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US20190352745A1 - Al-Mg-Si-Mn-Fe CASTING ALLOYS - Google Patents

Al-Mg-Si-Mn-Fe CASTING ALLOYS Download PDF

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US20190352745A1
US20190352745A1 US16/405,061 US201916405061A US2019352745A1 US 20190352745 A1 US20190352745 A1 US 20190352745A1 US 201916405061 A US201916405061 A US 201916405061A US 2019352745 A1 US2019352745 A1 US 2019352745A1
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aluminum casting
casting alloy
new aluminum
alloy
alloys
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Xinyan Yan
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Alcoa USA Corp
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Alcoa USA Corp
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
    • C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/02—Casting exceedingly oxidisable non-ferrous metals, e.g. in inert atmosphere
    • B22D21/04—Casting aluminium or magnesium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/047—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with magnesium as the next major constituent

Definitions

  • Aluminum alloys are useful in a variety of applications.
  • Aluminum casting (foundry) alloys for instance, are used in dozen of industries, including, for instance, the automotive and consumer electronics industries.
  • the present disclosure relates to new aluminum casting (foundry) alloys and associated products.
  • the new aluminum casting alloys generally comprise (and in some instances consist of or consist essentially of) from 2.5 to 5.0 wt. % Mg, from 0.70 to 2.5 wt. % Si, where the weight ratio of magensium to silicon (Mg/Si) is from 1.7:1 to 3.6:1, from 0.40 to 1.5 wt. % Mn, from 0.10 to 0.60 wt. % Fe, optionally up to 0.15 wt. % Ti, optionally up to 0.10 wt. % Sr, and optionally up to 0.15 wt.
  • Mg/Si magensium to silicon
  • the new aluminum casting alloys may realize an improve combination of properties, such as an improved combination of two or more of strength, ductility, castability, die soldering resistance and quality index, among others.
  • the new aluminum casting alloys generally include from 2.5 to 5.0 wt. % Mg. In one embodiment, a new aluminum casting alloy includes not greater than 4.75 wt. % Mg. In another embodiment, a new aluminum casting alloy includes not greater than 4.60 wt. % Mg. In one embodiment, a new aluminum casting alloy includes at least 2.75 wt. % Mg. In another embodiment, a new aluminum casting alloy includes at least 3.0 wt. % Mg.
  • the new aluminum casting alloys generally include from 0.70 to 2.5 wt. % Si.
  • a new aluminum casting alloy includes at least 0.80 wt. % Si.
  • a new aluminum casting alloy includes at least 0.90 wt. % Si.
  • a new aluminum casting alloy includes at least 0.95 wt. % Si.
  • a new aluminum casting alloy includes at least 1.00 wt. % Si.
  • a new aluminum casting alloy includes at least 1.05 wt. % Si.
  • a new aluminum casting alloy includes at least 1.10 wt. % Si.
  • a new aluminum casting alloy includes at least 1.15 wt. % Si.
  • a new aluminum casting alloy includes at least 1.20 wt. % Si. In one embodiment, a new aluminum casting alloy includes not greater than 2.4 wt. % Si. In another embodiment, a new aluminum casting alloy includes not greater than 2.3 wt. % Si. In yet another embodiment, a new aluminum casting alloy includes not greater than 2.2 wt. % Si. In another embodiment, a new aluminum casting alloy includes not greater than 2.1 wt. % Si. In yet another embodiment, a new aluminum casting alloy includes not greater than 2.0 wt. % Si.
  • the weight ratio of magnesium to silicon in the new aluminum casting alloys is generally from 1.7:1 to to 3.6:1 (wt. % Mg/wt. % Si). In one embodiment, the weight ratio of magensium to silicon in the new aluminum casting alloy is at least 1.8:1. In another embodiment, the weight ratio of magnesium to silicon in the new aluminum casting alloy is at least 1.85:1. In one embodiment, the weight ratio of magnesium to silicon in the new aluminum casting alloy is not greater than 3.6:1. In another embodiment, the weight ratio of magnesium to silicon in the new aluminum casting alloy is not greater than 3.5:1.
  • a new aluminum casting alloy includes an amount of magnesiumn and silicon sufficient to facilitate production of a crack-free cast product (e.g., a crack-free high pressure die cast product).
  • a crack-free product is a product sufficiently free of cracks so that it can be used for its intended purpose.
  • a new aluminum casting alloy includes an amount of magnesium and silicon sufficient to realize a hot cracking tendency index (HCTI) of not greater than 0.30, such as any of the low HCTI values disclosed herein.
  • HCTI hot cracking tendency index
  • the new aluminum casting alloys generally include from 0.40 to 1.5 wt. % Mn.
  • a new aluminum casting alloy includes at least 0.45 wt. % Mn.
  • a new aluminum casting alloy includes at least 0.50 wt. % Mn.
  • a new aluminum casting alloy includes at least 0.55 wt. % Mn.
  • a new aluminum casting alloy includes at least 0.60 wt. % Mn.
  • a new aluminum casting alloy includes not greater than 1.45 wt. % Mn.
  • a new aluminum casting alloy includes not greater than 1.40 wt. % Mn.
  • a new aluminum casting alloy includes not greater than 1.35 wt. % Mn. In another embodiment, a new aluminum casting alloy includes not greater than 1.30 wt. % Mn. In yet another embodiment, a new aluminum casting alloy includes not greater than 1.25 wt. % Mn. In another embodiment, a new aluminum casting alloy includes not greater than 1.20 wt. % Mn.
  • the new aluminum casting alloys generally include from 0.10 to 0.60 wt. % Fe.
  • a new aluminum casting alloy includes at least 0.12 wt. % Fe.
  • a new aluminum casting alloy includes at least 0.15 wt. % Fe.
  • a new aluminum casting alloy includes at least 0.20 wt. % Fe.
  • a new aluminum casting alloy includes at least 0.25 wt. % Fe.
  • a new aluminum casting alloy includes at least 0.30 wt. % Fe.
  • a new aluminum casting alloy includes at least 0.35 wt. % Fe.
  • a new aluminum casting alloy includes not greater than 0.55 wt. % Fe.
  • a new aluminum casting alloy includes not greater than 0.50 wt. % Fe.
  • a new aluminum casting alloy includes not greater than 0.45 wt. % Fe.
  • a new aluminum casting alloy includes an amount of iron and manganse sufficient to facilitate formation of alpha phase particles while restricting formation of beta phase particles. In one embodiment, at least due to the iron content, a new aluminum casting alloy includes not greater than 0.012 wt. % of ⁇ -Al5FeSi compounds. In another embodiment, a new aluminum casting alloy includes not greater than 0.010 wt. % of ⁇ -Al5FeSi compounds. In yet another embodiment, a new aluminum casting alloy includes not greater than 0.008 wt. % of ⁇ -Al5FeSi compounds. In another embodiment, a new aluminum casting alloy includes not greater than 0.006 wt. % of ⁇ -Al5FeSi compounds.
  • a new aluminum casting alloy includes not greater than 0.004 wt. % of ⁇ -Al5FeSi compounds. In another embodiment, a new aluminum casting alloy includes not greater than 0.002 wt. % of ⁇ -Al5FeSi compounds. In yet another embodiment, a new aluminum casting alloy includes not greater than 0.001 wt. % of ⁇ -Al5FeSi compounds. In another embodiment, a new aluminum casting alloy includes not greater than 0.0005 wt. % of ⁇ -Al5FeSi compounds.
  • a new aluminum casting alloy may include an amount of magnesium, silicon, manganese and iron sufficient to satisfy the following requirements:
  • the new aluminum casting alloys may optionally include up to 0.15 wt. % Ti.
  • a new aluminum casting alloy includes at least 0.01 wt. % Ti.
  • a new aluminum casting alloy includes at least 0.03 wt. % Ti.
  • a new aluminum casting alloy includes at least 0.05 wt. % Ti.
  • a new aluminum casting alloy includes at least 0.07 wt. % Ti.
  • a new aluminum casting alloy includes not greater than 0.13 wt. % Ti.
  • a new aluminum casting alloy includes not greater than 0.115 wt. % Ti.
  • a new aluminum casting alloy includes not greater than 0.10 wt. % Ti.
  • a new aluminum casting alloy include an amount of titanium sufficient to faciltiate grain refining while resticting/avoiding formation of primary titanium-containing particles.
  • titanium is included in a new aluminum casting alloy as an impurity.
  • the new aluminum casting alloys may optionally include up to 0.10 wt. % Sr.
  • a new aluminum casting alloy includes an amount of strontium sufficient to faciltiate modification of the Mg 2 Si eutectic while resticting/avoiding formation of primary strontium-containing particles.
  • a new aluminum casting alloy includes at least 0.005 wt. % Sr.
  • a new aluminum casting alloy includes not greater than 0.08 wt. % Sr.
  • a new aluminum casting alloy includes not greater than 0.05 wt. % Sr.
  • strontium is included in a new aluminum casting alloy as an impurity.
  • the new aluminum casting alloys may optionally include up to 0.15 wt. % of any of Zr, Sc, Hf, V, and Cr.
  • a new aluminum casting alloy includes an amount of zirconiun, scandium, hafnium, vanadium, and/or chromium sufficient to facilitate solid solution strengthening while restricting/avoiding formation of primary particles containing zirconium, scandium, hafnium, vanadium, and chromium.
  • a new aluminum casting alloy includes at least 0.01 wt. % of any of Zr, Sc, Hf, V, and Cr.
  • a new aluminum casting alloy includes at least 0.03 wt.
  • a new aluminum casting alloy includes at least 0.05 wt. % of any of Zr, Sc, Hf, V, and Cr. In one embodiment, a new aluminum casting alloy includes not greater than 0.10 wt. % of any of Zr, Sc, Hf, V, and Cr.
  • zirconium is included in a new aluminum casting alloy as an impurity.
  • scandium is included in a new aluminum casting alloy as an impurity.
  • hafnium is included in a new aluminum casting alloy as an impurity.
  • vanadium is included in a new aluminum casting alloy as an impurity.
  • chromium is included in a new aluminum casting alloy as an impurity.
  • the balance of the new aluminum casting alloys is generally aluminum and unavoidable impurities.
  • a new aluminum casting alloy comprises not greater than 0.30 wt. % of the unavoiable impurities, and wherein the new aluminum casting alloy comprises not greater than 0.10 wt. % of any one element of the unavoiable impurities.
  • a new aluminum casting alloy comprises not greater than 0.15 wt. % of the unavoiable impurities, and wherein the new aluminum casting alloy comprises not greater than 0.05 wt. % of any one element of the unavoidable impurities.
  • a new aluminum casting alloy comprises not greater than 0.10 wt. % of the unavoiable impurities, and wherein the new aluminum casting alloy comprises not greater than 0.03 wt. % of any one element of the unavoiable impurities.
  • the new aluminum casting alloys may be cast using any suitable casting method.
  • a new aluminum casting alloy is a direct chill cast as an ingot or billet.
  • a new aluminum casting alloy is shape cast into a shape cast product (e.g., a complex shape cast product, such as a complex automotive component).
  • the shape cast product is an automotive structural component.
  • the shape cast product is a door frame.
  • the shape cast product is a shock tower.
  • the shape cast product is a tunnel structure for an automobile.
  • the shape casting comproses high pressure die casting. In another embodiment, the shape casting comprises permanent mold casting.
  • the new aluminum casting alloys do not require a solution heat treatment step.
  • the new aluminum casting alloys may be provided, therefore, in the appropriate temper, such as in the F temper or the T5 temper.
  • the new aluminum casting alloys may realize an improved combination of properties, such as an improved combination of at least two of strength, ductility, castability, die soldering resistance and quality index.
  • Mechanical properties may be measured in accordance with ASTM E8 and B557 (e.g., when directionally solidified). Castability may be measured using the HCTI method described herein. Die soldering resistance may be determined by casting the alloy.
  • a new aluminum casting alloy realizes an ultimate tensile strength of at least 200 MPa. In another embodiment, a new aluminum casting alloy realizes an ultimate tensile strength of at least 210 MPa. In yet another embodiment, a new aluminum casting alloy realizes an ultimate tensile strength of at least 220 MPa. In another embodiment, a new aluminum casting alloy realizes an ultimate tensile strength of at least 230 MPa.
  • a new aluminum casting alloy realizes a tensile yield strength of at least 100 MPa. In another embodiment, a new aluminum casting alloy realizes an tensile yield strength of at least 105 MPa. In yet another embodiment, a new aluminum casting alloy realizes an tensile yield strength of at least 110 MPa. In another embodiment, a new aluminum casting alloy realizes an tensile yield strength of at least 115 MPa. In another embodiment, a new aluminum casting alloy realizes an tensile yield strength of at least 120 MPa. In another embodiment, a new aluminum casting alloy realizes an tensile yield strength of at least 125 MPa. Any of the above tensile yield strength values may be realized with any of the above ultimate tensile strength values.
  • a new aluminum casting alloy realizes an elongation of at least 7%. In another embodiment, a new aluminum casting alloy realizes an elongation of at least 8%. In yet another embodiment, a new aluminum casting alloy realizes an elongation of at least 9%. In another embodiment, a new aluminum casting alloy realizes an elongation of at least 10%. In yet another embodiment, a new aluminum casting alloy realizes an elongation of at least 11%. In another embodiment, a new aluminum casting alloy realizes an elongation of at least 12%. In yet another embodiment, a new aluminum casting alloy realizes an elongation of at least 13%. In another embodiment, a new aluminum casting alloy realizes an elongation of at least 14%.
  • a new aluminum casting alloy realizes an elongation of at least 15%. In another embodiment, a new aluminum casting alloy realizes an elongation of at least 16%, or higher. Any of the above elongation values may be realized with any of the above ultimate tensile strength or tensile yield strength values.
  • a new aluminum casting alloy realizes a HCTI of not greater than 0.30. In another embodiment, a new aluminum casting alloy realizes a HCTI of not greater than 0.25. In yet another embodiment, a new aluminum casting alloy realizes a HCTI of not greater than 0.20. In another embodiment, a new aluminum casting alloy realizes a HCTI of not greater than 0.15, or lower.
  • a new aluminum casting alloy is die soldering resistant wherein the as-cast aluminum alloy product is removed from the die without damage to the cast product and/or without sticking to the die. Die soldering can occur during high pressure die casting wherein molten aluminum solders to the die surface. In some embodiments, the new aluminum casting alloys described herein may be cast without being soldered to the die.
  • FIG. 1 is a graph showing silicon content versus hot cracking tendency index for Example 1 alloys.
  • FIG. 2 is a graph showing silicon content versus hot cracking tendency index for Example 2 alloys.
  • FIG. 3 is a graph showing silicon content versus hot cracking tendency index for Example 3 alloys.
  • FIG. 4 is a graph showing manganese content versus hot cracking tendency index for Example 4 alloys.
  • FIG. 5 a is a graph showing beta phase content (shown in wt. %) as a function of Mn and Fe content based on ICME modeling; the amounts of 3.6 wt. % Mg and 1.5 wt % Si were kept constant.
  • FIG. 5 b is a graph showing alpha phase content (shown in wt. %) as a function of Mn and Fe content based on ICME modeling; the amounts of 3.6 wt. % Mg and 1.5 wt % Si were kept constant.
  • FIG. 6 is a graph showing beta phase content (shown in wt. %) as a function of Fe content based on ICME modeling; the amounts of 3.6 wt. % Mg, 1.5 wt % Si and 0.5 wt. % Mn were kept constant.
  • FIG. 7 a is a graph showing ultimate tensile strength (MPa) versus iron content (wt. %) for Example 6 alloys.
  • FIG. 7 b is a graph showing elongtion (%) versus iron content (wt. %) for Example 6 alloys.
  • FIG. 7 c is a graph showing tensile yield strength (MPa) versus iron content (wt. %) for Example 6 alloys.
  • FIG. 7 d is a graph showing quality index (Q in MPa) versus iron content (wt. %) for Example 6 alloys.
  • FIG. 8 a is a graph showing HCI (computed hot cracking index) as a function of Si and Mg content based on ICME modeling; the amounts of 0.70 wt. % Mn and 0.25 wt. % Fe were kept constant.
  • FIG. 8 b is a graph showing non-equilibrium solidification temperature range (in ° C.) as a function of Si and Mg content based on ICME modeling; the amounts of 0.70 wt. % Mn and 0.25 wt. % Fe were kept constant.
  • FIG. 8 c is a graph showing showing HCI (computed hot cracking index) as a function of Si and Mn content based on ICME modeling; the amounts of 4.0 wt. % Mg and 0.25 wt. % Fe were kept constant.
  • FIG. 8 d is a graph showing showing HCI (computed hot cracking index) as a function of Si and Fe content based on ICME modeling; the amounts of 4.0 wt. % Mg and 0.70 wt. % Mn were kept constant.
  • HCTI hot cracking tendency index
  • the hot cracking tendency index (HCTI) of an alloy is defined as
  • HCTI ⁇ diameter ⁇ ⁇ of ⁇ ⁇ the ⁇ ⁇ cracked ⁇ ⁇ rod ( 4 + 6 + 8 + 10 + 12 + 14 + 16 )
  • the HCTI value will be 0. If cracking is found in all 7 connection rods (from 4 mm to 16 mm), the HCTI value will be 1. Therefore, a smaller HCTI indicates a higher hot cracking resistance for a specific alloy.
  • alloys having from about 1 to about 2 wt. % Si at similar amounts of Fe, Mn, Mg and Ti realized improved hot cracking resistance.
  • the Mg/Si ratio for these alloys is from about 2.0 to 3.0.
  • Alloy A4 with 1.56 wt. % Si had a Mg to Si ratio of 2.26.
  • Example 2 Four additional alloys were cast and their hot cracking susceptibility was determined, as per Example 1. Like Example 1, the silicon content was again varied, but using a lower nominal amount of magnesium and manganese.
  • the compositions of the Example 2 alloys are shown in Table 3, below.
  • the HCTI results for the Example 2 alloys are shown in the below figure.
  • Alloy B2 showed the best hot cracking resistance.
  • the Mg/Si ratio for this alloy is about 2.65.
  • FIG. 2 shows the experimental measured hot cracking tendency indexes of the Al2.5Mg-1.1Mn-x % Si alloys.
  • Alloy B2 with 0.96 wt. % Si and 2.54 wt. % Mg, showed the best ho cracking resistance.
  • the Mg/Si ratio for this alloy is about 2.65.
  • Example 3 The compositions of the Example 3 alloys are shown in Table 4, below.
  • the HCTI results for the Example 3 alloys are shown in FIG. 3 . As shown, the HCTI for all alloys is generally good. The lowest HCTI was realized by alloy C3 with a Mg/Si ratio of 2.22.
  • Examples 1-3 indicate that the Mg/Si (weight ratio) should be from about 1.7 to about 3.6, preferably from about 2.0 to about 3.0 to facilitate hot cracking resistance.
  • Example 4 Four additional alloys were cast and their hot cracking susceptibility was determined, as per Example 1. This time, the manganese content was varied, targeting a nominal magnesium amount of 3.6 wt. % and a nominal silicon amount of 1.5 wt. %.
  • the compositions of the Example 4 alloys are shown in Table 5, below.
  • the HCTI results for the Example 4 alloys are shown in FIG. 4 . As shown, the HCTI for all alloys is generally good. Alloy D4 with 1.20 wt. % Mn realized the best HCTI results.
  • Example 5 The compositions of the Example 5 alloys are shown in Table 6, below.
  • the HCTI results for the Example 5 alloys are shown in the below figure. As shown, the HCTI for all alloys is generally good. Alloy E4 with 0.29 wt. % Fe realized the best HCTI results.
  • FIGS. 5 a, 5 b and 6 show the correlation between manganese and iron content and the volume fraction on ⁇ -Al 5 FeSi and ⁇ -Al 15 FeMn 3 Si 2 phase particles (for a Al -3.6Mg-1.5Si alloys).
  • Adding Mn to the Al—Mg—Si alloys can promote formation of ⁇ -Al 15 FeMn 3 Si 2 phase and restrict or prevent formation of ⁇ -Al 5 FeSi phase.
  • a Al-3.6Mg-1.5Si alloy with from 0.4 to 0.6 wt. % Mn using increased iron amounts decreases the amount of ⁇ -Al 5 FeSi phase.
  • the amount of ⁇ -Al 5 FeSi phase decreases from about 0.018 wt. % to essentially 0 wt. % by increasing iron from 0.15 wt. % to 0.4 wt. %.
  • alloys having improved properties may be realized due to the increase in iron and the corresponding decrease in ⁇ -Al 5 FeSi phase within the alloy.
  • the first group (F) targeted a nominal magnesium amount of 3.6 wt. %, a nominal silicon amount of 1.5 wt. %, and a nominal manganese amount of 0.90 wt. %.
  • the second group (G) targeted a nominal magnesium amount of 4.0 wt. %, a nominal silicon amount of 1.7 wt. %, and a nominal manganese amount of 0.65 wt. %.
  • the compositions of the Example 6 alloys are shown in Table 7, below.

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EP3589766B1 (fr) 2023-06-28
KR20200140917A (ko) 2020-12-16
JP7438134B2 (ja) 2024-02-26
WO2019217319A1 (fr) 2019-11-14
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EP4234123A3 (fr) 2023-09-27
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ES2949017T3 (es) 2023-09-25
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