Aluminum alloy excellent in cutting ability, aluminum alloy materials and manufacturing method thereof

• US 20030143102A1
• Filed: 07/25/2002
• Published: 07/31/2003
• Est. Priority Date: 07/25/2001
• Status: Abandoned Application

• Current Assignee: Showa Denko KK
• Original Assignee: Showa Denko KK
• Inventors: Yamanaka, Masaki, Matsuoka, Hideaki, Yoshioka, Hiroki, Okamoto, Yasuo, Kitamura, Masakatsu
• Application Number:
  US10/202,669
• Publication Number:
  US 20030143102A1
• Time in Patent Office: Days
• US Class Current: 420/546
• CPC Class Codes: C22C 21/04 Modified aluminium-silicon alloys
• CPC Class Codes: C22C 21/08 with silicon
• CPC Class Codes: C22F 1/043 of alloys with silicon as the next major constituent
• CPC Class Codes: C22F 1/047 of alloys with magnesium as the next major constituent

Abstract

A first aluminum alloy of the present invention comprises Mg: 0.3-6 mass %, Si: 0.3-10 mass %, Zn: 0.05-1 mass %, Sr: 0.001-0.3 mass % and the balance being Al and impurities. A second aluminum alloy further contains one or more selective additional elements selected from the group consisting of Cu, Fe, Mn, Cr, Zr, Ti, Na and Ca. Furthermore, a third aluminum alloy comprises Mg: 0.1-6 mass %, Si: 0.3-12.5 mass %, Cu: 0.01 mass % or more but less than 1 mass %, Zn: 0.01-3 mass %, Sr: 0.001-0.5 mass % and the balance being Al and impurities. Furthermore, a fourth aluminum alloy further includes one or more optional additional elements selected from the group consisting of Ti, B, C, Fe, Cr, Mn, Zr, V, Sc, Ni, Na, Sb, Ca, Sn, Bi and In.

Claims

1. An aluminum alloy, comprising:

Mg;

0.3-6 mass %;

Si;

0.3-10 mass %;

Zn;

0.05-1 mass %;

Sr;

0.001-0.3 mass %; and

the balance being aluminum and impurities.

2. The aluminum alloy as recited in claim 1, wherein the content of Mg is 0.5-1.1 mass %.

3. The aluminum alloy as recited in claim 1, wherein the content of Si is 1.5-5 mass %.

4. The aluminum alloy as recited in claim 1, wherein the content of Zn is 0.1-0.3 mass %.

5. The aluminum alloy as recited in claim 1, wherein the content of Sr is 0.005-0.05 mass %.

6. An aluminum alloy, comprising:

Mg;

0.3-6 mass %;

Si;

0.3-10 mass %;

Zn;

0.05-1 mass %;

Sr;

0.001-0.3 mass %;

one or more of selective additional elements selected from the group consisting of Cu;

0.01 mass % or more but less than 1 mass %, Fe;

0.01-1 mass %, Mn;

0.01-1 mass %, Cr;

0.01-1 mass %, Zr;

0.01-1 mass %, Ti;

0.01-1 mass %, Na;

0.001-0.5 mass % and Ca;

0.001-0.5 mass %; and

the balance being Aluminum and impurities.

7. The aluminum alloy as recited in claim 6, wherein the content of Mg is 0.5-1.1 mass %.

8. The aluminum alloy as recited in claim 6, wherein the content of Si is 1.5-5 mass %.

9. The aluminum alloy as recited in claim 6, wherein the content of Zn is 0.1-0.3 mass %.

10. The aluminum alloy as recited in claim 6, wherein the content of Sr is 0.005-0.05 mass %.

11. The aluminum alloy as recited in claim 6, wherein the selective additional element is Cu.

12. The aluminum alloy as recited in claim 6, wherein the selective additional element is Fe.

13. The aluminum alloy as recited in claim 6, wherein the selective additional element is one or more elements selected from the group consisting Cr and Mn.

14. The aluminum alloy as recited in claim 6, wherein the selective additional element is Zr.

15. The aluminum alloy as recited in claim 6, wherein the selective additional element is Ti.

16. The aluminum alloy as recited in claim 6, wherein the selective additional element is one or more elements selected from the group consisting of Na and Ca.

17. The aluminum alloy as recited in claim 6, wherein the content of Cu is 0.1-0.3 mass %.

18. The aluminum alloy as recited in claim 6, wherein the content of Fe is 0.1-0.3 mass %.

19. The aluminum alloy as recited in claim 6, wherein the content of Mn is 0.1-0.3 mass %.

20. The aluminum alloy as recited in claim 6, wherein the content of Cr is 0.1-0.3 mass %.

21. The aluminum alloy as recited in claim 6, wherein the content of Zr is 0.1-0.3 mass %.

22. The aluminum alloy as recited in claim 6, wherein the content of Ti is 0.1-0.3 mass %.

23. The aluminum alloy as recited in claim 6, wherein the content of Na is 0.005-0.3 mass %.

24. The aluminum alloy as recited in claim 6, wherein the content of Ca is 0.005-0.3 mass %.

25. An aluminum alloy material composed of an aluminum alloy,

wherein the aluminum alloy comprises

Mg:

0.3-6 mass %,

Si;

0.3-10 mass %,

Zn;

0.05-1 mass %,

Sr;

0.001-0.3 mass %, and

the balance being aluminum and impurities, as a chemical composition thereof, and

wherein a mean particle diameter of Si particle is 1-5 μ

m and a mean aspect ratio of Si particle is 1-3, as an alloy texture of the aluminum alloy.

26. The aluminum alloy material as recited in claim 25, wherein the mean particle diameter of the Si particle is 3 μ

m or less.

27. The aluminum alloy material as recited in claim 25, wherein the mean aspect ratio of the Si particle is 2 or less.

28. An aluminum alloy material composed of aluminum alloy,

wherein the aluminum alloy comprises

Mg:

0.3-6 mass %,

Si;

0.3-10 mass %,

Zn;

0.05-1 mass %,

Sr;

0.001-0.3 mass %,

one or more selective additional elements selected from the group consisting of Cu;

0.01 mass % or more but less than 1 mass %, Fe;

0.01-1 mass %, Mn;

0.01-1 mass %, Cr;

0.01-1 mass %, Zr;

0.01-1 mass %, Ti;

0.01-1 mass %, Na;

0.001-0.5 mass % and Ca;

0.001-0.5 mass %, as a chemical composition thereof, and

the balance being aluminum and impurities, and

wherein a mean particle diameter of Si particle is 1-5 μ

m and a mean aspect ratio of Si particle is 1-3, as an alloy texture of the aluminum alloy.

29. An aluminum alloy material as recited in claim 28, wherein the mean particle diameter of the Si particle is 3 μ

m or less.

30. The aluminum alloy material as recited in claim 28, wherein the mean aspect ratio of the Si particle is 2 or less.

31. A method for manufacturing an aluminum alloy material, the method comprising:

making a billet at a casting rate of 10-180 mm/min., the billet composed of aluminum alloy comprising Mg;

0.3-6 mass %, Si;

0.3-10 mass %, Zn;

0.05-1 mass %, Sr;

0.001-0.3 mass %, and the balance being aluminum and impurities;

homogenizing the billet at 400-570°

C. for 6 hours or more to obtain a homogenized billet;

extruding the homogenized billet at a billet temperature of 300-550°

C., an extrusion rate of 0.5-100 m/min. and an extrusion ratio of 10-200 into an extruded article having a predetermined configuration;

executing a solution treatment to the extruded article at 400-570°

C. for 1 hour or more; and

aging the solution treated extruded article at 90-300°

C. for 1-30 hours.

32. The method for manufacturing an aluminum alloy material as recited in claim 31, wherein the casting rate is 30-130 mm/min.

33. The method for manufacturing an aluminum alloy material as recited in claim 31, wherein the homogenization is performed at 500-545°

C. for 10 hours or more.

34. The method for manufacturing an aluminum alloy material as recited in claim 31, wherein the extrusion is performed at the billet temperature of 350-500°

C., the extrusion rate of 2-30 m/min. and the extrusion ratio of 20-85.

35. The method for manufacturing an aluminum alloy material as recited in claim 31, wherein the solution treatment is performed at 500-545°

C. for 3 hours or more.

36. The method for manufacturing an aluminum alloy material as recited in claim 31, wherein the aging is performed at 140-200°

C. for 3-20 hours.

37. The method for manufacturing an aluminum alloy material as recited in claim 31, wherein the solution treated extruded article is drawn at a reduction rate of 5-30% into a predetermined configuration, and thereafter the aging is performed.

38. The method for manufacturing an aluminum alloy material as recited in claim 37, wherein the reduction rate of the drawing is 10-20%.

39. A method for manufacturing an aluminum alloy material, comprising:

making a billet at a casting rate of 10-180 mm/min., the billet composed of aluminum alloy comprising Mg;

0.3-6 mass %, Si;

0.3-10 mass %, Zn;

0.05-1 mass %, Sr;

0.001-0.3 mass %, one or more selective additional elements selected from the group consisting of Cu;

0.01 mass % or more but less than 1 mass %, Fe;

0.01-1 mass %, Mn;

0.01-1 mass %, Cr;

0.01-1 mass %, Zr;

0.01-1 mass %, Ti;

0.01-1 mass %, Na;

0.001-0.5 mass % and Ca;

0.001-0.5 mass %, and the balance being aluminum and impurities;

homogenizing the billet at 400-570°

C. for 6 hours or more to obtain a homogenized billet;

extruding the homogenized billet at a billet temperature of 300-550°

C., an extrusion rate of 0.5-100 m/min., and an extrusion ratio of 10-200 into an extruded article having a predetermined configuration;

executing a solution treatment to the extruded article at 400-570°

C. for 1 hour or more; and

aging the solution treated extruded article at 90-300°

C. for 1-30 hours.

40. The method for manufacturing an aluminum alloy material as recited in claim 39, wherein the casting rate is 30-130 mm/min.

41. The method for manufacturing an aluminum alloy material as recited in claim 39, wherein the homogenization is performed at 500-545°

C. for 10 hours or more.

42. The method for manufacturing an aluminum alloy material as recited in claim 39, wherein the extrusion is performed at the billet temperature of 350-500°

C., the extrusion rate of 2-30 m/min. and the extrusion ratio of 20-85.

43. The method for manufacturing an aluminum alloy material s recited in claim 39, wherein the solution treatment is performed at 500-545°

C. for 3 hours or more.

44. The method for manufacturing an aluminum alloy material as recited in claim 39, wherein the aging is performed at 140-200°

C. for 3-20 hours.

45. The method for manufacturing an aluminum alloy material as recited in claim 39, wherein the solution treated extruded article is drawn at a reduction rate of 5-30% into a predetermined configuration, and thereafter the aging is performed.

46. The method for manufacturing an aluminum alloy material as recited in claim 45, wherein the reduction rate of the drawing is 10-20%.

47. An aluminum alloy, comprising:

Mg;

0.1-6 mass %;

Si;

0.3-12.5 mass %;

Cu;

0.01 mass % or more but less than 1 mass %;

Zn;

0.01-3 mass %;

Sr;

0.001-0.5 mass %; and

the balance being aluminum and impurities.

48. The aluminum alloy as recited in claim 47, wherein the content of Mg is 0.3-5 mass %.

49. The aluminum alloy as recited in claim 47, wherein the content of Si is 0.8-12 mass %.

50. The aluminum alloy as recited in claim 47, wherein the content of Cu is 0.1-0.8 mass %.

51. The aluminum alloy as recited in claim 47, wherein the content of Zn is 0.05-1.5 mass %.

52. The aluminum alloy as recited in claim 47, wherein the content of Sr is 0.005-0.3 mass %.

53. An aluminum alloy, comprising:

Mg;

0.1-6 mass %;

Si;

0.3-12.5 mass %;

Cu;

0.01 mass % or more but less than 1 mass %;

Zn;

0.01-3 mass %;

Sr;

0.001-0.5 mass %;

one or more of selective additional elements selected from the group consisting of Ti;

0.001-1 mass %, B;

0.0001-0.03 mass %, C;

0.0001-0.5 mass %, Fe;

0.01-1 mass %, Cr;

0.01-1 mass %, Mn;

0.01-1 mass %;

Zr;

0.01-1 mass %, V;

0.01-1 mass %, Sc;

0.0001-0.5 mass %, Ni;

0.005-1 mass %, Na;

0.001-0.5 mass %, Sb;

0.001-0.5 mass %, Ca;

0.001-0.5 mass %, Sn;

0.01-1 mass %, Bi;

0.01-1 mass %, and In;

0.001-0.5 mass %; and

the balance being Aluminum and impurities.

54. The aluminum alloy as recited in claim 53, wherein the content of Mg is 0.3-5 mass %.

55. The aluminum alloy as recited in claim 53, wherein the content of Si is 0.8-12 mass %.

56. The aluminum alloy as recited in claim 53, wherein the content of Cu is 0.1-0.8 mass %.

57. The aluminum alloy as recited in claim 53, wherein the content of Zn is 0.05-1.5 mass %.

58. The aluminum alloy as recited in claim 53, wherein the content of Sr is 0.005-0.3 mass %.

59. The aluminum alloy as recited in claim 53, wherein the selective additional element is one or more elements selected from the group consisting of Ti, B, C and Sc.

60. The aluminum alloy as recited in claim 53, wherein the selective additional element is Fe.

61. The aluminum alloy as recited in claim 53, wherein the selective additional element is one or more elements selected from the group consisting Cr and Mn.

62. The aluminum alloy as recited in claim 53, wherein the selective additional element is one or more elements selected from the group consisting Zr and V.

63. The aluminum alloy as recited in claim 53, wherein the selective additional element is Ni.

64. The aluminum alloy as recited in claim 53, wherein the selective additional element is one or more elements selected from the group consisting Na, Sb and Ca.

65. The aluminum alloy as recited in claim 53, wherein the selective additional element is one or more elements selected from the group consisting Sn, Bi and In.

66. The aluminum alloy as recited in claim 53, wherein the content of Ti is 0.003-0.5 mass %.

67. The aluminum alloy as recited in claim 53, wherein the content of B is 0.0005-0.01 mass %.

68. The aluminum alloy as recited in claim 53, wherein the content of C is 0.001-0.3 mass %.

69. The aluminum alloy as recited in claim 53, wherein the content of Fe is 0.05-0.7 mass %.

70. The aluminum alloy as recited in claim 53, wherein the content of Cr is 0.03-0.7 mass %.

71. The aluminum alloy as recited in claim 53, wherein the content of Mn is 0.03-0.7 mass %.

72. The aluminum alloy as recited in claim 53, wherein the content of Zr is 0.03-0.7 mass %.

73. The aluminum alloy as recited in claim 53, wherein the content of V is 0.03-0.7 mass %.

74. The aluminum alloy as recited in claim 53, wherein the content of Sc is 0.01-0.3 mass %.

75. The aluminum alloy as recited in claim 53, wherein the content of Ni is 0.03-0.7 mass %.

76. The aluminum alloy as recited in claim 53, wherein the content of Na is 0.005-0.3 mass %.

77. The aluminum alloy as recited in claim 53, wherein the content of Sb is 0.005-0.3 mass %.

78. The aluminum alloy as recited in claim 53, wherein the content of Ca is 0.005-0.3 mass %.

79. The aluminum alloy as recited in claim 53, wherein the content of Sn is 0.05-0.5 mass %.

80. The aluminum alloy as recited in claim 53, wherein the content of Bi is 0.05-0.5 mass %.

81. The aluminum alloy as recited in claim 53, wherein the content of In is 0.01-0.3 mass %.

82. An aluminum alloy material composed of aluminum alloy,

wherein the aluminum alloy comprises Mg:

0.1-6 mass %, Si;

0.3-12.5 mass %, Cu;

0.01 mass % or more but less than 1 mass %, Zn;

0.01-3 mass %, Sr;

0.001-0.5 mass %, and the balance being aluminum and impurities,

wherein, in a metal texture, a mean dendrite arm spacing is 1-200 μ

m, a dendrite boundary zone includes eutectic Si particles of 0.01-5 μ

m of a mean particle diameter and other second phase particles, and an eutectic lamella texture in which a mean skeleton line length (Lm) in a longitudinal direction is 0.5 μ

m or more and a mean width (Wm) is 0.5 μ

m or more is formed in a shape of a network.

83. The aluminum alloy as recited in claim 82, wherein, in the eutectic lamella texture, the eutectic Si particles and other second phase particles exist 500 pieces/mm² or more in total, and the area share of these particles is 0.1-50%.

84. The aluminum alloy as recited in claim 82, wherein the mean dendrite arm spacing is 3-100 μ

m.

85. The aluminum alloy as recited in claim 82, wherein the mean particle diameter of the eutectic Si particle is 0.1-3 μ

m.

86. The aluminum alloy as recited in claim 82, wherein the eutectic lamella texture has a mean skeleton line length (Lm) of 3 μ

m or more and a mean width (Wm) of 1 μ

m or more.

87. The aluminum alloy as recited in claim 82, wherein a mean ratio (L/Wm) of the skeleton line length to the skeleton width in the eutectic lamella texture is 3 or more.

88. The aluminum alloy as recited in claim 83, wherein the eutectic Si particles and other second phase particles exist 1,000 pieces/mm² or more in total.

89. The aluminum alloy as recited in claim 83, wherein the area share of the eutectic Si particles and other second phase particles is 0.3-40%.

90. An aluminum alloy material composed of an aluminum alloy,

wherein the aluminum alloy comprises

Mg:

0.1-6 mass %;

Si;

0.3-12.5 mass %;

Cu;

0.01 mass % or more but less than 1 mass %;

Zn;

0.01-3 mass %;

Sr;

0.001-0.5 mass %;

one or more of selective additional elements selected from the group consisting of Ti;

0.001-1 mass %, B;

0.0001-0.03 mass %, C;

0.0001-0.5 mass %, Fe;

0.01-1 mass %, Cr;

0.01-1 mass %, Mn;

0.01-1 mass %, Zr;

0.01-1 mass %, V;

0.01-1 mass %, Sc;

0.0001-0.5 mass %, Ni;

0.005-1 mass %, Na;

0.001-0.5 mass %, Sb;

0.001-0.5 mass %, Ca;

0.001-0.5 mass %, Sn;

0.01-1 mass %, Bi;

0.01-1 mass %, and In;

0.001-0.5 mass %; and

the balance being Aluminum and impurities, and

wherein, in a metal texture, a mean dendrite arm spacing is 1-200 μ

m, a dendrite boundary zone includes eutectic Si particles of 0.01-5 μ

m of mean particle diameters and other second phase particles, and an eutectic lamella texture in which a mean skeleton line length (Lm) in a longitudinal direction is 0.5 μ

m or more and a mean width (Wm) is 0.5 μ

m or more is formed in a shape of a network.

91. The aluminum alloy as recited in claim 90, wherein, in the eutectic lamella texture, the eutectic Si particles and other second phase particles exist 500 pieces/mm² or more in total, and the area share of these particles is 0.1-50%.

92. The aluminum alloy as recited in claim 90, wherein the mean dendrite arm spacing is 3-100 μ

m.

93. The aluminum alloy as recited in claim 90, wherein the mean particle diameter of the eutectic Si particle is 0.1-3 μ

m.

94. The aluminum alloy as recited in claim 90, wherein the eutectic lamella texture has a mean skeleton line length (Lm) of 3 μ

m or more and a mean width (Wm) of 1 μ

m or more.

95. The aluminum alloy as recited in claim 90, wherein the mean ratio (L/Wm) of the skeleton line length to the skeleton width in the eutectic lamella texture is 3 or more.

96. The aluminum alloy as recited in claim 91, wherein the eutectic Si particles and other second phase particles exist 1,000 pieces/mm² or more in total.

97. The aluminum alloy as recited in claim 91, wherein the area share of the eutectic Si particles and other second phase particles is 0.3-40%.

98. A method for manufacturing an aluminum alloy material, the method comprising:

continuously casting molten aluminum alloy to obtain a shape member having a prescribed cross section at a casting rate of 30-5000 mm/min. and a cooling rate of 10-600°

C./sec., the molten aluminum alloy comprising Mg;

0.1-6 mass %, Si;

0.3-12.5 mass %, Cu;

0.01 mass % or more but less than 1 mass %, Zn;

0.01-3 mass %, Sr;

0.001-0.5 mass % and the balance being aluminum and impurities and held at the solidus temperature or more;

thereafter

aging the shape member at 100-300°

C. for 0.5-100 hours.

99. The method for manufacturing an aluminum alloy material as recited in claim 98, wherein the casting rate is 100-2000 mm/min.

100. The method for manufacturing an aluminum alloy material as recited in claim 98, wherein the cooling rate is 30-300°

C./sec.

101. The method for manufacturing an aluminum alloy material as recited in claim 98, wherein the aging is performed at 120-220°

C. for 1-30 hours.

102. The method for manufacturing an aluminum alloy material as recited in claim 98, wherein the shape member is a non-hollow member.

103. The method for manufacturing an aluminum alloy material as recited in claim 98, wherein the shape member circumscribes to a circle with a diameter of 10-150 mm in cross section.

104. The method for manufacturing an aluminum alloy material as recited in claim 98, further comprising a step of eliminating a surface layer portion of 0.1-10 mm depth from the continuously cast shape member.

105. The method for manufacturing an aluminum alloy material as recited in claim 104, wherein the eliminated surface layer portion is 0.2-5 mm in depth.

106. The method for manufacturing an aluminum alloy material as recited in claim 98, further comprising the step of performing a secondary forming processing of a cross-sectional area decreasing ratio of 30% or less to the shape member after the continuous casting at a temperature of 400°

C. or below.

107. The method for manufacturing an aluminum alloy material as recited in claim 106, wherein the processing temperature is 250°

C. or below.

108. The method for manufacturing an aluminum alloy material as recited in claim 106, wherein the cross-sectional area decreasing ratio is 20% or less.

109. A method for manufacturing an aluminum alloy material, the method comprising:

continuously casting molten aluminum alloy to obtain a shape member having a prescribed cross section at a casting rate of 30-5,000 mm/min. and a cooling rate of 10-600°

C./sec., the molten aluminum alloy comprising Mg;

0.1-6 mass %, Si;

0.3-12.5 mass %, Cu;

0.01 mass % or more but less than 1 mass %, Zn;

0.01-3 mass %, Sr;

0.001-0.5 mass %, one or more of selective additional elements selected from the group consisting of Ti;

0.001-1 mass %, B;

0.0001-0.03 mass %, C;

0.0001-0.5 mass %, Fe;

0.01-1 mass %;

Cr;

0.01-1 mass %, Mn;

0.01-1 mass %, Zr;

0.01-1 mass %, V;

0.01-1 mass %, Sc;

0.0001-0.5 mass %, Ni;

0.005-1 mass %, Na;

0.001-0.5 mass %, Sb;

0.001-0.5 mass %, Ca;

0.001-0.5 mass %, Sn;

0.01-1 mass %, Bi;

0.01-1 mass %, In;

0.001-0.5 mass %, and the balance being aluminum and impurities and held at the solidus temperature or more;

thereafter

aging the shape member at 100-300°

C. for 0.5-100 hours.

110. The method for manufacturing an aluminum alloy material as recited in claim 109, wherein the casting rate is 100-2,000 mm/min.

111. The method for manufacturing an aluminum alloy material as recited in claim 109, wherein the cooling rate is 30-300°

C./sec.

112. The method for manufacturing an aluminum alloy material as recited in claim 109, wherein the aging is performed at 120-220°

C. for 1-30 hours.

113. The method for manufacturing an aluminum alloy material as recited in claim 109, wherein the shape member is a non-hollow member.

114. The method for manufacturing an aluminum alloy material as recited in claim 109, wherein the shape member circumscribes to a circle with a diameter of 10-150 mm in cross section.

115. The method for manufacturing an aluminum alloy material as recited in claim 109, further comprising a step of eliminating a surface layer portion of 0.1-10 mm depth from the continuously cast shape member.

116. The method for manufacturing an aluminum alloy material as recited in claim 115, wherein the eliminated surface layer portion is 0.2-5 mm in depth.

117. The method for manufacturing an aluminum alloy material as recited in claim 109, further comprising the step of performing a secondary forming processing of a cross-sectional area decreasing ratio of 30% or less to the shape member after the continuous casting at a temperature of 400°

C. or below.

118. The method for manufacturing an aluminum alloy material as recited in claim 117, wherein the processing temperature is 250°

C. or below.

119. The method for manufacturing an aluminum alloy material as recited in claim 117, wherein the cross-sectional area decreasing ratio is 20% or less.