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US20110132504A1 - Aluminum Alloy Casting Material for Heat Treatment Excelling in Heat Conduction and Process for Producing the Same - Google Patents

Aluminum Alloy Casting Material for Heat Treatment Excelling in Heat Conduction and Process for Producing the Same Download PDF

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Publication number
US20110132504A1
US20110132504A1 US11/547,257 US54725705A US2011132504A1 US 20110132504 A1 US20110132504 A1 US 20110132504A1 US 54725705 A US54725705 A US 54725705A US 2011132504 A1 US2011132504 A1 US 2011132504A1
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US
United States
Prior art keywords
mass
aluminum alloy
silicon
thermal conductivity
alloy casting
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Abandoned
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US11/547,257
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English (en)
Inventor
Hiroshi Horikawa
Sanji Kitaoka
Masahiko Shioda
Toshihiro Suzuki
Takahiko Watai
Hidetoshi Kawada
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Nippon Light Metal Co Ltd
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Nippon Light Metal Co Ltd
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Filing date
Publication date
Priority claimed from JP2004111496A external-priority patent/JP4341453B2/ja
Priority claimed from JP2004113584A external-priority patent/JP4487615B2/ja
Application filed by Nippon Light Metal Co Ltd filed Critical Nippon Light Metal Co Ltd
Assigned to NIPPON LIGHT METAL COMPANY, LTD. reassignment NIPPON LIGHT METAL COMPANY, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HORIKAWA, HIROSHI, KITAOKA, SANJI, SHIODA, MASAHIKO, KAWADA, HIDETOSHI, SUZUKI, TOSHIHIRO, WATAI, TAKAHIKO
Publication of US20110132504A1 publication Critical patent/US20110132504A1/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
    • 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
    • C22F1/043—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 silicon as the next major constituent

Definitions

  • the present invention concerns an aluminum alloy casting material having a high thermal conductivity and a manufacturing methods thereof.
  • the aluminum alloy casting material having a high thermal conductivity according to the present invention may be used optimally for heatsinks having a complex shape in order to increase heat radiation, and heatsinks having a thin-walled portion and the like.
  • the thermal conductivity increases as the aluminum content of the alloy gets higher. Therefore, in cases where a high thermal conductivity is necessary, the use of pure aluminum may be considered, but pure aluminum has the problems of low strength and low castability, so it was not possible to cast things having complex shapes and thin-walled portions.
  • the present invention has the objective of an aluminum alloy casting material for heat treatment wherefor castability is improved by adding silicon, and at the same time having improved thermal conductivity.
  • the present invention has the objective of providing a method for manufacturing said aluminum alloy casting material.
  • the aluminum alloy casting material according to Claim 1 offered by the present invention in order to solve the abovementioned problems is an aluminum alloy casting material with excellent thermal conductivity, characterized by containing 5-10.0% by mass of silicon, 0.1-0.5% by mass of magnesium, the remainder comprising aluminum and inevitable impurities, whereon aging treatment has been performed.
  • the abovementioned aluminum alloy casting material may further contain 0.3-0.6% by mass of iron.
  • the aluminum alloy casting materials having such compositions are, as shall be described herebelow giving embodiments, aluminum alloy casting materials having excellent castability in addition to high thermal conductivity and strength.
  • the present invention according to Claim 4 suggests performing solution heat treatment by holding at 480-540 degrees Celsius for 1-10 hours before performing aging treatment, and subsequently, quenching by cooling to a temperature of 100 degrees Celsius or below at a cooling rate of 100 degrees Celsius per second or faster.
  • the inventors of the present invention found that the amount of silicon in solid solution within the matrix of an aluminum-silicon aluminum alloy casting, and the area ratio of crystallized products within the metal structure, affect the thermal conductivity and strength of the casting greatly, and by optimizing the values of the amount of silicon in solid solution and the area ratio of the crystallized products in the metal structure, an aluminum alloy casting with particularly excellent thermal conductivity, while having sufficient mechanical strength, is obtainable.
  • the amount of silicon in solid solution and the area ratio of the crystallized products could be controlled by heating and holding treatment after casting.
  • an aluminum alloy casting with excellent thermal conductivity characterized by containing 6.0-8.0% by mass of silicon, 0.6% by mass or less of any single elements other than silicon and aluminum, the amount of silicon in solid solution within the aluminum matrix being adjusted to 0.5-1.1% by mass, preferably 0.55-1.05% by mass, more preferably 0.6-1.0% by mass, and the area ratio of the crystallized products within the metal structure being adjusted to 5-8%, preferably 5.5-7.5%, more preferably 6.0-7.0%.
  • the abovementioned aluminum alloy casting has a composition comprising, for elements other than silicon and aluminum, 0.2-0.5% by mass of magnesium, 0.6% by mass or less of iron, and other elements whereof the total amount is 0.2% by mass or less.
  • the amount of titanium and/or zirconium is adjusted to 0.03% by mass or less.
  • said aluminum alloy casting has a thermal conductivity better than that of conventional aluminum alloy castings, and has a thermal conductivity of preferably 160 W/(m ⁇ k) or greater, more preferably 165 W/(m ⁇ k) or greater.
  • the invention according to Claim 9 of the present application provides a manufacturing method for an aluminum alloy casting with excellent thermal conductivity, characterized by containing 6.0-8.0% by mass of silicon, and conducting heating and holding treatment at 400-510 degrees Celsius for 1 hour or longer on an aluminum alloy casting material wherein the amount of any single element other than silicon or aluminum is 0.6% by mass or below.
  • the aluminum alloy casting material preferably contains 6.0-8.0% by mass of silicon, 0.2-0.5% by mass of magnesium, 0.6% by mass or less of iron, the remainder comprising aluminum and other elements whereof the total amount is 0.2% by mass or less, and the titanium and/or zirconium within the aluminum alloy casting material is adjusted to 0.03% by mass or less.
  • the length of time of the heating and holding treatment of the aluminum alloy casting material is 1 hour or longer. However, even if the heating and holding treatment is performed for 7 hours or longer, no further improvement in the characteristics can be obtained, so it is preferable to perform the treatment for 7 hours or less.
  • FIG. 1 A microphotograph showing the structures of as-cast material and aluminum alloy castings (No. 1, 4-6)
  • magnesium has the effect of improving mechanical strength but lowering thermal conductivity, so that for casting material requiring a high thermal conductivity, it is preferable to reduce the magnesium content as much as possible.
  • the invention of the present application makes the thermal conductivity of an aluminum alloy casting material higher by adding 0.1-0.5% by mass of magnesium to an aluminum-silicon aluminum alloy.
  • Silicon has the effect of improving castability. In the case of casting of things having a complex shape or a thin-walled portion such as heatsinks, from the viewpoint of castability, it becomes necessary to add 5% by mass or more of silicon. Additionally, silicon also has the effects of improving the mechanical strength, wear resistance, and vibration damping ability of the casting material. However, as the silicon increases, thermal conductivity and extensibility are reduced, and if the amount of silicon exceeds 10% by mass, plastic workability becomes insufficient, so that it is desirable for the silicon content to be 10.0% by mass or less.
  • Iron in addition to improving the mechanical strength of an aluminum alloy, has the effect of preventing sticking to the die when casting with the diecast method. This effect becomes marked when greater than 0.3% by mass of iron is contained. However, as the amount of iron gets greater, thermal conductivity and extensibility are reduced, so if the amount of iron exceeds 0.6% by mass, plastic workability becomes insufficient.
  • magnesium forms magnesium-silicon compounds with silicon within the matrix and precipitates, reducing the amount of silicon in solid solution within the matrix, and improving thermal conductivity. Further, by the addition of magnesium, the mechanical strength improves. This effect becomes marked when the added amount of magnesium is 0.1% by mass or greater, but when the added amount exceeds 0.5% by mass, the thermal conductivity gets reduced.
  • the thermal conductivity is reduced, it is preferable to keep the amount of inevitable impurities at 0.1% by mass or less.
  • the effect of titanium, manganese, and zirconium on thermal conductivity is great, it is preferable to suppress this value to 0.05% by mass or less.
  • the treatment temperature is less than 480 degrees Celsius, or if the amount of time the treatment is maintained is less than 1 hour, the abovementioned effect is insufficient, and on the other hand, if the treatment temperature exceeds 540 degrees Celsius, or if the amount of time the treatment is maintained exceeds 10 hours, localized melting occurs and the possibility of the strength decreasing becomes greater.
  • the treatment temperature it is preferable for the treatment temperature to be greater than 500 degrees Celsius.
  • cooling it is preferable for cooling to be done after casting at least until 200 degrees Celsius is reached, at a rate of 100 degrees Celsius per second or faster.
  • magnesium-silicon compounds improve the mechanical strength of an alloy. If the aging conditions are below 160 degrees Celsius or less than 1 hour, since the amount of magnesium-silicon compounds precipitated is relatively small, the improvement in thermal conductivity is small. On the other hand, if 270 degrees Celsius or 10 hours is exceeded, overaging occurs, and strength is reduced.
  • the conditions for heat treatment may be selected, similarly with the alloy composition, according to characteristics such as thermal conductivity and strength, and further, in consideration of restrictions due to industrial production, but in consideration of the balance between thermal conductivity and strength, it is desirable for the aging treatment to be done for 4-8 hours at 180-250 degrees Celsius.
  • Alloy casting materials wherein 0, 0.3, 0.5, and 0.6% by mass of magnesium was added to an aluminum alloy containing 7.0% by mass of silicon were prepared, and subsequently, the aging treatments shown in Table 1 were conducted on said casting materials, and thermal conductivity was measured. The measurement results for thermal conductivity are shown together in Table 1. Additionally, for the alloys containing 0 and 0.3% by mass of magnesium, the amount of silicon and magnesium dissolved in solid solution was also measured. The results are shown in Table 2. Casting was done by gravity die casting.
  • casting material with magnesium added has a lower thermal conductivity than casting material with no magnesium added, but it can be seen that if aging treatment is conducted, the thermal conductivity of casting material with magnesium added has a thermal conductivity equivalent to or greater than that of a casting material with no magnesium added.
  • the improvement in thermal conductivity is insufficient, and the thermal conductivity is lower than that for casting material with no magnesium added. It is thought that this is because the effect of the reduction in thermal conductivity due to an increase in the amount of magnesium dissolved in solid solution is greater than the improvement in thermal conductivity caused by a reduction in the amount of silicon dissolved in solid solution.
  • table 2 shows that if aging treatment is conducted, the amount of silicon dissolved in solid solution in an alloy whereto magnesium is added becomes lower.
  • Casting materials wherein 0 and 0.3% by mass of magnesium are added to an aluminum alloy containing 7.0% by mass of silicon and 0.4% by mass of iron were prepared.
  • the casting materials were cast using the PF die casting method. After conducting solution heat treatment on the obtained casting material for 2 hours at 500 degrees Celsius, water quenching was done. Subsequently, the thermal conductivity was measured, and after this, aging treatment was done for 4 hours at 250 degrees Celsius, and the thermal conductivity was measured again. The results are shown in table 3.
  • the aluminum alloy casting with excellent thermal conductivity of the present invention contains 6.0-8.0% by mass of silicon, 0.6% by mass or less of any single element other than silicon or aluminum, the amount of silicon in solid solution within the aluminum matrix being adjusted to 0.5-1.1% by mass, and the area ratio of the crystallized products within the metal structure being adjusted to 5-8%.
  • the abovementioned aluminum alloy casting preferably has a composition comprising, for elements other than silicon and aluminum, 0.2-0.5% by mass of magnesium, 0.6% by mass or less of iron, and other elements with a total amount of 0.2% by mass or less.
  • Silicon has the effect of improving castability.
  • it is necessary to make the silicon content 6.0% by mass or more.
  • This silicon crystallizes as silicon based crystallizations, and has the effect of improving the mechanical strength, wear resistance, and vibration damping of the casting. Additionally, the further the silicon content is increased, castability and the like improves, but if the silicon content exceeds 8.0% by mass, the thermal conductivity is reduced. Therefore, for the objective of the present invention, the silicon content must be within the range of 6.0-8.0% by mass.
  • Magnesium is not a necessary element for the present invention. However, magnesium forms magnesium based crystallized products, and has the effect of improving mechanical strength, so in cases where mechanical strength is particularly sought, it is preferable that magnesium be contained. This effect becomes marked at 0.2% by mass or greater, and when 0.5% by mass is exceeded, thermal conductivity is reduced. Further, a portion of the magnesium forms magnesium-silicon precipitates, having the effect of improving mechanical strength. Therefore, in cases where magnesium is contained, it is preferable that this is in the range of 0.2-0.5% by mass.
  • Iron is an impurity that gets mixed in inevitably, but along with improving mechanical strength, in cases where the die casting method is used, it has the effect of suppressing sticking to the die.
  • thermal conductivity and extensibility are reduced, and if the iron content exceeds 0.6% by mass, plastic workability becomes insufficient. Accordingly, even if iron gets mixed in inevitably, it is preferable to keep the iron content at 0.3% by mass or less.
  • the aluminum alloy casting of the present invention may contain elements other than silicon, magnesium, iron, and aluminum if their total amount is 0.2% by mass or less. These elements are normally inevitable impurities, but it is not necessary for them to be so considered. Substantially, titanium, manganese, chromium, boron, zirconium, phosphorus, calcium, sodium, strontium, antimony, zinc, and the like may be given as these elements.
  • titanium, manganese, and zirconium have on the thermal conductivity is great, so that it is preferable that their amounts be suppressed to 0.05% by mass or less.
  • the amount of silicon in solid solution has a large effect on the thermal conductivity thereof, and if the amount of silicon in solid solution exceeds 1.1% by mass, the thermal conductivity is reduced. On the other hand, if the amount of silicon in solid solution is less than 0.5% by mass, then a sufficient mechanical strength cannot be obtained.
  • the inventors of the present invention have newly discovered that in aluminum alloy castings, when the area ratio of crystallized products exceeds 8%, the crystallized products inhibit thermal conductivity. Additionally, extensibility becomes low. On the other hand, if the area ratio of crystallized products is low at less than 5%, sufficient strength cannot be obtained.
  • the inventors of the present invention discovered that the abovementioned aluminum alloy is obtainable by further performing heating and holding treatment to a predetermined temperature on a conventional aluminum alloy casting with excellent castability.
  • an aluminum alloy casting material having a predetermined composition is manufactured.
  • an appropriate conventionally known casting method may be used, such as the molten metal casting method, the DC method, the die casting method, and in some cases, commercially available aluminum alloy castings may be used as a material for the method of the present invention.
  • the aluminum alloy casting materials to be used contain 6.0-8.0% by mass of silicon, and 0.6% by mass or less of any single element other than silicon or aluminum, and more preferably contains 6.0-8.0% by mass of silicon, 0.2-0.5% by mass of magnesium, and 0.6% by mass or less of iron, the remainder comprising aluminum and other elements in a total amount of 0.2% by mass or less.
  • castings cast with JIS AC4C and AC4CH alloys may be given.
  • heating and holding treatment is done to 400-510 degrees Celsius on the abovementioned aluminum alloy casting material.
  • silicon that was in solid solution within the matrix precipitates, and the amount of silicon in solid solution within the matrix becomes in the range of 0.5-1.1% by mass, and concurrently, a portion of the crystallized products dissolves in solid solution in the matrix, and the area ratio of the crystallized products becomes in the range of 5-8%.
  • the heating and holding temperature exceeds 510 degrees Celsius, the amount of crystallized products that dissolve in solid solution in the matrix becomes great, and as a result, the area ratio of the crystallized products is reduced, and at the same time, the amount of silicon in solid solution becomes great, so the thermal conductivity is reduced. Additionally, the mechanical strength is also reduced. In contrast, if the heating and holding temperature is 400 degrees or less, the silicon within the matrix does not precipitate, and the amount of silicon in solid solution does not decrease, so the thermal conductivity does not improve. Additionally, a portion of the crystallized products is not dissolved in solid solution in the matrix, so that the area ratio of the crystallized products becomes large, and thermal conductivity is reduced.
  • the heating and holding treatment it is preferable for the heating and holding treatment to be performed for 1 hour or longer. Additionally, even if heating and holding is done for longer than 5 hours, the amount of silicon in solid solution and the area ratio of the crystallized products does not change much further. Therefore, from a cost standpoint, it is preferable that the holding time be less than 5 hours.
  • cooling is done to room temperature, but the subsequent cooling can be done by water cooling, or slow cooling can be done by furnace cooling.
  • the amount of precipitates differs according to the cooling rate, and the amount of silicon in solid solution changes, but in the case of the alloy of the present invention, silicon already precipitates during heating and holding treatment, and the amount of silicon in solid solution is small, so its effects are small.
  • water cooling is preferable.
  • the cooling rate will differ for different portions, so deformation can easily occur during cooling, so that for castings having a thin-walled portion such as heatsinks, slow cooling is preferable.
  • An aluminum alloy casting material (corresponding to JIS AC4C) comprising 7.1% by mass of silicon, 0.32% by mass of magnesium, 0.2% by mass of iron, and aluminum, the total content of other elements being 0.2% by mass or below, was cast into 2034 ⁇ 2000 mm by the DC casting method.
  • the obtained as-cast material (No. 1) was maintained at 380 degrees Celsius, 420 degrees Celsius, 450 degrees Celsius, 500 degrees Celsius, 535 degrees Celsius, and 550 degrees Celsius for 5 hours, and subsequently cooled to room temperature by water cooling, and aluminum alloy castings (No. 2-7) were obtained.
  • thermal conductivity tensile strength
  • amount of silicon in solid solution was measured.
  • the amount of silicon in solid solution the silicon content of the alloy and the amount of silicon within thermal phenol residue was determined by chemical analysis, and the amount of silicon in solid solution was taken to be the difference when the amount of silicon within the phenol residue was subtracted from the amount of silicon within the obtained alloy.
  • the thermal phenol dissolution residue was recovered by filtering the product with a membrane filter (0.1 ⁇ m) after dissolving the alloy with thermal phenol.
  • Measurement was done by measuring 10 fields of view where 1 field of view was 0.014 square millimeters, and taking the average values.
  • the aluminum alloy castings according to the present invention (No. 3-5), all have values for the amount of silicon in solid solution and the area of crystallized products that are within the optimal range, and it can be seen that the thermal conductivity, tensile strength, and elongation are all high numerical values.
  • Heating and holding treatment was done on the as-cast material obtained in embodiment 3 at 450 degrees Celsius for 0.5 hours, 1 hour, 3 hours, and 7 hours respectively, and subsequently slow-cooled to room temperature to obtain aluminum alloy castings (No. 8-11).
  • the amount of silicon in solid solution, the area ratio of the crystallized products, thermal conductivity, tensile strength, and elongation were measured in the same manner as embodiment 3.

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US11/547,257 2004-04-05 2005-04-05 Aluminum Alloy Casting Material for Heat Treatment Excelling in Heat Conduction and Process for Producing the Same Abandoned US20110132504A1 (en)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
JP2004-111496 2004-04-05
JP2004111496A JP4341453B2 (ja) 2004-04-05 2004-04-05 熱伝導性に優れたアルミニウム合金鋳物及びその製造方法
JP2004113584A JP4487615B2 (ja) 2004-04-07 2004-04-07 熱伝導性に優れたアルミニウム合金鋳造材の製造方法
JP2004-113584 2004-04-07
PCT/JP2005/006639 WO2005098065A1 (fr) 2004-04-05 2005-04-05 Materiau de coulage d’alliage aluminium pour traitement thermique d’excellente conduction thermique et procédé de fabrication de celui-ci

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PCT/JP2005/006639 A-371-Of-International WO2005098065A1 (fr) 2004-04-05 2005-04-05 Materiau de coulage d’alliage aluminium pour traitement thermique d’excellente conduction thermique et procédé de fabrication de celui-ci

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KR102203716B1 (ko) 2019-03-08 2021-01-15 한국생산기술연구원 압출성 및 강도가 향상된 고열전도도 알루미늄 합금, 상기 알루미늄 합금 제조 방법 및 상기 알루미늄 합금 압출성형제품 제작 방법
KR102203717B1 (ko) 2019-03-08 2021-01-15 한국생산기술연구원 열전도도 및 성형성이 향상된 알루미늄 합금 및 상기 알루미늄 합금 압출성형제품 제조 방법
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KR102465688B1 (ko) 2020-12-01 2022-11-14 한국생산기술연구원 전기전도도, 열전도도 및 성형성이 향상된 알루미늄 합금 및 상기 알루미늄 합금의 압출성형제품 제조 방법
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WO2005098065A1 (fr) 2005-10-20
KR20060130658A (ko) 2006-12-19
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