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WO2000043152A1 - Alloy for semi-solid casting process - Google Patents

Alloy for semi-solid casting process Download PDF

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Publication number
WO2000043152A1
WO2000043152A1 PCT/US1999/030322 US9930322W WO0043152A1 WO 2000043152 A1 WO2000043152 A1 WO 2000043152A1 US 9930322 W US9930322 W US 9930322W WO 0043152 A1 WO0043152 A1 WO 0043152A1
Authority
WO
WIPO (PCT)
Prior art keywords
less
casting
semi
slug
alloy
Prior art date
Application number
PCT/US1999/030322
Other languages
French (fr)
Inventor
Rathindra Dasgupta
Original Assignee
Spx Corporation
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
Application filed by Spx Corporation filed Critical Spx Corporation
Priority to AU21986/00A priority Critical patent/AU2198600A/en
Publication of WO2000043152A1 publication Critical patent/WO2000043152A1/en

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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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/007Semi-solid pressure die casting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/08Cold chamber machines, i.e. with unheated press chamber into which molten metal is ladled
    • B22D17/10Cold chamber machines, i.e. with unheated press chamber into which molten metal is ladled with horizontal press motion
    • 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

  • the present invention relates to the field of metal casting.
  • the invention is concerned with a semi-solid casting process using an aluminum alloy.
  • the present invention solves the prior art problems discussed above and provides a distinct advance in the state of the art.
  • the casting process hereof enables the use of 390 aluminum alloy in the semi-solid casting process.
  • the preferred method in accordance with the present invention includes the steps of producing a slug of aluminum alloy from an MHD or grain refined billet, heating the slug to a predetermined semi-solid temperature and maintain the temperature for a predetermined time, injecting the slug into a mold cavity to form a casting therein, and then removing the casting from the cavity.
  • these steps are performed without adding a reagent to the slug and the preferred alloy is 390 aluminum alloy.
  • Other preferred aspects of this present invention are described herein.
  • Figure 1 is the sole drawing figure and is a schematic illustration of the preferred semi-solid casting apparatus using a slug of 390 aluminum alloy for implementing the preferred method in accordance with the present invention.
  • Fig. 1 schematically illustrates conventional semi-solid casting apparatus 10 for implementing the preferred method in accordance with the present invention.
  • Apparatus 10 includes hydraulic cylinder or ram 12 and mold 14 defining mold cavity 16 therein.
  • ram 12 injects semi- solid slug 18 into cavity 16 to form casting 20 therein.
  • Casting 20 is then removed from mold 14 and cooled.
  • slug 18 is composed of 390 aluminum alloy or the equivalent thereof.
  • 390 aluminum alloy includes: silicon between about 16.0 and 18.0%(by weight), iron less than about 0.40 %, copper between about 4.0 and 5.0%, manganese less than about 0.10%, magnesium between about 0.50 and 0.65%, nickel less than about 0.10%, zinc less than about 0.05%, titanium less than about 0.20%, lead and tin less than about 0.03%, with the remainder of alloy being aluminum.
  • Slug 18 is produced by cutting from an MHD or grain refined billet. Such a billet presents the desired microstructure to produce casting 20. Other methods may also be used to produce slug 18, but this is the most common method in use today.
  • the volume of slug 18 is predetermined and substantially equal to the volume of finished casting 20. After cutting slug 18 from the billet, slug 18 is heated to about
  • slug 18 is solid enough to retain its shape but is sufficiently soft to flow into cavity 16 and take the shape thereof in order to form casting 20 during the semi-solid casting process.
  • a reagent or other chemicals cannot be added to slug 18 because of its semi-solid state.
  • a slug 18 of 390 aluminum alloy can be heated to the semi-solid temperature without significantly losing the desired microstructure as presented in the billet from which the slug was cut.
  • the slug 18, at the semi-solid temperature can be injected into mold cavity 16 of semi-solid casting apparatus 10 without significantly losing the desired microstructure in the resulting casting 20.
  • casting 20 presents a tensile strength between about 51 and 57 ksi and an elongation of less than about 1 % after the casting undergoes preferred heat treatment procedure T6 consisting of solution treatment at 496°C for eight hours, water quenched, and then artificially aged at 176°C for five hours followed by conventional cooling. Finally, it has been discovered that the semi-solid process can be used without abnormal wear on mold 14.
  • the present invention enables the production of wear resistant, aluminum alloy castings using the semi-solid casting process with all of the attendant benefits of the semi-solid casting process. It will also be appreciated that the present invention encompasses many variations in the preferred embodiment described herein. For example, some deviation can occur in the specified ranges for the chemical components of the preferred 390 aluminum alloy without substantially defecting the quality of the resulting casting. Also, other heat treatment procedures can be used. Having thus described the preferred embodiment, the following is claimed as new and desired to be secured by Letters Patent:

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Continuous Casting (AREA)

Abstract

A semi-solid casting process uses 390 aluminum alloy as the preferred casting alloy (18) for producing castings (20) with high wear resistance.

Description

ALLOY FOR SEMI-SOLID CASTING PROCESS
BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
The present invention relates to the field of metal casting. In particular, the invention is concerned with a semi-solid casting process using an aluminum alloy.
2. DESCRIPTION OF THE PRIOR ART
The use of aluminum in the automotive industry, has become more important with the increased need for weight reduction. Aluminum, however, is soft and various aluminum alloys with better wear resistance characteristics have been developed for use as a casting material. One of these alloys is 390 aluminum alloy which has been used for automotive components requiring high wear resistance. As those skilled in the art are aware, the use of 390 aluminum alloy, however, presents handling problems. For example, to achieve the desired microstructure for high wear resistance, this alloy Is normally cast in molten form with a reagent added to prevent clustering of the primary silicon particles. The nature of the semi-solid process is such that addition of reagents is not necessary, as the casting material is semi-solid and not molten.
SUMMARY OF THE INVENTION
The present invention solves the prior art problems discussed above and provides a distinct advance in the state of the art. In particular, the casting process hereof enables the use of 390 aluminum alloy in the semi-solid casting process.
The preferred method in accordance with the present invention includes the steps of producing a slug of aluminum alloy from an MHD or grain refined billet, heating the slug to a predetermined semi-solid temperature and maintain the temperature for a predetermined time, injecting the slug into a mold cavity to form a casting therein, and then removing the casting from the cavity. In the preferred embodiment these steps are performed without adding a reagent to the slug and the preferred alloy is 390 aluminum alloy. Other preferred aspects of this present invention are described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is the sole drawing figure and is a schematic illustration of the preferred semi-solid casting apparatus using a slug of 390 aluminum alloy for implementing the preferred method in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Fig. 1 schematically illustrates conventional semi-solid casting apparatus 10 for implementing the preferred method in accordance with the present invention. Apparatus 10 includes hydraulic cylinder or ram 12 and mold 14 defining mold cavity 16 therein. In operation, ram 12 injects semi- solid slug 18 into cavity 16 to form casting 20 therein. Casting 20 is then removed from mold 14 and cooled. ln the preferred embodiment, slug 18 is composed of 390 aluminum alloy or the equivalent thereof. Specifically, 390 aluminum alloy includes: silicon between about 16.0 and 18.0%(by weight), iron less than about 0.40 %, copper between about 4.0 and 5.0%, manganese less than about 0.10%, magnesium between about 0.50 and 0.65%, nickel less than about 0.10%, zinc less than about 0.05%, titanium less than about 0.20%, lead and tin less than about 0.03%, with the remainder of alloy being aluminum.
Slug 18 is produced by cutting from an MHD or grain refined billet. Such a billet presents the desired microstructure to produce casting 20. Other methods may also be used to produce slug 18, but this is the most common method in use today. The volume of slug 18 is predetermined and substantially equal to the volume of finished casting 20. After cutting slug 18 from the billet, slug 18 is heated to about
567 °C (predetermined semi-solid temperature) using heating equipment for semi-solid casting. At the semi-solid temperature, slug 18 is solid enough to retain its shape but is sufficiently soft to flow into cavity 16 and take the shape thereof in order to form casting 20 during the semi-solid casting process. In the prior art, it has been required to add a reagent to 390 aluminum alloy along with other chemical agents before casting while the material is in the molten state in order to achieve the desired microstructure of the finished casting. In the semi-solid process, a reagent or other chemicals cannot be added to slug 18 because of its semi-solid state. Contrary to the prior art, however, it has been discovered by the inventor hereof that a slug 18 of 390 aluminum alloy can be heated to the semi-solid temperature without significantly losing the desired microstructure as presented in the billet from which the slug was cut. Moreover, it has been discovered that the slug 18, at the semi-solid temperature, can be injected into mold cavity 16 of semi-solid casting apparatus 10 without significantly losing the desired microstructure in the resulting casting 20. Using the preferred method hereof, casting 20 presents a tensile strength between about 51 and 57 ksi and an elongation of less than about 1 % after the casting undergoes preferred heat treatment procedure T6 consisting of solution treatment at 496°C for eight hours, water quenched, and then artificially aged at 176°C for five hours followed by conventional cooling. Finally, it has been discovered that the semi-solid process can be used without abnormal wear on mold 14.
Those skilled in the art will now appreciate that the present invention enables the production of wear resistant, aluminum alloy castings using the semi-solid casting process with all of the attendant benefits of the semi-solid casting process. It will also be appreciated that the present invention encompasses many variations in the preferred embodiment described herein. For example, some deviation can occur in the specified ranges for the chemical components of the preferred 390 aluminum alloy without substantially defecting the quality of the resulting casting. Also, other heat treatment procedures can be used. Having thus described the preferred embodiment, the following is claimed as new and desired to be secured by Letters Patent:

Claims

CLAIMS:
1. In a semi-solid casting process in which a slug of an alloy is heated to a semi-solid temperature and injected into a mold cavity to form a casting therein, the improvement comprising: injecting an aluminum alloy as said alloy, said aluminum alloy including
silicon between about 16.0 and 18.0%, iron less than about 0.40 %, copper between about 4.0 and 5.0%, manganese less than about 0.10%, magnesium between about 0.50 and 0.65%, nickel less than about 0.10%, zinc less than about 0.05%, titanium less than about 0.20%, lead and tin less than about 0.03%, with the remainder of said alloy being aluminum.
2. The improvement as set forth in claim 1 , said aluminum alloy including 390 aluminum alloy.
3. A method of making a casting comprising:
(a) producing a slug of selected size from a billet of an aluminum alloy having a desired microstructure;
(b) heating said slug to a predetermined semi-solid temperature and maintaining said temperature for a predetermined time;
(c) in a semi-solid casting process, injecting said slug into a mold cavity to form a casting therein; and
(d) removing said casting from said cavity and allowing said casting to cool, said method further including the step of performing steps (a) - (c) without adding a reagent to said slug, said aluminum alloy including silicon between about 16.0 and 18.0%, iron less than about 0.40 %, copper between about 4.0 and 5.0%, manganese less than about 0.10%, magnesium between about 0.50 and 0.65%, nickel less than about 0.10%, zinc less than about 0.05%, titanium less than about 0.20%, lead and tin less than about 0.03%, with the remainder of said alloy being aluminum.
4. The method of claim 3, step (b) including the step of heating said slug to a temperature between about 565°C and 580°C.
5. The method of claim 3, step (b) including step of maintaining said semi-solid temperature for between about 10 and 20 minutes.
6. The method of claim 3, said method including the step of making one of a steering component, crank shaft hub, compressor piston, swash plate, and transmission oil housing as said casting.
PCT/US1999/030322 1999-01-26 1999-12-20 Alloy for semi-solid casting process WO2000043152A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU21986/00A AU2198600A (en) 1999-01-26 1999-12-20 Alloy for semi-solid casting process

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US23840599A 1999-01-26 1999-01-26
US09/238,405 1999-01-26

Publications (1)

Publication Number Publication Date
WO2000043152A1 true WO2000043152A1 (en) 2000-07-27

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Family Applications (1)

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PCT/US1999/030322 WO2000043152A1 (en) 1999-01-26 1999-12-20 Alloy for semi-solid casting process

Country Status (2)

Country Link
AU (1) AU2198600A (en)
WO (1) WO2000043152A1 (en)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2366225A (en) * 2000-07-11 2002-03-06 Honda Motor Co Ltd Injection molding metallic matertials
WO2004027101A2 (en) * 2002-09-20 2004-04-01 Spx Corporation Semi-solid metal casting process and product thereof
WO2005007912A1 (en) * 2003-07-15 2005-01-27 Spx Corporation Semi-solid metal casting process of hypereutectic aluminum alloys
CN100336619C (en) * 2005-07-29 2007-09-12 哈尔滨工业大学 Continuous preparation facilities for casting semisolid blank made from alloy in lightweight

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5846350A (en) * 1995-04-14 1998-12-08 Northwest Aluminum Company Casting thermal transforming and semi-solid forming aluminum alloys

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5846350A (en) * 1995-04-14 1998-12-08 Northwest Aluminum Company Casting thermal transforming and semi-solid forming aluminum alloys

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2366225A (en) * 2000-07-11 2002-03-06 Honda Motor Co Ltd Injection molding metallic matertials
GB2366225B (en) * 2000-07-11 2004-05-19 Honda Motor Co Ltd Method for injection molding metallic materials
WO2004027101A2 (en) * 2002-09-20 2004-04-01 Spx Corporation Semi-solid metal casting process and product thereof
WO2004027101A3 (en) * 2002-09-20 2004-06-03 Spx Corp Semi-solid metal casting process and product thereof
WO2005007912A1 (en) * 2003-07-15 2005-01-27 Spx Corporation Semi-solid metal casting process of hypereutectic aluminum alloys
US6994147B2 (en) 2003-07-15 2006-02-07 Spx Corporation Semi-solid metal casting process of hypereutectic aluminum alloys
CN100336619C (en) * 2005-07-29 2007-09-12 哈尔滨工业大学 Continuous preparation facilities for casting semisolid blank made from alloy in lightweight

Also Published As

Publication number Publication date
AU2198600A (en) 2000-08-07

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