Classifications

• • 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
  • 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

• 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 6.0 to 11.5 wt. % Si, from 0.30 to 0.80 wt. % Fe, optionally from 0.07 to 0.20 wt. % of X, wherein X is selected from the group consisting of Mg, Mo, Zr, and combinations thereof, and optionally 100-500 ppm Sr, the balance being aluminum and unavoidable impurities.
• the new aluminum casting alloys may realize an improve combination of properties, such as an improved combination of two or more of strength, thermal conductivity, corrosion resistance, fluidity, and die soldering resistance.
• the new aluminum casting alloys generally include from 6.0 to 11.5 wt. % Si.
• a new aluminum casting alloy includes at least 7.0 wt. % Si.
• a new aluminum casting alloy includes at least 8.0 wt. % Si.
• a new aluminum casting alloy includes at least 8.5 wt. % Si.
• a new aluminum casting alloy includes at least 9.0 wt. % Si.
• a new aluminum casting alloy includes at least 9.5 wt. % Si.
• a new aluminum casting alloy includes not greater than 11.0 wt. % Si.
• a new aluminum casting alloy includes not greater than 10.5 wt. % Si.
• the new aluminum casting alloys generally include from 0.30 to 0.80 wt. % Fe.
• a new aluminum casting alloy includes at least 0.35 wt. % Fe.
• a new aluminum casting alloy includes at least 0.40 wt. % Fe.
• a new aluminum casting alloy includes at least 0.45 wt. % Fe.
• a new aluminum casting alloy includes at least 0.50 wt. % Fe.
• a new aluminum casting alloy includes not greater than 0.75 wt. % Fe.
• a new aluminum casting alloy includes not greater than 0.70 wt. % Fe.
• a new aluminum casting alloy includes not greater than 0.65 wt. % Fe.
• the new alminum casting alloys may optionally contain from 0.07 to 0.20 wt. % of X, where X is selected from the group consisting of Mg, Mo, Zr, and combinations thereof.
• the group X elements may, for instance, provide enhanced strength.
• a new aluminum casdting alloy includes from 0.07 to 0.18 wt. % of X.
• a new aluminum casdting alloy includes from 0.07 to 0.15 wt. % of X.
• a new aluminum casdting alloy includes from 0.07 to 0.12 wt. % of X.
• a new aluminum casdting alloy includes from 0.07 to 0.10 wt. % of X.
• the new aluminum casting alloys are substantially free of all of Mg, Mo, and Zr, having less than 0.07 wt. % of each of Mg, Mo, and Zr.
• the new aluminum casting alloys include not greater than 0.05 wt. % of each of Mg, Mo, and Zr.
• the new aluminum casting alloys include not greater than 0.04 wt. % of each of Mg, Mo, and Zr.
• the new aluminum casting alloys include not greater than 0.03 wt. % of each of Mg, Mo, and Zr.
• the new aluminum casting alloys include not greater than 0.02 wt. % of each of Mg, Mo, and Zr.
• the new aluminuim casting alloys may optionally contain stronium (Sr), such as 100-500 ppm Sr.
• the new aluminum casting alloys are substantially free of strontium, having less than 100 ppm Sr.
• a new aluminum casting alloy includes not greater than 50 ppm Sr.
• a new aluminum casting alloy includes not greater than 25 ppm Sr.
• a new aluminum casting alloy includes not greater than 10 ppm Sr.
• the balance of the new aluminum casting alloys is generally aluminum and unavoiable impurities.
• the new aluminum casting alloys are generally substantially free of all of copper (Cu), manganese (Mn), titanium (Ti), chromium (Cr), nickel (Ni), zinc (Zn), and vanadium (V).
• substantially free of copper means that the new aluminum alloys contain less than 0.10 wt. % Cu. In one embodiment, a new aluminum alloy contains not greater than 0.05 wt. % Cu. In another embodiment, a new aluminum alloy contains not greater than 0.03 wt. % Cu. In yet another embodiment, a new aluminum alloy contains not greater than 0.01 wt. % Cu.
• substantially free of manganese means that the new aluminum alloys contain less than 0.05 wt. % Mn. In one embodiment, a new aluminum alloy contains not greater than 0.04 wt. % Mn. In another embodiment, a new aluminum alloy contains not greater than 0.03 wt. % Mn. In yet another embodiment, a new aluminum alloy contains not greater than 0.02 wt. % Mn.
• substantially free of zinc means that the new aluminum alloys contain less than 0.10 wt. % Zn. In one embodiment, a new aluminum alloy contains not greater than 0.05 wt. % Zn. In another embodiment, a new aluminum alloy contains not greater than 0.03 wt. % Zn. In yet another embodiment, a new aluminum alloy contains not greater than 0.01 wt. % Zn.
• substantially free means that the new aluminum alloy contains not greater than 0.04 wt. % of any of those elements, i.e., the new aluminum alloy contains not greater than 0.04 wt. % of each of Ti, Cr, Ni, and V. In one embodiment, a new aluminum alloy contains not greater than 0.03 wt. % of each of Ti, Cr, Ni, and V. In another embodiment, a new aluminum alloy contains not greater than 0.02 wt. % of each of Ti, Cr, Ni, and V. In one embodiment, the cummulative amounts of Ti, Cr, Ni, and V do not exceed 0.10 wt. %. In another embodiment, the cummulative amounts of Ti, Cr, Ni, and V do not exceed 0.08 wt. %. In yet another embodiment, the the cummulative amounts of Ti, Cr, Ni, and V do not exceed 0.06 wt. %.
• the new aluminum casting alloys may be cast using any suitable casting method.
• the new aluminum casting alloys are shape cast using high presssure die casting (HPDC).
• HPDC high presssure die casting
• a new aluminum casting alloy is shape cast into a shape cast product (e.g., a complex shape cast product).
• the shape cast product is a heat sink.
• the shape cast product is in the form of an antenna.
• the shape cast product has a wall thickness of from 1.5 to 5.0 mm.
• the shape cast product has a height of from 50 to 100 mm.
• the new aluminum casting alloys may be provided in any appopriate temper, including the as-cast temper.
• the new aluminum casting alloys may realize an improved combination of properties, such as an improved combination of at least two of strength, thermal conductivity, corrosion resistance, fluidity, and die soldering resistance.
• Mechanical properties may be measured in accordance with ASTM E8 and B557 (e.g., when directionally solidified). Die soldering resistance may be determined by casting the alloy.
• a new aluminum casting alloy realizes a tensile yield strength of at least 65 MPa. In one embodiment, a new aluminum casting alloy realizes an elongation of at least 2%.
• a new aluminum casting alloy realizes a thermal conductivity of at least 160 W/m/° C. at a temperature of 25° C. Thermal conductivity may be measured using equation 1 of ASTM equation 1 of ASTM E1461 using thermal diffusivity results obtained per ASTM E1461-13, specific heat capacity results obtained per ASTM E1269-11 (2016) and density results per ASTM B311-17.
• a new aluminum casting alloy realizes a thermal conductivity of at least 170 W/m/° C. at a temperature of 25° C.
• a new aluminum casting alloy realizes a thermal conductivity of at least 175 W/m/° C. at a temperature of 25° C.
• a new aluminum casting alloy realizes a thermal conductivity of at least 180 W/m/° C. at a temperature of 25° C. In yet another embodiment, a new aluminum casting alloy realizes a thermal conductivity of at least 185 W/m/° C. at a temperature of 25° C. In another embodiment, a new aluminum casting alloy realizes a thermal conductivity of at least 190 W/m/° C. at a temperature of 25° C. In yet another embodiment, a new aluminum casting alloy realizes a thermal conductivity of at least 195 W/m/° C., or higher, at a temperature of 25° C.
• a new aluminum casting alloy realizes an electical conductivity of at least 38% IACS (International Annealed Copper Standard). In another embodiment, a new aluminum casting alloy realizes an electical conductivity of at least 39% IACS. In yet another embodiment, a new aluminum casting alloy realizes an electical conductivity of at least 40% IACS. In another embodiment, a new aluminum casting alloy realizes an electical conductivity of at least 41% IACS. In yet another embodiment, a new aluminum casting alloy realizes an electical conductivity of at least 42% IACS. In another embodiment, a new aluminum casting alloy realizes an electical conductivity of at least 43% IACS. In yet another embodiment, a new aluminum casting alloy realizes an electical conductivity of at least 44% IACS.
• IACS International Annealed Copper Standard
• a new aluminum casting alloy realizes an electical conductivity of at least 45% IACS. In yet another embodiment, a new aluminum casting alloy realizes an electical conductivity of at least 46% IACS. In another embodiment, a new aluminum casting alloy realizes an electical conductivity of at least 47% IACS. In yet another embodiment, a new aluminum casting alloy realizes an electical conductivity of at least 48% IACS, or more.
• a new aluminum casting alloy is corrosion resistant.
• corrosion resistant means the new aluminum casting alloy realizes the same or better corrosion resistance as compared to conventional alloy A356 when tested in accordance with ASTM G110.
• a new aluminum casting alloy has good fluidity.
• “good fluidity” means the new aluminum casting alloy realizes the same or better fluidity as compared to conventional alloy A365 under similar high-pressure die casting conditions.
• 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.
• Thermal conductivity was measured at various temperatures, the results of which are shown in Table 2 below.
• Thermal conductivity may be measured using equation 1 of ASTM E1461 using thermal diffusivity results obtained per ASTM E1461-13, specific heat capacity results obtained per ASTM E1269-11 (2018) and density results per ASTM B311-17.
• alloys realize high thermal conductivity. Further alloys 1-4 are expected to realize good fluidity due to their silicon content. Alloy 1-2 are expected to have excellent fluidity.

Landscapes

• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Materials Engineering (AREA)
• Metallurgy (AREA)
• Organic Chemistry (AREA)
• Physics & Mathematics (AREA)
• Thermal Sciences (AREA)
• Crystallography & Structural Chemistry (AREA)
• Conductive Materials (AREA)
• Treatment Of Steel In Its Molten State (AREA)
• Cooling Or The Like Of Semiconductors Or Solid State Devices (AREA)

Priority Applications (1)

Applications Claiming Priority (3)

Related Parent Applications (1)

Publications (1)

Family

ID=78831477

Family Applications (1)

Country Status (8)

Families Citing this family (1)

Citations (4)

Family Cites Families (18)

• 2021
  • 2021-05-27 WO PCT/US2021/034577 patent/WO2021247373A1/fr not_active Ceased
  • 2021-05-27 EP EP21818989.2A patent/EP4158077A4/fr active Pending
  • 2021-05-27 JP JP2022573625A patent/JP2023527566A/ja active Pending
  • 2021-05-27 CN CN202180042097.0A patent/CN115917024A/zh active Pending
  • 2021-05-27 BR BR112022024477A patent/BR112022024477A2/pt unknown
  • 2021-05-27 MX MX2022014999A patent/MX2022014999A/es unknown
  • 2021-05-27 KR KR1020227046238A patent/KR20230023669A/ko active Pending
• 2022
  • 2022-11-29 US US18/070,783 patent/US20230099382A1/en active Pending

Patent Citations (4)

Non-Patent Citations (1)

Also Published As

Similar Documents

Legal Events