US20050100472A1 - High strength aluminum alloy casting and method of production of same - Google Patents

High strength aluminum alloy casting and method of production of same Download PDF

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US20050100472A1
US20050100472A1 US10/650,897 US65089703A US2005100472A1 US 20050100472 A1 US20050100472 A1 US 20050100472A1 US 65089703 A US65089703 A US 65089703A US 2005100472 A1 US2005100472 A1 US 2005100472A1
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United States
Prior art keywords
aluminum alloy
casting
high strength
strength aluminum
alloy casting
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US10/650,897
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Inventor
Kouji Yamada
Tomoyuki Hatano
Susumu Miyakawa
Hiromi Takagi
Hiroshi Horikawa
Akio Hashimoto
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Denso Corp
Nippon Light Metal Co Ltd
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Denso Corp
Nippon Light Metal Co Ltd
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Priority claimed from JP2002251956A external-priority patent/JP2004091818A/ja
Priority claimed from JP2002251984A external-priority patent/JP4141207B2/ja
Application filed by Denso Corp, Nippon Light Metal Co Ltd filed Critical Denso Corp
Assigned to DENSO CORPORATION, NIPPON LIGHT METAL CO., LTD. reassignment DENSO CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HASHIMOTO, AKIO, HATANO, TOMOYUKI, HORIKAWA, HIROSHI, MIYAKAWA, SUSUMU, TAKAGI, HIROMI, YAMADA, KOUJI
Publication of US20050100472A1 publication Critical patent/US20050100472A1/en
Priority to US11/986,853 priority Critical patent/US20080083478A1/en
Priority to US12/798,288 priority patent/US8246763B2/en
Abandoned legal-status Critical Current

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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
    • C22C21/04—Modified aluminium-silicon alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/043—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with silicon as the next major constituent

Definitions

  • the present invention relates to a high strength aluminum alloy casting having superior mechanical properties, a high strength aluminum alloy casting including a neutralizing casting defect element for increasing the strength (hereinafter also referred to as an “NCDE”), and parts made from this high strength aluminum alloy casting such as a scroll for a compressor for an air-conditioner, a vane rotor of a valve timing regulating device, and a housing of an antilock braking system.
  • NCDE neutralizing casting defect element for increasing the strength
  • the present invention relates to a method of production of the above high strength aluminum alloy casting, a method of production of a high strength aluminum alloy casting including a neutralizing casting defect element, and a method of production of parts made from this high strength aluminum alloy casting such as a scroll for a compressor of an air-conditioner, a vane rotor of a valve timing regulating device, and a housing of an antilock braking system.
  • Japanese Unexamined Patent Publication (Kokai) No. 9-256127 there is a method of water cooling or age hardening a cast or die-cast scroll die casting immediately after releasing it from the die. That is, the method of production of the die casting in Japanese Unexamined Patent Publication (Kokai) No. 9-256127 adjusts the contents of the precipitation hardening elements Cu and Mg in the elements contained in the aluminum alloy and performs water quenching and age hardening so as to improve the state of precipitation of Cu and Mg and enhance the strength of these alloys.
  • Japanese Unexamined Patent Publication (Kokai) No. 2000-192180 discloses a die casting of aluminum alloy having a chemical composition resembling the above and a method of production of the same. This method of production tries to improve the strength of the die casting by suppressing the amount of gas included in the die casting of the aluminum alloy and solubilizing the alloy.
  • aluminum alloy scrolls provided in air-conditioners in recent years have changed along with the higher efficiency of air-conditioning and changes in the refrigerant used. With just the improvements of the method of production described in Japanese Unexamined Patent Publication (Kokai) No. 2000-192180, it is not possible to satisfy the design requirements of aluminum alloy scrolls.
  • An object of the present invention is to provide a high strength aluminum alloy casting keeping down capital costs, raising productivity, extending the lifetime of the casting or die casting mold, and reducing the cost of the product.
  • Another object of the present invention is to provide a high strength aluminum alloy casting improving the tensile strength, yield strength, fatigue strength, etc. of the aluminum alloy casting, reducing casting defects, and increasing the fineness of dispersion of the structure.
  • Still another object of the present invention is to provide a scroll for an air-conditioner, a vane rotor of a valve timing regulating device, and a housing of an antilock braking system made from this high strength aluminum alloy casting.
  • a still further object of the present invention is to provide a method of production of this high strength aluminum alloy casting.
  • a high strength aluminum alloy casting obtained by casting an aluminum alloy comprised of 7.5 to 11.5 wt % of Si, 3.8 to 4.8 wt % of Cu, 0.45 to 0.65 wt % of Mg, 0.4 to 0.7 wt % of Fe, 0.35 to 0.45 wt % of Mn, and the balance of Al and not more than 0.2 wt % of unavoidable impurities, wherein 0.1 to 0.3 wt % of Ag is added to this aluminum alloy.
  • a high strength aluminum alloy casting obtained by casting an aluminum alloy comprised of 7.5 to 11.5 wt % of Si, 3.8 to 4.8 wt % of Cu, 0.45 to 0.65 wt % of Mg, 0.4 to 0.7 wt % of Fe, 0.35 to 0.45 wt % of Mn, and the balance of Al and not more than 0.2 wt % of unavoidable impurities, wherein this aluminum alloy contains 0.1 to 1.0 wt % of at least one element selected from the group of second additive elements comprised of Rb, K, Ba, Sr, Zr, Nb, Ta, V, and Pd and rare earth elements.
  • an amount of gas included in the high strength aluminum alloy casting is kept to not more than 1.5 cm 3 with respect to 100 g of the high strength aluminum alloy casting, and solubilization and age hardening are performed to enhance the strength.
  • the rare earth element reacts with molten hydrogen in the aluminum alloy to form a compound and suppress casting defects arising due to the molten hydrogen.
  • the rare earth element is at least one element selected from the group comprising La, Ce, Pr, Nb, Pm, Sm, Eu, Ga, Tb, Dy, Ho, Er, Tm, Yb, Lu, Y, and Sc.
  • the high strength aluminum alloy casting is solubilized by heating in a temperature range of 495 to 505° C. for 2 to 6 hours, then quenched and further then age hardened by heating in a temperature range of 160 to 220° C. for 2 to 6 hours.
  • the solubilized and age hardened high strength aluminum alloy casting has eutectic Si of a particle size of an average not more than 15 ⁇ m preferably not more than 12 ⁇ m, a Cu compound of a particle size of not more than an average 8 ⁇ m, an Mg—Si compound of a particle size of not more than an average 12 ⁇ m, and an Fe compound of a particle size of not more than an average 6 ⁇ m.
  • a method of production of a high strength aluminum alloy casting comprising the steps of filling a melt of an aluminum alloy in a mold to obtain a casting, taking out the aluminum alloy casting from the mold, solubilizing the high strength aluminum alloy casting by heating in a temperature range of 495 to 505° C. for 2 to 6 hours, quenching the high strength aluminum alloy casting after the solubilization, and age hardening the high strength aluminum alloy casting by heating in a temperature range of 160 to 220° C. for 2 to 6 hours after quenching.
  • the method of production is a die cast method and further comprises the steps of closing mold halves, pouring aluminum melt into a melt sleeve of a die cast machine, then using an injection plunger to close a melt pouring inlet of the die cast machine and reducing the pressure in the mold to not more than 13.3 kPa and filling a high strength aluminum alloy in the mold after reducing the pressure.
  • the method of production is a die cast method and further comprises the steps of closing mold halves, pouring aluminum melt into a melt sleeve of a die cast machine, then using an injection plunger to close a melt pouring inlet of the die cast machine and reducing the pressure in the mold to not more than 13.3 kPa, adjusting the atmosphere by blowing in oxygen of a pressure of at least atmospheric pressure, and filling a high strength aluminum alloy in the mold after adjusting the pressure.
  • the method of production is a die cast method and further comprises the step of closing mold halves, pouring aluminum melt into a melt sleeve of a die cast machine, then using low speed die casting to fill high strength aluminum alloy into the mold while advancing an injection plunger at a low speed so as to keep air and heat decomposition gas produced from a release agent etc. from being entrained.
  • a scroll for a compressor of an air-conditioner made from one of the above high strength aluminum alloy castings.
  • a method of production of a scroll for a compressor of an air-conditioner made from a high strength aluminum alloy casting comprising the steps of reducing the pressure inside the mold to not more than 13.3 kPa and filling the mold with a high strength aluminum alloy after reduction of pressure for die casting.
  • the method further comprises the steps of adjusting the atmosphere by blowing oxygen of a pressure of at least atmospheric pressure into the mold after the step of reducing the pressure inside the mold to not more than 13.3 kPa and filling the high strength aluminum alloy into the mold for die casting after adjusting the atmosphere.
  • a method of production of a scroll for a compressor of an air-conditioner using one of the above method of productions is a method of production of a scroll for a compressor of an air-conditioner using one of the above method of productions.
  • a vane rotor of a valve timing regulating device provided in a drive transmission system made from one of the above high strength aluminum alloy castings.
  • a housing of an antilock braking system made from one of the above high strength aluminum alloy castings.
  • FIG. 1 is a view of the state of distribution of alloy ingredients by EPMA observation for an aluminum alloy to which Ag is added of the present invention and an alloy to which Ag is not added of a comparative example;
  • FIGS. 2A and 2B show the strengths of a high strength aluminum alloy casting of the present invention and a conventional material, where FIG. 2A shows the relative tensile strength and FIG. 2B shows the relative fatigue strength;
  • FIGS. 3A to 3 C show the improvement in strength of the aluminum alloy of a basic composition by adjusting and adding Cu, Mg, and Mn, wherein FIG. 3A shows the addition of Cu, FIG. 3B shows the addition of Mg, and FIG. 3C shows the addition of Mn;
  • FIGS. 4A and 4B show the relationship between the content of the ingredient elements and relative strength, wherein FIG. 4A shows the case of Cu and FIG. 4B shows the case of Mg;
  • FIG. 5 shows the relationship between the dimensions of casting defects and the fatigue strength
  • FIGS. 6A and 6B show structures of aluminum alloy treated in various ways as observed by EPMA, wherein FIG. 6A shows a comparative example wherein the aluminum alloy is only subjected to T6 treatment and FIG. 6B shows an example where an aluminum alloy of the present invention containing a neutralizing casting defect element is subjected to T6 treatment;
  • FIG. 7 shows the state of distribution of Mg and Cu alloy ingredients resulting from the addition of a neutralizing casting defect element obtained by EPMA observation, wherein FIG. 7A shows the example of the present invention and FIG. 7B shows a comparative examples;
  • FIG. 8 shows the results of analysis of hydrogen emission by atmospheric pressure ionization mass spectrometry (API-MS).
  • FIG. 9 shows the results of extremal value statistical processing of a total of 100 casting defects for a D10FM aluminum alloy casting containing a neutralizing casting defect element and an alloy casting not containing the same;
  • FIG. 10 shows the results of a fatigue test (S-N curve) in an environment of a temperature of 180° C. for a casting containing a neutralizing casting defect element (NCDE) and a casting not containing it;
  • FIGS. 11A and 11B are a photograph of a fracture surface of a starting point of destruction according to a fatigue test, wherein FIG. 11A shows a comparative example and FIG. 11B shows the example of the present invention
  • FIGS. 12A and 12B are views of a relative tensile strength ( FIG. 12A ) and relative fatigue strength ( 12 B) between examples where a neutralizing casting defect element is added and comparative examples where it is not added.
  • the first high strength aluminum alloy casting of the present invention is an alloy casting comprised of an aluminum alloy comprised of 7.5 to 11.5 wt % of Si, 3.8 to 4.8 wt % of Cu, 0.45 to 0.65 wt % of Mg, 0.4 to 0.7 wt % of Fe, 0.35 to 0.45 wt % of Mn, and the balance of Al and not more than 0.2 wt % of unavoidable impurities to which 0.1 to 0.3 wt % of Ag is added.
  • First, in the present invention by adjusting the amounts of Cu, Mg, and Mn as shown in FIGS.
  • the amount of the Ag added to the aluminum alloy is limited to the range of 0.1 to 0.3 wt %.
  • the unavoidable impurities are preferably not more than 0.2 wt %.
  • the amount of gas included in the aluminum alloy casting of the present invention is kept to not more than 1.5 cm 3 , preferably not more than 0.5 cm 3 , with respect to 100 g of high strength aluminum alloy and solubilization and age hardening performed.
  • the high strength aluminum alloy casting of the present invention is solubilized by heating in a temperature range of 495 to 505° C. for 2 to 6 hours, then quenched and further then age hardened by heating in a temperature range of 160 to 220° C. for 2 to 6 hours.
  • compounds of the precipitation hardening elements included in the alloy that is, Cu, Mg, and Si, precipitate dispersed finely and uniformly in the alloy together with the Ag of the slight amount of the additive element, so the precipitation hardening of the aluminum alloy casting is improved.
  • the eutectic Si structure made finer by the Ag of the additive element in the alloy is granularized, so the aluminum alloy casting is further strengthened.
  • quenching in addition to water quenching, oil quenching, oil and water emulsion quenching, etc. are employed.
  • the amount of gas included in this high strength aluminum alloy casting of the present invention is made not more than 1.5 cm 3 with respect to 100 g of the alloy casting. Further, by reducing the pressure in the mold of the die cast machine to not more than 13.3 kPa or then blowing oxygen of a pressure of at least atmospheric pressure into the mold, it is possible to keep the amount of gas included in the aluminum alloy casting not more than 1.5 cm 3 with respect to 100 g of high strength aluminum alloy.
  • the solubilized and age hardened high strength aluminum alloy casting of the present invention has eutectic Si of a particle size of an average not more than 12 ⁇ m, a Cu compound of a particle size of not more than an average 8 ⁇ m, an Mg—Si compound of a particle size of not more than an average 12 ⁇ m, and an Fe compound of a particle size of not more than an average 6 Am.
  • the high strength aluminum alloy casting including Ag of the present invention the above particle size by the above solubilization and age hardening, it was possible to improve the tensile strength, yield strength, and fatigue strength by about 5 to 10% compared with a conventional aluminum alloy casting not including Ag, but having alloy ingredients equivalent to the present invention.
  • the second high strength aluminum alloy casting of the present invention achieves an improvement in the strength and a reduction of the variation in strength of the aluminum alloy casting by reducing the casting defects of the cast or die cast aluminum alloy casting, making the structure more uniform and making the structure more finely dispersed, and adding suitable amounts of Cu and Mg.
  • the method of reducing the casting defects of the aluminum alloy casting there are 1) the method of evacuation of the air and gas of the release agent etc. in the cavity for suppressing entrainment defects and filling the aluminum alloy melt in the cavity at a low speed and 2) local pressurization for suppressing sink marks.
  • defect preventing techniques are problematic in that the casting technology is difficult. It is difficult to suppress defects by just the casting technology. To prevent such defects, the solution is to add to the casting material:
  • the method of strengthening the aluminum alloy there is the method of increasing the uniformity of structure and increasing the fineness of dispersion of structure of the aluminum alloy casting.
  • ingredients such as Ti, Ca, Zr, Na, Sr, etc. These methods are aimed at increasing the fineness of the eutectic crystal and a crystal.
  • the precipitation hardening ingredients Cu and Mg it is necessary to add suitable amounts of the precipitation hardening ingredients Cu and Mg, but it is difficult to cause the Cu and Mg to uniformly disperse in the casting. If adding at least a certain amount of Cu, there is the detrimental effect that the casting will easily crack during casting.
  • the high strength aluminum alloy casting of the present invention contains 0.1 to 1.0 wt % of at least one type of a neutralizing casting defect element (NCDE) of the group of second additive elements of Rb, K, Ba, Sr, Zr, Nb, Ta, V, and Pd and rare earth elements.
  • NCDE neutralizing casting defect element
  • the neutralizing casting defect element (NCDE) suppresses the casting defects arising due to the molten hydrogen by forming a hydride with the molten hydrogen in the aluminum alloy.
  • the aluminum alloy of the present invention contains 7.5 to 11.5 wt % of Si, 3.8 to 4.8 wt % of Cu, 0.45 to 0.65 wt % of Mg, 0.4 to 0.7 wt % of Fe, 0.35 to 0.45 wt % of Mn, not more than 0.2 wt % of unavoidable impurities, and the balance of Al.
  • the amount of gas included in the high strength aluminum alloy casting of the present invention is suppressed to the range of 0.5 to 1.5 cm 3 with respect to 100 g of high strength aluminum alloy casting and solubilization and age hardening are applied to improve the strength. Further, the high strength aluminum alloy casting of the present invention is solubilized by heating in a temperature range of 495 to 505° C.
  • the solubilized and age hardened high strength aluminum alloy casting of the present invention has eutectic Si of a particle size of an average not more than 12 ⁇ m, a Cu compound of a particle size of not more than an average 8 ⁇ m, an Mg—Si compound of a particle size of not more than an average 12 ⁇ m, and an Fe compound of a particle size of not more than an average 6 ⁇ m.
  • the content of Mg is extremely influential on the strength. If too large or too small, the strength drops. To achieve higher strength, further, the Cu is limited to 3.8 to 4.8 wt % and the Mg to 0.45 to 0.65 wt %.
  • the method of production of a high strength aluminum alloy casting of the present invention comprises the steps of solubilizing a high strength aluminum alloy casting by heating in a temperature range of 495 to 505° C. for 2 to 6 hours, water quenching the high strength aluminum alloy casting after the solubilization, and age hardening the high strength aluminum alloy casting by heating in a temperature range of 160 to 220° C. for 2 to 6 hours after the water quenching.
  • a scroll for a compressor of an air-conditioner of the present invention is made from this high strength aluminum alloy casting.
  • the method of production of a scroll for a compressor of an air-conditioner comprises the steps of reducing the pressure inside the mold to not more than 13.3 kPa and filling the mold with high strength aluminum alloy after reduction of pressure for die casting or the step of closing mold halves, pouring aluminum melt into a melt sleeve of a die cast machine, then filling high strength aluminum alloy into the mold while advancing an injection plunger at a low speed so as to keep air, heat decomposition gas produced from a release agent, etc. from being entrained.
  • the method of production of the scroll comprises the steps of reducing the pressure in the mold to not more than 13.3 kPa, adjusting the atmosphere by blowing in oxygen of a pressure of at least atmospheric pressure, and filling a high strength aluminum alloy in the mold after adjusting the pressure.
  • the strength is sensitive, while below the limit casting defect dimension, the strength is not affected by a casting defect.
  • the present invention by adding a rare earth element to a die casting material with an amount of gas kept to less than 1.5 cm 3 /100 g Al, it is possible to make the casting defect dimensions small enough so as not to affect the strength. As a result, an improvement in strength and reduction of variation in strength are achieved.
  • the aluminum alloy of the present invention prepared for improving the strength of the alloy casting has a basic chemical composition of 10.5 wt % of Si, 4.5 wt % of Cu, 0.6 wt % of Mg, 0.5 wt % of Fe, 0.4 wt % of Mn, unavoidable impurities, and a balance of Al and, also, 0.2 wt % of Ag.
  • the basic composition with no Ag was prepared.
  • FIG. 1 shows the state of distribution of alloy ingredients by observation by EPMA for the aluminum alloy to which Ag is added of the present invention and the alloy to which Ag is not added of the comparative example.
  • the distribution of eutectic Si of the sample with no Ag added of the comparative example showed relatively coarse eutectic Si.
  • the eutectic Si distribution of the Ag-containing sample of the present invention shows eutectic Si increased in fineness.
  • the distributions of the Cu compound, Mg—Si compound, and Fe compound of the sample with no Ag added of the comparative example show local distribution of relatively coarse particles.
  • the precipitation hardening alloys of the Cu compound and Mg—Si compound become coarser and locally distributed, they cause a drop and variation in strength.
  • the distribution of the Cu compound, Mg—Si compound, and Fe compound of the Ag-containing sample of the present invention tend to be uniform distributions of fine particles. Since the precipitation hardening elements Cu and Mg are increased in fineness and uniformly distributed, it is possible to increase the strength and reduce the variation in strength. Further, the distribution of Fe did not cause almost any harmful needle structures due to the synergistic effect of the increased clumping due to addition of Mn and the dispersal of Fe caused due to the addition of Ag.
  • An alloy containing 10.5 wt % of Si, 4.5 wt % of Cu, 0.6 wt % of Mg, 0.5 wt % of Fe, 0.4 wt % of Mn, unavoidable impurities, and the balance of Al and further containing 0.2 wt % of Ag was prepared.
  • a melt of the aluminum alloy was die cast into a scroll for a compressor of an air-conditioner using a conventional die cast machine. After release from the mold, the casting of the scroll of the aluminum alloy was solubilized by heating in a temperature range of 495 to 505° C. for 2 to 6 hours. The solubilized casting of the scroll was then water quenched in the present example. After water quenching, the casting of the scroll was age hardened by heating in a temperature range of 160 to 220° C. for 2 to 6 hours. The casting of the scroll for a compressor of an air-conditioner obtained could be increased in tensile strength, yield strength, and fatigue strength by about 5 to 15%.
  • the inside of the mold of a die cast machine was reduced in pressure to not more than 13.3 kPa (100 Torr) using a vacuum pump.
  • the casting of the scroll of the aluminum alloy taken out from the mold, like in Example 1 was solubilized by heating in a temperature range of 495 to 505° C. for 2 to 6 hours and then, in the present example, water quenched and age hardened by heating in a temperature range of 160 to 220° C. for 2 to 6 hours.
  • Example 2 in the same way as in Example 2, the atmosphere was adjusted by reducing the pressure inside of the mold of the die cast machine to not more than 13.3 kPa (100 Torr) using a vacuum pump, then blowing oxygen of at least atmospheric pressure into the mold.
  • the melt of aluminum alloy shown in Example 1 was filled in the mold to die cast a scroll for a compressor of an air-conditioner.
  • the casting of the scroll of an aluminum alloy taken out from the mold, like in Example 1 was solubilized by heating in a temperature range of 495 to 505° C. for 2 to 6 hours and then, in the present example, water quenched and age hardened by heating in a temperature range of 160 to 220° C. for 2 to 6 hours.
  • the cause of occurrence of first casting defects is the bubbles caused by entrainment of the gas in the cavity in the melt when filling an aluminum alloy melt in a cavity of a mold of a die cast machine at a high speed and high pressure, that is, these are casting defects caused by gas in the cavity.
  • the cause of occurrence of second casting defects is the moisture in the mold (casting mold) and the moisture of the release agent etc. reacting with the melt of the aluminum alloy to produce hydrogen in the melt which then becomes included in the product as bubbles during the process of solidification. That is, these are casting defects caused by molten hydrogen produced in the melt during filling.
  • the casting defects occurred include entrainment cavities due to entrainment of air and heat decomposition gases produced from the release agent etc. and sink marks arising in the process of solidification of aluminum or another light metal in a mold.
  • the approach to reducing the first casting defects caused by the gas in the cavity is generally improvement of the casting method.
  • reduction of the casting defects by improvement of the casting method not only invites a rise in price of the die casting, but also requires limitations in the shape of the product.
  • the aluminum alloys of the example of the present invention and a comparative example contain 9.5 to 11.5 wt % of Si, 3.8 to 4.8 wt % of Cu, 0.45 to 0.65 wt % of Mg, 0.4 to 0.7 wt % of Fe, 0.35 to 0.45 wt % of Mn, not more than 0.2 wt % of unavoidable impurities, and the balance of Al.
  • the high strength aluminum alloy of the present invention contains 0.1 to 1.0 wt % of at least one type of neutralizing casting defect element selected from the group of Rb, K, Ba, Sr, Zr, Nb, Ta, V, Pd, La, and Ce.
  • FIG. 6 shows the EPMA observed structures of aluminum alloys of the example of the present invention and comparative example subjected to T6 treatment.
  • FIG. 6A shows a comparative example of the above aluminum alloy subjected to only T6 treatment. Eutectic Si of a relatively coarse needle structure was observed.
  • FIG. 6B shows an example of an aluminum alloy of the present invention containing a neutralizing casting defect element subjected to T6 treatment. Eutectic Si free of any needle structure, increased in fineness, and increased in dispersion was observed.
  • FIGS. 7A and 7B shows the results of observation of the state of distribution of the Mg and Cu alloy ingredients due to the addition or absence of a neutralizing casting defect element using EPMA.
  • a neutralizing casting defect element was added, both with the alloy ingredients of Mg and Cu, increased fineness and increased dispersion were exhibited compared with the comparative example ( FIG. 7A ) not including any neutralizing casting defect element.
  • time-of-flight secondary ion mass spectrometry was used to try to detect any hydride (HGE-H 3 ) and aluminum hydride (HGE (H 4 Al) 3 ). Further, molten gas analysis by atmospheric pressure ionization mass spectrometry (API-MS) was performed.
  • the results of analysis of the amount of gas of a casting to which a neutralizing casting defect element is added and a casting without such addition using the Lansley method (Table 1) will be explained next.
  • the amount of gas was 0.4 to 0.5 cm 3 /100 g Al or no different between a casting with no addition and a casting with addition.
  • an effect of reduction of the defect dimensions was observed as shown in FIG. 8 .
  • FIG. 8 shows the results of analysis of hydrogen emission by atmospheric pressure ionization mass spectrometry (API-MS). From the results of hydrogen emission of FIG. 8 , the hydrogen emission peak temperature of the alloy to which the neutralizing casting defect element (NCDE) was added increased largely at the high temperature side. This is believed to indicate that the hydrogen emission peak temperature increased due to the change in the hydrogen trap sites due to the addition of the neutralizing casting defect element (NCDE).
  • API-MS atmospheric pressure ionization mass spectrometry
  • FIG. 9 shows the results of extremal value statistical processing of a total of 100 casting defects for a casting of an invention example containing a neutralizing casting defect element and a casting of a comparative example not containing it.
  • the extremal value statistic of a casting of the invention example to which the neutralizing casting defect element is added exhibited a change in the distribution of the casting defects and a reduction in the dimensions of the casting defects.
  • the maximum defect dimension per 10 casting samples of the invention example to which the neutralizing casting defect element was added was 60 ⁇ m, while the maximum casting dimension per 10 casting samples of the comparative example to which no neutralizing casting defect element was added was 145 ⁇ m. That is, the maximum defect dimension of the casting sample of the invention example to which the neutralizing casting defect element was added was reduced to less than half the maximum defect dimension of the casting sample of the comparative example to which the neutralizing casting defect element was not added. Therefore, by adding a neutralizing casting defect element to the aluminum alloy, it was observed that the casting structure was improved and thereby the casting defects were reduced.
  • FIG. 10 shows the results of a fatigue test (S-N curve) in an environment of a temperature of 150° C. for a casting of an invention example containing a neutralizing casting defect element and a casting of a comparative example not containing it.
  • the fatigue strength of the casting sample of the invention example to which a neutralizing casting defect element is added exhibited a reduction in the variation of the fatigue strength and an improvement in the fatigue strength compared with the fatigue strength of a casting sample of the comparative example where no neutralizing casting defect element is added.
  • a photograph of the fracture surface of a starting point of destruction in a fatigue test is shown in FIG. 11 .
  • the casting sample where no neutralizing casting defect element is added has a starting point of a cavity defect of about 100 to 150 ⁇ , while the casting sample having the neutralizing casting defect element added was destroyed from the matrix without starting from a casting defect.
  • the casting sample to which the neutralizing casting defect element was added was improved in strength 7% and reduced in variation in strength at least 40%.
  • FIGS. 12A and 12B The relative tensile strength and relative fatigue strength of aluminum alloy castings of examples of the present invention where neutralizing casting defect elements are added and comparative examples are shown in FIGS. 12A and 12B .
  • a scroll of a compressor of an air-conditioner such as a scroll compressor or CO 2 compressor
  • a vane rotor in a valve timing regulating device provided in a drive transmission system for transmitting drive power from a drive shaft of an internal combustion engine to a driven shaft opening and closing an intake valve or exhaust valve of an internal combustion engine
  • a housing of chassis parts such as an antilock braking system, etc.
  • the relative tensile strength of an aluminum alloy casting to which a neutralizing casting defect element of the present invention is added reaches 1.51 and the relative fatigue strength reaches 1.2.
  • the alloy casting of the present invention is provided with extremely high strength properties.
  • the first alloy casting of the present invention could give a high strength aluminum alloy casting where increased fineness of the crystallization alloy elements and precipitation alloy elements are achieved by the addition of a minute amount of Ag to the aluminum alloy.
  • the high strength aluminum alloy casting to which Ag is added and subjected to T6 heat treatment of the present invention features a 1.47 times greater relative tensile strength.
  • a high strength aluminum alloy casting to which Ag is added and subjected to T6 heat treatment of the present invention features 1.2 times the relative tensile and fatigue strengths.
  • the aluminum alloy casting of the present invention achieves both improvement in strength and reduction of variation in strength.
  • the second aluminum alloy to which a neutralizing casting defect element is added is low in cost. Further, the aluminum alloy of the present invention enables a reduction of the casting defects when die casting regardless of the shape of the product and achieves increased fineness and increased uniformity of the casting structure, whereby the aluminum alloy casting of the present invention can achieve both an improvement of strength and a reduction of variation in strength.

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US20090032209A1 (en) * 2004-12-28 2009-02-05 Takeshi Nagasaka Aluminum alloy for die castings and production process of aluminum alloy castings
US20110164988A1 (en) * 2008-09-25 2011-07-07 Borgwarner Inc. Turbocharger and compressor impeller therefor
CN102817848A (zh) * 2011-06-08 2012-12-12 广东美芝制冷设备有限公司 旋转压缩机的滑片及其制作方法
CN107630154A (zh) * 2017-08-30 2018-01-26 佛山市高明高盛铝业有限公司 整铸式铝合金、铝合金加工方法及电热盘
CN107630155A (zh) * 2017-08-30 2018-01-26 佛山市高明高盛铝业有限公司 整铸式铝合金及电热盘
US9970494B2 (en) * 2013-10-21 2018-05-15 Itt Italia S.R.L. Method for the production of brake pads and associated brake pad
CN114001041A (zh) * 2021-09-18 2022-02-01 喻开怀 一种轻质合金风机叶轮及其制备方法
CN114411020A (zh) * 2022-01-13 2022-04-29 上海交通大学 一种非热处理强化高强高韧压铸铝硅合金及其制备方法
CN115233049A (zh) * 2022-07-29 2022-10-25 湖南江滨机器（集团）有限责任公司 一种免热处理铝合金及其制备方法
CN116024466A (zh) * 2023-02-13 2023-04-28 有研工程技术研究院有限公司 一种手机中板用压铸铝合金及其制备方法

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DE102004049074A1 (de) † 2004-10-08 2006-04-13 Trimet Aluminium Ag Kaltaushärtende Aluminiumgusslegierung und Verfahren zur Herstellung eines Aluminiumgussteils
JP4800864B2 (ja) * 2006-07-03 2011-10-26 株式会社豊田中央研究所 コンプレッサ
ES2526554T3 (es) * 2008-03-17 2015-01-13 Southwire Company, Llc Detección de porosidad
CN103740987B (zh) * 2014-01-27 2016-07-06 烟台三和新能源科技有限公司 高强度铝合金及其生产工艺
CN105680608B (zh) * 2016-01-16 2019-03-01 上海雷祥压铸有限公司 水冷管、电机外壳及其制造方法
DE102019000361A1 (de) 2019-01-18 2020-07-23 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Verschleißbeständige Leichtbaulegierung aus einem Metall-Matrix-Verbundwerkstoff mit einer metallischen Matrix und einer keramischen Hartphase, Verfahren zur Herstellung einer solchen verschleißbeständigen Leichtbaulegierung, und Bremsscheibe mlt einer solchen verschleißbeständigen Leichtbaulegierung
CN116479295B (zh) * 2023-04-04 2024-06-04 凤阳爱尔思轻合金精密成型有限公司 一种挤压铸造铝合金材料及其制备工艺

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US5993576A (en) * 1995-11-29 1999-11-30 The Furukawa Electric Co., Ltd. Wear resistant wrought aluminum alloy and scroll of wear-resistant wrought aluminum alloy
US5722036A (en) * 1996-01-09 1998-02-24 Hitachi Powdered Metals Co., Ltd. Manufacturing process of connecting rod assembly and compacting die

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090032209A1 (en) * 2004-12-28 2009-02-05 Takeshi Nagasaka Aluminum alloy for die castings and production process of aluminum alloy castings
US20110164988A1 (en) * 2008-09-25 2011-07-07 Borgwarner Inc. Turbocharger and compressor impeller therefor
CN102817848A (zh) * 2011-06-08 2012-12-12 广东美芝制冷设备有限公司 旋转压缩机的滑片及其制作方法
US9970494B2 (en) * 2013-10-21 2018-05-15 Itt Italia S.R.L. Method for the production of brake pads and associated brake pad
US20180223925A1 (en) * 2013-10-21 2018-08-09 Itt Italia S.R.I Method for the production of brake pads and associated brake pad
US10591005B2 (en) * 2013-10-21 2020-03-17 Itt Italia S.R.L. Method for the production of brake pads and associated brake pad
CN107630154A (zh) * 2017-08-30 2018-01-26 佛山市高明高盛铝业有限公司 整铸式铝合金、铝合金加工方法及电热盘
CN107630155A (zh) * 2017-08-30 2018-01-26 佛山市高明高盛铝业有限公司 整铸式铝合金及电热盘
CN114001041A (zh) * 2021-09-18 2022-02-01 喻开怀 一种轻质合金风机叶轮及其制备方法
CN114411020A (zh) * 2022-01-13 2022-04-29 上海交通大学 一种非热处理强化高强高韧压铸铝硅合金及其制备方法
CN115233049A (zh) * 2022-07-29 2022-10-25 湖南江滨机器（集团）有限责任公司 一种免热处理铝合金及其制备方法
CN116024466A (zh) * 2023-02-13 2023-04-28 有研工程技术研究院有限公司 一种手机中板用压铸铝合金及其制备方法

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DE10339705A1 (de) 2004-04-15
US8246763B2 (en) 2012-08-21

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