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WO2020018477A1 - Alliages de coulage d'aluminium - Google Patents

Alliages de coulage d'aluminium Download PDF

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Publication number
WO2020018477A1
WO2020018477A1 PCT/US2019/041912 US2019041912W WO2020018477A1 WO 2020018477 A1 WO2020018477 A1 WO 2020018477A1 US 2019041912 W US2019041912 W US 2019041912W WO 2020018477 A1 WO2020018477 A1 WO 2020018477A1
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WO
WIPO (PCT)
Prior art keywords
amount
aluminum alloy
mold
casting
aluminum
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/US2019/041912
Other languages
English (en)
Inventor
Randy S. BEALS
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.)
MAGNA INTERNATIONAL Inc
Magna International Inc
Original Assignee
MAGNA INTERNATIONAL Inc
Magna International Inc
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 MAGNA INTERNATIONAL Inc, Magna International Inc filed Critical MAGNA INTERNATIONAL Inc
Publication of WO2020018477A1 publication Critical patent/WO2020018477A1/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
    • C22C21/12—Alloys based on aluminium with copper as the next major constituent
    • C22C21/16—Alloys based on aluminium with copper as the next major constituent with magnesium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D18/00—Pressure casting; Vacuum casting
    • B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
    • 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
    • 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
    • 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
    • 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
    • C22C21/10—Alloys based on aluminium with zinc 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
    • C22C21/12—Alloys based on aluminium with copper as the next major constituent

Definitions

  • the present invention relates to an aluminum alloy, a casting formed of the aluminum alloy, and a method of casting a structural component formed of the aluminum alloy for an automotive vehicle.
  • Casting is a popular production process wherein molten material is poured into a cavity and allowed to cool and solidify into a useful article. These useful articles can range from modest household goods to complex automotive parts. Like the large variety of articles produced from casting, the molten material used therein ranges from an assortment of metals, plastics, plasters, and concretes. Like all other forms of large-scale production, efficiency is one of the major goals in the casting process.
  • the molten material is stored in a holding furnace and poured into a solid steel mold (usually H13 or P20 tool steel) from an injection machine where it remains until it cools enough to solidify into a casting. The time it takes molten material to be introduced into the mold, allowed solidify into a casting, and ejected is called a casting cycle.
  • a releasing agent is applied in a layer onto an interior surface of the mold that contacts the molten material.
  • This layer of releasing agent is called a“mold coating or mold paint coating.”
  • the release agent is the die lube that is applied after each and every cycle of the machine.
  • the releasing agent forms a matrix between the molten material and the mold, preventing bonding therebetween, to facilitate removal of the casting after the molten material has solidified.
  • additional releasing agent is applied to the mold to form additional castings. While the releasing agent is effective at preventing bonding, it is an additional step that must be carried out correctly.
  • releasing agent if the releasing agent is not applied such that it coats the entire inside of the mold, then parts of the casting can stick to the mold and tear or deform upon removal to create surface irregularities.
  • the inner mold surface must be scrubbed and dried between applications to prevent any disturbance from rust, dirt, or other impurities. While some releasing agents can be used for more than one cycle, the time it takes to apply the releasing agent can be substantial, ultimately being labor intensive and requiring onsite space to hold the releasing agent as it cannot be reused. Moreover, releasing agents are often times hazardous to the environment and operators and thus must be shipped, stored, and used according certain regulations.
  • Another problem is that the casting cycles are bottlenecked by the speed at which it takes the molten material to cool within the mold.
  • Conventional cooling of the molten material typically occurs in two discrete thermal transfer phases, convection followed by radiation.
  • the convection phase the mold is cooled causing the molten material therein to constrict away from sides of the mold. After constriction, the molten material is no longer in direct contact with the cooled mold and thus enters the second phase of cooling, radiation.
  • the radiation phase slows the casting cycle and creates larger dendridic arm spacing (DAS), resulting in lower mechanical properties.
  • DAS dendridic arm spacing
  • slower casting cycles place limits on the molten materials that can be used in preparation of castings.
  • the subject invention provides an aluminum alloy for a direct chill counter pressure permanent mold casting system and a casting formed of the aluminum alloy.
  • the aluminum alloy includes, in weight percent (wt.%) based on total weight of the alloy, manganese in an amount up to 1.8 wt.%, silicon in an amount of 0.1 wt.% to 7.5 wt.%, iron in an amount of 0.12 wt.% to 1.0 wt.%, copper in an amount of 0.05 wt.% to 5.0 wt.%, magnesium in an amount of 0.1 wt.% to 5.0 wt.%, zinc in an amount of 0.05 wt.% to 6.1 wt.%, strontium in an amount up to 0.06 wt.%, other elements each in an amount up to 0.05 wt.%, the other elements in a total amount of up to 0.1 wt.%, and a remaining balance of aluminum.
  • the subject invention also provides a method of casting a structural component for an automotive vehicle, comprising the steps of: filling a casting chamber defined by a mold with an aluminum alloy while the aluminum alloy is molten, wherein the aluminum alloy comprises manganese in an amount up to 1.8 wt.%, silicon in an amount of 0.1 wt.% to 7.5 wt.%, iron in an amount of 0.12 wt.% to 1.0 wt.%, copper in an amount of 0.05 wt.% to 5.0 wt.%, magnesium in an amount of 0.1 wt.% to 5.0 wt.%, zinc in an amount of 0.05 wt.% to 6.1 wt.%, strontium in an amount up to 0.06 wt.%, other elements each in an amount up to 0.05 wt.%, the other elements in a total amount of up to 0.1 wt.%, and a remaining balance of aluminum.
  • the aluminum alloy can be used in a gas quenching
  • FIG. 1 is a cross-sectional view of a direct chill counter pressure permanent mold casting system (DCCPPM);
  • DCCPPM direct chill counter pressure permanent mold casting system
  • FIG. 2A illustrates a conventional cooling system in a radiation heat transfer stage and FIG. 2B illustrates the direct chill counter pressure permanent mold casting system directly applying quench media during convection heat transfer;
  • FIG. 3 is a microscopic view of a mold having a plurality of pores allowing the permanent mold to be permeable
  • FIG. 4 is a perspective view of parts constructed in accordance to the subject method
  • FIG. 5A is a cross-sectional view of the direct chill counter pressure permanent mold casting system illustrating a releasing agent being applied to the mold with an applicator, which becomes unnecessary after an aluminum alloy with at least 1.2 wt.% manganese and/or 0.04 wt.% to 0.06 wt.% of strontium is used;
  • FIG. 5B is a cross-sectional view of the direct chill counter pressure permanent mold casting system illustrating pre-heating of the mold with a pre-heating element
  • FIG. 5C is a cross-sectional view of the direct chill counter pressure permanent mold casting system illustrating a lift mechanism in a closed condition
  • FIG. 5D is a cross-sectional view of the direct chill counter pressure permanent mold casting system illustrating compressed air being introduced to a furnace and pressurizing the furnace;
  • FIG. 5E is a cross-sectional view of the direct chill counter pressure permanent mold casting system illustrating quench media being introduced to a cooling chamber containing the mold and pressurizing the cooling chamber;
  • FIG. 5F is a cross-sectional view of the direct chill counter pressure permanent mold casting system illustrating a solidification process of the molten aluminum alloy as the cooling chamber and furnace are respectively pressurized;
  • FIG. 5G is a cross-sectional view of the direct chill counter pressure permanent mold casting system illustrating a step of depressurizing the furnace and cooling chamber including recapturing the quench media;
  • FIG. 5H is a cross-sectional view of the direct chill counter pressure permanent mold casting system illustrating the solidified casted part formed from the molten aluminum alloy being ejected from the mold;
  • FIG. 6 graphically represents a casting cycle in pressure as a function of time utilizing Ar and/or helium as a quench media as illustrated in of the casting system shown in FIGS. 5D through 5G;
  • FIG. 7 graphically represents a casting cycle of another embodiment using direct chill counter pressure with water used as the quench media with a casting rotary table
  • FIG. 8 graphically represents a cooling rate of molten aluminum material as a function of secondary dendritic arm spacing
  • FIG. 9 charts a non-exhaustive list of molten materials and a comparison of their material properties that can be used in accordance with the present invention
  • FIG. 10 charts a comparison of aluminum cooling cycles between He and N2 gas being introduced as quench media and cooling the molten material from 950F to 400F under various pressure loads;
  • FIG. 11 charts a comparison of sand cast aluminum (A356) cooling cycles between air, Ar, and He being introduced as quench media;
  • FIGS. 12A, 12B and 12C are tables illustrating different compositions of aluminum alloy in accordance with the subject invention wherein FIG. 12C illustrates the addition of Scandium and Zirconium; and
  • FIG. 13 illustrates the saving of time (in seconds) by eliminating the step of applying releasing agent as compared to the graph in FIG. 7.
  • Example embodiments will now be described more fully with reference to the accompanying drawings.
  • the subject embodiments are directed to an aluminum alloy for a direct chill counter pressure permanent mold casting system and a casted part produced by same.
  • the example embodiments are only provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
  • the aluminum casting alloy and associated direct chill counter pressure permanent mold casting system 20 is intended for reducing or eliminating the requirements of applying a releasing agent and producing casted parts 40 (including parts 40’ and 40”) with improved material properties.
  • this reduction of cooling cycles allows for the production of castings using raw materials and molten aluminum alloys that have proven difficult in the past. Additions of Mn and Sr to these materials, that have proven difficult to work with in the past further, allow the produced castings to be cleanly removed from a die without a releasing agent.
  • the casted parts 40 produced from the aluminum alloy exhibit increased strength and increases in Young’s modulus (Metal Matrix Composite) and are thus particularly useful as structural components for automotive vehicles.
  • the direct chill counter pressure permanent mold casting system 20 includes a molding assembly 22 and a furnace assembly 24.
  • the molding assembly 22 includes a mold 26 disposed between a bottom plate 28 and a top plate 30.
  • the mold 26 includes a upper mold part 32 and a lower mold part 34.
  • the upper mold part 32 is attached to the top plate 30 and the lower mold part 34 is attached to the bottom plate 28.
  • a lift mechanism 36 which preferably operates via hydraulic actuation, moves the bottom plate 28 axially towards and away from the top plate 30.
  • the lift mechanism 36 includes a closed condition, wherein the upper mold part 32 and lower mold part 34 are sealingly brought together to form a casting chamber 38 for retention of molten aluminum alloy.
  • the lift mechanism 36 further includes an open condition wherein the upper mold part 32 and lower mold part 34 are separated, such that a solidified molten aluminum alloy or casted part 40 can be removed.
  • a pressure vessel 42 is attached to the top plate 30 and extends downwardly towards the bottom plate 38 to a seal end 44.
  • the seal end 44 of the pressure vessel 42 comes into sealing contact with the bottom plate 28 when the lift mechanism 36 is in the closed condition to impermeably surround the mold 26 and casting chamber 38 in a cooling chamber 46.
  • An input port 48 is disposed through the pressure vessel 42 for selectively filling the cooling chamber 46 with quench media.
  • the quench media can be gas or liquid, however, if the quench media is gas it is preferable that it be cooled air, helium, N2 or Ar. Still, it should be appreciated that the quench media can also be liquid without departing from the scope of the subject disclosure. As best illustrated in FIGS.
  • the mold 26 defines a plurality of pores 50 extending therethrough into the casting chamber 38.
  • the pores 50 are approximately 7 to 20 microns in diameter and are sized to allow entry of the quench media into the casting chamber 38 without allowing seepage of the molten aluminum alloy out of the casting chamber 38.
  • the mold 26 is preferably comprised of semi sintered steel alloy and more specifically (35/38 HRC) powder tool steel, non-hipped porous steel.
  • a release of gas or steam can be vacuumed out of the input port 48 or a separate output port not shown.
  • the output port includes a relief valve for exiting heated media upon a certain pressure threshold.
  • FIGS. 2A and 2B compare a conventional casting system to the direct chill counter pressure permanent mold casting system.
  • FIG. 2A illustrates the conventional cooling system in a radiation heat transfer phase
  • FIG. 2B illustrates the direct chill counter pressure permanent mold casting system directly applying quench media during the convection heat transfer phase.
  • the furnace assembly 24 includes a furnace 52 for heating and maintaining the molten aluminum alloy.
  • the furnace 52 has an interior chamber 54 containing a crucible 56 that holds the molten aluminum alloy and a pressure line 58 extends through the furnace 52 for pressurizing a fill stalk 60.
  • the fill stalk 60 extends from the crucible 56 to an intermediate stalk tube 62 that extends through the bottom plate 28 of the mold assembly 22 to an insert tube 63 in the lower mold part 34.
  • the fill stalk 60 transfers molten aluminum alloy from the crucible 56 when the pressure line 58 pressurizes at least the fill stalk 60 and urges the molten aluminum alloy upwards into the mold 26 when the lift mechanism 36 is in the closed condition and the mold 26 is sealed.
  • a power supply 64 extends into the furnace 52 for supplying energy thereto.
  • FIG. 4 illustrates various parts 40’, 40” constructed in accordance with the subject method.
  • the parts are utilized in an automobile.
  • these parts can include chassis components 40’ and sub-frame components 40”.
  • the direct chill counter pressure permanent mold casting system 20 further requires an applicator 98 for coating the inside of the casting chamber 38 with the releasing agent, facilitating removal of a casting upon solidification.
  • the releasing agent can interfere with the pores 50 and make is difficult for quench media to enter the mold 26.
  • the direct chill counter pressure permanent mold casting system 20 also includes a pre-heating element 100 that is applied to the mold 26 before injection of the molten aluminum alloy.
  • the pre-heating element 100 includes an outer layer 102 that has a high emissivity for increased effectiveness in emitting thermal radiation and an inner layer 104 of thermally conductive material.
  • an outer layer 102 that has a high emissivity for increased effectiveness in emitting thermal radiation
  • an inner layer 104 of thermally conductive material In a preferred
  • the outer layer 102 comprises graphite and the inner layer 104 comprises plasma.
  • This pre-heating element 100 preheats the mold for improved initial disbursement of the molten aluminum alloy into the casting chamber 38.
  • the application of quench media through the pores 50 of the mold 26 thus maintains a uniform contact with the solidifying molten aluminum alloy resulting in an accelerated heat loss.
  • This uniform contact remedies past shortcoming of the conventional methods, namely the uniform contact persists through shrinkage of the molten aluminum alloy such that the cooling cycle does not experience the phase shift between convention heat transfer to the slower radiation heat transfer.
  • the aluminum alloys typically comprise, in weight percent (wt.%) based on the total weight of the alloy: silicon (minimum 0.4 wt.%, maximum 0.8 wt.%); iron (no minimum, maximum 0.7 wt.%); copper (minimum 0.15 wt.%, maximum 0.4 wt.%); manganese (no minimum, maximum 0.15 wt.%); magnesium (minimum 0.8 wt.%, maximum 1.2 wt.%); chromium (minimum 0.04 wt.%, maximum 0.35 wt.%); zinc (no minimum, maximum 0.25 wt.%); titanium (no minimum, maximum 0.15 wt.%); aluminum (minimum 95.85 wt.%, maximum 98.56 wt.%); and other elements.
  • the aluminum alloy 6061 or other aluminum alloys have a high amount of strontium (Sr), such as approximately 0.360 wt.% instead of the normal 0.015 to 0.025 wt.% found in some aluminum alloys and/or an increase of manganese (Mn), to a range between minimum 1.2 wt.%, maximum 1.8 wt.% then no release agent is necessary.
  • the chill casting system 20 can be utilized in low-pressure casting or high-pressure casting and can also utilize sand cores, without any danger of their destruction even under varying pressures, for producing casted parts 40 with hollow cores.
  • Aluminum alloy with increased levels of manganese are presented in Tables 1-3 below. These aluminum alloys include, in weight percent (wt.%) based on total weight of the alloy, manganese in an amount up to 1.8 wt.%, silicon in an amount of 0.1 wt.% to 7.5 wt.%, iron in an amount of 0.12 wt.% to 1.0 wt.%, copper in an amount of 0.05 wt.% to 5.0 wt.%, magnesium in an amount of 0.1 wt.% to 5.0 wt.%, zinc in an amount of 0.05 wt.% to 6.1 wt.%, strontium in an amount up to 0.06 wt.% (600ppm), other elements each in an amount up to 0.05 wt.%, the other elements in a total amount of up to 0.1 wt.%, and a remaining balance of aluminum.
  • the other elements are optional and can include, for example, impurities.
  • the aluminum alloy includes manganese in an amount of 1.2 wt.% to 1.8 wt.%, silicon in an amount of 0.1 wt.% to 1.3 wt.%, iron in an amount of 0.15 wt.% to 1.0 wt.%, copper in an amount of 0.05 wt.% to 2.0 wt.%, magnesium in an amount of 0.1 wt.% to 2.9 wt.%, zinc in an amount of 0.1 wt.% to 0.25 wt.%, strontium in an amount up to 1.0 wt.%, other elements each in an amount up to 0.05 wt.%, the other elements in a total amount of up to 0.1 wt.%, and a remaining balance of aluminum.
  • the aluminum alloy includes silicon in an amount of 0.1 wt.% to 1.3 wt.%, iron in an amount of 0.15 wt.% to 0.95 wt.%, copper in an amount of 0.05 wt.% to 2.0 wt.%, magnesium in an amount of 0.15 wt.% to 2.9 wt.%, zinc in an amount of 0.1 wt.% to 3.0 wt.%, strontium in an amount of 0.02 wt.% to 0.04 wt.%, titanium in an amount up to 0.2 wt.%, chromium in an amount up to 0.25 wt.%, scandium in an amount up to 0.1 wt.%, zirconium in an amount up to 0.1 wt.%, other elements each in an amount up to 0.05 wt.%, the other elements in a total amount of up to 0.1 wt.%, and a remaining balance of aluminum.
  • the aluminum alloy includes manganese in an amount of 0.1 to 1.8 wt.%, silicon in an amount of 5.5 wt.% to 7.5 wt.%, iron in an amount of 0.12 wt.% to 1.0 wt.%, copper in an amount of 0.05 wt.% to 4.0 wt.%, magnesium in an amount of 0.1 wt.% to 0.6 wt.%, zinc in an amount of 0.05 wt.% to 3.0 wt.%, strontium in an amount of 0.04 wt.% (400ppm) to 0.06 wt.% (600ppm), other elements each in an amount up to 0.05 wt.%, the other elements in a total amount of up to 0.1 wt.%, and a remaining balance of aluminum.
  • the afore-described direct chill counter pressure permanent mold casting system 20 includes a method of operation. Referring in order to FIGS. 5B through 5H, aluminum alloy containing high amounts of Sr and/or Mn as described above is melted in a furnace into a molten condition. The mold 26 is heated to a
  • both the fill stalk 60 and cooling chamber 46 are initially pressurized to lOOpsi.
  • the pressure in cooling chamber 46 is reduced to 93psi to gradually fill the mold 26 with aluminum alloy such that there is less solidification and gas shrinkage making wrought (low silicon) aluminum alloys possible.
  • the molten aluminum alloy is cooled by the quench media until it becomes a casted part 40 wherein the casted part 40 containing high amounts of Sr and/or Mn can be removed from the mold without being damaged from the absence of releasing agent.
  • the cooling rate can be adjusted by the type of quench gas used, which can include one of He, N, Ar, air, etc. and the pressure of the gas.
  • the charts in FIGS. 11 and 12 are graphical representations of gravity sand casting with 1” diameter round tensile bars.
  • tests show a faster cooling rate when He is used as the quench media.
  • the direct pressure gas suppresses the release of naturally occurring He in aluminum alloys, keeping it in a dissolved state thus eliminating gas porosity in the final casted part 40.
  • the pressure in the fill stalk 60 and cooling chamber 46 are simultaneously reduced.
  • the quench media is recaptured via the port 48 or a distinct output port. The lift mechanism is then brought to the open condition and the solidified casted part 40 is ejected from the molding.
  • FIGS. 6 through 11 are graphical representations and charts of various embodiments of the subject disclosure.
  • a graphical representation illustrates the introduction of quench media in units of pressure as a function of time in a chill casting system 20.
  • FIG. 7 represents steps of the direct chill counter pressure permanent mold casting system 20 are shown as a function of time in a 90-second casting cycle when the molten material is something other than aluminum alloy containing high amounts of Sr and/or Mn and thus require the application of releasing agent.
  • FIG. 8 illustrates a cooling rate of molten aluminum material as a function of secondary dendritic arm spacing.
  • FIG. 9 provides a non-exhaustive list of additional molten materials that can be used with the direct chill system 20 with a comparison of material properties.
  • FIG. 10 provides a chart comparing the cooling cycles between He and N2 gas being introduced as quench media and cooling the molten material from 950F to 400F under various pressure loads.
  • FIG. 11 charts a comparison of cooling cycles between air, Ar, and He being introduced as quench media.
  • the alloys comprise, in weight percent (wt.%) based on the total weight of the alloy manganese (minimum 1.2 wt.%, maximum 1.8 wt.%) in addition to: silicon (minimum 0.1 wt.%, maximum 7.5 wt.%); iron (minimum 0.15 wt.%, maximum 1.0 wt.%); copper (minimum 0.05 wt.%, maximum 5.0 wt.%); magnesium (minimum 0.1 wt.%, maximum 0.6 wt.%); zinc (minimum 0.1 wt.%, maximum 3.0 wt.%); strontium (minimum .02 wt.%, maximum 0.04 wt.%); and the remainder being aluminum.
  • each of the alloy compositions of Table 1 there is a minimum of 1.2 wt.% manganese (Mn) and/or 0.04 wt.% (400 ppm) of strontium (Sr).
  • Mn manganese
  • Sr strontium
  • the predominantly aluminum castings affinity to the tool steel mold is reduced or eliminated and so is the required releasing agent.
  • the AlMn eutectic fluidity reduces susceptibility to soldering and hot cracking.
  • modification of the AlSi eutectic fluidity can also reduce susceptibility to soldering due to a reduction in Fe.
  • Titanium increases the strength of the casted part 40 while maintaining a relatively low density.
  • Chromium increases hardness and improves surface quality of the casted part 40.
  • a reduction of silicon avoids a brittle AlSiFeMn Phase and an increase in magnesium and/or zinc further strengthen the alloy.
  • the addition of up to 10% in volume of Nano Alumina Decorated Aluminum as in Aluminum Alloy 1100 increases the modulus of the metal matrix composite of the casted part 40.
  • FIG. 13 illustrates the reduction in time of a casting cycle using aluminum alloy in accordance with the subject invention resulting from no longer having to apply a releasing agent. As shown, the casting cycle is improved from approximately 90 seconds to approximately 80 seconds.
  • the afore described aluminum alloys and systems decrease the casting cycle, improves the quality of the final casting, enables the casting of materials that have traditionally proven difficult, and reduces or eliminates the required use of the releasing agent.
  • the system and method improve infiltration of the molten aluminum alloy into the mold 26 by efficient feeding of molten aluminum alloy thus preventing the formation setbacks associated with shrinkage and metal defects such as micro porosity (natural porosity) and cavities. Elimination of the metal defects also results in better infiltration of the molten aluminum alloy between arising crystallites and plastic micro deformation during the process of crystallization.
  • the prolonged time of contact between the mold 26 and solidifying molten aluminum alloy before formation of the shrink gap and thereafter directly chilling via quench gas increases the depth of fine macro structure.
  • the improved cooling process results in smaller secondary dendritic arm spacing (DAS) which increases the mechanical properties of the final casted part 40 and, combined with above advantages, improves the ultimate tensile strength, the yield, and ductility of the casting.
  • DAS secondary dendritic arm spacing
  • the increased cooling rate produces aluminum castings without the common metallurgical defects.
  • the increased cooling rate allows casting of predominantly raw materials with additions of Mn, Sr or combinations of Mn, Sr and Fe that eliminate or reduce traditional requirements of a releasing agent.
  • the improved solidification rate of the direct chill counter pressure permanent mold casting system 20 prevents wrought alloys from hot tearing as a result of absolute venting and wet out particularly through counter pressure at multiple atmospheres and/or heights.
  • the casting comprises a fine aluminum alloy solidification microstructure that is finer than the microstructure of castings having a similar metal of a similar weight or section thickness produced by a conventional steel mold casting process.
  • the fine microstructure of the improved casting comprises one or more grains, dendrites, eutectic phases or
  • the microstructure of the improved casting is free of porosity and comprises approximately twice as fine of microstructure than that of conventional castings.
  • the mold 26 of the present invention can comprise of powder metal non-hipped semi sintered alloy, having a high degree of permeability.
  • the permeability size and concentration of pores 50 is such that it prohibits molten metal from entering the pore 50 (due to surface tension effects) while allowing a quench media to travel though the pore 50 under pressure.
  • the quench media for example, liquid which may include water or gas which may include air, helium, nitrogen, argon
  • the quench media is forced under pressure though the porous steel mold 26 such that it contacts and directly chills the shaped metal casting.
  • the aluminum alloy solidifies under the direct chill casting conditions with a higher amount of strontium (approx. 0.1 wt.% to 1 wt.%) or manganese (at least 1.2 wt.%) than the conventional aluminum alloy chemical composition, the aluminum alloy can solidify and be removed without the previous required application of releasing agent.
  • the shaped casting includes an aggregate sand core that forms a hollow structure in the porous steel mold 26.

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Abstract

L'invention concerne un alliage d'aluminium, comprenant des quantités élevées de manganèse et/ou de strontium, et un procédé de production d'une pièce coulée formée de l'alliage d'aluminium dans un système de coulage de moule permanent à contre-pression à refroidissement direct. Outre le manganèse et/ou le strontium accrus, l'alliage d'aluminium contient également du silicium, du fer, du cuivre, du magnésium, du zinc et de l'aluminium. Le système de coulage comporte un moule délimitant une pluralité de pores conçus pour permettre au milieu de trempe d'entrer dans le moule pour refroidir l'alliage d'aluminium fondu contenu dans ce dernier, sans permettre à l'alliage d'aluminium fondu de s'infiltrer dans les pores et hors du moule. Les taux accrus de manganèse et/ou de strontium permettent à l'alliage d'aluminium fondu d'être placé au sein du moule, solidifié et retiré de manière nette sans avoir à ajouter un agent de libération au moule.
PCT/US2019/041912 2018-07-16 2019-07-16 Alliages de coulage d'aluminium Ceased WO2020018477A1 (fr)

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US201862698564P 2018-07-16 2018-07-16
US62/698,564 2018-07-16

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WO2020018477A1 true WO2020018477A1 (fr) 2020-01-23

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CN111690843A (zh) * 2020-07-08 2020-09-22 沈阳航空航天大学 用于厨具的高Fe含量Al-Fe-Mn合金及其制法
CN111690844A (zh) * 2020-07-08 2020-09-22 沈阳航空航天大学 一种共晶型Al-Fe-Mn-Si-Mg压铸合金及制备方法与应用
CN112893806A (zh) * 2021-01-22 2021-06-04 南宁智鸿技研机械技术有限公司 一种高强度的汽车用铝合金铸件低压铸造工艺
WO2022139717A1 (fr) 2020-12-23 2022-06-30 Assan Alümi̇nyum Sanayi̇ Ve Ti̇caret Anoni̇m Şi̇rketi̇ Matériau d'alliage d'aluminium approprié pour être utilisé dans l'industrie alimentaire et son procédé de production
US20230095748A1 (en) * 2021-09-24 2023-03-30 GM Global Technology Operations LLC Low carbon footprint aluminum casting component
CN116287891A (zh) * 2023-05-25 2023-06-23 小米汽车科技有限公司 一种免热处理压铸铝合金及其制备方法和应用
US20240139803A1 (en) * 2022-10-31 2024-05-02 Xiaomi Ev Technology Co., Ltd. Die-casting aluminum alloy without heat-treatment and preparation method and application thereof
WO2024233635A1 (fr) * 2023-05-08 2024-11-14 Magna International Inc. Alliage d'aluminium pour des processus d'extrusion

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Cited By (11)

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Publication number Priority date Publication date Assignee Title
CN111690843A (zh) * 2020-07-08 2020-09-22 沈阳航空航天大学 用于厨具的高Fe含量Al-Fe-Mn合金及其制法
CN111690844A (zh) * 2020-07-08 2020-09-22 沈阳航空航天大学 一种共晶型Al-Fe-Mn-Si-Mg压铸合金及制备方法与应用
CN111690844B (zh) * 2020-07-08 2021-12-31 沈阳航空航天大学 一种共晶型Al-Fe-Mn-Si-Mg压铸合金及制备方法与应用
WO2022139717A1 (fr) 2020-12-23 2022-06-30 Assan Alümi̇nyum Sanayi̇ Ve Ti̇caret Anoni̇m Şi̇rketi̇ Matériau d'alliage d'aluminium approprié pour être utilisé dans l'industrie alimentaire et son procédé de production
US12325900B2 (en) 2020-12-23 2025-06-10 Assan Alüminyum Sanayi Ve Ticaret Anonim Sirketi Aluminum alloy material suitable for use in the food industry and production method thereof
CN112893806A (zh) * 2021-01-22 2021-06-04 南宁智鸿技研机械技术有限公司 一种高强度的汽车用铝合金铸件低压铸造工艺
US20230095748A1 (en) * 2021-09-24 2023-03-30 GM Global Technology Operations LLC Low carbon footprint aluminum casting component
US20240139803A1 (en) * 2022-10-31 2024-05-02 Xiaomi Ev Technology Co., Ltd. Die-casting aluminum alloy without heat-treatment and preparation method and application thereof
WO2024233635A1 (fr) * 2023-05-08 2024-11-14 Magna International Inc. Alliage d'aluminium pour des processus d'extrusion
CN116287891A (zh) * 2023-05-25 2023-06-23 小米汽车科技有限公司 一种免热处理压铸铝合金及其制备方法和应用
CN116287891B (zh) * 2023-05-25 2023-08-08 小米汽车科技有限公司 一种免热处理压铸铝合金及其制备方法和应用

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