EP3250722B1 - Process for obtaining a low silicon aluminium alloy part - Google Patents
Process for obtaining a low silicon aluminium alloy part Download PDFInfo
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- EP3250722B1 EP3250722B1 EP16703341.4A EP16703341A EP3250722B1 EP 3250722 B1 EP3250722 B1 EP 3250722B1 EP 16703341 A EP16703341 A EP 16703341A EP 3250722 B1 EP3250722 B1 EP 3250722B1
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- 238000000034 method Methods 0.000 title claims description 19
- 229910052710 silicon Inorganic materials 0.000 title claims description 13
- 239000010703 silicon Substances 0.000 title claims description 13
- 229910000838 Al alloy Inorganic materials 0.000 title claims description 5
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 title description 16
- 229910045601 alloy Inorganic materials 0.000 claims description 29
- 239000000956 alloy Substances 0.000 claims description 29
- 239000010949 copper Substances 0.000 claims description 15
- 229910052802 copper Inorganic materials 0.000 claims description 8
- 238000005266 casting Methods 0.000 claims description 7
- 229910052748 manganese Inorganic materials 0.000 claims description 6
- 239000011572 manganese Substances 0.000 claims description 6
- 229910052712 strontium Inorganic materials 0.000 claims description 5
- 238000001816 cooling Methods 0.000 claims description 3
- 229910052749 magnesium Inorganic materials 0.000 claims description 3
- 239000011777 magnesium Substances 0.000 claims description 3
- 238000003825 pressing Methods 0.000 claims description 3
- 239000010936 titanium Substances 0.000 claims description 3
- 229910052719 titanium Inorganic materials 0.000 claims description 3
- 229910052782 aluminium Inorganic materials 0.000 claims description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 2
- 230000002301 combined effect Effects 0.000 claims description 2
- 241000711981 Sais Species 0.000 claims 1
- 239000004411 aluminium Substances 0.000 claims 1
- 239000012535 impurity Substances 0.000 claims 1
- 238000004898 kneading Methods 0.000 claims 1
- 238000003303 reheating Methods 0.000 claims 1
- 238000007711 solidification Methods 0.000 description 21
- 230000008023 solidification Effects 0.000 description 21
- 239000002244 precipitate Substances 0.000 description 19
- 238000005242 forging Methods 0.000 description 9
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 8
- 230000007547 defect Effects 0.000 description 8
- 238000010438 heat treatment Methods 0.000 description 8
- 230000005496 eutectics Effects 0.000 description 6
- 239000000203 mixture Substances 0.000 description 6
- 229910019018 Mg 2 Si Inorganic materials 0.000 description 5
- 230000000694 effects Effects 0.000 description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 4
- 230000035945 sensitivity Effects 0.000 description 4
- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 description 4
- 238000004090 dissolution Methods 0.000 description 3
- 239000011159 matrix material Substances 0.000 description 3
- 238000001556 precipitation Methods 0.000 description 3
- 239000011265 semifinished product Substances 0.000 description 3
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 2
- 229910000676 Si alloy Inorganic materials 0.000 description 2
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 2
- CSDREXVUYHZDNP-UHFFFAOYSA-N alumanylidynesilicon Chemical compound [Al].[Si] CSDREXVUYHZDNP-UHFFFAOYSA-N 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000005096 rolling process Methods 0.000 description 2
- 229910018464 Al—Mg—Si Inorganic materials 0.000 description 1
- 229910019752 Mg2Si Inorganic materials 0.000 description 1
- 229910018594 Si-Cu Inorganic materials 0.000 description 1
- 229910008465 Si—Cu Inorganic materials 0.000 description 1
- 240000008042 Zea mays Species 0.000 description 1
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical group [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 230000006378 damage Effects 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 229940082150 encore Drugs 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 229910001338 liquidmetal Inorganic materials 0.000 description 1
- 150000002696 manganese Chemical class 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000001000 micrograph Methods 0.000 description 1
- 235000011837 pasties Nutrition 0.000 description 1
- 230000007226 seed germination Effects 0.000 description 1
- 238000005204 segregation Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
Images
Classifications
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/02—Alloys based on aluminium with silicon as the next major constituent
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/002—Hybrid process, e.g. forging following casting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/02—Die forging; Trimming by making use of special dies ; Punching during forging
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/09—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure
- B22D27/11—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure making use of mechanical pressing devices
-
- 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
-
- 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
- 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
-
- 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
- C22F1/05—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 of the Al-Si-Mg type, i.e. containing silicon and magnesium in approximately equal proportions
Definitions
- the invention relates to the technical sector of the foundry, for the manufacture of aluminum parts, particularly in the field of automotive, aerospace and more generally, all types of industries.
- the alloys mentioned have been developed for obtaining semi-finished products (billets or ingots for forging or rolling) intended to be transformed during hot or cold operations with high deformation rates (> 50%).
- the geometries of these semi-finished products are simple (bar, bar or ingot) which makes it possible to solidify these alloys with a minimum of defects by using processes with high solidification rates.
- These geometries and these processes lead, according to currently controlled techniques, to semi-finished products free from defects among which we may mention: shrinkage, cracks, macro-segregations, macro-precipitation (prevents the formation of too coarse precipitates,> 100 ⁇ m).
- the problem posed that the invention proposes to solve is to be able to produce parts responding to standards of quality and safety, and likely to have complex shapes.
- the object of the invention relates to a method of manufacturing a piece of low silicon aluminum alloy, type 6000.
- the latter is heated by being placed in a tunnel oven.
- the silicon content is between 0.5 and 3%.
- a silicon content of less than 1% leads to the highest elastic limits and elongations. However, this is the rate at which the alloy is most sensitive to crack and has the lowest flowability. It is therefore necessary to be able to adapt the silicon content according to the geometry of the part. Complex geometries will require a higher rate to reduce this crack sensitivity.
- the maximum rate of 3% corresponds to a rate beyond which the elongation and the yield point become too low so that it is always interesting to produce with an alloy of this type.
- the magnesium level is between 0, 65 and 1%. This rate makes it possible to optimize the density of Mg 2 Si precipitates in the aluminum matrix. It compensates for the decrease in silicon content while having a minimum of macroscopic Mg 2 Si precipitates that are damaging and must be dissolved or transformed during heat treatment. If the precipitates are too numerous, or too big, the heat treatment will have a weak effect for their dissolution, the critical size of dissolution having been exceeded.
- the copper content is between 0.20 and 0.40%. This rate allows the formation of Al 2 Cu precipitates in the matrix and the total absence of macroscopic Al 2 Cu precipitates. The absence of these macroscopic precipitates makes it possible to maintain high forging temperatures and thus to minimize forging efforts (which is carried out in a single step). Indeed, the main precipitates formed in the presence of copper are Al 2 Cu and AlMgSiCu respectively melting at 490 ° C and 525 ° C, their presence would prevent forging at higher temperatures without risk of burning of the alloy that would make the parts unusable. This degradation is similar to a destruction of the alloy.
- a higher copper content also increases the crack sensitivity of the alloy, because there remains a eutectic to be solidified at low temperatures (490 ° C or 525 ° C) for which the mechanical stresses (related to the removal of solidification) exercised on the piece are important.
- the manganese content is between 0.15 and 0.25%. This rate avoids the formation of AlFeSi precipitates in ⁇ -form (very damaging plate) and makes it possible to form AlFeMnSi precipitates in ⁇ -form (Chinese writing less damaging). This maximizes the finished part elongation resulting from the Cobapress process. This effect is most often used with larger amounts of manganese and iron, these two elements leading to a hardening of the alloy but also to larger precipitates during solidification. These large precipitates are penalizing for a good elongation.
- the alloy according to the invention is intended, as indicated, the Cobapress process, which is forged in a single step, which does not have the large deformations encountered in forging, rolling or extrusion.
- the titanium content is between 0.10 and 0.20%. This rate is necessary for efficient seed germination and fine grain size which has a significant effect on the mechanical characteristics of these alloys.
- the strontium level is between 0 and 120 ppm. This rate is necessary to have a fibrous solidification of the small amounts of eutectic that are formed. This occurs mainly for silicon levels higher than 1.5%.
- composition of this alloy is adapted to lead to a solidification which will maximize the mechanical characteristics despite the low levels of deformation encountered during the Cobapress process.
- the forging operation Cobapress allows to close and rewrite these defects with a control in design of the rate of deformation.
- the temperature / deformation couple allows a rectification of the defects.
- the table below shows the mechanical properties on casting and parts, according to the Cobapress process, after T6 heat treatment of the low silicon alloy.
- Rp Elastic limit
- this composition makes it possible to reduce the complexity of the usual heat treatment for Al-Mg-Si-Cu type alloys.
- the rate of silicon, solidification rates and grain refinement lead to macroscopic Mg 2 Si precipitates whose size and morphology facilitate dissolution during heat treatment.
- FIG 1 shows a foundry microstructure, without manganese, precipitated "in needles", type ⁇
- FIG 2 shows the monostructure with manganese, precipitated "in Chinese writing", type ⁇ .
- the copper content is greater than 0.40%, which leads to the presence of Al 2 Cu precipitates.
- figure 4 shows an example where one can observe the AlFeMnSi and Mg 2 Si precipitation surrounded by precipitates Al 2 Cu.
- the figure 5 shows a copper content of between 0.20% and 0.40%, according to the invention, showing an absence of Al 2 Cu precipitates,
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- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Engineering & Computer Science (AREA)
- Organic Chemistry (AREA)
- Metallurgy (AREA)
- Materials Engineering (AREA)
- Crystallography & Structural Chemistry (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Forging (AREA)
- Manufacture Of Alloys Or Alloy Compounds (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
- Conductive Materials (AREA)
Description
L'invention se rattache au secteur technique de la fonderie, pour la fabrication de pièces aluminium, notamment dans le domaine de l'automobile, de l'aéronautique et plus généralement, tous types d'industries.The invention relates to the technical sector of the foundry, for the manufacture of aluminum parts, particularly in the field of automotive, aerospace and more generally, all types of industries.
Il existe de nombreux alliages dit « bas silicium ». Ces alliages présentent de hautes caractéristiques mécaniques après traitement thermique T6 (Rp0,2 300 MPa ; A% 8 %). Ils sont rassemblés dans la série 6000 (Al-Mg-Si) de la classification des alliages d'aluminium. Les plus connus sont les 6082, 6061, 6151. De nombreuses compositions existent également avec des teneurs semblables aux alliages normés, parmi lesquelles on peut citer par exemple les documents
Les alliages cités ont été développés pour l'obtention de produits semi-finis (billettes ou lingots pour forge ou laminage) destinés à être transformés lors d'opérations à chaud ou à froid avec de grands taux de déformation (> 50 %). De plus les géométries de ces produits semi-finis sont simples (barre, barreau ou lingot) ce qui permet de solidifier ces alliages avec un minimum de défauts en utilisant des procédés avec de hautes vitesses de solidification. Ces géométries et ces procédés conduisent selon des techniques aujourd'hui maîtrisées, à des produits semi-finis exempts de défauts parmi lesquels on peut citer : retassures, criques, macro-ségrégations, macro-précipitations (prévient la formation de précipités trop grossiers, >100 µm).The alloys mentioned have been developed for obtaining semi-finished products (billets or ingots for forging or rolling) intended to be transformed during hot or cold operations with high deformation rates (> 50%). In addition, the geometries of these semi-finished products are simple (bar, bar or ingot) which makes it possible to solidify these alloys with a minimum of defects by using processes with high solidification rates. These geometries and these processes lead, according to currently controlled techniques, to semi-finished products free from defects among which we may mention: shrinkage, cracks, macro-segregations, macro-precipitation (prevents the formation of too coarse precipitates,> 100 μm).
A partir de cet état de la technique, le problème posé que se propose de résoudre l'invention est de pouvoir réaliser des pièces répondant à des normes de qualité et de sécurité élevées, et susceptibles d'avoir des formes complexes.From this state of the art, the problem posed that the invention proposes to solve is to be able to produce parts responding to standards of quality and safety, and likely to have complex shapes.
Pour résoudre ce problème, l'objet de l'invention porte sur un procédé de fabrication d'une pièce en alliage d'aluminium bas silicium, type 6000.To solve this problem, the object of the invention relates to a method of manufacturing a piece of low silicon aluminum alloy, type 6000.
Plus particulièrement, l'invention concerne un procédé d'obtention d'une pièce en alliage d'aluminium bas silicium, comprenant du silicium à un taux compris entre 0,5 et 3 %, du magnésium à un taux compris entre 0,65 et 1 %, du cuivre à un taux compris entre 0,20 et 0,40 %, du manganèse à un taux compris entre 0,15 et 0,25 %, du titane à un taux compris entre 0,10 et 0,20 %, et du strontium à un taux compris entre 0 et 120 ppm, selon lequel :
- on coule dans un moule ledit alliage pour obtenir la pièce,
- après la coulée, on démoule la pièce constituant une préforme encore chaude,
- on refroidit ladite préforme que l'on soumet ensuite à une opération apte à la réchauffer à une température comprise entre 470 °C et 550 °C.
- on positionne ladite pièce entre deux coquilles d'une matrice définissant une empreinte de dimensions sensiblement égales, mais inférieures à celle du moule,
- on presse fortement les deux coquilles l'une contre l'autre pour exercer sur la pièce disposée entre lesdites coquilles un effet combiné de pressage et de corroyage superficiel.
- casting said alloy to obtain the part,
- after casting, the part constituting a still hot preform is removed from the mold,
- said preform is cooled and subjected to an operation capable of heating it to a temperature of between 470 ° C. and 550 ° C.
- said piece is positioned between two shells of a matrix defining a footprint of substantially equal dimensions, but smaller than that of the mold,
- the two shells are strongly urged against each other to exert on the piece disposed between said shells a combined effect of pressing and surface treatment.
La présente invention a également pour objets :
- la mise en oeuvre du procédé ci-dessus dans le domaine automobile ou dans le domaine aéronautique ;
- l'utilisation d'une pièce obtenue par le procédé mentionné ci-dessus, dans le domaine automobile ; et
- l'utilisation de l'alliage dans le procédé mentionné ci-dessus, dans le domaine aéronautique.
- the implementation of the above method in the automotive field or in the aeronautical field;
- the use of a part obtained by the method mentioned above, in the automotive field; and
- the use of the alloy in the process mentioned above, in the aeronautical field.
Dans une forme de réalisation du procédé, après refroidissement de la préforme, cette dernière est réchauffée en étant disposée dans un four tunnel.In one embodiment of the method, after cooling the preform, the latter is heated by being placed in a tunnel oven.
Il résulte de ces caractéristiques que l'opération de fonderie suivie de la forge en une étape de la préforme ne présentent pas les mêmes paramètres de températures, vitesse de solidification, taux de déformation, température de forge que les procédés de l'état antérieur de la technique.It follows from these characteristics that the foundry operation followed by forging in one step of the preform do not have the same temperature parameters, solidification rate, deformation rate, forging temperature as the processes of the prior state of the preform. the technique.
L'alliage revendiqué répond à ces contraintes et permet d'obtenir des pièces avec une qualité satisfaisante, tout particulièrement si celles-ci relèvent d'une obligation de sécurité (pièce de liaison au sol = pièces de sécurité).The claimed alloy responds to these constraints and makes it possible to obtain parts with a satisfactory quality, especially if they come under a safety obligation (ground connection piece = safety parts).
Parmi ces contraintes, on note, à titre d'exemples :
- la géométrie de la préforme, contrairement à des barreaux ou des lingots, comprend dès sa conception les ébauches des zones fonctionnelles de la pièce et peut donc avoir une géométrie complexe comprenant des nervures ou des variations de section conduisant à des masses isolées de métal liquide. Ces masses isolées peuvent être « tolérées » en augmentant le taux de silicium (type AS7G03, alliage standard de fonderie). Une diminution de ce taux rend l'alliage plus sensible lors de la solidification et conduit à des défauts de retassure (porosités) plus nombreux et d'un volume plus important.
- l'intervalle de solidification, qui est défini par la différence entre la température de liquidus et la température eutectique de l'alliage considéré. Pour un alliage, type AS7G03 modifié au strontium, cet intervalle est de 50 °C env. (611 °C - 562 °C). Pour un alliage bas silicium type 6000, il est de l'ordre de 90 °C (655 °C - 562 °C) en retenant la précipitation des Mg2Si macroscopiques (ou du silicium) comme pseudo palier eutectique. Un intervalle de solidification grand conduit à une zone pâteuse plus étendue à travers la pièce, de sorte qu'il devient plus difficile de diriger le front de solidification pour réduire les défauts comme cela se fait traditionnellement et presque naturellement avec un alliage AS7G03.
- l'AS7G03 a une sensibilité presque nulle à la crique du fait de la grande quantité d'eutectique qui va pouvoir combler les criques qui apparaissent lors du retrait en solidification. Ce n'est pas le cas d'un alliage bas silicium, qui comporte très peu d'eutectique ce qui entraine une forte sensibilité à la crique et demande d'adapter la composition et de maîtriser les gradients thermiques de solidification.
- the geometry of the preform, unlike bars or ingots, comprises from its design the blanks of the functional areas of the part and can therefore have a complex geometry comprising ribs or sectional variations leading to isolated masses of liquid metal. These insulated masses can be "tolerated" by increasing the silicon content (AS7G03 type, standard foundry alloy). A decrease in this rate makes the alloy more sensitive during solidification and leads to more numerous and larger volume shrinkage defects (porosities).
- the solidification range, which is defined by the difference between the liquidus temperature and the eutectic temperature of the alloy considered. For an alloy, type AS7G03 modified with strontium, this interval is 50 ° C approx. (611 ° C - 562 ° C). For a low silicon type 6000 alloy, it is of the order of 90 ° C (655 ° C - 562 ° C) by retaining the precipitation of macroscopic Mg 2 Si (or silicon) as a eutectic pseudo-plateau. A large solidification range leads to a larger pasty area across the workpiece, so that it becomes more difficult to direct the solidification front to reduce defects as is traditionally and almost naturally with an AS7G03 alloy.
- the AS7G03 has an almost zero sensitivity to the crack because of the large amount of eutectic that will be able to fill the cracks that appear during the solidification shrinkage. This is not the case of a low silicon alloy, which has very little eutectic which causes a high sensitivity to crack and requires to adapt the composition and control the thermal gradients of solidification.
Il est également nécessaire d'ajuster la composition chimique pour obtenir le meilleur compromis entre les paramètres de fonderie, de forge, de traitement thermique et les caractéristiques mécaniques voulues sur pièces finies. Dans ce but on détaille ci-après chacun des éléments de l'alliage, leur teneur et les effets ayant conduit à retenir ces valeurs :
Le taux de silicium est compris entre 0,5 et 3 %. Un taux de silicium inférieur à 1%, conduit aux limites élastiques et allongements les plus élevés. Cependant, il s'agit du taux pour lequel l'alliage est le plus sensible à la crique et a la plus faible coulabilité. Il est donc nécessaire de pouvoir adapter le taux de silicium en fonction de la géométrie de la pièce. Des géométries complexes demanderont un taux plus élevé afin de réduire cette sensibilité à la crique. Le taux maximum de 3% correspondant à un taux au-delà duquel l'allongement et la limite élastique deviennent trop faibles pour qu'il soit toujours intéressant de produire avec un alliage de ce type.It is also necessary to adjust the chemical composition to obtain the best compromise between the foundry, forging, heat treatment parameters and the desired mechanical characteristics on finished parts. For this purpose we detail below each of the elements of the alloy, their content and the effects that led to retain these values:
The silicon content is between 0.5 and 3%. A silicon content of less than 1% leads to the highest elastic limits and elongations. However, this is the rate at which the alloy is most sensitive to crack and has the lowest flowability. It is therefore necessary to be able to adapt the silicon content according to the geometry of the part. Complex geometries will require a higher rate to reduce this crack sensitivity. The maximum rate of 3% corresponds to a rate beyond which the elongation and the yield point become too low so that it is always interesting to produce with an alloy of this type.
Le taux de magnésium est compris entre 0, 65 et 1 %. Ce taux permet d'optimiser la densité de précipités Mg2Si dans la matrice aluminium. Il compense la diminution du taux de silicium tout en ayant un minimum de précipités Mg2Si macroscopiques qui sont endommageant et doivent être dissouts ou transformés lors du traitement thermique. Si les précipités sont trop nombreux, ou trop gros, le traitement thermique n'aura qu'un faible effet pour leur dissolution, la taille critique de dissolution ayant été dépassée.The magnesium level is between 0, 65 and 1%. This rate makes it possible to optimize the density of Mg 2 Si precipitates in the aluminum matrix. It compensates for the decrease in silicon content while having a minimum of macroscopic Mg 2 Si precipitates that are damaging and must be dissolved or transformed during heat treatment. If the precipitates are too numerous, or too big, the heat treatment will have a weak effect for their dissolution, the critical size of dissolution having been exceeded.
Le taux de cuivre est compris entre 0,20 et 0,40 %. Ce taux permet la formation de précipités Al2Cu dans la matrice et l'absence totale de précipités Al2Cu macroscopiques. L'absence de ces précipités macroscopiques permet de conserver des températures de forge élevées et ainsi de minimiser les efforts de forge (qui est réalisée en une seule étape). En effet, les principaux précipités formés en présence de cuivre sont Al2Cu et AlMgSiCu fondant respectivement à 490 °C et 525 °C, leur présence empêcherait de forger à des températures plus élevées sans risque de brûlure de l'alliage qui rendrait les pièces inutilisables. Cette dégradation s'apparente à une destruction de l'alliage. Un taux de cuivre plus élevé augmente aussi la sensibilité à la crique de l'alliage, car il reste un eutectique à solidifier à des températures faibles (490 °C ou 525 °C) pour lesquels les contraintes mécaniques (liées au retrait de solidification) exercées sur la pièce sont importantes.The copper content is between 0.20 and 0.40%. This rate allows the formation of Al 2 Cu precipitates in the matrix and the total absence of macroscopic Al 2 Cu precipitates. The absence of these macroscopic precipitates makes it possible to maintain high forging temperatures and thus to minimize forging efforts (which is carried out in a single step). Indeed, the main precipitates formed in the presence of copper are Al 2 Cu and AlMgSiCu respectively melting at 490 ° C and 525 ° C, their presence would prevent forging at higher temperatures without risk of burning of the alloy that would make the parts unusable. This degradation is similar to a destruction of the alloy. A higher copper content also increases the crack sensitivity of the alloy, because there remains a eutectic to be solidified at low temperatures (490 ° C or 525 ° C) for which the mechanical stresses (related to the removal of solidification) exercised on the piece are important.
Le taux de manganèse est compris entre 0,15 et 0,25 %. Ce taux évite la formation de précipités AlFeSi sous forme β (plaque très endommageante) et permet de former plutôt des précipités AlFeMnSi sous forme α (écriture chinoise moins endommageante). Ceci permet de maximiser l'allongement sur pièce finie résultant du procédé Cobapress. Cet effet est le plus souvent utilisé avec des quantités plus importantes de manganèse et de fer, ces deux éléments conduisant à un fort durcissement de l'alliage mais également à de plus gros précipités lors de la solidification. Ces gros précipités sont pénalisants pour un bon allongement. Cependant, l'alliage selon l'invention est destiné, comme indiqué, au procédé Cobapress, selon lequel on forge en une seule étape, qui ne présente pas les grandes déformations rencontrées en forge, laminage ou extrusion. Ces grandes déformations permettent de fragmenter ces gros précipités et de les rendre beaucoup moins endommageant tout en conservant leur effet durcissant. Dans le cas de l'alliage, selon l'invention, il convient de minimiser dès la coulée l'impact des précipités à base de fer sur les caractéristiques mécaniques. En effet, leur morphologie ne sera plus modifiée, la forge en une étape ne déformant pas suffisamment la pièce pour changer leur morphologie. Enfin, ce taux de manganèse est adapté aux vitesses de refroidissement obtenues lors de la coulée en moule permanent, en regard de ces vitesses, il favorise la formation de précipités AlFeMnSi sous-forme α.The manganese content is between 0.15 and 0.25%. This rate avoids the formation of AlFeSi precipitates in β-form (very damaging plate) and makes it possible to form AlFeMnSi precipitates in α-form (Chinese writing less damaging). This maximizes the finished part elongation resulting from the Cobapress process. This effect is most often used with larger amounts of manganese and iron, these two elements leading to a hardening of the alloy but also to larger precipitates during solidification. These large precipitates are penalizing for a good elongation. However, the alloy according to the invention is intended, as indicated, the Cobapress process, which is forged in a single step, which does not have the large deformations encountered in forging, rolling or extrusion. These large deformations can break these large precipitates and make them much less damaging while maintaining their hardening effect. In the case of the alloy, according to the invention, the impact of the iron-based precipitates on the mechanical characteristics should be minimized as soon as they are poured. Indeed, their morphology will not be changed, the forge in one step does not deform the room enough to change their morphology. Finally, this manganese content is adapted to the cooling rates obtained during casting in permanent mold, with respect to these speeds, it promotes the formation of AlFeMnSi precipitates α-form.
Le taux de titane est compris entre 0,10 et 0,20 %. Ce taux est nécessaire pour une germination efficace des grains et une taille de grain fine qui a un effet important sur les caractéristiques mécaniques de ces alliages.The titanium content is between 0.10 and 0.20%. This rate is necessary for efficient seed germination and fine grain size which has a significant effect on the mechanical characteristics of these alloys.
Le taux de strontium est compris entre 0 et 120 ppm. Ce taux est nécessaire pour avoir une solidification fibreuse des faibles quantités d'eutectique qui se forment. Ceci se produit majoritairement pour des taux de silicium supérieurs à 1,5 %.The strontium level is between 0 and 120 ppm. This rate is necessary to have a fibrous solidification of the small amounts of eutectic that are formed. This occurs mainly for silicon levels higher than 1.5%.
On a vu que la composition de cet alliage est adaptée pour conduire à une solidification qui permettra de maximiser les caractéristiques mécaniques malgré les faibles niveaux de déformation rencontrés lors du procédé Cobapress.It has been seen that the composition of this alloy is adapted to lead to a solidification which will maximize the mechanical characteristics despite the low levels of deformation encountered during the Cobapress process.
Toutefois, des défauts de solidification persistent, défauts de solidification intergranulaire de retassure localisée aux joints de grains avec une morphologie ramifiée et diffuse qui fragilise la pièce de fonderie.However, defects of solidification persist, defects of intergranular solidification of localized shrinkage at the grain boundaries with a branched and diffuse morphology which weakens the casting.
L'opération de forge Cobapress permet de refermer et de ressouder ces défauts avec une maîtrise en conception du taux de déformation. Le couple température/déformation permet une ressoudure des défauts. Le tableau, ci-dessous, présente les caractéristiques mécaniques sur pièce de fonderie et sur pièces, selon le procédé Cobapress, après traitement thermique T6 de l'alliage bas silicium. On peut noter l'amélioration de limite à rupture Rm et de l'allongement à rupture :
Rm = Résistance mécanique
A% = Allongement
Rm = Mechanical resistance
A% = Lengthening
Enfin, cette composition permet de diminuer la complexité du traitement thermique usuel pour des alliages type Al-Mg-Si-Cu. Le taux de silicium, les vitesses de solidification et l'affinage du grain conduisent à des précipités macroscopiques Mg2Si dont la taille et la morphologie facilite la dissolution lors du traitement thermique.Finally, this composition makes it possible to reduce the complexity of the usual heat treatment for Al-Mg-Si-Cu type alloys. The rate of silicon, solidification rates and grain refinement lead to macroscopic Mg 2 Si precipitates whose size and morphology facilitate dissolution during heat treatment.
On renvoie aux figures des dessins annexés représentant la micrographie d'une pièce, afin de montrer l'importance du taux de manganèse et de cuivre. La
Les
Aux
La
Claims (3)
- A method of obtaining a part made of low-silicon aluminum alloy, containing:- silicon at a content lying in the range of 0.5% to 3%;- magnesium at a content lying in the range of 0.65% to 1%;- copper at a content lying in the range of 0.20% to 0.40%;- manganese at a content lying in the range of 0.15% to 0.25%;- titanium at a content lying in the range of 0.10% to 0.20%; and- strontium at a content lying in the range of 0 ppm to 120 ppm;the remainder of the alloy consisting of aluminium and possible impurities,
wherein the method comprises the steps of :- casting said alloy in a mold so as to obtain the part;- after the casting, demolding the part constituting a preform that is still hot;- cooling said preform and then subjecting said preform to an operation adapted for reheating sais preform to a temperature lying in the range of 470°C to 550°C;- positioning said part between two shells of a die that defines a cavity of dimensions substantially equal to but less than those of the mold; and- strongly pressing the two shells together to exert on the part disposed between said shells a combined effect of pressing and surface kneading. - Use of a part obtained by the method according to claim 1, in the automobile sector.
- Use of the alloy in the method according to claim 1, in the aviation sector.
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PL16703341T PL3250722T3 (en) | 2015-01-29 | 2016-01-14 | Process for obtaining a low silicon aluminium alloy part |
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FR1550700A FR3032204B1 (en) | 2015-01-29 | 2015-01-29 | ALUMINUM LOW SILICON ALLOY PIECE |
PCT/FR2016/050069 WO2016120541A1 (en) | 2015-01-29 | 2016-01-14 | Process for obtaining a low silicon aluminium alloy part |
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US5571347A (en) * | 1994-04-07 | 1996-11-05 | Northwest Aluminum Company | High strength MG-SI type aluminum alloy |
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