molding of aluminum-alloy wheels of heavy-duty vehicle and molding method
CN103725938B (en) * 2013-11-27 2016-01-13 余姚市吴兴铜业有限公司 A kind of High-performance aluminum alloy automobile part
KR101606525B1 (en) * 2014-10-29 2016-03-25 주식회사 케이엠더블유 Aluminum alloy for die casting having excellent corrosion resistance
CN105256192A (en) * 2015-11-13 2016-01-20 无锡清杨机械制造有限公司 Aluminium alloy panel and preparation method thereof
WO2017210916A1 (en) * 2016-06-10 2017-12-14 GM Global Technology Operations LLC Magnesium-containing, aluminum-based alloy for thin-wall castings
EP3339465B1 (en) * 2016-12-23 2020-01-15 Brunswick Corporation Method for solution heat treating with pressure
CN109593996A (en) * 2018-12-28 2019-04-09 宁波合力模具科技股份有限公司 A kind of high tough squeeze casting Al mg-si master alloy and preparation method thereof
JP7238545B2 (en) * 2019-03-29 2023-03-14 株式会社アイシン Method for manufacturing aluminum alloy and cast parts
KR102716443B1 (en) * 2024-01-10 2024-10-15 티아이엘씨 주식회사 SUV luggage board

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US20010016175A1 (en) * 2000-01-19 2001-08-23 Hubert Koch Aluminum casting alloy
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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR100691328B1 (en) 2006-02-07 2007-03-12 (주)새서울경금속 Die-cast aluminum alloy
WO2011031183A1 (en) * 2009-09-14 2011-03-17 Anisimov Oleg Vladimirovich Method for producing a construction material from an aluminium-based alloy
US9617623B2 (en) 2011-07-28 2017-04-11 Korea Automotive Technology Institute Aluminum alloy including iron-manganese complete solid solution and method of manufacturing the same
WO2013144343A1 (en) 2012-03-30 2013-10-03 Jaguar Land Rover Limited Alloy and method of production thereof
US11203801B2 (en) 2019-03-13 2021-12-21 Novelis Inc. Age-hardenable and highly formable aluminum alloys and methods of making the same
US11932924B2 (en) 2019-03-13 2024-03-19 Novelis, Inc. Age-hardenable and highly formable aluminum alloys and methods of making the same
US12247271B2 (en) 2019-03-13 2025-03-11 Novelis Inc. Age-hardenable and highly formable aluminum alloys and methods of making the same

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NO20050682L (en) 2005-08-12
MXPA05001576A (en) 2005-08-19
EP1564308B1 (en) 2006-08-30
BRPI0500277A (en) 2005-09-27
JP2005226161A (en) 2005-08-25
ES2270403T3 (en) 2007-04-01
KR20050081168A (en) 2005-08-18
CA2496140A1 (en) 2005-08-11
DE502005000072D1 (en) 2006-10-12
CN1654694A (en) 2005-08-17
NO20050682D0 (en) 2005-02-09
ATE338149T1 (en) 2006-09-15
EP1564308A1 (en) 2005-08-17

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