U.S. patent application number 13/501816 was filed with the patent office on 2012-09-27 for process for producing brake piston.
This patent application is currently assigned to SHOWA DENKO K.K.. Invention is credited to Yasuo Okamoto.
Application Number | 20120241055 13/501816 |
Document ID | / |
Family ID | 43876245 |
Filed Date | 2012-09-27 |
United States Patent
Application |
20120241055 |
Kind Code |
A1 |
Okamoto; Yasuo |
September 27, 2012 |
PROCESS FOR PRODUCING BRAKE PISTON
Abstract
A brake piston having required mechanical strength is produced
through fewer steps than in conventional processes. An aluminum
alloy containing Si and Mg, wherein the aluminum alloy has a Si
concentration (C.sub.Si, mass %) and a Mg concentration (C.sub.Mg
mass %) falling within a range surrounded by four points A (0.75,
1.25), B (1.4, 1), C (1.4, 0.6), and D (0.75, 0.85) in terms of a
relationship thereof (C.sub.Si, C.sub.Mg), and further has a Cu
concentration of 0.07 to 0.9 mass %, a Mn concentration of 0.1 to
0.9 mass %, a Ti concentration of 0.005 to 0.15 mass %, a Cr
concentration of 0.2 mass % or less, and a Fe concentration of 0.5
mass or less %, the balance being A1 and inevitable impurities is
cast to obtain a rod-shaped ingot. The rod-shaped ingot, without
being subjected to a homogenization treatment, is straightened
within 3 (three) days after the casting. The straightened
rod-shaped ingot is cut into a given thickness to obtain a forging
raw material. This forging raw material, without being subjected to
annealing, is cold-forged at a reduction rate of 25 to 90% within 7
(seven) days after the casting of the rod-shaped ingot into a cup
shape, which is subjected to age-hardening without being subjected
to a solution heat treatment.
Inventors: |
Okamoto; Yasuo;
(Kitakata-shi, JP) |
Assignee: |
SHOWA DENKO K.K.
Minato-ku, Tokyo
JP
|
Family ID: |
43876245 |
Appl. No.: |
13/501816 |
Filed: |
October 15, 2010 |
PCT Filed: |
October 15, 2010 |
PCT NO: |
PCT/JP2010/068124 |
371 Date: |
June 15, 2012 |
Current U.S.
Class: |
148/552 |
Current CPC
Class: |
B22D 21/007 20130101;
C21D 9/0068 20130101; C22C 21/02 20130101; C22F 1/05 20130101; C22C
21/08 20130101; F16D 2125/06 20130101; F16D 2200/003 20130101; B21K
1/18 20130101; B21J 5/00 20130101; C22F 1/047 20130101; C22F 1/043
20130101; B22D 11/003 20130101 |
Class at
Publication: |
148/552 |
International
Class: |
C22F 1/043 20060101
C22F001/043; C22F 1/047 20060101 C22F001/047; C22F 1/05 20060101
C22F001/05 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 16, 2009 |
JP |
2009-239295 |
Claims
1. A production method of a brake piston, comprising the steps of:
casting a rod-shaped ingot of aluminum alloy containing Si and Mg,
wherein the aluminum alloy has a Si concentration (C.sub.Si mass %)
and a Mg concentration (C.sub.Mg mass %) falling within a range
surrounded by four points A (0.75, 1.25), B (1.4, 1), C (1.4 0.6),
and D (0.75, 0.85) in terms of a relationship thereof (C.sub.Si,
C.sub.Mg), and further has a Cu concentration of 0.07 to 0.9 mass
%, a Mn concentration of 0.1 to 0.9 mass %, a Ti concentration of
0.005 to 0.15 mass %, a Cr concentration of 0.2 mass % or less, and
a Fe concentration of 0.5 mass % or less, the balance being A1 and
inevitable impurities; straightening the rod-shaped ingot within 3
(three) days after the casting without being subjected to a
homogenization treatment; cutting the straightened rod-shaped ingot
into a given thickness to obtain a forging raw material;
cold-forging the forging raw material at a reduction rate of 25 to
90% within 7 (seven) days after the casting of the rod-shaped ingot
without being subjected to annealing to form a cup-shaped brake
piston; and age-hardening the formed cup-shaped brake piston
without being subjected to a solution heat treatment.
2. The production method of a brake piston as recited in claim 1,
wherein the rod-shaped ingot is continuously cast at a casting rate
of 200 m/min or more.
3. The production method of a brake piston as recited in claim 1,
wherein a Rockwell hardness of the continuously cast rod-shaped
ingot naturally aged for 30 days after the continuous casting is
defined as a reference hardness, and wherein the straightening of
the rod-shaped ingot is performed within a period of time during
which a relative hardness of the rod-shaped ingot given by the
following equation is 0.9 or less: [the relative hardness of the
rod-shaped ingot]=[Rockwell hardness of the rod-shaped ingot]/[the
reference hardness].
4. The production method of a brake piston as recited in claim 1,
wherein a Rockwell hardness of a continuously cast rod-shaped ingot
naturally aged for 30 days after the continuous casting is defined
as a reference hardness, and wherein the straightening of the
rod-shaped ingot is performed within a period of time during which
a relative hardness of the rod-shaped ingot given by the following
equation is 0.95 or less: [the relative hardness of the rod-shaped
ingot]=[Rockwell hardness of the rod-shaped ingot]/[the reference
hardness].
5. The production method of a brake piston as recited in claim 2,
wherein a Rockwell hardness of the continuously cast rod-shaped
ingot naturally aged for 30 days after the continuous casting is
defined as a reference hardness, and wherein the straightening of
the rod-shaped ingot is performed within a period of time during
which a relative hardness of the rod-shaped ingot given by the
following equation is 0.9 or less: [the relative hardness of the
rod-shaped ingot]=[Rockwell hardness of the rod-shaped ingot]/[the
reference hardness].
6. The production method of a brake piston as recited in claim 2,
wherein a Rockwell hardness of a continuously cast rod-shaped ingot
naturally aged for 30 days after the continuous casting is defined
as a reference hardness, and wherein the straightening of the
rod-shaped ingot is performed within a period of time during which
a relative hardness of the rod-shaped ingot given by the following
equation is 0.95 or less: [the relative hardness of the rod-shaped
ingot]=[Rockwell hardness of the rod-shaped ingot]/[the reference
hardness].
Description
TECHNICAL FIELD
[0001] The present invention relates to a process for producing a
brake piston by means of cold forging.
BACKGROUND TECHNIQUE
[0002] In recent years, in a brake disk for a vehicle, such as,
e.g., a four-wheel vehicle or a two-wheel vehicle, for the purpose
of attaining higher performance and/or lower-fuel consumption, a
brake piston of aluminum alloy has been employed. Such a brake
piston is a slide member, which is required to have excellent
mechanical strength. The cup-shaped brake piston 1 shown in FIG. 1
is one example of such slide members (see Patent Document 1). In
producing such a cup-shaped brake piston, conventionally, a billet
was extruded and then drawn into a rod-shaped raw material.
Thereafter, the raw material was subjected to a solution treatment
and also to an aging treatment to thereby obtain a given mechanical
strength, and then formed into a cup-shape by mechanical
working.
[0003] The aforementioned production method, however, was extremely
poor in material yield, and therefore there has been proposed a
method in which shaping into a cup-shape is performed by forging to
improve material yield and a heat treatment is performed to obtain
predetermined mechanical strength (see Patent Document 2).
[0004] The slide member described in Patent Document 2 is a member
in which the particle diameter and the number of eutectic Si
particles dispersed in a matrix of an Al--Si series alloy formed
article are regulated and that the thickness and the hardness of
the anode oxide film are also regulated. The production method, as
described in the paragraph [0070], includes the steps of: casing a
rod member of aluminum alloy; homogenizing the rod member; peeling
the cast surface of the homogenized rod member; cutting the peeled
member into a given length; annealing the cut member; bonderizing
the annealed member; forging the bonderized member into a
cup-shape; subjecting the cup-shaped member to a T6 treatment
(solution treatment and subsequent aging treatment); subjecting the
T6 treated forged member to mechanical working (to improve the
dimensional accuracy and remove distorted portions caused during
the solution treatment); and then anodizing the machined member. In
cases where a member obtained by cutting a rod-shaped member into a
given thickness is used as a forging raw material, it is normally
performed to correct/straighten the rod-shaped member before
execution of peeling and perform inspection after execution of the
peeling. FIG. 6 shows the flaw of the aforementioned steps.
[0005] Further, as a forging raw material, there is a case to use a
material obtained by casting a billet, homogenizing the billet,
extruding the homogenized billet and drawing the extruded member
into a rod member with a given diameter, and then cutting the
rod-shaped member to have a given thickness. The forging raw
material is annealed before cold forging in the same manner as in a
raw material produced by cutting a cast rod-shaped member.
PRIOR ARTS
Patent Documents
[0006] Patent Document 1: Japanese Unexamined Laid-open Patent
Application Publication No. 2002-70902 (JP-A-2002-70902) [0007]
Patent Document 2: Japanese Unexamined Laid-open Patent Application
Publication No. 2004-232087 (JP-A-2002-232087) (see claims, and
[0070])
SUMMARY OF THE INVENTION
Problems to be Solved by the Invention
[0008] The aforementioned production steps for a slide member
include a plurality of heat treatments including a homogenization
treatment of a cast rod member or a billet, annealing of a forging
raw material, a solution treatment of a forged article, and an
aging treatment. Thus, there is a problem that the number of steps
is large and the production efficiency is poor. Also from the
viewpoint of saving energy and reducing the amount of CO.sub.2
emission, it is desired to reduce the number of heat treatment
steps to be executed.
Means for Solving the Problems
[0009] In view of the above technical background, the present
invention provides a production method capable of producing a brake
piston having required mechanical strength with fewer steps than in
conventional methods.
[0010] A production method of a brake piston according to the
present invention has a structure as recited in the following items
[1] to [6].
[0011] A production method of a brake piston, comprising the steps
of:
[0012] casting a rod-shaped ingot of aluminum alloy containing Si
and Mg, wherein the aluminum alloy has a Si concentration (C.sub.Si
mass %) and a Mg concentration (C.sub.Mg mass %) falling within a
range surrounded by four points A (0.75, 1.25) B (1.4, 1), C (1.4,
0.6), and D (0.75, 0.85) in terms of a relationship thereof
(C.sub.Si, C.sub.Mg), and further has a Cu concentration of 0.07 to
0.9 masse, a Mn concentration of 0.1 to 0.9 mass %, a Ti
concentration of 0.005 to 0.15 mass %, a Cr concentration of 0.2
mass % or less, and a Fe concentration of 0.5 mass %, the balance
being Al and inevitable impurities;
[0013] straightening the rod-shaped ingot within 3 (three) days
after the casting without being subjected to a homogenization
treatment;
[0014] cutting the straightened rod-shaped ingot into a given
thickness to obtain a forging raw material;
[0015] cold-forging the forging raw material at a reduction rate of
25 to 90% within 7 (seven) days after the casting of the rod-shaped
ingot without being subjected to annealing to form a cup-shaped
brake piston; and
[0016] age-hardening the formed cup-shaped brake piston without
being subjected to a solution heat treatment.
[0017] [2] The production method of a brake piston as recited in
the aforementioned Item 1, wherein the rod-shaped ingot is
continuously cast at a casting rate of 200 m/min. or above.
[0018] [3] The production method of a brake piston as recited in
the aforementioned Item 1 or 2,
[0019] wherein a Rockwell hardness of the continuously cast
rod-shaped ingot naturally aged for 30 days after the continuous
casting is defined as a reference hardness, and
[0020] wherein the straightening of the rod-shaped ingot is
performed within a period of time during which a relative hardness
of the rod-shaped ingot given by the following equation is 0.9 or
less:
[the relative hardness of the rod-shaped ingot]=[Rockwell hardness
of the rod-shaped ingot]/[the reference hardness].
[0021] [4] The production method of a brake piston as recited in
any one of the aforementioned items 1 to 3,
[0022] wherein a Rockwell hardness of a continuously cast
rod-shaped ingot naturally aged for 30 days after the continuous
casting is defined as a reference hardness, and
[0023] wherein the straightening of the rod-shaped ingot is
performed within a period of time during which a relative hardness
of the rod-shaped ingot given by the following equation is 0.95 or
less:
[the relative hardness of the rod-shaped ingot]=[Rockwell hardness
of the rod-shaped ingot]/[the reference hardness]
Effects of the Invention
[0024] According to the invention as recited in the aforementioned
item [1], in producing a brake piston of aluminum alloy having a
prescribed composition, the steps up to the cold forging are
performed within a fewer number of days lapsed after the casting of
the rod-shaped ingot. Concretely, straightening of the rod-shaped
ingot is performed within 3 (three) days after the casting and cold
forging of the forging raw material obtained by cutting the
rod-shaped ingot is performed within 7 (seven) days after the
casting. During the time periods, since the material is low in
hardness and therefore the workability thereof is good, and good
workability can be secured even without subjecting it to heat
treatments before the straightening and before the cold forging.
The brake piston formed by the cold forging is enhanced in hardness
due to solution hardening and crystal dispersion by the elements
contained in the aluminum alloy, and can have hardness required for
a brake piston by the age-hardening without performing a solution
treatment due to work hardening resulting from the cold-forging
performed at a reduction rate of 25 to 90%. That is, without
executing a homogenization treatment before the straightening,
annealing before the cold forging, and a solution treatment after
the cold forging, it is possible to produce a brake piston having
required hardness. Therefore, as compared with a conventional
production method in which heat treatments mentioned above are
performed, the method of the present invention is higher in
production efficiency and can reduce energy costs. Furthermore, not
performing a solution treatment after the casting causes no quench
distortions, rendering a machining step for removing distortions
unnecessary, which reduces waist of material.
[0025] According to the invention as recited in the aforementioned
item [2], the rod-shaped ingot is cooled quickly at the time of
casting, which effectively exerts the hardness improving effect by
the age-hardening.
[0026] According to the invention as recited in the aforementioned
item [3], a Rockwell hardness of the continuously cast rod-shaped
ingot naturally aged for 30 days after the continuous casting is
defined as a reference hardness, and the relative hardness of the
rod-shaped ingot at the time of the straightening and given by the
equation of "the relative hardness of the rod-shaped
ingot"="Rockwell hardness of the rod-shaped ingot"/"the reference
hardness" is 0.9 or less. The relative hardness supports that the
straightening can be performed easily.
[0027] According to the invention as recited in the aforementioned
item [4], a Rockwell hardness of a continuously cast rod-shaped
ingot naturally aged for 30 days after the continuous casting is
defined as a reference hardness, and the relative hardness of the
forging material given by the equation of "the relative hardness of
the forging material"="Rockwell hardness of the forging
material"/"the reference hardness" is 0.95 or less. The relative
hardness supports that the straightening can be performed
easily.
BRIEF EXPLANATION OF THE DRAWINGS
[0028] FIG. 1 is a perspective view of a brake piston.
[0029] FIG. 2 is a flowchart showing production steps of the brake
piston according to the present invention.
[0030] FIG. 3 is a graph showing a hardness transition of a cast
member.
[0031] FIG. 4 is a drawing showing a relation between a Si
concentration and a Mg concentration in the aluminum alloy used in
the present invention.
[0032] FIG. 5 is a cross-sectional view showing shape changes from
a raw material to a forged member by cold forging.
[0033] FIG. 6 is a flowchart showing conventional production steps
of a brake piston.
EMBODIMENTS FOR CARRYING OUT THE INVENTION
[0034] FIG. 1 shows an embodiment of a cup-shaped brake piston 1 to
be produced in accordance with the present invention, and FIG. 2 is
a flowchart showing production steps according to the present
invention. The brake piston 1 is to be movably inserted into a
hydraulic cylinder, for example, in a disk brake so as to press a
friction pad against the brake disk with the opening end
portion.
[0035] Aluminum alloy is low in hardness immediately after the
casting, but increases in hardness by natural aging with time, and
eventually has certain hardness. FIG. 3 shows a graph showing a
transition of relative hardness of a cast member of aluminum alloy
measured with time with respect to hardness of the cast member
after 30 days. The aluminum alloy used to create this graph had a
chemical composition consisting of Si: 1.06 mass %, Mg: 0.86 mass
%, Cu: 0.4 mass %, Mn: 0.49 mass %, Cr: 0.14 mass %, Fe: 0.25 mass
%, Ti: 0.015 mass %, and the balance being Al and inevitable
impurities. A test piece was obtained by cutting a cast rod into a
length of 20 mm immediately after the casting and machining the end
face, and the RF hardness of the machined face was measured with a
Rockwall hardness gauge. Immediately after the production of the
test piece having a thickness of 20 mm, the HRF hardness thereof
was initially measured immediately after the casting (after passing
0 day), and thereafter the HRF hardness of the same machined face
was measured every day until the 30.sup.th day. The relative
hardness was calculated by the following formula, wherein the HRF
hardness on the 30.sup.th day, i.e., Rockwell hardness (HRF
hardness) of the test piece naturally aged for 30 days after the
continuous casting of the rod-shaped ingot, was defined as the
reference hardness.
[the relative hardness]=[Rockwall hardness on each measurement
day]/[the reference hardness]
[0036] Although FIG. 3 shows the hardness transition of the
aluminum alloy having the aforementioned composition based on the
actually measured data, the hardness of the aluminum alloy having
the chemical composition defined by the present invention undergoes
the same hardness transition pattern because of the following
reasons.
[0037] FIG. 4 shows a relation between the Si concentration
(C.sub.Si mass %) and the Mg concentration (C.sub.Mg) in the
aluminum alloy, and the range surrounded by the 4 (four) points of
A (0.75, 1.25), B (1.4, 1) C (1.4, 0.6), and D (0.75, 0.85) shows
the Si concentration and the Mg concentration of the aluminum
alloy. The straight line F depicts the formula F showing the
relation of the Si concentration (C.sub.Si mass %) and the Mg
concentration (C.sub.Mg mass %) forming Mg.sub.2Si crystals.
Si concentration(C.sub.Si)=[Si atomic weight/(Mg atomic
weight.times.2)].times.Mg concentration(C.sub.Mg mass
%)=0.58.times.Mg concentration (C.sub.Mg) Formula F
[0038] As shown FIG. 4, the aluminum alloy each used in the present
invention is an Al--Mg--Si series alloy in which the Si
concentration exceeds 0.58.times.Mg concentration and contains
excessive Si with respect to Mg. For this reason, the aluminum
alloy used in the present invention has an aging behavior similar
to that of the aluminum alloy in which the hardness transition
shown in FIG. 3 was actually measured, and undergoes the hardness
transition in the same pattern as shown in FIG. 3 after the
continuous casting.
[0039] FIG. 3 shows that the aluminum alloy is low in hardness for
a few days after the casting. Focusing attention on the fact that
the hardness increases from a few days after the casting, in the
present invention, processing up to the cold forging are performed
within fewer days after the casting during which the hardness is
low and the workability is excellent, and no heat treatment prior
to processing which had been conventionally executed is performed.
According to a conventional production process, a homogenization
treatment was performed before straightening and annealing was
performed before cold forging (see FIG. 6). The reasons for
performing a heat treatment before plastic forming were to
uniformize the workability of the raw material because there was a
case in which a raw material increased in hardness after a long
time has passed since the casting was used or a case in which raw
materials different in hardness due to the difference of elapsed
time were processed by the same operation. In other words, no
attention was conventionally paid to hardness transition of a raw
material to be processed. In return for it, uniformizing by heat
treatments before processing was performed as essential
processing.
[0040] In a conventional method, the reasons for requiring a
homogenization treatment of a rod-shaped ingot, annealing of a
forging raw material and a solution treatment of a forged member as
essential steps are as follows. Simply omitting a homogenization
treatment of a rod-shaped ingot renders a straightening process
difficult since the ingot is still high in hardness. Furthermore,
simply omitting annealing of the forging raw material makes a
forging process by cold forging difficult since the forging raw
material is still high in hardness. In addition, simply omitting a
solution treatment of a forged member for the purpose of
simplifying heat treatment processing results in non-annealing,
which in turn deteriorates the product strength.
[0041] On the other hand, in the present invention, the technical
concept has been changed from conventional steps. The technical
problem to be solved by the present invention is to produce a
product having preferable hardness with the maximum help of a
quench hardening effect due to a rapid cooling effect during the
continuous casting without preforming a solution treatment. To
solve the problem, heat treatments (homogenizing treatment and
annealing), which deteriorate quench hardening due to a rapid
cooling effect during the continuous casting, are omitted to attain
enhanced strength, and execution timings for straightening and cold
forging are defined based on the elapsed time from the casting to
secure excellent workability by performing straightening and cold
forging within a period of time during which the hardness is kept
low, without performing heat treatments before the processing.
Furthermore, the alloy composition is adjusted to improve the
strength. Further, a raw material shape is designed so as to
increase the reduction rate during the cold forging to attain
enhanced strength by the work hardening. Specifically, by defining
the alloy composition and setting the timings for the straightening
and cold forging from the casting as defined in the present
invention, the straightening and cold forging could have been
performed without any problem and that a brake piston material with
satisfactory strength could have been produced.
[0042] The present invention defines the timing for straightening
the rod-shaped ingot and the timing for cold-forging the forging
material by the elapsed time after the continuous casting or the
material hardness at the time of processing, or by both the elapsed
time after the continuous casting and the material hardness at the
time of processing.
[0043] The present invention can be realized by a brake piston
production method including
[0044] a straightening step for straightening a rod-shaped ingot
within 3 (three) days after the casting, wherein the straightening
step follows a casting step,
[0045] a cutting step for cutting the straightened rod-shaped ingot
into a given thickness to obtain a forging raw material,
[0046] a forging step for forming a cup-shaped brake piston by
cold-forging the forging raw material at a reduction rate of 25 to
90% within 7 (seven) days after the casting of the rod-shaped
ingot, wherein the forging step follows the cutting step, and
[0047] an age-hardening step for age-hardening the formed brake
piston, wherein the age-hardening step follows the forging
step.
[0048] Hereinafter, the present invention will be detailed.
[Chemical Composition of Aluminum Alloy]
[0049] The aluminum alloy used in the present invention includes
Si, Mg, Cu, and Mn, wherein Ti, Cr and Fe are regulated, and the
balance being Al and inevitable impurities.
[0050] Si and Mg are elements to be added to obtain strength
required for a brake piston, and FIG. 4 shows the relation between
a Si concentration (C.sub.Si mass %) and a Mg concentration
(C.sub.Mg mass %). The Si concentration (C.sub.Si mass %) and the
Mg concentration (C.sub.Mg mass %) are regulated so as to fall
within a range surrounded by four points A (0.75, 1.25), B (1.4,
1), C (1.4, 0.6), and D (0.75, 0.85) in terms of a relationship of
these concentrations (C.sub.Si, C.sub.Mg). From the aforementioned
A, B, C, and D, the possible range of the Si concentration
(C.sub.Si, mass %) is 0.75 to 1.4 mass %, the possible range of the
Mg concentration (C.sub.Mg mass %) is 0.6 to 1.25 mass %. If the Si
concentration is less than 0.75 mass % or the Mg concentration is
less than 0.60 mass %, the strength enhancing effect can be less
expected, resulting in insufficient strength. On the other hand, if
the Si concentration exceeds 1.4 mass % or the Mg concentration
exceeds 1.25 mass %, the workability at the straightening and
cold-forging steps deteriorates, causing processing defects. In
order to attain both the excellent strength and the excellent
workability, it is required for both the concentrations to fall
within the range surrounded by the four points of A, B, C, and
D.
[0051] In FIG. 4, the formula showing the straight line passing two
points can be calculated as follows:
[0052] The straight line passing the points A and B:
C.sub.Mg=-0.385.times.C.sub.s, +1.538
[0053] The straight line passing the points B and C:
C.sub.Mg=1.4
[0054] The straight line passing the points C and D:
C.sub.Mg=-0.385.times.C.sub.Si+1.138
[0055] The straight line passing the points D and A:
C.sub.Mg=0.75
[0056] Accordingly, the Si concentration (C.sub.Si mass %) and the
Mg concentration (C.sub.Mg mass %) according to the present
invention fall within the range satisfying the following four
formulas (i), (ii), (iii), and (iv):
C.sub.Mg.ltoreq.-0.385.times.C.sub.Si+1.538 (i)
C.sub.Mg.ltoreq.1.4 (ii)
C.sub.Mg.ltoreq.-0.385.times.C.sub.Si+1.138 (iii)
C.sub.Mg.ltoreq.0.75 (iv)
[0057] The more preferable range can be suggested by a range
surrounded by A' (0.9, 1.1), B' (1.3, 0.95), C' (1.3, 0.7), and D'
(0.9, 0.85) (see FIG. 4).
[0058] Cu and Mn are also elements to be added to enhance the
strength. If the Cu concentration is less 0.07 mass %, or the Mn
concentration is less than 0.1 mass %, the strength enhancing
effect can be less expected, resulting in insufficient strength. On
the other hand, if the Cu concentration exceeds 0.9 mass % or the
Mn concentration exceeds 0.9 mass %, the workability at the
cold-forging step deteriorates, causing processing defects. The
more preferable Cu concentration is 0.2-0.7 mass %, and the more
preferable Mn concentration is 0.3-0.8 mass %.
[0059] Ti is an element to be added to miniaturize the cast
structure to thereby enhance the workability at the cold-forging
step. If the Ti concentration is less than 0.005 mass %, the
aforementioned effect can be less expected. On the other hand, if
it exceeds 0.15 mass %, coarse intermetallic compounds will be
formed to deteriorate the workability at the cold-forging step. The
more preferable Ti concentration is 0.008-0.1 mass %.
[0060] Cr and Fe are elements which deteriorate the workability at
the cold forging step, and it is required to control such that the
Cr concentration is 0.2 mass % or less and the Fe concentration is
0.5 mass % or less. The more preferable Cr concentration is 0.15
mass % or less, and the more preferable Fe concentration is 0.4
mass % or less.
[0061] The balance of the aluminum alloy containing the
aforementioned elements falling within the aforementioned
concentration ranges is Al and inevitable impurities.
[0062] [Production Step]
[0063] In FIG. 2 showing the production steps according to the
present invention, the steps each shown by a solid block are
essential steps, and the steps each shown by a dashed block are
arbitrary steps. Hereinafter, each step will be detailed with
reference to the flowchart shown in FIG. 2.
[0064] (Casting)
[0065] A rod-shaped ingot of aluminum alloy having the
aforementioned composition is cast. Although the casting method is
not specifically limited, it is preferable that the casting method
is a continuous casting method. A continuous casting can be either
a horizontal type casting or a vertical type casting, and a hot-top
casting is specifically recommended on the grounds that a great
quenching effect can be expected due to the rapid cooling of the
ingot and that metal texture having an even and fine casting
surface can be obtained. It is preferable to perform the casting at
a casting rate of 200 m/min. or higher because the increased
casting rater causes rapid cooling of the ingot, resulting in an
increased hardening enhancing effect due to aging. The more
preferable casting rate is 250 m/min. or higher.
[0066] (Straightening)
[0067] The rod-shaped ingot is straightened to enhance the
straightness. It is required to perform the straightening step
before the peeling step for removing the surface of the
straightened rod-shaped ingot in order to prevent a possible jam of
the rod-shaped ingot in a peeling machine when inserted into the
peeling machine to enhance the smooth feeding through the peeling
machine. The straightening is performed within 3 days (72 hours)
after the casting without performing a homogenization treatment. As
shown in FIG. 3, the hardness on the 3.sup.rd day after the casting
in a state of being left unattended at normal temperature is 0.90
or less in relative hardness with respect to the reference hardness
on the 30.sup.th day, and therefore straightening can be performed
without performing a homogenization treatment. If age-hardening
develops over 3 days after the casting, it becomes difficult to
straighten the ingot without performing a homogenization treatment.
The more preferable timing for the straightening is within 2 days
after the casting.
[0068] Furthermore, whether or not smooth straightening can be
performed without performing a homogenization treatment is affected
by the hardness at the time of the straightening, and therefore the
timing for the straightening can be regulated by the hardness of
the rod-shaped ingot. For example, it is preferable that the
Rockwell hardness before the straightening is less than 76.3. For
example, when the Rockwell hardness of the continuously cast
rod-shaped ingot naturally aged for 30 days after the continuous
casting is defined as a reference hardness, if it is within the
period in which the relative hardness of the rod-shaped ingot
defined by the following formula is 0.9 or less, the straightening
can be performed without performing a homogenization treatment.
Especially, if it is within a period in which the relative hardness
is less than 0.889, the hardness is further lower, which is more
suitable to the straightening. Furthermore, it is more preferable
to satisfy both the Rockwell hardness condition and the relative
hardness condition.
[0069] The relative hardness of the rod-shaped ingot=Rockwell
hardness of the rod-shaped ingot/the reference hardness
[0070] In the present invention, the execution timing for the
straightening of the rod-shaped ingot can be defined by either the
elapsed days after the casting or Rockwell hardness and/or the
relative hardness. Furthermore, when the straightening execution
timing is provisionally set by the elapsed days after the casting,
it can be continued by the Rockwell hardness and/or the relative
hardness that the provisionally set straightening execution timing
is suitable for the straightening.
[0071] The straightening method is not specifically limited, and
the straightening can be performed by any well-known straightening
method, such as, e.g., a method in which the straightening is
performed by pinching the ingot by and between rollers.
[0072] (Peeling, Inspection)
[0073] The straightened rod-shaped ingot is subjected to peeling to
remove the inhomogeneous portions of the surface thereof, and then
subjected to following inspection. Such peeling and inspection are
not essential steps of the present invention, and therefore the
production method which does not include these steps can be covered
by the present invention.
[0074] (Cutting)
[0075] The rod-shaped ingot is cut into a predetermined thickness
to produce a forging material having a volume corresponding to the
volume of a brake piston.
[0076] (Bonderizing treatment)
[0077] As a pretreatment for the cold forging, the forging raw
material is subjected to a bonderizing treatment as a lubricating
treatment to give a lubricating property to the surface. Such
bonderizing treatment is not an essential step in the present
invention, and therefore the case in which no bonderizing treatment
is performed and the case in which a lubricating property is given
by any other method can be covered by the present invention.
[0078] (Cold Forging)
[0079] As illustrated in FIG. 5, the forging material 2 is
subjected to cold-forging to form a cup-shaped brake piston 1. The
cold-forging is executed within 7 days (within 168 hours) after the
casting of the rod-shaped ingot, without annealing the rod-shaped
ingot. As shown in FIG. 3, the hardness on the 7.sup.th day after
the casting is 0.95 or less in the relative hardness with respect
to the reference hardness on the 30.sup.th day after the casting,
and therefore it is possible to form a brake piston high in
dimensional accuracy without performing annealing. If the
age-hardening develops over 7 days after the casting, it becomes
difficult to forge a brake piston high in dimensional accuracy. The
more preferable execution timing for the cold-forging is within 5
days after the casting.
[0080] Furthermore, whether or not the cold forging can be smoothly
performed without performing annealing is affected by the hardness
at the time of the cold forging, and therefore the timing for the
cold forging can also be defined by the hardness of the forging raw
material. For example, it is preferable that the Rockwell hardness
before the forging is less than 77.3. For example, when the
Rockwell hardness of the continuously cast rod-shaped ingot
naturally aged for 30 days after the continuous casting is defined
as a reference hardness, if it is within the period in which the
relative hardness of the rod-shaped ingot defined by the following
formula is 0.95 or less, the cold forging can be performed without
performing annealing. Especially, if it is within a period in which
the relative hardness is less than 0.899, the hardness is further
lower, which is more suitable to the cold forging. Furthermore, it
is more preferable to satisfy both the Rockwell hardness condition
and the relative hardness condition.
[0081] The relative hardness of the rod-shaped ingot=Rockwell
hardness of the rod-shaped ingot/the reference hardness
[0082] In the present invention, the execution timing for the cold
forging of the rod-shaped ingot can be defined by either the
elapsed days after the casting or the relative hardness.
Furthermore, when the cold forging execution timing is
provisionally set by the elapsed days after the casting, it can be
confirmed by the Rockwell hardness and/or the relative hardness
that the provisionally set straightening execution timing is
suitable to the cold forging.
[0083] Further, the reduction rate at the cold forging, which is
calculated based on the following formula, is set to 25-90% to
enhance the hardness by work hardening. If the reduction rate is
less than 25%, the work hardening becomes insufficient, which makes
it difficult to obtain hardness required for a brake piston. On the
other hand, if the reduction rate exceeds 90%, forging defects,
such as, e.g., forging cracks, readily occur. The preferable
reduction rate is 50-70%. The forging is preferably a closed
forging, not forging with burr.
The reduction rate(%)=[(h.sub.0-h.sub.1)/h.sub.0].times.100 [0084]
where h.sub.0 is a thickness of the forging raw material 2, and
[0085] h.sub.1 is a thickness of the bottom portion of the forged
brake piston 1
[0086] (Aging)
[0087] The cold forged brake piston is subjected to an aging
treatment to enhance the hardness, without performing a solution
treatment. Although the aging condition is not specifically
limited, it is recommended for the preferable aging condition to
hold the cold forged brake piston for 0.5-3 hours at
165-18.5.degree. C., more preferably 1-2.5 hours at 170-180.degree.
C.
[0088] (Mechanical Working, Anodizing Treatment)
[0089] The age hardened brake piston is subjected to mechanical
working for the purpose of improving the dimensional accuracy of
the inner and outer diameters and the surface roughness.
Furthermore, in order to improve the abrasion resistance, the brake
piston is further subjected to a anodizing treatment to form a hard
film on the surface thereof. Since the mechanical working and the
anodizing treatment are not essential steps of the present
invention, the case in which these processing are not performed is
also covered by the present invention.
[0090] The brake piston produced in accordance with the present
invention is enhanced in hardness by the solution hardening and
crystal dispersion by the elements contained in the aluminum alloy,
and is work-hardened by the cold forging performed at the
prescribed reduction rate. Therefore, required hardness can be
secured after the aging without performing a solution treatment.
Normally, hardness required for a brake piston is 93 or more in
Rockwell hardness, which can be secured by the present
invention.
[0091] According to the method of the present invention, without
performing three conventional heat treatments, i.e., a
homogenization treatment before a straightening step, annealing
before a cold forging step, and a solution treatment after a cold
forging step performed in a conventional production processing, a
brake piston having predetermined hardness can be produced. By
omitting these three heat treatments, the production efficiency can
be improved and the energy cost can be reduced. Furthermore, not
performing a solution treatment after casting causes no generation
of quench distortion, rendering a machining step for removing
distortions unnecessary. Thus, the machining to be performed after
the cold forging can be simply performed to improve the dimensional
accuracy, resulting in a smaller cutting amount than a conventional
cutting amount, which reduces waist of material.
EXAMPLES
[0092] Using aluminum alloys "a" to "m" of 13 types shown in Table
1, cup-shaped brake pistons were forged through different
productions steps (except for Comparative Examples 1, 3-6, 10, and
15).
[0093] The relationship between the Si concentration and the Mg
concentration in each aluminum alloy is shown in FIG. 4. The
composition of each of the aluminum alloys "a" to "g" falls within
the range specified by the present invention, and the composition
of each of the aluminum alloys "h" to "m" deviates from the range
specified by the present invention.
TABLE-US-00001 TABLE 1 Reference Alloy Chemical Composition of
Aluminum Alloy Hardness symbol Used forged product Mg Si Cu Mn Cr
Fe Ti (HRF) a Embodiments 1 to 3, 14, 15 0.96 1.31 0.89 0.78 0.10
0.25 0.015 85.7 Comparative Examples 1, 2, 20, 21 b Embodiment 4
0.68 1.32 0.88 0.79 0.11 0.25 0.015 79.9 c Embodiments 5, 6 0.86
1.06 0.40 0.49 0.14 0.25 0.015 76.1 Comparative Example 3 d
Embodiments 7, 8 0.89 1.00 0.07 0.58 0.12 0.25 0.014 79.1
Comparative Example 4 e Embodiments 9, 10 1.02 0.81 0.39 0.20 0.19
0.25 0.015 76.0 Comparative Example 5 f Embodiment 11 1.19 0.80
0.40 0.20 0.20 0.25 0.015 75.5 g Embodiments 12, 13 0.89 0.81 0.10
0.12 0.08 0.25 0.014 72.7 Comparative Example 6 h Comparative
Examples 7 1.03 0.59 0.24 0.19 0.01 0.25 0.015 61.6 to 11 i
Comparative Examples 12 0.58 1.01 0.02 0.61 0.01 0.25 0.014 67.4 to
15 j Comparative Example 16 1.24 0.91 0.41 0.21 0.20 0.25 0.014
78.0 k Comparative Example 17 0.59 1.30 0.87 0.77 0.11 0.25 0.015
72.6 1 Comparative Example 18 1.12 1.31 0.88 0.79 0.10 0.25 0.015
87.4 m Comparative Example 19 0.86 1.46 0.89 0.78 0.78 0.25 0.015
88.8
[0094] [Production Method]
[0095] As a common step in each Example, an aluminum alloy was
continuously cast with a hot-top casting machine to obtain a
rod-shaped ingot round in cross-section at a casting rate: 250
m/min. The Rockwell hardness of the rod-shaped ingot when the ingot
was naturally aged for 30 days after the continuous casting, i.e.,
the reference hardness of the present invention, is shown in Table
1.
Examples 1-13
[0096] A rod-shaped ingot was straightened 3 days (72 hours) after
the casting without performing a homogenizing treatment by pinching
by and between correcting rolls. The straightened rod-shaped ingot
was peeled, and the inspected rod-shaped ingot was cut into a short
columnar member having a predetermined thickness to obtain a
forging raw material 2.
[0097] The forging raw material 2 was subjected to a bonderizing
treatment without being subjected to annealing, and then
cold-forged 7 days (168 hours) after the casting to form a
cup-shaped brake piston 1 as shown in FIG. 5. The reduction rate of
the cold-forging was either one of 25%, 50%, and 71%. The reduction
rate in each Example is shown in Table 2.
Examples 14 and 15
[0098] A cup-shaped brake piston 1 was faulted in the same steps as
in Example 1 except that the execution timing for the straightening
and cold-forging were changed as described in Table 2.
[0099] The formed brake piston was subjected to an aging treatment
by holding it for 2 hours at 175.degree. C. without being subjected
to a solution treatment, and then subjected to mechanical working
to enhance the dimensional accuracy of the inner and outer
diameters.
Comparative Examples 1, 3-6, 10, and 15
[0100] A rod-shaped ingot was pinched by and between correcting
rolls 3 days (72 hours) after the casting, without being subjected
to a homogenization treatment. The straightened rod-shaped ingot
was peeled and the inspected rod-shaped ingot was cut into a short
columnar member having a given thickness.
[0101] The columnar member was subjected to an aging treatment
under the same conditions as in Examples without being subjected to
a cold forging treatment and a solution treatment. In other words,
in these Comparative Examples, only straightening, peeling,
inspection, cutting and aging were performed.
Comparative Example 2
[0102] A brake piston was produced by the same steps as in Examples
except that the straightening was performed 7 days (168 hours)
after the casting and the cold forging was performed 13 days (312
hours) after the casting.
Comparative Example 11
[0103] Before subjecting a rod-shaped ingot to straightening to be
performed 3 days after the casting, the rod-shaped ingot was
subjected to a homogenization treatment of 560.degree. C..times.7
hours. Before subjecting a forging raw material to a bonderizing
treatment, the forging raw material was subjected to annealing of
380.degree. C..times.4 hours before bonderizing the forging raw
material. After cold forging, the forged material was subjected to
a solution treatment of 530.degree. C..times.2.5 hours (solution
treatment condition). After being water quenched, the forged
material was subjected to an aging treatment of 180.degree.
C..times.6 hours. Thus, a brake piston was produced. The steps of
this Comparative Example correspond to the conventional production
steps shown in FIG. 6.
Comparative Examples 7-9, 12-14, and 16-19
[0104] A brake piston was produced by the same steps as in
Examples. In these Comparative Examples, only the aluminum alloy
composition deviates from the present invention.
Comparative Examples 20, 21
[0105] A brake piston 1 was produced by the same steps as in
Example 1 except that the timings for performing the straightening
and the cold forging were changed as described in Table 2.
Hardness and Evaluation
[0106] As for the rod-shaped ingot after the casting, the
rod-shaped ingot before the straightening, the forging raw material
before the forging, the brake piston after the forging, and the
brake piston after the aging, the Rockwell hardness (HRF) was
measured. As for Comparative Examples 1, 3-6, 10, and 15 in which
no cold forging was performed, the hardness was measured after the
straightening but before the aging treatment, and the measured
hardness is shown in the column of the hardness before forging in
Table 2. The relative hardness of the rod-shaped ingot before the
straightening and that of the forging raw material before the
forging were calculated by the following formula and listed in
Table 2 together with the reference hardness of each alloy shown in
Table 1.
The relative hardness of the rod-shaped ingot before the
straightening=Rockwell hardness of the rod-shaped ingot/the
reference hardness
[0107] The relative hardness of the forging raw material before the
forging=Rockwell hardness of the forging raw material/the reference
hardness
[0108] The straightening performance, the forging performance, and
the energy saving performance were evaluated based on the following
standards.
[0109] (Straightening Performance)
[0110] As for curvature of a rod-shaped ingot, it was evaluated as
a good straightening performance (.smallcircle.) when the bent
amount per 1,000 mm length was straightened so as to fall within 2
mm or less, and evaluated as a poor straightening performance (x)
when a bent amount exceeding 2 mm remained after the
straightening.
[0111] (Forging Performance)
[0112] As for the cold forged brake piston, it was evaluated as a
good forging performance (.smallcircle.) when no underfill and/or
sags were found, and evaluated as a poor forging performance (x)
when underfill and/or sags were found.
[0113] (Energy Saving Performance)
[0114] Comparative Example 11 was evaluated as a poor energy saving
performance (x) considering that the homogenization treatment,
annealing and solution treatment were performed, and Examples in
which no such treatments were performed were evaluated as a good
energy saving performance.
[0115] Furthermore, it was checked whether or not it was required
to perform cutting of thermal strain portions during the mechanical
working after the aging.
[0116] Table 2 shows the schematic production steps and the
evaluation results.
TABLE-US-00002 TABLE 2 Manufacturing Process COM- Homog- Straight-
Cold Forging Aging POSI- eniza- ening Peeling/ Anneal- Bond-
Reduction Solution Treat- Mechanical TION tion timing Insection
Cutting ing erizing Time ratio Treatment ment working Embodiment 1
a -- 3 days .smallcircle. .smallcircle. -- .smallcircle. 7 days 71%
-- .smallcircle. .smallcircle. 2 a -- 3 days .smallcircle.
.smallcircle. -- .smallcircle. 7 days 50% -- .smallcircle.
.smallcircle. 3 a -- 3 days .smallcircle. .smallcircle. --
.smallcircle. 7 days 25% -- .smallcircle. .smallcircle. 4 b -- 3
days .smallcircle. .smallcircle. -- .smallcircle. 7 days 50% --
.smallcircle. .smallcircle. 5 c -- 3 days .smallcircle.
.smallcircle. -- .smallcircle. 7 days 71% -- .smallcircle.
.smallcircle. 6 c -- 3 days .smallcircle. .smallcircle. --
.smallcircle. 7 days 50% -- .smallcircle. .smallcircle. 7 d -- 3
days .smallcircle. .smallcircle. -- .smallcircle. 7 days 71% --
.smallcircle. .smallcircle. 8 d -- 3 days .smallcircle.
.smallcircle. -- .smallcircle. 7 days 50% -- .smallcircle.
.smallcircle. 9 e -- 3 days .smallcircle. .smallcircle. --
.smallcircle. 7 days 71% -- .smallcircle. .smallcircle. 10 e -- 3
days .smallcircle. .smallcircle. -- .smallcircle. 7 days 50% --
.smallcircle. .smallcircle. 11 f -- 3 days .smallcircle.
.smallcircle. -- .smallcircle. 7 days 50% -- .smallcircle.
.smallcircle. 12 g -- 3 days .smallcircle. .smallcircle. --
.smallcircle. 7 days 50% -- .smallcircle. .smallcircle. 13 g -- 3
days .smallcircle. .smallcircle. -- .smallcircle. 7 days 71% --
.smallcircle. .smallcircle. 14 a -- 2 days .smallcircle.
.smallcircle. -- .smallcircle. 7 days 50% -- .smallcircle.
.smallcircle. 15 a -- 3 days .smallcircle. .smallcircle. --
.smallcircle. 5 days 50% -- .smallcircle. .smallcircle. Comparative
1 a -- 3 days .smallcircle. .smallcircle. -- -- -- 0% --
.smallcircle. .smallcircle. Example 2 a -- 7 days .smallcircle.
.smallcircle. -- .smallcircle. 13 days 50% -- .smallcircle.
.smallcircle. 3 c -- 3 days .smallcircle. .smallcircle. -- -- -- 0%
-- .smallcircle. .smallcircle. 4 d -- 3 days .smallcircle.
.smallcircle. -- -- -- 0% -- .smallcircle. .smallcircle. 5 e -- 3
days .smallcircle. .smallcircle. -- -- -- 0% -- .smallcircle.
.smallcircle. 6 g -- 3 days .smallcircle. .smallcircle. -- -- -- 0%
-- .smallcircle. .smallcircle. 7 h -- 3 days .smallcircle.
.smallcircle. -- .smallcircle. 7 days 71% -- .smallcircle.
.smallcircle. 8 h -- 3 days .smallcircle. .smallcircle. --
.smallcircle. 7 days 50% -- .smallcircle. .smallcircle. 9 h -- 3
days .smallcircle. .smallcircle. -- .smallcircle. 7 days 25% --
.smallcircle. .smallcircle. 10 h -- 3 days .smallcircle.
.smallcircle. -- -- -- 0% -- .smallcircle. .smallcircle. 11 h
.smallcircle. 3 days .smallcircle. .smallcircle. .smallcircle.
.smallcircle. 7 days 50% .smallcircle. .smallcircle. .smallcircle.
12 i -- 3 days .smallcircle. .smallcircle. -- .smallcircle. 7 days
71% -- .smallcircle. .smallcircle. 13 i -- 3 days .smallcircle.
.smallcircle. -- .smallcircle. 7 days 50% -- .smallcircle.
.smallcircle. 14 i -- 3 days .smallcircle. .smallcircle. --
.smallcircle. 7 days 25% -- .smallcircle. .smallcircle. 15 i -- 3
days .smallcircle. .smallcircle. -- -- -- 0% -- .smallcircle.
.smallcircle. 16 j -- 3 days .smallcircle. .smallcircle. --
.smallcircle. 7 days 50% -- .smallcircle. .smallcircle. 17 k -- 3
days .smallcircle. .smallcircle. -- .smallcircle. 7 days 50% --
.smallcircle. .smallcircle. 18 l -- 3 days .smallcircle.
.smallcircle. -- .smallcircle. 7 days 50% -- .smallcircle.
.smallcircle. 19 m -- 3 days .smallcircle. .smallcircle. --
.smallcircle. 7 days 50% -- .smallcircle. .smallcircle. 20 a -- 5
days .smallcircle. .smallcircle. -- .smallcircle. 7 days 50% --
.smallcircle. .smallcircle. 21 a -- 3 days .smallcircle.
.smallcircle. -- .smallcircle. 10 days 50% -- .smallcircle.
.smallcircle. Relative Reference Hardness (HRF) hardness Energy
After Before Before After After Before After Straightening Forging
saving Stress casting straightening forging forging aging
straightening forging performance performance performance relief
Embodiment 1 75.4 76.0 76.3 98.7 102.9 0.887 0.891 .smallcircle.
.smallcircle. .smallcircle. no 2 75.4 76.0 76.3 93.9 100.7 0.887
0.891 .smallcircle. .smallcircle. .smallcircle. no 3 75.1 76.0 76.3
85.9 97.3 0.887 0.891 .smallcircle. .smallcircle. .smallcircle. no
4 70.3 70.8 71.1 89.1 96.6 0.885 0.890 .smallcircle. .smallcircle.
.smallcircle. no 5 67.0 67.6 67.9 95.4 99.6 0.885 0.892
.smallcircle. .smallcircle. .smallcircle. no 6 67.0 67.6 67.9 88.3
97.4 0.886 0.890 .smallcircle. .smallcircle. .smallcircle. no 7
69.6 70.1 70.4 93.9 98.6 0.886 0.890 .smallcircle. .smallcircle.
.smallcircle. no 8 69.6 70.1 70.4 88.9 96.3 0.886 0.890
.smallcircle. .smallcircle. .smallcircle. no 9 66.9 67.2 67.5 92.6
97.0 0.884 0.888 .smallcircle. .smallcircle. .smallcircle. no 10
66.9 67.2 67.5 86.8 94.8 0.894 0.888 .smallcircle. .smallcircle.
.smallcircle. no 11 66.4 65.9 67.3 86.3 94.4 0.887 0.892
.smallcircle. .smallcircle. .smallcircle. no 12 64.0 64.5 64.9 86.3
94.2 0.888 0.892 .smallcircle. .smallcircle. .smallcircle. no 13
64.0 64.6 64.9 90.4 96.4 0.888 0.892 .smallcircle. .smallcircle.
.smallcircle. no 14 75.4 75.8 76.3 93.7 100.6 0.885 0.891
.smallcircle. .smallcircle. .smallcircle. no 15 75.4 76.0 76.2 93.8
100.5 0.887 0.889 .smallcircle. .smallcircle. .smallcircle. no 1
75.4 76.0 76.3 -- 91.8 0.887 0.891 .smallcircle. -- .smallcircle.
no 2 75.4 76.3 77.3 94.2 100.9 0.891 0.902 x x .smallcircle. no 3
67.0 67.6 67.9 -- 85.2 0.888 0.892 .smallcircle. -- .smallcircle.
no 4 69.6 70.1 70.4 -- 83.9 0.806 0.890 .smallcircle. --
.smallcircle. no 5 66.9 67.2 67.5 -- 82.7 0.884 0.888 .smallcircle.
-- .smallcircle. no 6 64.0 64.6 64.9 -- 82.1 0.884 0.888
.smallcircle. -- .smallcircle. no 7 54.2 55.6 56.1 85.1 91.3 0.903
0.911 .smallcircle. .smallcircle. .smallcircle. no 8 54.2 55.6 56.1
78.0 85.3 0.903 0.911 .smallcircle. .smallcircle. .smallcircle. no
9 54.2 55.6 50.1 67.8 82.4 0.903 0.911 .smallcircle. .smallcircle.
.smallcircle. no 10 54.2 55.6 56.1 -- 75.5 0.903 0.911
.smallcircle. -- .smallcircle. no 11 54.2 55.5 56.1 -- 96.7 0.903
0.911 .smallcircle. .smallcircle. x yes 12 59.3 60.5 61.1 67.6 82.4
0.898 0.907 .smallcircle. .smallcircle. .smallcircle. no 13 59.3
60.5 61.1 80.6 89.5 0.896 0.907 .smallcircle. .smallcircle.
.smallcircle. no 14 59.3 60.5 61.1 70.6 83.7 0.898 0.907
.smallcircle. .smallcircle. .smallcircle. no 15 59.3 60.5 61.1 --
77.1 0.898 0.907 .smallcircle. -- .smallcircle. no 16 68.6 69.1
69.5 85.1 95.4 0.886 0.892 x x .smallcircle. no 17 63.9 64.4 64.7
84.9 91.1 0.887 0.891 .smallcircle. .smallcircle. .smallcircle. no
18 76.9 77.4 77.9 95.4 102.0 0.886 0.891 x x .smallcircle. no 19
78.1 78.5 78.9 96.7 104.1 0.885 0.889 x x .smallcircle. no 20 75.4
76.2 76.3 93.9 100.7 0.889 0.889 x .smallcircle. .smallcircle. no
21 75.4 76.0 77.0 94.1 100.6 0.887 0.899 .smallcircle. x
.smallcircle. no
[0117] From Table 2, in Examples 1-15, a hard brake piston having
Rockwell hardness (HRF) exceeding 93 could be produced without
performing a heat treatment before processing and/or a solution
treatment after the casting.
[0118] On the other hand, in Comparative Examples 2, 20, and 21 in
which the execution timing for the straightening and/or the cold
forging was late, sufficient straightening of the rod-shaped ingot
was not performed due to the poor workability, and the forging
performance during the cold forging was also poor.
[0119] In Comparative Examples in which the reduction rate of the
cold forging was 0%, the work hardening was insufficient, and the
hardness was insufficient even after the aging.
[0120] Further, in Comparative Examples in which either the
aluminum alloy composition or the reduction rate deviates from the
range specified by the present invention, either one of
insufficient strength, insufficient straightening due to the
difficulty of working, and a forging defect was found.
[0121] In Comparative Example 11, since three heat treatments were
added to Examples, the energy cost was high, and it was required to
remove the thermal strain portions caused by the solution
treatment.
[0122] In Comparative Example 16, although the hardness before the
straightening and that before the forging were lower than that in
Example 2 (the reduction rate of the cold goring was the same as in
Comparative Example 16), the straightening performance and the
forging performance were poor. This is considered because the
amount of crystallized Mg.sub.2Si increased due to the high Si
concentration and high Mg concentration in the alloy of Comparative
Example 16. Crystallized Mg.sub.2Si does not contribute to
increasing of the hardness of the aluminum base, but deteriorates
the straightening performance and the forging performance, which
caused the aforementioned result. In Comparative Example 18, the
hardness of the aluminum alloy was high, which caused deterioration
of the straightening performance and the forging performance.
Furthermore, since the Si concentration was excessive as compared
with Comparative Example 16, the hardness was further increased,
resulting in deteriorated straightening performance and the forging
performance. Also in Comparative Example 19, the high hardness of
the aluminum alloy caused deteriorated straightening performance
and forging performance. This Comparative Example deviates from the
range of the Mg concentration and the Si concentration of the
present invention surrounded by the points of A, B, C, and D in
FIG. 4, and the increased amount of crystallized Mg.sub.2Si
including excessive Si caused deteriorated straightening
performance and forging performance.
[0123] This application claims priority to Japanese Patent
Application No. 2009-239295 filed on Oct. 16, 2009, and the entire
disclosure of which is incorporated herein by reference in its
entirety.
[0124] It should be understood that the terms and expressions used
herein are used for explanation and have no intention to be used to
construe in a limited manner, do not eliminate any equivalents of
features shown and mentioned herein, and allow various
modifications falling within the claimed scope of the present
invention.
INDUSTRIAL APPLICABILITY
[0125] The present invention can contribute to energy saving in
producing a brake piston.
DESCRIPTION OF THE REFERENCE NUMERALS
[0126] 1 . . . brake piston [0127] 2 . . . forging raw material
* * * * *