WO2024048895A1 - Matériau de coulée en alliage d'aluminium et disque de frein comprenant celui-ci - Google Patents

Matériau de coulée en alliage d'aluminium et disque de frein comprenant celui-ci Download PDF

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WO2024048895A1
WO2024048895A1 PCT/KR2023/005785 KR2023005785W WO2024048895A1 WO 2024048895 A1 WO2024048895 A1 WO 2024048895A1 KR 2023005785 W KR2023005785 W KR 2023005785W WO 2024048895 A1 WO2024048895 A1 WO 2024048895A1
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weight
aluminum alloy
casting material
alloy casting
experimental example
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PCT/KR2023/005785
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English (en)
Korean (ko)
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이정무
조영희
손현우
이승욱
이지영
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한국재료연구원
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Publication of WO2024048895A1 publication Critical patent/WO2024048895A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • 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
    • 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 an aluminum alloy casting material, and more specifically, to an aluminum alloy casting material having excellent high-temperature strength and corrosion resistance and a brake disc containing the same.
  • brake discs which are braking parts of automobiles, are mainly manufactured from cast iron.
  • braking is performed only by mechanical braking.
  • the braking environment required for mechanical braking applied to electric vehicles can be alleviated compared to internal combustion engine vehicles. Due to this braking environment, attempts are being made to use aluminum alloy castings as brake discs in electric vehicles.
  • the technical problem to be achieved by the technical idea of the present invention is to provide an aluminum alloy casting material having high high-temperature strength and excellent corrosion resistance, and a brake disc containing the same.
  • an aluminum alloy casting material having high high-temperature strength and excellent corrosion resistance and a brake disc including the same are provided.
  • the aluminum alloy casting material contains more than 13.0% by weight to 15% by weight of silicon (Si); 2.7% to 4.1% magnesium (Mg) by weight; Greater than 0% to 2% copper (Cu) by weight; and the remainder may include aluminum (Al) and inevitable impurities.
  • it may further include more than 0% by weight to 1.0% by weight of manganese (Mn).
  • it may further include more than 0% by weight to 1.5% by weight of nickel (Ni).
  • it may further include zirconium (Zr) in an amount greater than 0% by weight to 0.25% by weight.
  • titanium (Ti) in an amount greater than 0% by weight to 0.05% by weight; And it may further include boron (B) in an amount of more than 0% by weight to 0.005% by weight.
  • the aluminum alloy cast material may have a microstructure consisting of at least one of eutectic Si, eutectic Mg 2 Si, primary Si, and primary Mg 2 Si.
  • the aluminum alloy casting material may have a corrosion rate of 0.2 mm/year or less.
  • the aluminum alloy cast material may have a high temperature tensile strength of 250°C in the range of 190 MPa to 230 MPa.
  • the aluminum alloy casting material may be subjected to solution treatment and then subjected to aging treatment.
  • the aluminum alloy casting material may be aged without solution treatment.
  • the aluminum alloy casting material contains more than 13.0% by weight to 15% by weight of silicon (Si); 2.81% to 3.5% magnesium (Mg) by weight; 0.021% to 1.603% by weight copper (Cu); 0.002% to 0.537% by weight manganese (Mn); and the remainder may include aluminum (Al) and inevitable impurities.
  • it may further include 0.021% by weight to 0.641% by weight of nickel (Ni).
  • it may further include 0.004% by weight to 0.185% by weight of zirconium (Zr).
  • the aluminum alloy casting material contains more than 13.0% by weight to 15% by weight of silicon (Si); 2.7% to 4.1% magnesium (Mg) by weight; Greater than 0% to 1% by weight manganese (Mn); and the remainder may include aluminum (Al) and inevitable impurities.
  • the brake disc includes more than 13.0% by weight to 15% by weight of silicon (Si); 2.7% to 4.1% magnesium (Mg) by weight; Greater than 0% to 2% copper (Cu) by weight; and the remainder may be composed of aluminum alloy casting material containing aluminum (Al) and inevitable impurities.
  • Figure 1 is a phase diagram of an aluminum-silicon binary alloy for alloy design of an aluminum alloy cast material according to an embodiment of the present invention.
  • Figure 2 is a phase diagram of an aluminum-silicon-magnesium alloy obtained through thermodynamic computational calculations for alloy design of an aluminum alloy cast material according to an embodiment of the present invention.
  • Figures 3 and 4 are optical microscope photographs showing the microstructure of an aluminum alloy cast material for alloy design of the aluminum alloy cast material according to an embodiment of the present invention.
  • Figure 5 is a graph showing the room temperature tensile strength and elongation of an aluminum alloy cast material subjected to T6 heat treatment according to an embodiment of the present invention.
  • Figure 6 is a graph showing the room temperature tensile strength and elongation of an aluminum alloy cast material subjected to T5 heat treatment according to an embodiment of the present invention.
  • Figure 7 is a graph calculated by thermodynamic calculation of the fraction of the formed phase upon addition of copper in an aluminum alloy casting material according to an embodiment of the present invention.
  • Figure 8 is a graph calculated by thermodynamic calculation of the fraction of phases formed upon adding nickel in an aluminum alloy casting material according to an embodiment of the present invention.
  • Figures 9 and 10 are optical microscope photographs showing the microstructure of an aluminum alloy cast material according to an embodiment of the present invention.
  • Figure 11 is a schematic diagram showing a brake system including a brake disc formed of aluminum alloy casting according to an embodiment of the present invention.
  • the aluminum alloy casting material according to an embodiment of the present invention contains more than 13.0% by weight to 15% by weight of silicon (Si); 2.7% to 4.1% magnesium (Mg) by weight; Greater than 0% to 2% copper (Cu) by weight; and the remainder may include aluminum (Al) and inevitable impurities. Additionally, the content of silicon (Si) contained in the aluminum alloy casting may range from 13.1% by weight to 15% by weight.
  • the aluminum alloy casting material according to an embodiment of the present invention contains more than 13.0% by weight to 15% by weight of silicon (Si); 2.7% to 4.1% magnesium (Mg) by weight; Greater than 0% to 2% copper (Cu) by weight; Greater than 0% to 1.0% by weight manganese (Mn); and the remainder may include aluminum (Al) and inevitable impurities. That is, the aluminum alloy cast material further contains manganese (Mn) in an amount of more than 0% by weight to 1.0% by weight.
  • the aluminum alloy casting material according to an embodiment of the present invention contains more than 13.0% by weight to 15% by weight of silicon (Si); 2.7% to 4.1% magnesium (Mg) by weight; Greater than 0% to 1% by weight manganese (Mn); and the remainder may include aluminum (Al) and inevitable impurities.
  • the aluminum alloy casting material may further include nickel (Ni) in an amount of more than 0% by weight to 1.5% by weight in addition to the above elements, or it may further include zirconium (Zr) in an amount of more than 0% by weight to 0.25% by weight in addition to the elements. , more than 0% by weight to 1.5% by weight of nickel (Ni) in addition to the above elements; And it may further include zirconium (Zr) in an amount of more than 0% by weight to 0.25% by weight.
  • the aluminum alloy casting material includes titanium (Ti) in an amount of more than 0% by weight to 0.05% by weight in addition to the above elements; And it may further include boron (B) in an amount of more than 0% by weight to 0.005% by weight.
  • the aluminum alloy casting material may further include iron (Fe) in an amount of more than 0% by weight to 0.2% by weight as an inevitable impurity in addition to the above elements.
  • the aluminum alloy casting material may further contain 30 ppm to 200 ppm of phosphorus.
  • the phosphorus may be included in the form of AlP.
  • the aluminum alloy casting material may further include 50 ppm to 200 ppm of strontium (Sr).
  • the aluminum alloy casting material according to an embodiment of the present invention contains more than 13.0% by weight to 15% by weight of silicon (Si); 2.81% to 3.5% magnesium (Mg) by weight; 0.021% to 1.603% by weight copper (Cu); 0.002% to 0.537% by weight manganese (Mn); and the remainder may include aluminum (Al) and inevitable impurities. Additionally, the content of silicon (Si) contained in the aluminum alloy casting may range from 13.3% by weight to 14.6% by weight.
  • the aluminum alloy casting material may further include 0.021% to 0.641% by weight of nickel (Ni) in addition to the above elements, or may further include 0.004% to 0.185% by weight of zirconium (Zr) in addition to the above elements. 0.021% to 0.641% by weight of nickel (Ni) in addition to the element; And it may further include 0.004% by weight to 0.185% by weight of zirconium (Zr).
  • the aluminum alloy casting material includes, in addition to the above elements, 0.034% by weight to 0.040% by weight of titanium (Ti); And it may further include 0.001% by weight to 0.004% by weight of boron (B).
  • the aluminum alloy casting material may further include 0.120% to 0.158% by weight of iron (Fe) as the inevitable impurity in addition to the above elements.
  • the aluminum alloy casting material may further contain 30 ppm to 200 ppm of phosphorus.
  • the phosphorus may be included in the form of AlP.
  • the aluminum alloy casting material may further include 50 ppm to 200 ppm of strontium (Sr).
  • the aluminum alloy cast material may have a microstructure consisting of at least one of eutectic Si, eutectic Mg 2 Si, primary Si, and primary Mg 2 Si.
  • the aluminum alloy cast material may be subjected to heat treatment after casting, for example, T6 heat treatment, which is an aging treatment after solution treatment.
  • the aluminum alloy casting material subjected to the T6 heat treatment may have a corrosion rate in the range of 0.2 mm/year or less, and may have a corrosion rate in the range of more than 0 mm/year to less than 0.2 mm/year.
  • the corrosion rate is calculated by measuring the weight loss after immersing the aluminum alloy cast material in a 5.0% NaCl aqueous solution for 480 hours.
  • the aluminum alloy casting material subjected to the T6 heat treatment may have a room temperature tensile strength in the range of 300 MPa to 360 MPa.
  • the aluminum alloy casting may have a high temperature tensile strength of 200°C in the range of 240 MPa to 300 MPa.
  • the aluminum alloy cast material may have a high temperature tensile strength of 250°C in the range of 190 MPa to 230 MPa.
  • the aluminum alloy casting material may have a high temperature tensile strength of 300°C in the range of 90 MPa to 140 MPa.
  • the aluminum alloy casting material may have a high temperature tensile strength of 350°C in the range of 70 MPa to 80 MPa.
  • the aluminum alloy cast material may be subjected to T5 heat treatment, which is aging treatment without solution treatment.
  • the aluminum alloy casting material subjected to the T5 heat treatment may have a corrosion rate in the range of 0.4 mm/year or less, and may have a corrosion rate in the range of more than 0 mm/year to less than 0.4 mm/year.
  • the corrosion rate is calculated by measuring the weight loss after immersing the aluminum alloy cast material in a 5.0% NaCl aqueous solution for 480 hours.
  • the aluminum alloy casting material subjected to the T5 heat treatment may have a room temperature tensile strength in the range of 200 MPa to 230 MPa.
  • the aluminum alloy casting material may have a high temperature tensile strength of 200°C in the range of 180 MPa to 210 MPa.
  • the aluminum alloy cast material may have a high temperature tensile strength of 250°C in the range of 130 MPa to 150 MPa.
  • the aluminum alloy cast material may have a high temperature tensile strength of 300°C in the range of 90 MPa to 110 MPa.
  • the aluminum alloy casting may have a high temperature tensile strength of 350°C in the range of 60 MPa to 80 MPa.
  • composition range of the aluminum alloy cast material of the present invention the critical significance of the composition range of the aluminum alloy cast material of the present invention, the formation of intermetallic compounds according to the composition range, and the resulting effects will be explained in detail.
  • a widely used aluminum alloy casting material is an aluminum-silicon alloy. Therefore, the aluminum-silicon binary alloy will be described.
  • Figure 1 is a phase diagram of an aluminum-silicon binary alloy for alloy design of an aluminum alloy cast material according to an embodiment of the present invention.
  • a phase diagram of an aluminum-silicon binary alloy is shown.
  • silicon (Si) is 12.6% by weight
  • the composition is a eutectic reaction between aluminum and silicon.
  • a microstructure composed of ⁇ -Al and fine eutectic Si is formed below the eutectic composition (i.e., less than 12.6 wt% silicon).
  • eutectic Si fine eutectic Si
  • the eutectic composition is exceeded, that is, if silicon exceeds 12.6% by weight, a microstructure composed of ⁇ -Al, eutectic Si (eutectic Si), and primary Si (primary Si) is formed.
  • silicon has higher hardness than ⁇ -Al, which is a matrix, and can contribute to high-temperature strength and wear resistance.
  • the primary Si is formed, and as the content of silicon increases, the primary Si exists in a coarse polygonal form, which reduces the contribution to high temperature strength and also reduces wear resistance. You can. Therefore, control of the silicon content is required.
  • the interconnectivity of the generated phases within the microstructure is important, and the higher the interconnectivity, the higher the high-temperature strength.
  • the interconnectivity of the formation phases refers to the degree to which individual formation phases are in contact with each other, and can be easily understood as a truss structure.
  • the produced phase is needle-shaped or fibrous, interconnectivity is high, and if the produced phase is square or spherical, interconnectivity is low.
  • primary Si has low interconnectivity
  • eutectic Si has high interconnectivity.
  • eutectic Si appears two-dimensionally in the form of needles or fine spheres, and three-dimensionally is connected in a fibrous form, so interconnectivity is high. Therefore, the more eutectic Si, the higher the high-temperature strength can be.
  • alloys containing 10% to 13% by weight of silicon, which is near the eutectic composition of aluminum-silicon are used.
  • an alloy having a composition close to the eutectic point in the Al-Si binary phase diagram is referred to as an Al-Si approximate binary eutectic alloy (near eutectic Al-Si alloy).
  • copper (Cu) or nickel (Ni) may be added, for example, copper in an amount of 2 to 4 wt% and nickel in an amount of 2 to 3 wt%. Weight percent can be added.
  • molybdenum (Mo), chromium (Cr), manganese (Mn), cobalt (Co), titanium (Ti), zirconium (Zr), vanadium (V), etc. can be added, for example, 1% by weight of each. The following can be added.
  • Copper (Cu) can react with aluminum (Al), silicon (Si), magnesium (Mg), etc. to form various types of intermetallic compounds (IMCs).
  • the intermetallic compound may include, for example, CuAl 2 , CuMgAl, AlCuMgSi, etc.
  • the intermetallic compound can increase the hardness of the aluminum matrix and improve high-temperature strength by improving interconnectivity together with eutectic Si.
  • Nickel (Ni) can react with aluminum (Al), copper (Cu), etc. to form various types of intermetallic compounds.
  • the intermetallic compound may include, for example, Al 3 Ni, AlCuNi, etc. Most of the intermetallic compounds have a needle-like or polygonal shape, are stable at high temperatures, and have significantly higher hardness than the aluminum matrix.
  • the intermetallic compound can improve high-temperature strength by improving interconnectivity with eutectic Si.
  • the intermetallic compound may include, for example, AlMo, AlCr, AlMn, AlCo, AlZr, AlTi, AlV, AlSiTi, AlSiZr, etc. Most of the intermetallic compounds have a needle-like or polygonal shape, are stable at high temperatures, and have significantly higher hardness than the aluminum matrix.
  • the intermetallic compound can improve high-temperature strength by improving interconnectivity with eutectic Si.
  • magnesium (Mg) can be added to increase the matrix hardness of aluminum.
  • Magnesium (Mg) reacts with silicon (Si) to form a Mg 2 Si intermetallic compound.
  • the Mg 2 Si intermetallic compound has a lower corrosion potential than the aluminum matrix and can act as a sacrificial anode to improve the corrosion resistance of the alloy. there is.
  • the corrosion potential is higher than that of aluminum (Al), but the current density is low and the corrosion resistance of the alloy is not significantly reduced.
  • Magnesium (Mg) can be added, for example, in an amount of 1% by weight or less, but in the present invention, it is added in an amount of 2.7% by weight to 4.1% by weight to increase corrosion resistance.
  • the content of silicon, which relatively does not decrease corrosion resistance, and magnesium, which improves corrosion resistance are controlled, and in particular, Mg 2 Si is produced finely and densely, thereby producing
  • elements such as copper (Cu), nickel (Ni), molybdenum (Mo), chromium (Cr), manganese (Mn), cobalt (Co), titanium (Ti), zirconium (Zr), and vanadium (V).
  • Cu copper
  • Ni nickel
  • Mo molybdenum
  • Cr chromium
  • Mn manganese
  • Co cobalt
  • Ti titanium
  • V vanadium
  • Figure 2 is a phase diagram of an aluminum-silicon-magnesium alloy obtained through thermodynamic computational calculations for alloy design of an aluminum alloy cast material according to an embodiment of the present invention.
  • a ternary phase diagram of an aluminum-silicon-magnesium alloy is shown. It can be seen that when a large amount of magnesium is added to an Al-Si alloy, eutectic Si, primary Si, eutectic Mg 2 Si, and primary Mg 2 Si are produced depending on the added amounts of silicon and magnesium. At this time, in order to maximize the fraction of eutectic Si or eutectic Mg 2 Si, it is important to control the added amounts of silicon and magnesium.
  • the ternary eutectic point of Al-Si-Mg 2 Si is calculated to be 14.0% by weight of silicon and 5.1% by weight of magnesium. That is, in the Al-Si binary system, silicon added by more than 12.6% exists as polygonal primary Si as described above, but if a large amount of magnesium is added here, the excess added silicon reacts with magnesium to form eutectic Mg rather than primary Si. 2 Si is formed. Interconnectivity can be improved by forming a eutectic structure composed of fine eutectic Si and eutectic Mg 2 Si.
  • the silicon content exceeds 17% by weight, the size of primary Si increases. In order to satisfy the desired corrosion resistance and strength properties, it is desirable to increase the fraction of eutectic Si and minimize the production of primary Si.
  • primary Si has higher hardness than primary Mg 2 Si, it is more effective in improving high temperature characteristics and wear resistance, and does not significantly reduce corrosion resistance, so the characteristics can be improved even if some primary Si remains. Therefore, if the silicon content is 13.0% by weight or less, eutectic Si cannot be sufficiently secured and it is difficult to obtain a dense eutectic structure, and if the silicon content is more than 15% by weight, a large amount of primary Si may be formed. Accordingly, the content of silicon may range from more than 13.0% by weight to 15% by weight.
  • an alloy to which more than 13.0 wt% to 15.0 wt% of silicon (Si) and 2.7 wt% to 4.1 wt% of magnesium (Mg) are added to aluminum (Al) is subjected to an Al-Si-Mg 2 Si approximate ternary process. It will be referred to as the composition (near ternary eutectic Al-Si-Mg 2 Si).
  • the approximate ternary eutectic composition refers to an alloy having a composition close to the eutectic point of the ternary phase diagram shown in FIG. 2.
  • manganese (Mn) when added to the approximate ternary eutectic composition of Al-Si-Mg 2 Si, manganese reacts with aluminum, silicon, and iron, which is an inevitable impurity, to form Al(Fe, Mn)Si, etc. can be formed. As the manganese content increases, the fraction of the produced phase increases and its size becomes coarse. The addition of manganese does not significantly impair corrosion resistance, and the resulting Al(Fe, Mn)Si phase can provide the advantage of improving high-temperature tensile strength. However, if the Mn content is too excessive, Al(Fe, Mn)Si becomes coarse and may act as sludge in the molten metal. Therefore, the content of manganese may be 1% by weight or less. Additionally, the content of manganese may be 0.8% by weight or less and may range from 0.3% by weight to 0.7% by weight.
  • composition range and mechanical properties of the aluminum alloy cast material will be described in detail through experimental examples of the present invention.
  • Heat treatment (T6) was performed on the aluminum alloy casting material as follows.
  • the solution treatment was carried out in a temperature range of 490°C to 540°C. After solution treatment, it was quenched in water. Subsequently, aging treatment was performed at a temperature range of 160°C to 200°C. Details of the heat treatment were carried out in a conventional manner. The solution treatment temperature and aging treatment temperature were changed depending on the copper (Cu) content.
  • Some of the aluminum alloy castings were heat treated (T5) by only aging treatment at a temperature range of 180°C to 240°C without solution heat treatment.
  • the aging treatment temperature was changed depending on the copper (Cu) content.
  • a tensile test was performed on the aluminum alloy casting at room temperature and high temperature (200°C to 350°C) in accordance with ASTM E8 and ASTM E21 regulations.
  • a salt spray test was conducted on the aluminum alloy casting material according to ISO 9227 regulations. The salt spray test was conducted for 480 hours using a 5.0% NaCl aqueous solution, and after the test, corrosion products were removed according to ASTM G1 regulations, weight loss was measured, and the corrosion rate was calculated using this.
  • the tensile strength and corrosion rate of aluminum alloy castings are shown in Table 2 below.
  • the microstructure of the aluminum alloy cast material was observed using an optical microscope.
  • Table 1 is a table showing the composition and content of the aluminum alloy casting material according to an embodiment of the present invention.
  • the alloy composition in Table 1 refers to weight percent. In all experimental examples, the balance includes aluminum and other unavoidable impurities.
  • iron (Fe) was included as an inevitable impurity without intentional addition
  • titanium (Ti) and boron (B) were included by the addition of AlTiBor, a particle refiner.
  • Experimental Examples 1 to 3 are different in that silicon (Si) and magnesium (Mg) are included within the scope of the present invention, and copper (Cu) and manganese (Mn) are included as inevitable impurities rather than intentionally added.
  • Experimental Example 4 includes silicon (Si) within the scope of the present invention, but includes magnesium (Mg) in excess of the upper limit of the scope of the present invention, and copper (Cu) and manganese (Mn) are added without intentional addition. There is a difference in the inclusion of impurities.
  • Experimental Example 5 includes silicon (Si) and magnesium (Mg) within the scope of the present invention, but is different in that copper (Cu) and manganese (Mn) are included as inevitable impurities rather than intentionally added.
  • Experimental Example 6 includes silicon (Si) within the scope of the present invention, but includes magnesium (Mg) in excess of the upper limit of the scope of the present invention, and copper (Cu) and manganese (Mn) are added without intentional addition. There is a difference in the inclusion of impurities.
  • Experimental Example 7 contains silicon (Si) exceeding the upper limit of the range of the present invention, magnesium (Mg) below the lower limit of the range of the present invention, and copper (Cu) and manganese (Mn) are intentionally added. There is a difference in that it does not contain it as an inevitable impurity.
  • Experimental Example 8 contains silicon (Si) exceeding the upper limit of the range of the present invention, magnesium (Mg) below the lower limit of the range of the present invention, and copper (Cu) exceeding the upper limit of the range of the present invention. There is a difference in that manganese (Mn) is not added intentionally but is included as an inevitable impurity.
  • Experimental Example 9 contains silicon (Si) above the upper limit of the range of the present invention, magnesium (Mg) below the lower limit of the range of the present invention, and copper (Cu) within the range of the present invention, There is a difference in that manganese (Mn) is not added intentionally but is included as an inevitable impurity.
  • Experimental Example 10 contained silicon (Si) exceeding the upper limit of the range of the present invention, magnesium (Mg) below the lower limit of the range of the present invention, and copper (Cu) and manganese (Mn) were intentionally added. There is a difference in that it does not contain it as an inevitable impurity.
  • Experimental Example 11 includes silicon (Si) and magnesium (Mg) within the scope of the present invention, but has the difference in that copper (Cu) and manganese (Mn) are included as inevitable impurities rather than intentionally added.
  • Experimental Example 12 includes silicon (Si) below the lower limit of the range, magnesium (Mg) within the scope of the present invention, copper (Cu) within the scope of the present invention, and manganese (Mn) within the scope of the present invention. There are differences that include exceeding the upper limit of the range.
  • Experimental Example 13 contains silicon (Si) above the upper limit of the range of the present invention, magnesium (Mg) below the lower limit of the range of the present invention, and copper (Cu) and manganese (Mn) are intentionally added. There is a difference in that it does not contain it as an inevitable impurity.
  • Experimental Example 14 contained silicon (Si) exceeding the upper limit of the range of the present invention, magnesium (Mg) below the lower limit of the range of the present invention, and copper (Cu) exceeding the upper limit of the range of the present invention. There is a difference in that manganese (Mn) is not added intentionally but is included as an inevitable impurity.
  • Experimental Example 15 further includes manganese (Mn) within the scope of the present invention, and includes copper (Cu), nickel (Ni), and zirconium (Zr) as inevitable impurities without intentional addition.
  • Mn manganese
  • Cu copper
  • Ni nickel
  • Zr zirconium
  • Experimental Example 16 further includes copper (Cu) within the scope of the present invention, and includes manganese (Mn), nickel (Ni), and zirconium (Zr) as inevitable impurities without intentional addition.
  • Experimental Example 17 further includes copper (Cu) and manganese (Mn) within the scope of the present invention, and includes nickel (Ni) and zirconium (Zr) as inevitable impurities without intentional addition.
  • Experimental Example 18 further includes copper (Cu), manganese (Mn), and zirconium (Zr) within the scope of the present invention, and includes nickel (Ni) as an inevitable impurity without intentional addition.
  • Experimental Example 19 further includes copper (Cu) and nickel (Ni) within the scope of the present invention, and includes manganese (Mn) and zirconium (Zr) as inevitable impurities without intentional addition.
  • Experimental Example 20 further includes copper (Cu), manganese (Mn), and nickel (Ni) within the scope of the present invention, and includes zirconium (Zr) as an inevitable impurity without intentional addition.
  • Experimental Example 21 further includes copper (Cu), manganese (Mn), nickel (Ni), and zirconium (Zr) within the scope of the present invention.
  • Experimental Examples 22 and 23 further include copper (Cu) and manganese (Mn) within the scope of the present invention, and include nickel (Ni) and zirconium (Zr) as inevitable impurities without intentional addition.
  • Experimental Example 24 further includes copper (Cu), manganese (Mn), and nickel (Ni) within the scope of the present invention, and includes zirconium (Zr) as an inevitable impurity without intentional addition.
  • Experimental Example 25 further includes copper (Cu) and manganese (Mn) within the scope of the present invention, and includes nickel (Ni) and zirconium (Zr) as inevitable impurities without intentional addition.
  • Experimental Examples 7 to 12 and Experimental Examples 15 to 22 are cases in which T6 heat treatment is performed, and Experimental Examples 13, 14, and 23 to 25 are cases in which T5 heat treatment is performed.
  • Experimental Example 7 and Experimental Example 13 had the same alloy composition, but Experimental Example 7 was subjected to T6 heat treatment and Experimental Example 13 was subjected to T5 heat treatment.
  • Experimental Example 8 and Experimental Example 14 correspond.
  • Figures 3 and 4 are optical microscope photographs showing the microstructure of an aluminum alloy cast material for alloy design of the aluminum alloy cast material according to an embodiment of the present invention.
  • the microstructure of Experimental Examples 7 to 10 as an Al-18Si alloy is shown.
  • the microstructure consists of ⁇ -Al, eutectic Si (Eutectic Si), and primary Si. It can be confirmed that a certain amount of ⁇ -Al exists even when a large amount of silicon is added, up to 18% by weight. This means that during solidification, primary Si crystallizes first, and there is a local shortage of silicon in the vicinity of the crystallized primary Si, thereby generating ⁇ -Al. In other words, it can be seen that adding more silicon above the eutectic point of 12.6% by weight silicon in the Al-Si alloy leads to an increase in coarse primary Si rather than an increase in the eutectic structure. In addition, when adding a large amount of magnesium (Mg) to Al-18Si alloy, eutectic Mg 2 Si is generated as in Experimental Example 10, but the problem of primary Si becoming coarse is confirmed.
  • Mg magnesium
  • the ternary eutectic point of Al-Si-Mg 2 Si (Si 14.0 wt%, Mg 5.1 wt%) is an ideal case, so the magnesium content was changed from silicon 14.0 wt% Si to determine the silicon and magnesium contents. .
  • the microstructure of the aluminum alloy cast material of Experimental Examples 1 to 6, which is an Al-14Si-Mg alloy, is shown. It can be seen that the microstructure is densely composed of ⁇ -Al, eutectic Si, and eutectic Mg 2 Si. It can be seen that as the magnesium content increases, the process structure becomes more dense. For example, when the magnesium content is 4.02% by weight or more, primary Mg 2 Si is generated. On the other hand, during melting and casting, magnesium is oxidized and forms an oxide film such as MgO or MgAl 2 O 4 , which may cause casting defects. Although the casting defect did not occur in Experimental Example 3 where the magnesium content was 4.02% by weight, it was confirmed that casting defects occurred in Experimental Example 4 where the magnesium content was 4.50% by weight and Experimental Example 6 where the magnesium content was 5.33% by weight.
  • the magnesium content is less than 2.7% by weight, it is difficult to form a dense process structure, and if the magnesium content exceeds 4.1% by weight, casting defects may occur. Accordingly, the content of magnesium may range from 2.7% to 4.1% by weight.
  • Table 2 is a table showing the corrosion resistance, room temperature tensile strength, and high temperature tensile strength of aluminum alloy castings subjected to T6 heat treatment according to an embodiment of the present invention.
  • Table 2 shows the corrosion resistance, room temperature tensile strength, and high temperature tensile strength of the aluminum alloy cast material that underwent the T6 heat treatment.
  • the corrosion resistance is indicated by the corrosion rate, and the smaller the corrosion rate, the better the corrosion resistance.
  • Room temperature tensile strength was performed at 20°C
  • high temperature tensile strength was performed at 200°C, 250°C, 300°C, and 350°C.
  • Figure 5 is a graph showing the room temperature tensile strength and elongation of an aluminum alloy cast material subjected to T6 heat treatment according to an embodiment of the present invention.
  • Experimental Example 7 Experimental Example 8, Experimental Example 9, and Experimental Example 10 were alloys based on Al-18Si, and showed low high-temperature tensile strength and elongation, which was attributed to the presence of primary Si due to the high silicon content. is analyzed.
  • Experimental Examples 8 and 9 containing copper the room temperature tensile strength was increased and the high temperature tensile strength was slightly increased, but the corrosion resistance was significantly reduced, compared to Experimental Examples 7 and 10 that did not contain copper. It is analyzed as a result of the copper content.
  • Experimental Example 10 in which 1.88% by weight of magnesium was added along with a high content of silicon, showed significantly low elongation and room temperature tensile strength, which is believed to be due to coarsening of primary Si.
  • the Al-18Si-based aluminum alloy casting material has low elongation and high-temperature tensile strength, and does not satisfy corrosion resistance when it contains copper. Therefore, a method of reducing the silicon content may be considered.
  • Experimental Example 11 is an Al-14Si-based alloy, and has excellent corrosion resistance, room temperature tensile strength, and elongation, but does not satisfy the scope of the present invention because it does not contain copper and manganese, and thus has low high-temperature tensile strength.
  • Experimental Examples 16 to 22 based on Al-14Si have better corrosion resistance than Experimental Example 9 based on Al-18Si, and at 250 ° C. or higher. High temperature tensile strength was increased.
  • the silicon content was less than 13% by weight, so the corrosion resistance was reduced and the high temperature tensile strength above 250°C was reduced.
  • the silicon content range of more than 13.0% by weight to 15% by weight of the present invention can provide excellent corrosion resistance and high high temperature tensile strength.
  • Experimental Example 12 is based on Al-14Si and contains copper and manganese in excess of 1% by weight, and has excellent corrosion resistance, but the elongation is reduced and the high-temperature tensile strength is particularly low. It is analyzed that when manganese exceeds 1% by weight, the Al(Fe, Mn)Si phase becomes coarse in the form of a polygon and does not improve interconnectivity, thereby reducing high temperature tensile strength. In addition, the inclusion of manganese can more effectively suppress the decrease in corrosion resistance due to copper content. Therefore, the content of manganese may be 1% by weight or less. Additionally, the content of manganese may be 0.8% by weight or less and may range from 0.3% by weight to 0.7% by weight.
  • Experimental Example 15 does not contain copper but contains manganese, and the corrosion resistance and room temperature tensile strength are excellent, but the high temperature tensile strength tends to decrease somewhat, but compared to Experimental Example 11, which does not contain manganese, it shows excellent corrosion resistance and room temperature tensile strength up to 250°C. It is analyzed that it improves the high temperature tensile strength of. In addition, compared to Experimental Example 5 or Experimental Example 8, it is analyzed that corrosion resistance, room temperature tensile strength, and high temperature tensile strength are all improved.
  • Experimental Examples 16 to 22 are alloys within the content range of the present invention, and although the corrosion resistance is somewhat reduced compared to the case without copper, they are within the scope of the present invention, and the high room temperature tensile strength and especially high temperature tensile strength are notable. has increased significantly. In particular, compared to Experimental Examples 8 and 9 containing only copper and not manganese, it was found that the high-temperature tensile strength was increased by including copper and manganese, and it was also possible to prevent a decrease in corrosion resistance due to the addition of copper. You can.
  • the copper content that minimizes corrosion resistance degradation may be 2% by weight.
  • Experimental Example 22 is analyzed as an alloy composition showing the best properties in corrosion resistance, elongation, room temperature tensile strength, and high temperature tensile strength.
  • T5 heat treatment In general, the mechanical properties of T5 heat-treated aluminum alloy specimens are significantly lower than those of T6 heat-treated specimens. This creates various crystal phases during casting.
  • solution treatment is performed like T6 heat treatment, part of the crystalline phase is decomposed and dissolved into solid solution in the aluminum matrix, and the matrix composition becomes uniform.
  • elements supersaturated and dissolved in the matrix precipitate out during aging treatment and contribute to strength improvement, and corrosion resistance improves as production phase decomposition and matrix composition uniformity increase.
  • Table 3 is a table showing the corrosion resistance, room temperature tensile strength, and high temperature tensile strength of aluminum alloy castings subjected to T5 heat treatment according to an embodiment of the present invention.
  • Table 3 shows the corrosion resistance, room temperature tensile strength, and high temperature tensile strength of the aluminum alloy cast material that underwent the T5 heat treatment.
  • the corrosion resistance is indicated by the corrosion rate, and the smaller the corrosion rate, the better the corrosion resistance.
  • Room temperature tensile strength was performed at 20°C
  • high temperature tensile strength was performed at 200°C, 250°C, 300°C, and 350°C.
  • Figure 6 is a graph showing the room temperature tensile strength and elongation of an aluminum alloy cast material subjected to T5 heat treatment according to an embodiment of the present invention.
  • Experimental Example 13 had excellent corrosion resistance, but the room temperature tensile strength and high temperature tensile strength were significantly low.
  • Experimental Example 14 is a case containing only copper, and when compared with Experimental Example 13 not containing copper and manganese, room temperature tensile strength and high temperature tensile strength were increased, but corrosion resistance was significantly reduced.
  • Experimental Examples 23 and 25 contained copper and manganese, and the room temperature tensile strength and high temperature tensile strength were significantly increased compared to Experimental Example 13 and slightly lower than Experimental Example 14. Corrosion resistance was lower than that of Experimental Example 13, but was significantly improved compared to Experimental Example 14. Additionally, the elongation was significantly increased compared to Experimental Examples 13 and 14.
  • Experimental Example 24 is a case in which copper and manganese are included and further nickel is included, and the room temperature tensile strength and high temperature tensile strength are increased, showing a value at the level of Experimental Example 14. Corrosion resistance was lower than that of Experimental Example 13, but was significantly improved compared to Experimental Example 14. Additionally, the elongation was significantly increased compared to Experimental Examples 13 and 14.
  • Figure 7 is a graph calculated by thermodynamic calculation of the fraction of the formed phase upon addition of copper in an aluminum alloy casting material according to an embodiment of the present invention.
  • Experimental Example 15 does not contain copper, the Cu-containing phase does not appear, but the Mg-containing phase appears.
  • the fraction of the Cu-containing phase increases and at the same time, the fraction of the Mg-containing phase decreases. That is, when copper is added, the copper reacts with aluminum, silicon, and magnesium to form a Cu-rich phase such as CuAl 2 and AlCuMgSi. As the copper content increases, the fraction of the Cu-containing phase increases.
  • the fraction of Mg-rich phase such as Mg 2 Si and AlFeMgSi, which are effective for corrosion resistance, decreases. In other words, as the copper content increases, high-temperature tensile strength increases but corrosion resistance decreases.
  • the copper content may be 2.0% by weight or less. Additionally, the copper content may be 1.61% by weight or less.
  • Figure 8 is a graph calculated by thermodynamic calculation of the fraction of phases formed upon adding nickel in an aluminum alloy casting material according to an embodiment of the present invention.
  • Ni When nickel (Ni) is added to the approximate ternary composition of Al-Si-Mg 2 Si, nickel reacts with aluminum, copper, iron, etc. to form Ni-rich phases such as Al 3 Ni, AlCuNi, and AlFeNi. form As the nickel content increases, the fraction of the Ni-containing phase increases, and the high-temperature tensile strength increases but the corrosion resistance decreases. It is analyzed that at a nickel content of 2.0% by weight, high temperature tensile strength is advantageous, but corrosion resistance is likely to decrease. Therefore, in the present invention, considering the combination of high-temperature tensile strength and corrosion resistance, the nickel content may be 1.5% by weight or less. Additionally, the nickel content may be 1.0% by weight or less.
  • zirconium When zirconium (Zr) is added to the approximate ternary eutectic composition of Al-Si-Mg 2 Si, zirconium reacts with aluminum, silicon, etc. to form a product phase such as AlSiZr. As the zirconium content increases, the fraction of the produced phase increases and its size becomes coarse. The addition of zirconium improves high-temperature tensile strength without almost deteriorating corrosion resistance. However, zirconium is a high-melting point element, so as the content increases, the dissolution temperature must increase when dissolving.
  • the liquidus line of 0.25% by weight zirconium is 740°C, and the liquidus line of 0.3% by weight zirconium is 760°C. Therefore, in the present invention, considering the dissolution temperature, the zirconium content may be 0.25% by weight or less.
  • the aluminum alloy casting material according to the technical idea of the present invention may further include at least one of chromium (Cr), molybdenum (Mo), titanium (Ti), and vanadium (V).
  • TiB 2 , TiC, AlB 2 , etc. is added as a grain refiner in aluminum alloy castings.
  • the refiner is added to 0.2%.
  • 50 ppm to 200 ppm of Sr is added to refine eutectic Si
  • P AlP form
  • the aluminum alloy casting material according to the technical idea of the present invention may further include at least one of titanium (Ti), boron (B), and strontium (Sr).
  • 9 and 10 are optical microscope photographs showing the microstructure of an aluminum alloy cast material according to an embodiment of the present invention.
  • Experimental Example 21 is a case where copper (Cu), manganese (Mn), nickel (Ni), and zirconium (Zr) along with silicon (Si) and magnesium (Mg) are included within the scope of the present invention, and eutectic Si (eutectic It can be confirmed that it has a dense microstructure composed of Si) and eutectic Mg 2 Si, and that primary Si (primary Si) and primary Mg 2 Si are also formed in trace amounts.
  • Mg magnesium
  • Zr zirconium
  • Experimental Examples 12 and 22 contain similar amounts of silicon (Si), magnesium (Mg), and copper (Cu), but in Experimental Example 12, the manganese content is 1.34% by weight, which exceeds 1% by weight, and Example 22 is 0.344% by weight, which is 1% by weight or less. As described above, it can be seen that as the content of manganese increases, the fraction of the Al(Fe, Mn)Si formation phase increases and its size also becomes coarse.
  • Figure 11 is a schematic diagram showing a brake system including a brake disc formed of aluminum alloy casting according to an embodiment of the present invention.
  • the brake system 100 includes a brake disc 120 inserted into the rotation shaft 110 of a vehicle, and a brake pad (brake pad) that slows down the rotation of the brake disc 120 by frictional contact with the brake disc 120. 130), and a caliper that secures the brake pads 130 to be disposed on both outer sides of the brake disc 120.
  • the brake disc 120 may be made of an aluminum alloy casting material having the composition described above.
  • the brake disc 120 includes, for example, more than 13.0% by weight to 15% by weight of silicon (Si); 2.7% to 4.1% magnesium (Mg) by weight; Greater than 0% to 2% copper (Cu) by weight; and the remainder may be composed of aluminum alloy casting material containing aluminum (Al) and inevitable impurities.
  • the brake disc 120 includes, for example, more than 13.0% by weight to 15% by weight of silicon (Si); 2.7% to 4.1% magnesium (Mg) by weight; Greater than 0% to 2% copper (Cu) by weight; Greater than 0% to 1.0% by weight manganese (Mn); and the remainder may be composed of aluminum alloy casting material containing aluminum (Al) and inevitable impurities.
  • the brake disc 120 includes, for example, more than 13.0% by weight to 15% by weight of silicon (Si); 2.7% to 4.1% magnesium (Mg) by weight; Greater than 0% to 1% by weight manganese (Mn); and the remainder may be composed of aluminum alloy casting material containing aluminum (Al) and inevitable impurities.
  • the aluminum alloy casting materials may further include nickel (Ni) in an amount of more than 0% by weight to 1.5% by weight in addition to the above elements, or may further include zirconium (Zr) in an amount of more than 0% by weight to 0.25% by weight in addition to the elements. or more than 0% by weight to 1.5% by weight of nickel (Ni) in addition to the above elements; And it may further include zirconium (Zr) in an amount of more than 0% by weight to 0.25% by weight.
  • the aluminum alloy casting materials include titanium (Ti) in an amount of more than 0% by weight to 0.05% by weight in addition to the above elements; And it may further include boron (B) in an amount of more than 0% by weight to 0.005% by weight.
  • the aluminum alloy casting materials may further include iron (Fe) in an amount of more than 0% by weight to 0.2% by weight as an inevitable impurity in addition to the above elements.
  • the aluminum alloy casting material may further contain 30 ppm to 200 ppm of phosphorus.
  • the phosphorus may be included in the form of AlP.
  • the aluminum alloy casting material may further include 50 ppm to 200 ppm of strontium (Sr).
  • the brake disc 120 includes, for example, more than 13.0% by weight to 15% by weight of silicon (Si); 2.81% to 3.5% magnesium (Mg) by weight; 0.021% to 1.603% by weight copper (Cu); 0.002% to 0.537% by weight manganese (Mn); and the remainder may be composed of aluminum alloy casting material containing aluminum (Al) and inevitable impurities. Additionally, the content of silicon (Si) contained in the aluminum alloy casting may range from 13.3% by weight to 14.6% by weight.
  • the aluminum alloy casting material may further include 0.021% to 0.641% by weight of nickel (Ni) in addition to the above elements, or may further include 0.004% to 0.185% by weight of zirconium (Zr) in addition to the above elements.
  • the aluminum alloy casting material includes, in addition to the above elements, 0.034% by weight to 0.040% by weight of titanium (Ti); And it may further include 0.001% by weight to 0.004% by weight of boron (B).
  • the aluminum alloy casting material may further include 0.120% by weight to 0.158% by weight of iron (Fe) as the inevitable impurity.
  • the aluminum alloy casting material may further contain 30 ppm to 200 ppm of phosphorus. The phosphorus may be included in the form of AlP. Additionally, the aluminum alloy casting material may further include 50 ppm to 200 ppm of strontium (Sr).
  • the aluminum alloy casting material can be applied to parts of transportation such as automobiles, ships, or aircraft, and can be applied to various parts manufactured by die casting, for example.
  • this is illustrative and the technical idea of the present invention is not limited to this use.
  • an aluminum alloy casting material having high high-temperature strength and excellent corrosion resistance and wear resistance can be provided by controlling the alloy composition and content of copper and manganese. Additionally, a brake disc for an electric vehicle can be manufactured using the alloy.

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Abstract

La présente invention concerne un matériau de coulée d'alliage d'aluminium ayant d'excellentes résistance à la traction à haute température et résistance à la corrosion. Le matériau de coulée d'alliage d'aluminium comprend 13,0 % en poids (exclu) à 15 % en poids (inclus) de silicium (Si), 2,7 % en poids à 4,1 % en poids de magnésium (Mg), 0 % en poids (exclu) à 2 % en poids (inclus) de cuivre (Cu), et le reste étant de l'aluminium (Al) et des impuretés inévitables.
PCT/KR2023/005785 2022-09-01 2023-04-27 Matériau de coulée en alliage d'aluminium et disque de frein comprenant celui-ci WO2024048895A1 (fr)

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KR20220110427 2022-09-01
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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2002535488A (ja) * 1999-01-21 2002-10-22 アルミニウム ペシネイ 半固体状態での成形のための過共晶アルミニウム−珪素合金生成物
KR20090046868A (ko) * 2006-08-01 2009-05-11 쇼와 덴코 가부시키가이샤 알루미늄 합금 성형품의 제조 방법, 알루미늄 합금 성형품 및 생산 시스템
JP2018184659A (ja) * 2017-04-27 2018-11-22 株式会社コイワイ 高強度アルミニウム合金積層成形体及びその製造方法
WO2019161137A1 (fr) * 2018-02-14 2019-08-22 Arconic Inc. Produits en alliage d'aluminium et leurs procédés de production
CN111074114A (zh) * 2020-01-03 2020-04-28 北京科技大学 一种Al-Si-Mg-Li系铝合金及其制备方法

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2002535488A (ja) * 1999-01-21 2002-10-22 アルミニウム ペシネイ 半固体状態での成形のための過共晶アルミニウム−珪素合金生成物
KR20090046868A (ko) * 2006-08-01 2009-05-11 쇼와 덴코 가부시키가이샤 알루미늄 합금 성형품의 제조 방법, 알루미늄 합금 성형품 및 생산 시스템
JP2018184659A (ja) * 2017-04-27 2018-11-22 株式会社コイワイ 高強度アルミニウム合金積層成形体及びその製造方法
WO2019161137A1 (fr) * 2018-02-14 2019-08-22 Arconic Inc. Produits en alliage d'aluminium et leurs procédés de production
CN111074114A (zh) * 2020-01-03 2020-04-28 北京科技大学 一种Al-Si-Mg-Li系铝合金及其制备方法

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