U.S. patent application number 14/196093 was filed with the patent office on 2014-08-21 for aluminum casting alloys containing vanadium.
This patent application is currently assigned to ALCOA GMBH. The applicant listed for this patent is ALCOA GMBH. Invention is credited to Claus Michael Mueller, Ralf Scheid, Martijn Vos.
Application Number | 20140234160 14/196093 |
Document ID | / |
Family ID | 46924421 |
Filed Date | 2014-08-21 |
United States Patent
Application |
20140234160 |
Kind Code |
A1 |
Mueller; Claus Michael ; et
al. |
August 21, 2014 |
ALUMINUM CASTING ALLOYS CONTAINING VANADIUM
Abstract
Improved aluminum casting alloys having vanadium are disclosed,
The new alloys generally include from 4,0 to 10.0 wt. % Si, from
0.01 to 0.15 wt. % V, and up to 0.10 wt. % Fe, among other
elements. The improved aluminum casting alloys may realize, for
example, improved strength and/or elongation properties.
Inventors: |
Mueller; Claus Michael;
(Lich, DE) ; Scheid; Ralf; (Aachen, DE) ;
Vos; Martijn; (Boppelsen, CH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ALCOA GMBH |
Frickenhausen |
|
DE |
|
|
Assignee: |
ALCOA GMBH
Frickenhausen
DE
|
Family ID: |
46924421 |
Appl. No.: |
14/196093 |
Filed: |
March 4, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
PCT/EP2012/068465 |
Sep 19, 2012 |
|
|
|
14196093 |
|
|
|
|
61536451 |
Sep 19, 2011 |
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Current U.S.
Class: |
420/544 |
Current CPC
Class: |
C22C 21/02 20130101;
C22C 21/04 20130101 |
Class at
Publication: |
420/544 |
International
Class: |
C22C 21/02 20060101
C22C021/02 |
Claims
1. An aluminum casting alloy comprising: from 4.0 to 10.0 wt. %
silicon (Si); from 0.01 to 0.15 wt. % vanadium (V), up to 0.08 wt.
% iron (Fe); optionally one or more of the following secondary
elements: from 0.05 to 1.5 wt. % magnesium (Mg); from 0.40 to 5.0
wt. % copper (Cu); from 0.25 to 5.0 wt. % zinc (Zn); and from 0.50
to 3.0 wt. % nickel (Ni); optionally 0.01-1.0 wt. % each of one or
more of the following tertiary elements: manganese (Mn), chromium
(Cr), titanium (Ti), strontium (Sr), sodium (Na), and antimony
(Sb); optionally from 0.001 to 0.03 wt. % boron (13); optionally
from 0.001 to 0.03 wt. % carbon (C); not more than 0.25 wt. % each
of any other element, with the total combined amount of these other
elements not exceeding 0.50 wt. %; the balance being aluminum and
impurities.
2. The aluminum casting alloy of claim 1, comprising from 0.03 to
0.12 wt. % V.
3. The aluminum casting alloy of claim 1, comprising from 0.05 to
0.10 wt. % V.
4. The aluminum casting alloy of claim 1, comprising not greater
than 0.05 wt. % iron.
5. The aluminum casting alloy of claim 1, comprising at least 0.01
wt. % iron.
6. The aluminum casting alloy of claim 1, comprising from 6.0 to
9.0 wt. % silicon.
7. The aluminum casting alloy of claim 1, comprising from 6.5 to
8.5 wt. % silicon.
8. The aluminum casting alloy of claim 1, comprising from 0.01 to
0.8 wt. % manganese.
9. The aluminum casting alloy of claim 1, comprising from 0,01 to
0.5 wt. % chromium.
10. The aluminum casting alloy of claim 1, comprising from 0.01 to
0.25 wt. % titanium.
11. The aluminum casting alloy of claim 1, comprising from 0.001 to
0.1 wt. % strontium.
12. The aluminum casting alloy of claim 1, comprising from 0.001 to
0.1 wt. % sodium.
13. The aluminum casting alloy of claim 1, comprising from 0.001 to
0.1 wt. % antimony.
14. The aluminum casting alloy of claim 1, wherein the alloy
comprises not more than 0.10 wt. % each of the other elements, with
the total combined amount of these other elements not exceeding
0.35 wt. %.
15. The aluminum casting alloy of claim 1, wherein the alloy
comprises not more than 0.05 wt. % each of the other elements, with
the total combined amount of these other elements not exceeding
0.15 wt. %.
16. The aluminum casting alloy of claim 1, Wherein the alloy
comprises not more than 0.03 wt. % each of the other elements, with
the total combined amount of these other elements not exceeding
0.10 wt. %.
17. The aluminum casting alloy of claim 1, wherein the alloy
realizes a Secondary Dendrite Arm Spacing (SDAS) of from 1
micrometer to 100 micrometers.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims priority to International
Patent Application No. PCT/EP2012/068465, filed Sep. 19, 2012,
which claims priority to U.S. Provisional Patent Application No.
61/536,451, filed Sep. 19, 2011, both entitled "IMPROVED ALUMINUM
CASTING ALLOYS CONTAINING VANADIUM", both of which are incorporated
herein by reference in their entirety.
BACKGROUND
[0002] Aluminum casting alloys are useful in a variety of
applications. However, improving one property of an aluminum
casting alloy without degrading another property is elusive. For
example, it is difficult to increase the strength of an alloy
without decreasing the ductility of an alloy.
SUMMARY OF THE DISCLOSURE
[0003] Broadly, the present patent application relates to improved
aluminum casting alloys (also known as foundry alloys), and methods
for producing the same. Specifically, the present patent
application relates to aluminum casting alloys having vanadium and,
optionally, iron. Generally, the new aluminum casting alloys
including vanadium, and optionally iron, achieve an improved
combination of properties.
[0004] The new aluminum casting alloys generally include from about
0.01 to 0.15 wt. % vanadium (V). In one embodiment, the new
aluminum casting alloy may include from about 0.03 to 0.12 wt. %
vanadium. In another embodiment, the new aluminum casting alloy may
include from about 0.05 to 0.10 wt. % vanadium. By maintaining
vanadium within the aluminum casting alloy in the above-described
amounts, optionally with iron, an improved combinations of
properties may be realized. For example, the aluminum casting alloy
may realize an improved combination of strength and elongation,
among other properties.
[0005] In one approach, the aluminum casting alloy includes not
greater than 0.10 wt. % iron. In one embodiment, the aluminum
casting alloy includes not greater than 0.08 wt. % iron. In another
embodiment, the aluminum casting alloy includes not greater than
0.05 wt. iron. In some embodiments, iron is included in the alloy.
In these embodiments, the aluminum casting alloy includes at least
0.01 wt. % iron. In one embodiment, the aluminum casting alloy
includes 0.01-0.10 wt. % iron. In another embodiment, the aluminum
casting alloy includes 0.01-0.08 wt. % iron.
[0006] In one approach, the aluminum casting alloy is a
silicon-based casting alloy including the above-described amounts
of vanadium, optionally with iron. The silicon-based casting alloys
may be any of the 3xx series of casting alloys known to those
skilled in the art. In this approach, the silicon-based casting
alloy may include from 4.0 to 10.0 wt. % silicon, and silicon is
the predominate alloying element of the casting alloy, except for
aluminum. The silicon-based casting alloys may optionally include
secondary element, tertiary elements, and other elements, defined
below. In one embodiment, the silicon-based casting alloy includes
from about 6.0 to 9.0 wt. % silicon. In one embodiment, the
silicon-based casting alloy includes from about 6.5 to 8.5 wt.
%
[0007] The silicon-based aluminum alloy may include one or more
secondary elements. These secondary elements are selected from the
group consisting of magnesium, copper, zinc, nickel, and
combinations thereof. The secondary elements may be included in the
alloy for various purposes, such as for strengthening (e.g., solid
solution, precipitate and constituent strengthening). In one
approach, the silicon-based casting alloy includes magnesium. In
one embodiment, the silicon-based casting alloy includes magnesium,
and in the range of from about 0.05 to 1.5 wt. % magnesium. In
other embodiments, the silicon-based casting alloy includes
magnesium as an impurity, i.e., not greater than 0.04 wt. %
magnesium.
[0008] In one approach, the silicon-based casting alloy includes
copper. In one embodiment, the silicon-based casting alloy includes
copper, and in the range of from about 0.40 to 5.0 wt. copper. In
other embodiments, the silicon-based casting alloy includes copper
as an impurity, i.e., not greater than 0.39 wt. % copper.
[0009] In one approach, the silicon-based casting alloy includes
zinc. In one embodiment, the silicon-based casting alloy includes
zinc, and in the range of from about 0.25 to 5.0 wt. % zinc. In
other embodiments, the silicon-based casting alloy includes zinc as
an impurity, i.e., not greater than 0.24 wt. % zinc.
[0010] In one approach, the silicon-based casting alloy includes
nickel. In one embodiment, the silicon-based casting alloy includes
nickel, and in the range of from about 0.50 to 3.0 wt. % nickel. In
other embodiments, the silicon-based casting alloy includes nickel
as an impurity, i.e., not greater than 0.49 wt. % nickel.
[0011] The silicon-based aluminum alloy may include tertiary
elements, such as manganese, chromium, titanium, strontium, sodium,
antimony, and combinations thereof One or more of these tertiary
elements may be added to the alloy for various purposes. For
example, manganese and/or chromium may be included in the
silicon-based aluminum alloy to prevent die soldering for high
pressure die casting. Titanium may be included in the silicon-based
aluminum alloy for grain refining. Strontium, sodium and/or
antimony may be added for silicon particle modification. in these
embodiments, the silicon-based aluminum alloy generally includes
not greater than about 1.0 wt. % each of the tertiary elements.
When a tertiary element is included, the alloy generally includes
at least about 0.01 wt. % of that tertiary element (e.g., 0.01-1.0
wt. % Mn). In one embodiment, the silicon-based aluminum alloy
includes 0.01 to 0.8 wt. % manganese. In one embodiment, the
silicon-based aluminum alloy includes 0.01 to 0.5 wt. % chromium.
In one embodiment, the silicon-based aluminum alloy includes 0.01
to 0.25 wt. % titanium. In one embodiment, the silicon-based
aluminum alloy includes 0.001 to 0.1 wt. % strontium. In one
embodiment, the silicon-based aluminum alloy includes 0.001 to 0.1
wt. % sodium. In one embodiment, the silicon-based aluminum alloy
includes 0.001 to 0.1 wt. % antimony.
[0012] In addition to titanium grain refining, the silicon-based
aluminum alloy may include TiB.sub.2 and/or TiC as a grain refiner.
In one embodiment, the silicon-based aluminum alloy includes 0.001
to 0.03 wt. % boron. In one embodiment, the silicon-based aluminum
alloy includes 0.001 to 0.03 wt. % carbon.
[0013] The silicon-based aluminum alloy may be substantially free
of other elements (e.g., deoxidizers, impurities). Other elements
means any other element of the periodic table that may be included
in the silicon-based aluminum alloy, except for aluminum, the
silicon, the vanadium, the iron, the secondary elements, and the
tertiary elements, described above. In the context of this
paragraph the phrase "substantially free" means that the aluminum
alloy body contains not more than 0.25 wt. % each of any element of
the other elements, with the total combined amount of these other
elements not exceeding 0.50 wt. %. In one embodiment, each one of
these other elements, individually, does not exceed about 0.10 wt.
% in the silicon-based aluminum alloy, and the total combined
amount of these other elements does not exceed about 0.35 wt. %, in
the silicon-based aluminum alloy. In another embodiment, each one
of these other elements, individually, does not exceed about 0.05
wt. % in the silicon-based aluminum alloy, and the total combined
amount of these other elements does not exceed about 0.15 wt. % in
the silicon-based aluminum alloy. In another embodiment, each one
of these other elements, individually, does not exceed about 0.03
wt. % in the silicon-based aluminum alloy, and the total combined
amount of these other elements does not exceed about 0.10 wt. % in
the silicon-based aluminum alloy.
[0014] The silicon-based aluminum alloy may be used in various
types of foundry casting processes, such as sand mold casting,
investment casting (ceramic shell mold), lost foam casting,
permanent mold casting, high pressure die casting, squeeze casting,
and semi-solid casting, to name a few. The Secondary Dendrite Arm
Spacing (SDAS) of the silicon-based aluminum alloy produced by
various casting methods may range from 1 micrometer (e.g., with a
fast solidification rate) to 100 micrometers (e.g., with a slow
solidification rate).
[0015] These and other aspects, advantages, and novel features of
this new technology are set forth in part in the description that
follows and will become apparent to those skilled in the art upon
examination of the following description and figures, or may be
learned by practicing one or more embodiments of the technology
provided for by the patent application.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a graph illustrating the performance of various
silicon-based aluminum casting alloys.
[0017] FIG. 2 is a graph illustrating the performance of various
silicon-based aluminum casting alloys.
[0018] FIGS. 3a-3c are pictures illustrating the microstructure of
various silicon-based aluminum casting alloys.
DETAILED DESCRIPTION
EXAMPLE 1
[0019] Several silicon-based aluminum casting alloys having the
compositions listed in Table 1, below, are cast via sand mold
casting.
TABLE-US-00001 TABLE 1 Composition of Silicon-based casting alloy
(all values in weight percent) Alloy Si Mg Fe V Ti Na Other, Each
Others, Total Bal. 1 6.92 0.318 0.074 0.083 0.113 0.0078
.ltoreq.0.05 .ltoreq.0.15 Al 2 7.06 0.332 0.077 <0.001 0.108
0.0046 .ltoreq.0.05 .ltoreq.0.15 Al 3 7.08 0.319 0.141 0.079 0.113
0.0039 .ltoreq.0.05 .ltoreq.0.15 Al
After casting, the properties of the alloys are measured (i.e., in
the F temper). The results are illustrated in FIG. 1. Alloy 1 with
0.08 wt. % V and 0.08 wt. % Fe has both better strength and
elongation than Alloys 2-3 achieving an ultimate tensile strength
of about 143 MPa, and an elongation of about 4.2-4.4%. By
comparison, Alloys 2-3 achieve only about 123-130 MPa in ultimate
tensile strength, and with much lower elongation (2.6-2.8%).
[0020] These alloys are also aged to a T6 temper, the results of
which are illustrated in FIG. 2 (one with water quench and one with
air cooling).
[0021] Again, Alloy 1 with 0.08 wt. % vanadium and 0.08 wt. % iron
outperforms Alloys 2-3 in terms of strength and elongation,
achieving both higher strength and elongation than Alloys 2-3.
[0022] The microstructures of Alloys 1-3 are illustrated in FIGS.
3a-3c, below.
[0023] Alloy 1 contains smaller .beta.-AlFeSi particles and
less/smaller .pi.-AlFeMgSi particles. The porosity of Alloys 1-3 is
also measured (by image analysis), the results of which are
provided in Table 2, below. Alloys 1 and 3 with 0.08 wt. % V have
reduced porosity. It is believed that both factors, i.e.,
less/smaller particles and less porosity, may contribute to the
higher strength and elongation properties.
TABLE-US-00002 TABLE 2 Porosity of Silicon-based casting alloy (all
porosity values in percent) Measurement Alloy 1 Alloy 2 Alloy 3 1
0.88 5.03 1.57 2 2.04 3.96 1.63 3 1.91 6.32 1.31 4 1.36 5.9 1.44 5
1.87 4.84 1.17 6 1.13 7.19 1.19 7 0.84 2.92 1.37 8 1.28 3.48 1.07 9
1.26 4.05 2.18 10 0.96 4.83 1.59 11 0.67 3.71 0.57 12 5.93 1.37 13
3.08 1.91 14 1.94 1.31 15 1.86 0.93 16 1.49 0.92 17 1.09 18 2.11
Average 1.291 3.874 1.346 STDEV 0.467 1.792 0.392
[0024] While various embodiments of the present disclosure have
been described in detail, it is apparent that modifications and
adaptations of those embodiments will occur to those skilled in the
art. However, it is to be expressly understood that such
modifications and adaptations are within the spirit and scope of
the present disclosure.
* * * * *