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WO2015118307A1 - Alliage - Google Patents

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Publication number
WO2015118307A1
WO2015118307A1 PCT/GB2015/050263 GB2015050263W WO2015118307A1 WO 2015118307 A1 WO2015118307 A1 WO 2015118307A1 GB 2015050263 W GB2015050263 W GB 2015050263W WO 2015118307 A1 WO2015118307 A1 WO 2015118307A1
Authority
WO
WIPO (PCT)
Prior art keywords
aluminium
silicon alloy
alloy according
alloy
silicon
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/GB2015/050263
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English (en)
Inventor
Ashley Edward BROUGH
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
JBM INTERNATIONAL Ltd
Original Assignee
JBM INTERNATIONAL Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by JBM INTERNATIONAL Ltd filed Critical JBM INTERNATIONAL Ltd
Publication of WO2015118307A1 publication Critical patent/WO2015118307A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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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
    • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
    • C22C21/04—Modified aluminium-silicon alloys

Definitions

  • the present invention relates to an aluminium alloy, more particularly a hypo -eutectic aluminium-silicon alloy.
  • the alloy may be suitable for use in die casting of components, particularly automotive components.
  • the invention also relates to components, particularly cast components, comprising the aluminium alloy.
  • a die cast component depends on the chemical composition and structure of the aluminium alloy used as well as the machine setting and the process selected. Ductility may be particularly important, particularly in components of complex design, e.g. a component with a complex geometry and thin walls.
  • a die casting alloy should typically have a high elongation to fracture in the cast state.
  • the alloy should typically be easily weldable and flangeable , able to be riveted and have good corrosion resistance.
  • US 6,824,737 discloses an aluminium alloy suitable for die casting of components with high elongation in the cast state.
  • the alloy comprises 9.0 to 1 1.0 wt% silicon, 0.5 to 0.9 wt% manganese, max 0.06 wt% magnesium, 0.15 wt% iron, max 0.03 wt% copper, max 0.10 wt% zinc, max 0.15 wt% titanium, 0.05 to 0.5 wt% molybdenum and 30 to 300 ppm strontium or 5 to 30 ppm sodium and/or 1 to 30 ppm calcium for permanent refinement.
  • AlSi9Mn pressure die casting alloy within the scope of US 6,824,737 is produced and sold commercially by Rheinfelden as Castasil®-37.
  • Aluminium casting alloys such as the alloy disclosed in US 6,824,737, typically may be relatively expensive and consequently may not be cost -competitive with other materials, in particular steel. This is because the chemistry and composition of the casting alloy may be tightly controlled and/or may require the addition of rare and expensive alloying elements such as molybdenum or strontium and/or may typically be manufactured only from primary sources of aluminium.
  • a first aspect of the invention provides a hypo-eutectic aluminium-silicon alloy comprising more than 0.15 wt% iron.
  • the alloy may be a casting alloy, which may be suitable for die casting of components with high elongation state.
  • the alloy may be suitable for high pressure die casting (HPDC) of components.
  • the aluminium-silicon alloy contains a relatively high proportion of iron.
  • the iron content has been limited to a lower level , since iron may generally have been seen as a largely unwanted impurity.
  • the strength of the alloy may be improved by having a higher iron content.
  • the aluminium-silicon alloy may comprise no more than 0.6 wt% iron, no more than 0.55 wt% iron, no more than 0.45 wt% iron, no more than 0.35 wt% iron or no more than 0.3 wt% iron.
  • the aluminium- silicon alloy may comprise at least 0.16 wt% iron, at least 0.2 wt% iron , at least 0.25 wt% iron or at least 0.3 wt% iron.
  • the aluminium-silicon alloy may comprise from 0.16 wt% to 0.3 wt% iron.
  • the aluminium-silicon alloy may comprise no more than 0.01 wt% molybdenum or no more than 0.001 wt% molybdenum.
  • the aluminium-silicon alloy may be substantially free of molybdenum. Conveniently, no additional molybdenum may need to be added to the alloy during manufacture. This may be economically advantageous, since molybdenum is a relatively expensive alloying addition.
  • the aluminium-silicon alloy may comprise no more than 0.05 wt% strontium, no more than 0.01 wt% strontium or no more than 0.001 wt% strontium.
  • the aluminium- silicon alloy may comprise up to 200 ppm strontium. Conveniently, no strontium may need to be added to the alloy during manufacture. This may be economically advantageous, since strontium is relatively rare and expensive.
  • the aluminium-silicon alloy may comprise at least 8.5 wt% silicon, e.g. 9 wt% silicon or more.
  • the aluminium-silicon alloy may comprise up to 1 1 wt% silicon, e.g. 10.5 wt% silicon or less.
  • the aluminium-silicon alloy may comprise at least 0.6 wt% manganese or at least 0.65 wt% manganese. Additionally or alternatively, the aluminium-silicon alloy may comprise up to 0.85 wt% manganese or up to 0.8 wt% manganese.
  • the aluminium-silicon alloy may comprise up to 0.1 wt% magnesium.
  • the aluminium-silicon alloy may comprise no more than 0.025 wt% of zinc. Typically, the aluminium-silicon alloy may comprise only trace amounts of zinc.
  • the aluminium-silicon alloy may comprise up to 0.25 wt% of other alloying and/or refining elements, which other alloying and/or refining elements may include one or more of chromium, nickel, copper, lead, tin and titanium.
  • chromium, nickel, lead, tin and titanium together may make up no more than 0.05 wt , preferably no more than 0.04 wt , of the aluminium-silicon alloy.
  • the remaining balance of the aluminium-silicon alloy may be made up of aluminium and unavoidable impurities.
  • hypo-eutectic aluminium-silicon alloy may comprise or consist essentially of:
  • the ratio by weight of iron to manganese may be no less than 1 :5 and/or no more than 4:5.
  • the ratio by weight of iron to manganese may be no more than or no less than 1 :2, 1 :3 or 2:5.
  • the ratio by weight of iron to manganese may be around 2:5.
  • the aluminium-silicon alloy may contain a relatively high proportion of iron and other impurities, increased use of aluminium from secondary sources, e.g. scrap, during manufacture may be enabled. Significant cost and environmental benefits may be realised by making use of secondary aluminium during the manufacture of the aluminium-silicon alloy.
  • the aluminium-silicon alloy may have: a yield strength of 120 MPa or more or 130 MPa or more; and/or a tensile strength of 250 MPa or more; and/or an elongation of 7% or more.
  • the aluminium - silicon alloy may have: a yield strength of 90 MPa or more; and/or a tensile strength of 175 MPa or more; and/or an elongation of 15% or more.
  • a second aspect of the invention provides an article or a component, e.g. a structural component, for a structure such as a building or a vehicle comprising an alloy according to the first aspect of the invention.
  • the structural component may be a part of a vehicle chassis, a part of an automotive suspension system, an engine mount bracket or a shock tower, e.g. a front shock tower.
  • a third aspect of the invention provides a structure such as a building or a vehicle comprising a component, e.g. a structural component, according to the second aspect of the invention.
  • the vehicle may be a car or a lorry or a bus or a coach or a boat or a railway locomotive or rolling stock.
  • a fourth aspect of the invention provides a method of manufacture of an article or component comprising casting, e.g. die casting, the article or component from an alloy according to the first aspect of the invention.
  • a fifth aspect of the invention provides a die casting tool or machine comprising a chamber containing a casting alloy, the chamber being in fluid communication with a mould cavity, wherein, in use, the casting alloy is urgable under pressure from the chamber to the mould cavity, wherein the casting alloy is an aluminium-silicon alloy according to the first aspect of the invention.
  • Figures 4, 5 and 6 are optical micrographs of a second alloy according to the invention
  • Figures 7, 8 and 9 are optical micrographs of a third alloy according to the invention
  • Figures 10, 1 1 and 12 are optical micrographs of a sample of Castasil® -37;
  • Figure 13 is an analysis of variance (ANOVA) boxplot of measured mean yield strengths for alloys A, B and C and Castasil®-37
  • Figure 14 is an analysis of variance (ANOVA) boxplot of measured mean tensile strengths for alloys A, B and C and Castasil®-37
  • Figure 15 is an analysis of variance (ANOVA) boxplot of measured mean elongation of alloys A, B and C and Castasil®-37.
  • Table 1 below details the composition of three example alloys (A , B and C) of an aluminium-silicon alloy according to the invention.
  • the iron content in alloy A (0.16 wt%) is lower than in alloy B (0.31 wt ), which in turn is lower than in alloy C (0.55 wt%).
  • the iron to manganese ratio by weight in alloy A is 0.22, in alloy B the ratio is 0.43 and in alloy C the ratio is 0.76. All three alloys A, B and C contain only trace amounts of molybdenum.
  • the alloys A, B and C also have a very low strontium content of 70- 190 ppm strontium.
  • the samples of the alloys A, B and C were heat treated at 385 °C for 25 minutes in accordance with a suitable manufacturing process for forming a casting phase and hence achieving ductile fracture behaviour.
  • the microstructure of the samples was then examined under an optical microscope.
  • the microstructure observed in the samples of alloys A, B and C comprised a- Al, Al-Si eutectic and (FeMn) 3 Si 2 Al 15 particles.
  • the (FeMn) 3 Si 2 Al 15 particles were found to fall into two distinct size classes.
  • Figures 1 , 2 and 3 are optical micrographs of a sample of alloy A.
  • the general microstructure shown comprises a-Al, Al-Si eutectic and (FeMn) 3 Si 2 Al 15 particles.
  • a modified eutectic microstructure can be seen clearly.
  • Figure 3 "script" form (FeMn) 3 Si 2 Al 15 particles can be seen clearly.
  • FIGS 4, 5 and 6 are optical micrographs of a sample of alloy B .
  • the general microstructure shown comprises a-Al, Al-Si eutectic and (FeMn) 3 Si 2 Al 15 particles.
  • Figure 5 a modified eutectic microstructure can be seen clearly.
  • Figure 6 "script" form (FeMn) 3 Si 2 Al 15 particles can be seen clearly.
  • 4441 (FeMn) 3 Si 2 Al 15 particles were counted in the sample of alloy B .
  • the average particle size of large particles was 15.05 ⁇ and the average particle size of small particles was 2.64 ⁇ .
  • Figures 7, 8 and 9 are optical micrographs of a sample of alloy C.
  • the general microstructure shown comprises a-Al, Al-Si eutectic and (FeMn) 3 Si 2 Al 15 particles.
  • a modified eutectic microstructure can be seen clearly.
  • "script" form (FeMn) 3 Si 2 Al 15 particles can be seen clearly.
  • Figures 10, 1 1 and 12 are optical micrographs of a sample of Castasil® -37.
  • Castasil®-37 is an AlSi9Mn alloy produced by Rheinfelden.
  • Castasil®-37 provides a useful comparison, as it is a speciality alloy used in die casting of structural components, e.g. front shock towers, in the automotive industry.
  • the general microstructure shown in Figures 10, 1 1 and 12 comprises a-Al, Al-Si eutectic and a low level of (FeMn) 3 Si 2 Al 15 particles.
  • a modified eutectic microstructure can be seen clearly.
  • the average particle size of large (FeMn) 3 Si 2 Al 15 particles was 1 1.20 ⁇ .
  • the average particle size of small (FeMn) 3 Si 2 Al 15 particles was 2. 1 1 ⁇ .
  • Castasil®-37 is an AlSi9Mn alloy produced by Rheinfelden. Castasil®-37 was chosen as a suitable benchmark, because it is a speciality alloy used in die casting of structural components, e.g. front shock towers, in the automotive industry.
  • the heat treatment schedule was 25 minutes at 385°C.
  • Table 2 summarises the results of tensile tests carried out on heat-treated samples of alloys A, B and C and on samples of Castasil® -37.
  • the measured mean yield strengths (measured as 0.2% proof stress, R p o .2 ) of heat- treated alloys A, B and C were 93 MPa, 96 MPa and 94 MPa respectively.
  • the measured mean yield strength of Castasil® -37 was 102 MPa.
  • the measured mean yield strength of alloy A was 91 % of the mean yield strength of Castasil®-37.
  • the measured mean yield strength of alloy B was 94% of the mean yield strength of Castasil®-37.
  • the measured mean yield strength of alloy C was 92% of the mean yield strength of Castasil®-37.
  • Figure 13 is an analysis of variance (ANOVA) boxplot, which shows that the measured mean yield strengths for alloys A, B and C are statistically different from the measured mean yield strength of Castasil®-37.
  • ANOVA analysis of variance
  • the measured mean tensile strengths (R m ) of heat-treated alloys A, B and C were 178 MPa, 183 MPa and 182 MPa respectively.
  • the measured mean tensile strength of Castasil®-37 was 201 MPa.
  • the measured mean tensile strength of alloy A was 89% of the mean tensile strength of Castasil®-37.
  • the measured mean tensile strength of alloy B was 91 % of the mean tensile strength of Castasil®-37.
  • the measured mean tensile strength of alloy C was 91 % of the mean yield strength of Castasil®-37.
  • Figure 14 is an analysis of variance (ANOVA) boxplot, which shows that the measured mean tensile strengths for alloys A, B and C are statistically different from the measured mean tensile strength of Castasil® -37. Nevertheless, while the measured mean tensile strengths of alloys A, B and C are lower than that of Castasil®-37, the difference is not so great that alloys A, B and C would not be acceptable for use as a viable substitute for Castasil® -37 in some instances.
  • ANOVA analysis of variance
  • the measured mean elongation of heat-treated alloys A, B and C were 21 %, 15% and 17% respectively. By comparison, the measured tensile strength of Castasil® -37 was 15% .
  • Figure 15 is an analysis of variance (ANOVA) boxplot, which shows that the measured mean elongation of alloys A, B and C are statisti cally identical to the measured mean elongation of Castasil® -37. Accordingly, alloys A, B and C could be acceptable for use as a viable substitute for Castasil®-37 in some instances.
  • Table 3 summarises the results of a series of Vickers hardness (HVio) tests carried out on heat-treated samples of alloys A, B and C and on samples of Castasil®-37.
  • the measured mean hardness (HV io) of heat-treated alloys A, B and C were 59.3 , 62.8 and 61.7 respectively.
  • the standard deviations in the results were 2.2, 6.0 and 2.1 for alloys A, B and C respectively.
  • the measured mean hardness of Castasil®-37 was 65.8 with a standard deviation of 2.1.
  • the measured mean hardness of alloy A was 90% of the mean hardness of Castasil® - 37.
  • the measured mean hardness of alloy B was 95 % of the mean hardness of Castasil®-37.
  • the measured mean hardness of alloy C was 94% of the mean yield strength of Castasil®-37. While the measured mean hardnesses of alloys A, B and C are lower than that of Castasil® -37, the difference is not so great that alloys A, B and C would not be acceptable for use as a viable substitute for Castasil® -37 in some instances. Rivetability tests showed that the rivetability of alloys A, B and C was similar to that of Castasil®-37.
  • the rivetability tests also indicated that alloys A, B and C could be acceptable for use as a viable substitute for Castasil® -37 in some instances.
  • the mechanical performance and rivetability of the alloys A, B and C in these comparative studies were such as to indicate that the alloys A, B and C could be used as an acceptable substitute for Castasil® -37 in at least some instances. This could provide significant cost savings, since the aluminium-silicon alloy of the invention may be considerably cheaper to manufacture than Castasil® -37.
  • Table 4 summarises the results of tensile tests carried out on as cast (pre -heat treatment) samples of alloys A, B and C.
  • Alloy A had a measured mean yield strength (R p o. 2 ) of 131.6 MPa, a measured mean tensile strength (R m ) of 260.6 MPa and a measured mean elongation of 9.8%.
  • Alloy B had a measured mean yield strength (R p o. 2 ) of 130.3 MPa, a measured mean tensile strength (R m ) of 260.8 MPa and a measured mean elongation of 9.1 %.
  • Alloy C had a measured mean yield strength (R p o. 2 ) of 132.8 MPa, a measured mean tensile strength (R m ) of 258.6 MPa and a measured mean elongation of 7.4%.
  • the invention provides a hypo-eutectic, ductile aluminium-silicon alloy.
  • the alloy may be suitable for casting, e.g. high pressure die casting (HPDC), into components, particularly structural components, for the automotive industry.
  • HPDC high pressure die casting
  • the alloy according to the present invention may be particularly suitable for use in the manufacture, typically by high pressure die casting, of structural automotive components.
  • structural compone nts that could be die cast using the alloy may comprise any part of a vehicle chassis, shock towers, e.g. front shock towers, engine mount brackets and/or suspension system components.
  • the alloy according to the present invention may be used in the manufacture of other, non -structural components such as powertrain components and body parts, e.g. panels . Accordingly, manufacture and assembly of a vehicle may be simplified by using the same aluminium alloy for a wider variety of components.
  • the alloy may be especially useful in the automotive industry, it may also be useful in other manufacturing industries, e.g. train manufacture or the manufacture of components for the construction industry.
  • composition and chemistry of the alloy may allow for increased use of secondary sources of aluminium, e.g. waste or scrap aluminium.
  • the aluminium-silicon alloy of the invention may be relatively cheap to manufacture, since fewer expensive alloying elements such as molybdenum or strontium are required and/or the aluminium-silicon alloy may be manufactured using aluminium from secondary sources.
  • secondary aluminium may be blended with primary aluminium during production of the alloy. This may be more energy efficient, since it may take only around 5% of the energy to make one tonne of recycled aluminium (i.e. from a secondary source) that it does to make one tonne of primary aluminium.
  • the aluminium-silicon alloy of the invention may be more cost-competitive with steel than known aluminium casting alloys.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Body Structure For Vehicles (AREA)

Abstract

La présente invention concerne un alliage aluminium-silicium hypo-eutectique comprenant plus de 0,15 % en poids de fer.
PCT/GB2015/050263 2014-02-04 2015-02-02 Alliage Ceased WO2015118307A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB1401906.1 2014-02-04
GB1401906.1A GB2522715B (en) 2014-02-04 2014-02-04 Die cast structural components

Publications (1)

Publication Number Publication Date
WO2015118307A1 true WO2015118307A1 (fr) 2015-08-13

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PCT/GB2015/050263 Ceased WO2015118307A1 (fr) 2014-02-04 2015-02-02 Alliage

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GB (1) GB2522715B (fr)
WO (1) WO2015118307A1 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108486426A (zh) * 2018-03-20 2018-09-04 山东交通职业学院 发动机缸盖及铸造方法
CN113817938A (zh) * 2020-06-18 2021-12-21 比亚迪股份有限公司 一种铝合金及其制备方法、应用
CN117062926A (zh) * 2021-02-01 2023-11-14 特里梅特铝制品公司 铝合金、由铝合金制成的部件和制造由铝合金制成的部件的方法

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112662921B (zh) * 2020-12-04 2022-03-25 成都慧腾创智信息科技有限公司 一种高强韧压铸铝硅合金及其制备方法
CN113720712B (zh) * 2021-09-02 2024-03-19 合肥工业大学 一种新能源汽车铝合金压铸后减震塔硬度多点自动测量装置

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108486426A (zh) * 2018-03-20 2018-09-04 山东交通职业学院 发动机缸盖及铸造方法
CN108486426B (zh) * 2018-03-20 2019-11-15 山东交通职业学院 发动机缸盖及铸造方法
CN113817938A (zh) * 2020-06-18 2021-12-21 比亚迪股份有限公司 一种铝合金及其制备方法、应用
CN117062926A (zh) * 2021-02-01 2023-11-14 特里梅特铝制品公司 铝合金、由铝合金制成的部件和制造由铝合金制成的部件的方法

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GB2522715B (en) 2016-12-21
GB2522715A (en) 2015-08-05
GB201401906D0 (en) 2014-03-19

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