EP0796926B1 - Verfahren zur Herstellung eines druckgegossenen hochfesten Produktes - Google Patents

Verfahren zur Herstellung eines druckgegossenen hochfesten Produktes Download PDF

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Publication number
EP0796926B1
EP0796926B1 EP19970104527 EP97104527A EP0796926B1 EP 0796926 B1 EP0796926 B1 EP 0796926B1 EP 19970104527 EP19970104527 EP 19970104527 EP 97104527 A EP97104527 A EP 97104527A EP 0796926 B1 EP0796926 B1 EP 0796926B1
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EP
European Patent Office
Prior art keywords
cast product
die cast
production method
high strength
mold
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.)
Expired - Lifetime
Application number
EP19970104527
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English (en)
French (fr)
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EP0796926A1 (de
Inventor
Hiromi Takagi
Sumi Yoshikawa
Hiroshi Yamashita
Shigeki Iwanami
Yasushi Watanabe
Shinya Yamamoto
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Toyota Industries Corp
Denso Corp
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Toyota Industries Corp
Denso Corp
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    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • 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

Definitions

  • This invention relates to a production method for a die cast product which uses an aluminum-silicon eutectic type casting material and for which excellent mechanical strength such as a high tensile strength and a high fatigue strength is required, such as a component for a scroll compressor.
  • Known production methods for high strength die cast products of this kind include a method which casts an aluminum-silicon eutectic casting material by a low speed die casting method at an injection speed of about 0.08 m/sec and then conducts a heat-treatment such as a solution heat-treatment. Because the injection speed of a molten metal is low according to such a low speed die casting method, the entrapped gas quantity is small and a drop in the strength due to the occurrence of cavities (hollow portions) in the die cast product hardly occurs.
  • the solidification speed of the die cast product is low by this low speed die casting method, and in the case of casting of an aluminum alloy, or the like, solid solution reinforcement components such as copper, magnesium, etc., are selectively precipitated and exist locally inside the aluminum base.
  • the die cast product produced by the low speed die casting method is subjected to a solution heat-treatment which retains the die cast product at a temperature of about 500 to about 540°C for several to dozens of hours, in order to improve the mechanical strength.
  • this solution heat-treatment is effected, the solid solution reinforcement components such as copper and magnesium that are localized inside the aluminum base are uniformly dispersed in the aluminum base, and again undergo solid solution by subsequent water cooling.
  • the low speed die casting method according to the prior art has a low injection speed and moreover, needs a solution heat-treatment of the die cast product for a long time. Therefore, the cycle time for the production of the product inevitably becomes extremely long, thereby inviting the problems that productivity is extremely low and the production cost becomes high. Because the solidification structure becomes coarse in the die cast product produced by the low speed die casting method, variation in the mechanical strength is great. When the product is applied to a scroll compressor component on which a large load acts repeatedly, therefore, a sufficient and constant durability cannot be obtained in some cases.
  • the Al-Si eutectic type materials (Si content of 7.5 to 12%) have been used, but because the production method is the low speed die casting method, the production time is long and productivity is low, too.
  • a high speed die casting method having a high injection speed and high production efficiency may be applied. Because the injection speed of the molten metal is high and the molten metal is quickly poured into the mold according to the high speed die casting method, however, this method involves the problems that the entrapped gas quantity is great and cavities (hollow portions) are likely to occur in the die cast product. When the die cast product having such a large number of cavities are subjected to the solution heat-treatment, the gas of the cavity portions inflates and, due to this swelling, the product becomes inferior. In other words, the mechanical strength of the die cast product by the high die casting method cannot be improved by solution heat-treatment.
  • Japanese Unexamined Patent Publication (Kokai) No. 54-153728 teaches to cool the resulting die cast with water after high speed die casting, but the problem of low cuttability exists because this method uses an Al-Si hypereutectic casting material (having a Si content of 17 to 18%).
  • the present invention aims at providing a die casting method which can produce a high strength die cast product having excellent mechanical properties such as tensile strength, fatigue strength, cuttability, and so forth, within a short time.
  • a production method of a high strength die cast product according to the present invention comprises the steps of claim 1.
  • the invention set forth in claim 2 is characterized in that the surface temperature of the die cast product before water cooling falls to within the range of 250 to 450°C.
  • the invention set forth in claim 3 is characterized in that the water cooling temperature is within the range of 20 to 80°C.
  • the invention set forth in claim 4 is characterized in that the ageing treatment temperature falls within the range of 150 to 250°C.
  • the invention set forth in claim 5 is characterized in that the time period of said ageing treatment is from 0.5 to 8 hours.
  • the invention set forth in claim 6 is characterized in that the ageing treatment time at 180°C is about 4 hours.
  • the invention set forth in claim 7 is characterized in that the die cast product is a component for a scroll compressor.
  • a production method of a high strength die cast product according to the present invention uses an aluminum-silicon eutectic type casting material (hereinafter called merely the "casting material"), casts the casting material by a high speed die casting method, and applies at least one of water cooling and an ageing treatment, after mold release, to the resulting die casting.
  • an aluminum-silicon eutectic type casting material hereinafter called merely the "casting material”
  • Al-Si-Cu, Al-Si-Mg or Al-Si-Cu-Mg system is used as the casting material.
  • the casting material used in the present invention may contain either one of copper and magnesium or may contain both of them.
  • silicon has the functions of improving the mechanical strength of the die cast and castability, that is, fluidity of the molten metal.
  • the silicon content is preferably 7.5 to 12 wt% and further preferably, 9 to 12 wt%.
  • the silicon content is less than 7.5 wt%, the mechanical strength drops gradually and the mechanical strength of the die cast product is likely to be insufficient.
  • problems such as sink or shrinkage are likely to develop in the die cast product.
  • the silicon content exceeds 12 wt%, on the other hand, primary crystal silicon precipitates, so that fluidity of the molten metal drops to invite the drop of castability, and the cuttability of the die cast product drops remarkably.
  • breakage of a cutter of the cutting machine occurs frequently and mass-production of the products is difficult.
  • Copper is one of the solid solution reinforcement components for improving the mechanical strength of the die cast product, and its content is preferably 1.5 to 4.8 wt% and more preferably, 2.5 to 4.8 wt%. When the copper content is less than 1.5 wt% or exceeds 4.8 wt%, the mechanical strength of the die cast product becomes insufficient.
  • Magnesium is also one of the solid solution reinforcing component for improving the mechanical strength of the die cast product in the same way as copper, and its content is preferably 0.2 to less than 0.5 wt% and further preferably, 0.3 to less than 0.5 wt%. When the magnesium content is less than 0.2 wt% or exceeds 0.7 wt%, the mechanical strength of the die cast product becomes insufficient.
  • the molten metal is quickly charged into the mold at a high speed and a high pressure by a high speed die casting method. While the mold is filled with the molten metal, the product portion inside the mold is directly pressurized so as to solidify the die cast product.
  • high speed die casting method used in this specification represents a die casting method which injects the molten metal into the mold at an injection speed of not lower than 1 m/sec. Most typically, the injection speed can be at least 2 m/sec. In contrast, a typical injection speed according to the prior art low speed die casting method is not higher than about 0.1 m/sec.
  • the die cast product is molded while omitting the oxide removing treatment and the degassing treatment described above, the occurrence of mold cavities varies from die cast product to die cast product and great variance occurs in the mechanical strength. Therefore, it is in no way preferred to omit the oxide removing treatment and the degassing treatment of the molten metal.
  • the die cast product is immersed in a water tank for water cooling.
  • the surface temperature of the die cast product subjected to water cooling is preferably within the range of 250 to 450°C and further preferably, within the range of 300 to 400°C. If cooling with water is carried out when the surface temperature of the die cast is less than 250°C, the mechanical strengths of the die cast product, such as its tensile strength and fatigue strength, become insufficient. When cooling with water is carried out under the condition where the surface temperature exceeds 450°C, on the other hand, defects of appearance and internal quality such as local sink and seizure occur, and die cast products having high quality cannot be obtained easily. Incidentally, the water temperature at the time of water cooling hardly affects the mechanical properties of the die cast product, and is set to the range of 40 to 60°C in this embodiment.
  • the die cast product after water cooling or mold release is left standing for ageing treatment for a predetermined time under a heated state.
  • the temperature of this ageing treatment is preferably within the range of 150 to 250°C, and further preferably within the range of 170 to 210°C. If the ageing treatment is carried out at a treating temperature less than 150°C or exceeding 250°C, the hardness of the die cast product cannot be improved sufficiently, and its mechanical strength is likely to be insufficient.
  • the ageing treatment time is generally from 0.5 to 8 hours, and in the case of the ageing treatment at 180°C, for example, it is sufficient that the treatment time be about 4 hours.
  • a molten metal of an aluminum-silicon eutectic type casting material containing 10.5 wt% of silicon, 4.2 wt% of copper and 0.5 wt% of magnesium was first subjected to an oxide removing treatment and a degassing treatment.
  • This molten metal was injected into a mold for a scroll compressor component at an injection speed of 2.0 m/s by using a 650-ton horizontal die casting machine.
  • a casting pressure of 750 kgf/cm 2 was allowed to act on the mold so that the product portion could be directly pressurized.
  • This pressurized state was kept for a predetermined time, and the molded die cast product was released from the mold and withdrawn.
  • the die cast product after mold release was immediately immersed into a water tank, was cooled with water and was retained at 180°C for 4 hours for an ageing treatment.
  • Example 2 Casting was carried out in the same way as in Example 1 with the exception that a low speed casting method was employed and the molten metal was injected into the mold at an injection speed of 0.08 m/s. The other conditions were the same as those in Example 1.
  • Fig. 1 shows the mean particle size of the solidified structure of the die cast product of each of Example 1 and Comparative Example 1, and a tensile strength ratio of the die cast product of Example 1 relative to that of the die cast product of Comparative Example 1.
  • the mean particle size of the solidified structure was about 2 ⁇ m in the die cast product of Example 1, whereas it was about 30 ⁇ m in the die cast product of Comparative Example 1.
  • the die cast product of Example 1 exhibited a value which was by about 50% greater than that of the die cast product of Comparative Example 1.
  • the die cast product of Example 1 casted by the high speed die casting method had a compact solidified structure and a high tensile strength.
  • the molten metal of a casting material having the same composition as that of the material of Example 1 was injected into the mold at an injection speed of 0.08 m/s, to form a die cast product by a low speed die casting method.
  • Solid solution treatment and ageing treatment were carried out by holding the die cast product at 520°C for 8 hours.
  • Fig. 2 shows the ratio of the lower limit value of variance of the fatigue strength of the die cast product of Example 1 to that of Comparative Example 2 when each die cast product was actually fitted to a scroll compressor and the compression operation was carried out 10 7 times.
  • the die cast product of Example 1 had a tensile strength by about 50% higher than that of the die cast product of Comparative Example 2.
  • the fatigue strength of the die cast product of Example 1 casted by the high speed die casting method exhibited its variance at a high level, and the product was suitable for a scroll compressor component to which a large load was repeatedly applied.
  • Example 2 represents the case where water cooling was omitted in Example 1, and the die cast product after mold release was annealed and was then subjected to ageing treatment.
  • Example 3 represents the case where the ageing treatment was omitted in Example 1.
  • Comparative Example 3 represents the case where both water cooling and ageing treatment were omitted in Example 1, and the die cast product after mold release was annealed.
  • Fig. 3 shows the tensile strength ratio of the die cast product of each of Examples 1 to 3 to that of the die cast product of Comparative Example 3.
  • the tensile strength value of the die cast products of Examples 2 and 3, wherein water cooling or the ageing treatment was carried out was by about 20% greater than the tensile strength value of Comparative Example 3 in which they were not carried out.
  • the improvement in the tensile strength could be observed in Examples 2 and 3.
  • the tensile strength was about 50% greater than that of the die cast product of Comparative Example 3, and the tensile strength could be improved greatly.
  • Example 3 Si Cu Mg
  • Example 1 YES 10.5 4.2 0.5 1.5 4 YES 10.6 3.0 0.5 1.3 5 YES 10.5 4.1 0.3 1.2
  • Table 1 shows the tensile strength ratio of the die cast product of each of Examples 1, 4 and 5 and Comparative Examples 3 to 5. As shown in Table 1, the tensile strength was greater, by 30%, even in the die cast product of Example 4 using the casting material having the copper content of 3.0 wt% than the tensile strength of Comparative Example 3, and the improvement in the tensile strength could be observed. In contrast, in the die cast product of Comparative Example 4 which used the casting material having the copper content of 5.5 wt%, the drop of the tensile strength was observed in comparison with the die cast product of Comparative Example 3.
  • the present invention provides the following excellent effects.
  • casting is carried out by the high speed die casting method using the aluminum-silicon eutectic casting material. Therefore, the charging time of the molten metal into the mold becomes shorter than in the conventional low speed die casting method. As a result, the casting time as well as the production cycle time of the die cast products can be reduced.
  • the solidification speed of the die cast product is high and the solid solution reinforcement components such as copper and magnesium undergo uniform solid solution in the aluminum base. Accordingly, the die cast product after mold release can be cooled with water and hardened, and because the ageing treatment is carried out for only a short time, a sufficient mechanical strength can be obtained. In other words, the solid solution treatment for a long time need not be conducted, and the cycle time of the production can be shortened.
  • the casting material contains 7.5 to 12 wt% of silicon and at least one of 1.5 to 4.8 wt% of copper and 0.2 to less than 0.5 wt% of magnesium. Therefore, the characteristic properties of each element can be fully exploited.
  • the surface temperature of the die cast product before water cooling is adjusted to the temperature within the range of 250 to 450°C. Consequently, the mechanical strength of the die cast product can be improved.
  • the ageing treatment is carried out at a temperature within the range of 150 to 250°C.
  • the mechanical strength of the die cast product can be improved.
  • the die cast product can be treated at a lower temperature than the solid solution heat-treatment, the present invention is advantageous from the aspect of energy.
  • the solidification structure can be made compact and directivity of the crystal can be eliminated, so that a die cast product having an excellent fatigue strength can be obtained.
  • a die cast product is suitable for a scroll compressor component on which a large load repeatedly acts. Therefore, the component is not easily broken and the durability of the scroll compressor can be improved.

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  • 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)
  • Rotary Pumps (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Claims (7)

  1. Herstellungsverfahren für ein hochfestes Druckgußprodukt, umfassend die Schritte:
    Behandeln eines Aluminium-Silicium-Gußmaterials vom eutektischen Typ zur Entfernung von Oxid davon und zum Entgasen desselbigen vor einem Einfüllen in eine Form;
    Injizieren des Aluminium-Silicium-Gußmaterials vom eutektischen Typ in die Form mit einer Injektionsgeschwindigkeit von mindestens 1 m/s durch ein Druckgußverfahren, wobei das Gußmaterial 7,5 bis 12 Gew.-% an Silicium, 1,5 bis 4,8 Gew.-% an Kupfer und 0,2 bis weniger als 0,5 Gew.-% an Magnesium, den Rest an Aluminium und normale Verunreinigungen enthält;
    Herauslösen des resultierenden Druckgußproduktes aus der Form;
    Kühlen des aus der Form gelösten Druckgußproduktes mit Wasser; und
    Altern des gekühlten Druckgußproduktes.
  2. Herstellungsverfahren für ein hochfestes Druckgußprodukt nach Anspruch 1, wobei das Druckgußprodukt vor dem Wasserkühlen eine Oberflächentemperatur in einem Bereich von 250 bis 450°C besitzt.
  3. Herstellungsverfahren für ein hochfestes Druckgußprodukt nach Anspruch 1 oder 2, wobei die Wasserkühlungstemperatur in einem Bereich von 20 bis 80°C liegt.
  4. Herstellungsverfahren für ein hochfestes Druckgußprodukt nach einem der Ansprüche 1 bis 3, wobei die Temperatur der Alterungsbehandlung in einem Bereich von 150 bis 250°C liegt.
  5. Herstellungsverfahren für ein hochfestes Druckgußprodukt nach einem der Ansprüche 1 bis 4, wobei der Zeitraum der Alterungsbehandlung 0,5 bis 8 Stunden beträgt.
  6. Herstellungsverfahren für ein hochfestes Druckgußprodukt nach Anspruch 4 oder 5, wobei die Zeit der Alterungsbehandlung ungefähr 4 Stunden bei 180°C beträgt.
  7. Herstellungsverfahren für ein hochfestes Druckgußprodukt nach einem der Ansprüche 1 bis 6, wobei das Druckgußprodukt eine Komponente für einen Spiralverdichter ist.
EP19970104527 1996-03-19 1997-03-17 Verfahren zur Herstellung eines druckgegossenen hochfesten Produktes Expired - Lifetime EP0796926B1 (de)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP06290696A JP3764200B2 (ja) 1996-03-19 1996-03-19 高強度ダイカスト品の製造方法
JP62906/96 1996-03-19
JP6290696 1996-03-19

Publications (2)

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EP0796926A1 EP0796926A1 (de) 1997-09-24
EP0796926B1 true EP0796926B1 (de) 2003-10-15

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DE (1) DE69725490T2 (de)

Families Citing this family (18)

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Publication number Priority date Publication date Assignee Title
US6250368B1 (en) 1996-09-25 2001-06-26 Honda Giken Kabushiki Kaisha Casting mold for producing a fiber-reinforced composite article by die-casting process
JPH1094853A (ja) * 1996-09-25 1998-04-14 Honda Motor Co Ltd ダイカスト法による繊維強化複合体鋳造用金型
JPH10103261A (ja) * 1996-09-27 1998-04-21 Sanyo Electric Co Ltd スクロール圧縮機
IT1299077B1 (it) * 1997-04-16 2000-02-07 Luk Fahrzeug Hydraulik Pompa rotativa a palette
JP2001049376A (ja) * 1999-05-12 2001-02-20 Daiki Aluminium Industry Co Ltd 高強度加圧鋳造用アルミニウム合金及び同アルミニウム合金鋳物
ATE255646T1 (de) * 1999-09-24 2003-12-15 Honsel Guss Gmbh Verfahren zur wärmebehandlung von strukturgussteilen aus einer dafür zu verwendenden aluminiumlegierung
JP2003003970A (ja) * 2001-06-20 2003-01-08 Fujitsu General Ltd スクロール圧縮機
DE10339705B4 (de) 2002-08-29 2008-03-13 Nippon Light Metal Co. Ltd. Hochfester Aluminiumlegierungsguss und Verfahren zu dessen Herstellung
EP1844174A4 (de) * 2004-12-23 2008-03-05 Commw Scient Ind Res Org Wärmebehandlung von druckgussstücken aus aluminiumlegierung
JP4765600B2 (ja) * 2005-12-13 2011-09-07 アイシン精機株式会社 アルミニウム合金部材の製造方法
DE102006057660B4 (de) * 2006-12-07 2019-08-22 Bayerische Motoren Werke Aktiengesellschaft Verfahren zum Druckgießen von Bauteilen und Verwendung einer Sprühvorrichtung einer Druckgießvorrichtung
US8636855B2 (en) 2009-03-05 2014-01-28 GM Global Technology Operations LLC Methods of enhancing mechanical properties of aluminum alloy high pressure die castings
US9068252B2 (en) 2009-03-05 2015-06-30 GM Global Technology Operations LLC Methods for strengthening slowly-quenched/cooled cast aluminum components
JP5355320B2 (ja) * 2009-09-10 2013-11-27 日産自動車株式会社 アルミニウム合金鋳物部材及びその製造方法
JP2011208253A (ja) * 2010-03-30 2011-10-20 Honda Motor Co Ltd 車両材料用アルミダイカスト合金
WO2013039247A1 (ja) * 2011-09-15 2013-03-21 国立大学法人東北大学 ダイカスト方法及びダイカスト装置ならびにダイカスト品
WO2018161311A1 (en) 2017-03-09 2018-09-13 GM Global Technology Operations LLC Aluminum alloys
EP3550036B1 (de) * 2018-04-06 2022-01-05 GF Casting Solutions AG Direct aging

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JPS54153728A (en) * 1978-05-26 1979-12-04 Hitachi Ltd High wear resistant aluminum diecast parts
JPS62127447A (ja) * 1985-11-26 1987-06-09 Mitsubishi Heavy Ind Ltd 鋳造アルミニウム合金
JPH0650114B2 (ja) * 1985-11-26 1994-06-29 三菱重工業株式会社 スクロ−ル型流体機械
DE3817350A1 (de) * 1987-05-23 1988-12-22 Sumitomo Electric Industries Verfahren zur herstellung von spiralfoermigen teilen sowie verfahren zur herstellung einer aluminiumpulverschmiedelegierung
JPS6465242A (en) * 1987-09-04 1989-03-10 Nippon Light Metal Co Scroll made of aluminum alloy
JPH0828493A (ja) * 1994-07-14 1996-01-30 Furukawa Electric Co Ltd:The アルミニウム合金製スクロールの製造方法
JP3684247B2 (ja) * 1995-01-24 2005-08-17 株式会社豊田自動織機 スクロール型圧縮機及びその製造方法

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Publication number Publication date
JP3764200B2 (ja) 2006-04-05
EP0796926A1 (de) 1997-09-24
DE69725490T2 (de) 2004-08-12
DE69725490D1 (de) 2003-11-20
JPH09256127A (ja) 1997-09-30

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