+

US20020106301A1 - High corrosion resistance aluminum alloy - Google Patents

High corrosion resistance aluminum alloy Download PDF

Info

Publication number
US20020106301A1
US20020106301A1 US09/777,769 US77776901A US2002106301A1 US 20020106301 A1 US20020106301 A1 US 20020106301A1 US 77776901 A US77776901 A US 77776901A US 2002106301 A1 US2002106301 A1 US 2002106301A1
Authority
US
United States
Prior art keywords
percent
weight
aluminum
alloy
amount
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US09/777,769
Inventor
Kurt O'Connor
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Delphi Technologies Inc
Original Assignee
Delphi Technologies Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Assigned to DELPHI TECHNOLOGIES, INC. reassignment DELPHI TECHNOLOGIES, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: O'CONNOR, KURT F.
Application filed by Delphi Technologies Inc filed Critical Delphi Technologies Inc
Priority to US09/777,769 priority Critical patent/US20020106301A1/en
Priority to US10/215,205 priority patent/US6733726B2/en
Publication of US20020106301A1 publication Critical patent/US20020106301A1/en
Abandoned legal-status Critical Current

Links

Classifications

    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • C22C21/02Alloys based on aluminium with silicon as the next major constituent
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/12Making non-ferrous alloys by processing in a semi-solid state, e.g. holding the alloy in the solid-liquid phase

Definitions

  • This invention relates to aluminum alloys, and more particularly to aluminum casting alloys, especially those used for pressure-die casting.
  • the total weight of die cast aluminum products exceeds the total weight of aluminum alloy castings prepared by all other casting techniques combined. Further, aluminum alloys are used more frequently in die castings than any other base metal.
  • the extensive use of aluminum die-cast alloys for various articles such as machine parts, housings for machines, electronics, instruments, etc. is attributable at least in part to the high dimensional accuracy and smooth and attractive casting surfaces of aluminum die-cast alloys in the as-cast condition.
  • the known aluminum castings alloys exhibit acceptable corrosion resistance for moderately harsh environments
  • the known aluminum casting alloys, and in particular the known aluminum die casting alloys are not sufficiently resistant to corrosion for certain highly corrosive environments.
  • aluminum castings that are used in highly corrosive exterior automotive applications in which the castings are routinely exposed to temperature extremes, water, snow, ice and humidity, as well as corrosion inducing materials such as salt, and dirt and road grime that can retain moisture and salt eventually tend to exhibit significant corrosion.
  • the known aluminum die casting alloys generally contain silicon in an amount that is effective to improve fluidity of the alloy in a molten state during the die casting operation.
  • Additions of silicon also improve hot tear resistance and have beneficial effect on tensile strength and elongation properties of cast compounds.
  • the most commonly used aluminum-silicon alloy for die casting is alloy 380.0 and its modifications.
  • the 380.0 family of alloys exhibit a balanced combination of low cost, strength, and corrosion resistance, as well as high fluidity and freedom from hot shortness that are required to achieve good die-castability.
  • the 380.0 alloys and other aluminum die casting alloys typically contain copper in an amount of from about 2 to about 4.5 percent. Copper is added to improve strength and hardness, but generally reduces resistance to general corrosion.
  • the 380.0 family of aluminum alloys does not exhibit high corrosion resistance, and is unsuitable for certain automotive applications, such as for exposed parts that are mounted in the engine compartment of a vehicle.
  • alloys low in copper such as 360.0 and 413.0 are typically used. These alloys still contain a significant amount of copper (0.6 and 1.0 percent by weight, respectively) and consequently show clearly visible signs of corrosion when exposed to a highly corrosive environment for a prolonged period.
  • the known aluminum die casting alloys are not especially well suited for those applications in which it is desired to use a die cast aluminum component which maintains a good, non-corroded appearance after prolonged exposure to a highly corrosive environment. Therefore, it would be highly desirable to have an aluminum die casting alloy that is highly resistant to corrosion for use in making automotive components that are mounted in the engine compartment of a vehicle, and components for outdoor use such as light fixtures, electronic housings, telephone cases, etc.
  • This invention is directed to an aluminum alloy having improved corrosion resistance.
  • the aluminum alloys of this invention are characterized by a very low copper content and a silicon content that is sufficient to impart excellent fluidity, hot tear resistance and feeding characteristics for good die-castability.
  • an aluminum die casting alloy having improved corrosion resistance and excellent die-castability properties has a relatively low copper content that is effective to achieve enhanced corrosion resistance, in conjunction with a relatively high silicon content that is effective to impart good die-castability.
  • the aluminum alloys of this invention typically have a silicon content of from about 4.5 percent by weight to about 12 percent by weight to impart suitable fluidity, hot tear resistance, wear resistance and feeding characteristics. More desirably, the silicon content is from about 8 percent by weight to about 12 percent by weight, with optimum die-castability properties for the highly corrosion resistant alloys of this invention being achieved in a range of from about 9.5 to about 12 percent silicon by weight.
  • alloys typically contain relatively high amounts of copper in order to improve the machinability, strength and hardness of the casting.
  • copper reduces resistance to general corrosion, and, therefore, is present in the aluminum alloys of this invention in relatively low amounts, if at all.
  • the aluminum alloys of this invention typically contain 0.08 percent copper by weight or less, and more preferably 0.05 percent or less.
  • Iron is preferably added to the aluminum die casting alloys of this invention to improve hot tear resistance, and decrease the tendency for die sticking or soldering during die casting.
  • a suitable amount of iron is from about 0.8 percent to about 2.0 percent by weight, with an amount of from about 0.8 to about 1.3 percent by weight being preferred, and an amount of 0.8 to about 1.0 percent by weight being most preferred.
  • the most commonly used aluminum die casting alloy (alloy 380.0) contains from about 79 to about 83 percent aluminum by weight.
  • the aluminum die casting alloys of this invention have a relatively high aluminum content, and as a result, exhibit a thermal conductivity that is about 20 percent greater than that of alloy 380.0.
  • the alloys of this invention can be processed through liquid hot isostatic pressing to achieve a thermoconductivity that is about 40 percent greater than that of the 380.0 alloy.
  • the alloys of this invention typically contain at least 87 percent, more preferably at least 88 percent, and most preferably at least 89 percent aluminum by weight.
  • Manganese may be present in an amount up to about 0.6 percent by weight to enhance strength, but is not necessary if improved strength is unnecessary for the particular application in which the casting is to be used.
  • Magnesium, nickel, zinc and tin may be present in the alloy in relatively minor amounts, preferably about 1.5 percent or less, more preferably about 1 percent or less, and even more preferably about 0.5 percent or less.
  • Test coupons made of an alloy according to this invention were compared with similar coupons prepared from conventional corrosion resistant aluminum die-cast alloys (alloy 360.0) under rigorous salt spray conditions.
  • the salt spray conditions induce accelerated corrosion.
  • the coupons cast from the alloys of this invention exhibited a noticeable improvement in corrosion resistance and maintained an improved appearance for a longer period of time than the coupons cast from the conventional alloy.
  • the corrosion resistant aluminum alloys of this invention are expected to be used primarily for die casting corrosion resistant components, the alloys are also suitable for use in semi-solid molding processes and semi-solid forging processes. Die-casting, semi-solid molding, and semi-solid forging operations are all well known in the industry and, therefore, are not described herein.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Abstract

An aluminum-based die casting alloy exhibiting improved corrosion resistance and good die-castability contains from about 4.5 to about 12 percent silicon by weight, at least 87 percent aluminum by weight, and a maximum of 0.2 percent copper by weight. The alloys preferably contain iron in an amount sufficient to improve hot tear resistance and to decrease the tendency for die sticking or soldering during die casting.

Description

    TECHNICAL FIELD
  • This invention relates to aluminum alloys, and more particularly to aluminum casting alloys, especially those used for pressure-die casting. [0001]
  • BACKGROUND OF THE INVENTION
  • The total weight of die cast aluminum products exceeds the total weight of aluminum alloy castings prepared by all other casting techniques combined. Further, aluminum alloys are used more frequently in die castings than any other base metal. The extensive use of aluminum die-cast alloys for various articles such as machine parts, housings for machines, electronics, instruments, etc. is attributable at least in part to the high dimensional accuracy and smooth and attractive casting surfaces of aluminum die-cast alloys in the as-cast condition. [0002]
  • While many of the known aluminum castings alloys exhibit acceptable corrosion resistance for moderately harsh environments, the known aluminum casting alloys, and in particular the known aluminum die casting alloys, are not sufficiently resistant to corrosion for certain highly corrosive environments. For example, aluminum castings that are used in highly corrosive exterior automotive applications in which the castings are routinely exposed to temperature extremes, water, snow, ice and humidity, as well as corrosion inducing materials such as salt, and dirt and road grime that can retain moisture and salt, eventually tend to exhibit significant corrosion. The known aluminum die casting alloys generally contain silicon in an amount that is effective to improve fluidity of the alloy in a molten state during the die casting operation. Additions of silicon also improve hot tear resistance and have beneficial effect on tensile strength and elongation properties of cast compounds. The most commonly used aluminum-silicon alloy for die casting is alloy 380.0 and its modifications. The 380.0 family of alloys exhibit a balanced combination of low cost, strength, and corrosion resistance, as well as high fluidity and freedom from hot shortness that are required to achieve good die-castability. However, the 380.0 alloys and other aluminum die casting alloys typically contain copper in an amount of from about 2 to about 4.5 percent. Copper is added to improve strength and hardness, but generally reduces resistance to general corrosion. Thus, the 380.0 family of aluminum alloys does not exhibit high corrosion resistance, and is unsuitable for certain automotive applications, such as for exposed parts that are mounted in the engine compartment of a vehicle. [0003]
  • Where better corrosion resistant is required, alloys low in copper, such as 360.0 and 413.0 are typically used. These alloys still contain a significant amount of copper (0.6 and 1.0 percent by weight, respectively) and consequently show clearly visible signs of corrosion when exposed to a highly corrosive environment for a prolonged period. Thus, the known aluminum die casting alloys are not especially well suited for those applications in which it is desired to use a die cast aluminum component which maintains a good, non-corroded appearance after prolonged exposure to a highly corrosive environment. Therefore, it would be highly desirable to have an aluminum die casting alloy that is highly resistant to corrosion for use in making automotive components that are mounted in the engine compartment of a vehicle, and components for outdoor use such as light fixtures, electronic housings, telephone cases, etc. [0004]
  • SUMMARY OF THE INVENTION
  • This invention is directed to an aluminum alloy having improved corrosion resistance. The aluminum alloys of this invention are characterized by a very low copper content and a silicon content that is sufficient to impart excellent fluidity, hot tear resistance and feeding characteristics for good die-castability. [0005]
  • These and other features, advantages and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification and claims.[0006]
  • DESCRIPTION OF THE PREFERRED EMBODIMENTS
  • In accordance with the principles of this invention, an aluminum die casting alloy having improved corrosion resistance and excellent die-castability properties has a relatively low copper content that is effective to achieve enhanced corrosion resistance, in conjunction with a relatively high silicon content that is effective to impart good die-castability. [0007]
  • The aluminum alloys of this invention typically have a silicon content of from about 4.5 percent by weight to about 12 percent by weight to impart suitable fluidity, hot tear resistance, wear resistance and feeding characteristics. More desirably, the silicon content is from about 8 percent by weight to about 12 percent by weight, with optimum die-castability properties for the highly corrosion resistant alloys of this invention being achieved in a range of from about 9.5 to about 12 percent silicon by weight. [0008]
  • Conventional aluminum casting, alloys typically contain relatively high amounts of copper in order to improve the machinability, strength and hardness of the casting. However, copper reduces resistance to general corrosion, and, therefore, is present in the aluminum alloys of this invention in relatively low amounts, if at all. In order to achieve excellent corrosion resistance, the aluminum alloys of this invention typically contain 0.08 percent copper by weight or less, and more preferably 0.05 percent or less. [0009]
  • Iron is preferably added to the aluminum die casting alloys of this invention to improve hot tear resistance, and decrease the tendency for die sticking or soldering during die casting. A suitable amount of iron is from about 0.8 percent to about 2.0 percent by weight, with an amount of from about 0.8 to about 1.3 percent by weight being preferred, and an amount of 0.8 to about 1.0 percent by weight being most preferred. [0010]
  • Most aluminum casting alloys, and especially aluminum die casting alloys, have an aluminum content of about 86 percent by weight or less. For example, the most commonly used aluminum die casting alloy (alloy 380.0) contains from about 79 to about 83 percent aluminum by weight. The conventional corrosion resistant aluminum die casting alloys, alloys 360.0 and 413.0, contain from about 85 to about 86.5 percent aluminum by weight and from about 82 percent to about 84 percent aluminum by weight, respectively. In contrast, the aluminum die casting alloys of this invention have a relatively high aluminum content, and as a result, exhibit a thermal conductivity that is about 20 percent greater than that of alloy 380.0. Further, the alloys of this invention can be processed through liquid hot isostatic pressing to achieve a thermoconductivity that is about 40 percent greater than that of the 380.0 alloy. The alloys of this invention typically contain at least 87 percent, more preferably at least 88 percent, and most preferably at least 89 percent aluminum by weight. [0011]
  • Manganese may be present in an amount up to about 0.6 percent by weight to enhance strength, but is not necessary if improved strength is unnecessary for the particular application in which the casting is to be used. Magnesium, nickel, zinc and tin may be present in the alloy in relatively minor amounts, preferably about 1.5 percent or less, more preferably about 1 percent or less, and even more preferably about 0.5 percent or less. [0012]
  • Other elements are not desirable, and are preferably present in an amount of less than 0.5 percent by weight, and more preferably less than 0.25 percent by weight. [0013]
  • Test coupons made of an alloy according to this invention were compared with similar coupons prepared from conventional corrosion resistant aluminum die-cast alloys (alloy 360.0) under rigorous salt spray conditions. The salt spray conditions induce accelerated corrosion. Under such conditions, the coupons cast from the alloys of this invention exhibited a noticeable improvement in corrosion resistance and maintained an improved appearance for a longer period of time than the coupons cast from the conventional alloy. [0014]
  • Although the corrosion resistant aluminum alloys of this invention are expected to be used primarily for die casting corrosion resistant components, the alloys are also suitable for use in semi-solid molding processes and semi-solid forging processes. Die-casting, semi-solid molding, and semi-solid forging operations are all well known in the industry and, therefore, are not described herein. [0015]
  • It will be understood by those who practice the invention and those skilled in the art, that various modifications and improvements may be made to the invention without departing from the spirit of the disclosed concept. The scope of protection afforded is to be determined by the claims and by the breadth of interpretation allowed by law. [0016]

Claims (20)

1. An aluminum-based alloy comprising:
at least about 87 percent aluminum by weight;
from about 4.5 percent to about 12 percent silicon by weight;
a maximum of about 0.08 percent copper by weight; and
from about 0.8 percent to about 2.0 percent iron by weight.
2. The alloy of claim 1, wherein the iron is present in an amount of from about 0.8 to about 1.3 percent by weight.
3. The alloy of claim 1, wherein the iron is present in an amount of from about 0.8 percent to about 1.0 percent by weight.
4. The alloy of claim 1, having a maximum of 0.05 percent copper by weight.
5. The alloy of claim 1, containing silicon in an amount of from about 8 percent to about 12 percent by weight.
6. The alloy of claim 1, containing silicon in an amount of from about 9.5 percent to about 12 percent by weight.
7. The alloy of claim 1, wherein the aluminum is present in the alloy in an amount of at least 88 percent by weight.
8. The alloy of claim 1, wherein the aluminum is present in the alloy in an amount of at least 89 percent by weight.
9. An article of manufacture made from an aluminum alloy comprising:
at least about 87 percent aluminum by weight;
from about 4.5 percent to about 12 percent silicon by weight;
a maximum of about 0.08 percent copper by weight; and
from about 0.8 percent to about 2.0 percent iron by weight.
10. The article of claim 9, wherein the iron is present in an amount of from about 0.8 percent to about 1.3 percent by weight.
11. The article of claim 9, wherein the iron is present in an amount of from about 0.8 percent to about 1.0 percent by weight.
12. The article of claim 9, having a maximum of 0.05 percent copper by weight.
13. The article of claim 9, containing silicon in an amount of from about 8 percent to about 12 percent by weight.
14. The article of claim 9, containing silicon in an amount of from about 9.5 percent to about 12 percent by weight.
15. The article of claim 9, wherein the aluminum is present in the alloy in an amount of at least 88 percent by weight.
16. The article of claim 9, wherein the aluminum is present in the alloy in an amount of at least 89 percent by weight.
17. A process for making an aluminum alloy component, comprising:
shaping an aluminum alloy into the desired component, the alloy containing at least about 87 percent aluminum by weight, from about 4.5 to about 12 percent silicon by weight, a maximum of about 0.08 percent copper by weight, and from about 0.8 percent to about 2.0 percent iron by weight.
18. The process of claim 17, wherein the shaping is achieved by a die casting operation.
19. The process of claim 17, wherein the shaping is achieved by a semi-solid molding operation.
20. The process of claim 17, wherein the shaping is achieved by a semi-solid forging operation.
US09/777,769 2001-02-05 2001-02-05 High corrosion resistance aluminum alloy Abandoned US20020106301A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US09/777,769 US20020106301A1 (en) 2001-02-05 2001-02-05 High corrosion resistance aluminum alloy
US10/215,205 US6733726B2 (en) 2001-02-05 2002-08-08 High corrosion resistance aluminum alloy

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US09/777,769 US20020106301A1 (en) 2001-02-05 2001-02-05 High corrosion resistance aluminum alloy

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US10/215,205 Continuation-In-Part US6733726B2 (en) 2001-02-05 2002-08-08 High corrosion resistance aluminum alloy

Publications (1)

Publication Number Publication Date
US20020106301A1 true US20020106301A1 (en) 2002-08-08

Family

ID=25111207

Family Applications (1)

Application Number Title Priority Date Filing Date
US09/777,769 Abandoned US20020106301A1 (en) 2001-02-05 2001-02-05 High corrosion resistance aluminum alloy

Country Status (1)

Country Link
US (1) US20020106301A1 (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030175421A1 (en) * 2002-03-13 2003-09-18 Delphi Technologies, Inc. Process for reducing contaminants on surfaces of die cast components
WO2006066314A1 (en) * 2004-12-23 2006-06-29 Commonwealth Scientific And Industrial Research Organisation Heat treatment of aluminium alloy high pressure die castings
WO2023231352A1 (en) * 2022-05-30 2023-12-07 中兴通讯股份有限公司 High-thermal-conductivity die-cast aluminum alloy product and preparation method therefor, and radiator

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030175421A1 (en) * 2002-03-13 2003-09-18 Delphi Technologies, Inc. Process for reducing contaminants on surfaces of die cast components
WO2006066314A1 (en) * 2004-12-23 2006-06-29 Commonwealth Scientific And Industrial Research Organisation Heat treatment of aluminium alloy high pressure die castings
US20090038720A1 (en) * 2004-12-23 2009-02-12 Roger Neil Lumley Heat Treatment of Aluminium Alloy High Pressure Die Castings
US8409374B2 (en) 2004-12-23 2013-04-02 Commonwealth Scientific And Industrial Research Organisation Heat treatment of aluminium alloy high pressure die castings
WO2023231352A1 (en) * 2022-05-30 2023-12-07 中兴通讯股份有限公司 High-thermal-conductivity die-cast aluminum alloy product and preparation method therefor, and radiator

Similar Documents

Publication Publication Date Title
EP3121302B1 (en) Aluminum alloy for die casting, and die-cast aluminum alloy using same
KR100199362B1 (en) Aluminum alloy for die casting and ball joints using the same
JP5435939B2 (en) Aluminum alloy
KR20070102952A (en) Magnesium alloy
JP6427268B2 (en) Die-casting aluminum alloy with improved corrosion resistance, frequency filter and method of manufacturing communication device parts
KR101691001B1 (en) Die-cast aluminum alloy composition with excellent corrosion resistance and strength
CN105296818A (en) Aluminum alloy and preparation method and application thereof
JPH10324941A (en) Magnesium alloy having excellent high temperature characteristic and die castability
JPH08283889A (en) High strength and high hardness copper alloy
US6733726B2 (en) High corrosion resistance aluminum alloy
US20020106301A1 (en) High corrosion resistance aluminum alloy
JP5969713B1 (en) Aluminum alloy for die casting and aluminum alloy die casting using the same
EP1096028A2 (en) High-strength aluminum alloy for pressure casting and cast aluminum alloy comprising the same
US4919736A (en) Aluminum alloy for abrasion resistant die castings
JPH0649572A (en) High strength zinc alloy for die casting and zinc alloy die-cast parts
CN106884111A (en) A kind of aluminium alloy and preparation method thereof
JPH04173935A (en) Wear resistant aluminum alloy
CN103911528A (en) High corrosion resistance aluminum alloy for die-casting process
KR102346994B1 (en) Al-Zn-Cu alloy with high wear resistance and article using the same
CN1965098A (en) Heat-treatable Al-Zn-Mg alloys for aerospace and automotive castings
JP2002226932A (en) Aluminum alloy for heat sink having excellent strength and thermal conductivity and production method therefor
US20100310414A1 (en) High corrosion resistance aluminum alloy for sand and permanent mold processes
KR960005232B1 (en) CU-AL alloy composition
JPH01268839A (en) Aluminum alloy for processing
JP2005179776A (en) Magnesium alloy

Legal Events

Date Code Title Description
AS Assignment

Owner name: DELPHI TECHNOLOGIES, INC., MICHIGAN

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:O'CONNOR, KURT F.;REEL/FRAME:011552/0791

Effective date: 20010129

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION

点击 这是indexloc提供的php浏览器服务,不要输入任何密码和下载