High strength aluminum base alloy

Details High strength aluminum base alloy High strength aluminum base alloy

2002-02-15

2004-04-13

Wyszomierski, George (Department: 1742)

Metal treatment

Process of modifying or maintaining internal physical...

With casting or solidifying from melt

C148S698000, C148S700000, C164S900000, C164S113000

Reexamination Certificate

active

06719859

ABSTRACT:

BACKGROUND OF THE INVENTION
This invention relates to aluminum base alloys and more particularly it relates to an aluminum base alloy containing silicon, copper and magnesium and a method of semi-solid forming the aluminum alloy to provide a formed member or product having improved properties.
There is great interest in the use of semi-solid forming of aluminum alloys to improve both yield strength and tensile strength of formed products. The properties of the formed products are strongly influenced by selection of the elements comprising the aluminum alloy.
The references disclose that the properties are improved by different mechanisms. For example, U.S. Pat. No. 1,595,058 discloses an aluminum base alloy containing 3 to 15 wt. % Si, 0.5 to 3 wt. % Cu and 0.25 to 1 wt. % Mn having improved tensile strength, the properties improved by an alkali metal treatment.
U.S. Pat. No. 1,924,727 discloses an aluminum base alloy containing 3 to 8 wt. % Si, 0.5 to 3 wt. % Cu, 0.2 to 1.5 wt. % Mg and 0.3 to 2 wt. % Mn. The alloy is improved by the addition of manganese or nickel.
U.S. Pat. No. 4,808,374 discloses a method for producing aluminum alloy castings and the resulting product having improved toughness. An Al—Si or Al—Si—Cu alloy containing 4 to 24 wt % of silicon, iron and other incidental impurities, the balance being aluminum is melted, and the melt is heated to a temperature between 780° C. and 950° C. The melt is poured into a mold and solidified. Solution heat treatment and aging are then conducted. The process is suitable for an alloy containing 0.25 to 1.4 wt % of iron. In a preferred embodiment, the alloy consists essentially of 6 to 12 wt % Si, 2 wt % Cu, 0.2 to 0.4 wt % Mg and other incidental impurities, the balance being aluminum. The solution heat treatment is preferably carried out by heating between 525°-545° C. for a period of 1 to 5 hours.
U.S. Pat. No. 5,028,393 discloses an Al-based alloy for use as sliding material, superior in fatigue resistance and anti-seizure property consisting, by weight, of 1-10% Zn, 1-15% Si, 0.1-5% Cu, 0.1-5% Pb, 0.005-0.5% Sr, and the balance Al and incidental impurities.
U.S. Pat. No. 5,338,168 discloses an oil pump comprises a casing of aluminum alloy and at least one rotor housed therein. The rotor is produced by powder metallurgy by a rapidly solidified aluminum alloy comprising, by weight, of 5 to 25% of Si, up to 15% of one or more alloy elements selected from the group consisting of 3 to 10% of Fe, 3 to 10% of Ni and 1 to 8% of Cr, and the balance of Al and inevitable impurities. The casing may be produced by powder metallurgy or ingot metallurgy with an aluminum alloy consisting essentially, by weight, of 5 to 25%, preferably 5 to 17%, of Si, 1 to 5% of Cu, 0.2 to 1.5% of Mg, 0.2 to 1% of Mn, and the balance of Al and inevitable impurities. The rotor and casing are so combined that the sum of the Si content of said rapidly solidified aluminum alloy for casing and that of said rapidly solidified aluminum alloy for rotor being equal to or more than 15 percent by weight.
U.S. Pat. No. 5,879,478 discloses an aluminum alloy for thixoforming with the composition (by weight): Si: 5%-7.2%, Cu: 1%-5%, Mg<1%, Zn<3%, Fe<1.5%, other elements <1% each and <3% in total, with % Si<7.5-% Cu/3, which, when reheated to the semisolid state to the point at which a liquid fraction ratio between 35 and 55% is obtained, has an absence of non-remelted polyhedral silicon crystals.
U.S. Pat. No. 2,811,439 discloses an aluminum casting alloy containing 2 to 5 wt. % Cu, 1.5 to 2.5 wt. % Fe, 0.2 to 2 wt. % Si, and 0.05 to 0.3 wt. % Ti.
U.S. Pat. No. 4,284,429 discloses an aluminum casting alloy consisting essentially of 5.0% to 22.0% silicon, 0.5 to 7.0% copper, 1.5 to 5.5% magnesium, 2.0 to 8.0% zinc, iron not over 1.35%, manganese not over 0.65%, nickel not over 0.50%, titanium not over 0.20%, and chromium and other residual elements not over 0.15%, balance aluminum.
U.S. Pat. No. 4,785,092 discloses aluminum brazing alloys for assembling aluminum heat exchangers by brazing which consist essentially of 4.5 to 13.5% of Si, from 0.005% to less than 0.1% of Sr and the balance essentially Al and, further, optionally may contain at least one element selected from the group consisting of 0.3 to 3.0% of Mg, 2.3 to 4.7% of Cu and 9.3 to 10.7% of Zn. The aluminum brazing alloys provide high strength brazed joints with highly refined microstructure and brazing operation can be performed in a good condition without causing any detrimental cavity. Such excellent properties make the brazing alloys especially suited for the fabrication of superhigh pressure heat exchangers.
U.S. Pat. No. 5,925,315 discloses an antifrictional aluminum alloy and a method for making an aluminum alloy without lead are provided. The alloy has improved tribological characteristics and a base composition, in weight percent as follows: silicon: 3.0-6.0, copper: 2.0-5.0, zinc: 0.5-5.0, magnesium: 0.25-0.5, nickel: 0.2-0.6, tin: 0.5-5.0, bismuth: 0.1-1.0, iron: up to 0.7, aluminum: essentially the balance.
U.S. Pat. No. 6,059,902 discloses an aluminum alloy containing Si: 1.5-12% (mass % here and hereinafter), Mg: 0.5-6% and, optionally, at least one of Mn: 0.5-2%, Cu: 0.15-3% and Cr: 0.04-0.35% and, further, containing Ti: 0.01-0.1% and the balance of Al and inevitable impurities, in which the average grain size of crystallized grains of Si system compounds is from 2 to 20 tm and an area ratio thereof is from 2 to 12%. The alloy is melted to obtain a cast ingot having DAS (Dendrite Arm Spacing) of 10 to 50 &mgr;m, which is then put to a soaking treatment at 450 to 520° C. and then to extrusion molding. The aluminum alloy has excellent machinability with no addition of low melting metals.
U.S. Pat. No. 5,911,843 discloses a process for casting, thermally transforming and semi-solid forming an aluminum base alloy into an article, the process comprising the steps of: casting a molten body of aluminum base alloy comprising 2 to 7 wt. % Si, 0.3 to 1.7 wt. % Mg, 0.3 to 3 wt. % Cu, 0.05 to 0.4 wt. % Fe, and at least one of the group consisting of 0.01 to 1 wt. % Mn, 0.01 to 0.35 wt. % Cr, max. 0.2 wt. % Ti, max. 0.3 wt. % V to provide a solidified body, the molten aluminum base alloy being solidified at a rate between liquidus and solidus temperatures of the aluminum base alloy to provide a solidified body having a dendritic microstructure.
U.S. Pat. No. 5,846,350 discloses a process for casting, thermally transforming and semi-solid forming an aluminum base alloy into an article, the process comprising the steps of: casting a molten body of aluminum base alloy comprising 2 to 5 wt. % Si, 0.3 to 1.7 wt. % Mg, 0.3 to 1.2 wt. % Cu, 0.05 to 0.4 wt. % Fe, and at least one of the group consisting of 0.01 to 1 wt. % Mn, 0.01 to 0.35 wt. % Cr, max. 0.2 wt. % Ti, max. 0.3 wt. % V to provide a solidified body, the molten aluminum base alloy being solidified at a rate between liquidus and solidus temperatures of the aluminum base alloy to provide a solidified body having a dendritic microstructure. Thereafter, heat is applied to the solidified body to bring it to a superheated temperature of 3° to 50° C. above the solidus temperature of the aluminum base alloy while maintaining the body in a solid shape, effecting thermal transformation of the body having the dendritic structure when the body is heated to above the solidus temperature. The body, having a non-dendritic structure, is formed in a semi-solid condition into the article.
U.S. Pat. No. 5,571,346 discloses a process for casting, thermally transforming and semi-solid forming an aluminum base alloy into an article, the process comprising the steps of: casting a molten body of aluminum base alloy to provide a solidified body, the molten aluminum base alloy being solidified at a rate between liquidus and solidus temperatures of the aluminum base alloy in a range of 5° to 100° C./sec. to provide an entire solidified body having a dendritic microstructure. Thereafter, heat is applied to the solidified body to bring the body to a superhea

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