Method of Making Aluminum or Magnesium Based Composite Engine Blocks or Other Parts With In-Situ Formed Reinforced Phases Through Squeeze Casting or Semi-Solid Metal Forming and Post Heat Treatment

• US 20160361764A1
• Filed: 06/15/2015
• Published: 12/15/2016
• Est. Priority Date: 06/15/2015
• Status: Active Grant

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations LLC (General Motors Company)
• Inventors: Osborne, Richard J., Wang, Yucong, McClory, Brian J.
• Granted Patent: US 9,999,921 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B22D 17/007 Semi-solid pressure die casting
• CPC Class Codes: B22D 17/08 Cold chamber machines, i.e. with unheated press chamber into which molten metal is ladled
• CPC Class Codes: B22D 21/007 with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
• CPC Class Codes: B22D 25/02 by its peculiarity of shape; of works of art cylinders, pistons B22D15/02
• CPC Class Codes: B22D 27/20 Measures not previously mentioned for influencing the grain structure or texture; Selection of compositions therefor
• CPC Class Codes: B22F 2003/248 Thermal after-treatment
• CPC Class Codes: B22F 2202/01 Use of vibrations
• CPC Class Codes: B22F 2202/07 by induction
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 5/008 of engine cylinder parts or of piston parts other than piston rings of piston rings B22F5/02
• CPC Class Codes: C22C 1/026 Alloys based on aluminium
• CPC Class Codes: C22C 1/0408 Light metal alloys
• CPC Class Codes: C22C 1/0416 Aluminium-based alloys
• CPC Class Codes: C22C 1/1036 starting from a melt
• CPC Class Codes: C22C 1/1073 Infiltration or casting under mechanical pressure, e.g. squeeze casting
• CPC Class Codes: C22C 32/00 Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
• CPC Class Codes: C22F 1/04 of aluminium or alloys based thereon
• CPC Class Codes: C22F 1/06 of magnesium or alloys based thereon

Abstract

A method of making a reinforced metal alloy component, the method including introducing a reinforcing phase precursor into a bulk alloy that is selected from the group consisting of high-entropy alloys, aluminum-based alloys, magnesium-based alloys and combinations thereof. The precursor is converted to a reinforcing phase by exposing the bulk alloy and precursor to an elevated temperature during one or more of a subsequent heat treating step, squeeze casting shaping or semi-solid metal shaping.

Claims

1. A method of making a reinforced metal alloy component, said method comprising:

introducing at least one reinforcing phase precursor into a bulk alloy that is selected from the group consisting of aluminum-based alloys, magnesium-based alloys, high-entropy alloys and combinations thereof; and

forming said component as a composite of said bulk alloy and at least one reinforcing phase that is produced upon activation of said at least one reinforcing phase precursor by using either squeeze casting or semi-solid metal forming such that a linear dimension of said at least one reinforcing phase is in the nanometer to micrometer range.

2. The method of claim 1, wherein said activation comprises catalyzing said at least one reinforcing phase precursor by increasing the temperature of said bulk alloy above its solidus temperature.

3. The method of claim 2, wherein said activation further takes place in at least one subsequent heat treating step.

4. The method of claim 2, wherein said introducing by said squeeze casting comprises having said bulk alloy be in melted form at the time said at least one reinforcing phase precursor is added thereto.

5. The method of claim 4, wherein said forming comprises:

maintaining said composite in a substantially melted form;

placing said substantially melted composite into a shot sleeve;

forcing said substantially melted composite into a substantially final shape die cavity; and

maintaining an elevated pressure on said substantially melted composite until a final shape of said component defined by said final shape die cavity has substantially solidified.

6. The method of claim 5, wherein said substantially final shape die cavity is shaped to define an automobile component.

7. The method of claim 5, further comprising heat treating said component once it has been has substantially solidified.

8. The method of claim 1, wherein said activation comprises catalyzing said at least one reinforcing phase precursor by at least one of increasing the pressure on said reinforcing phase precursor, applying ultrasonic vibration to said reinforcing phase precursor and applying an electromagnetic field to said reinforcing phase precursor.

9. The method of claim 1, wherein said aluminum-based bulk alloy is selected from the group consisting of eutectic alloys, near-eutectic alloys, hypoeutectic alloys, hypereutectic alloys and forged alloys.

10. The method of claim 1, wherein said reinforcing phase defines a higher modulus of elasticity than said bulk alloy.

11. The method of claim 1, wherein said reinforcing phase is selected from the group consisting of ceramics, intermetallics, rare earth elements and dispersoids.

12. The method of claim 1, wherein said introducing by said semi-solid metal forming comprises providing said bulk alloy in particulate form at the time said at least one reinforcing phase precursor is introduced thereto.

13. The method of claim 12, wherein said forming comprises:

introducing said composite into a substantially preliminary shape die cavity; and

providing a combination of heat and pressure until a preliminary shape of said component defined by said preliminary shape die cavity has substantially solidified.

14. The method of claim 13, further comprising:

transferring said solidified composite to a substantially final shape die cavity;

heating said substantially final shape die cavity such that said solidified composite therein is at least partially melted; and

applying additional pressure to said at least partially melted composite until a final shape of said component defined by said final shape die cavity has substantially solidified.

15. The method of claim 14, wherein said substantially final shape die cavity is shaped to define an automotive engine block.

16. The method of claim 13, further comprising heat treating said component once it has been has substantially solidified.

17. The method of claim 1, wherein said introducing by said semi-solid metal forming comprises:

maintaining said composite in a substantially melted form;

placing said substantially melted composite into a substantially preliminary shape die cavity; and

providing a combination of heat and pressure until said substantially melted composite defined by said preliminary shape die cavity has substantially solidified.

18. The method of claim 17, further comprising:

transferring said solidified composite from said preliminary shape die cavity to a substantially final shape die cavity;

heating said substantially final shape die cavity such that said solidified composite therein is at least partially melted; and

applying additional pressure to said at least partially melted composite until a final shape of said component defined by said final shape die cavity has substantially solidified.

19. An automobile component made by the process of claim 1.

20. A method of making a reinforced metal alloy component, said method comprising:

introducing at least one reinforcing phase precursor into a bulk alloy that is selected from the group consisting of high-entropy alloys, aluminum-based alloys, magnesium-based alloys and combinations thereof;

catalyzing said reinforcing phase precursor such that a reinforcing phase will grow therefrom; and

forming said component as a composite of said bulk alloy and said reinforcing phase using one of squeeze casting and semi-solid metal, said forming comprising;

heating said composite until it is in an at least partially melted form;

placing said at least partially melted composite into a die cavity; and

imparting an elevated pressure on said at least partially melted composite until a shape of said component defined by said die cavity has substantially solidified.

21. The method of claim 20, wherein said bulk alloy is in a substantially solid powder form at the time said at least one reinforcing phase precursor is introduced thereto.

22. The method of claim 20, wherein said bulk alloy is in a substantially melted liquid form at the time said at least one reinforcing phase precursor is introduced thereto.

23. The method of claim 20, wherein said reinforcing phase is selected from the group consisting of ceramics, intermetallics, rare earth elements and dispersoids.

24. A method of making a reinforced metal alloy component, said method comprising:

introducing at least one reinforcing phase precursor into a bulk alloy that is selected from the group consisting of high-entropy alloys, aluminum-based alloys, magnesium-based alloys and combinations thereof; and

shaping said component as a composite of said bulk alloy and a reinforcing phase that is formed by activation of said reinforcing phase precursor, said shaping selected from the group consisting essentially of squeeze casting and semi-solid metal forming, said shaping comprising;

heating said composite until it is in an at least partially melted form;

placing said at least partially melted composite into a die cavity; and

imparting an elevated pressure on said at least partially melted composite until a shape of said component defined by said die cavity has substantially solidified.

25. The method of claim 24, wherein said activation comprises catalyzing said at least one reinforcing phase precursor by increasing the temperature of said bulk alloy during at least one of said shaping or at least one subsequent heat treating step.

26. The method of claim 25, wherein said activation comprises catalyzing said at least one reinforcing phase precursor by increasing the temperature of said bulk alloy above its solidus temperature during said shaping and increasing the temperature of said reinforced metal alloy component during at least one subsequent heat treating step.