Metal treatment – Stock – Aluminum base
Reexamination Certificate
1997-11-14
2001-11-06
Kastler, Scott (Department: 1742)
Metal treatment
Stock
Aluminum base
C360S100100, C420S528000, C420S529000, C420S533000, C420S542000, C148S400000
Reexamination Certificate
active
06312534
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates generally to alloys and, more particularly, to a novel cast aluminum-beryllium alloy having superior strength, corrosion resistance, x-ray cross-section, and environmental acceptability.
Aluminum-beryllium alloys are known for their unique combination of properties, including strength, stiffness, lightness, machinability and corrosion resistance. Their appeal for commercial applications ranging from aircraft components to actuator armsets for computer disk drives has been recognized for some time.
Efforts have been made to refine and develop properties of these alloys in order to expand their commercial viability. This is typically accomplished by varying the alloy constituent levels. For instance, increased beryllium levels are known to prevent oxidation of aluminum and other alloy components. Nickel, cobalt and copper additions have been found to as enhance alloy strength and toughness.
In an attempt to make aluminum-beryllium alloys more commercially feasible, magnesium addition have also been used. While this has improved ductility, other characteristics of magnesium have precluded its use in vacuum cast alloy applications. They include volatility, strength, and work hardening coefficient. As a result, commercial viability of conventional aluminum-beryllium alloys has been limited.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to expand the commercial viability of high performance aluminum-beryllium alloys.
Another object of the present invention to provide a high performance alloy with improved ductility.
Still another object of the present invention is to provide a high performance aluminum-beryllium alloy suitable for investment casting processes.
Another object of the present invention is the production of a high strength, cast aluminum-beryllium alloy containing magnesium.
Yet another object of the present invention is to provide an aluminum-beryllium-copper alloy containing magnesium with improved ductility without sacrificing investment castability.
A further object of the present invention is to provide an aluminum-beryllium-nickel alloy containing magnesium with improved ductility, without sacrificing investment castability.
Still a further object of the present invention is to provide simple and efficient production of investment cast aluminum-beryllium alloy products.
Yet a further object of the present invention is to provide economical, high strength, investment cast products of aluminum-beryllium-copper alloys containing magnesium.
Another object of the present invention is to provide economical, high strength, investment cast products of aluminum-beryllium-nickel alloys containing magnesium.
In accordance with one aspect of the present invention is a high strength cast aluminum-beryllium alloy containing magnesium represented by the formula (25-60% Al)+(40-75% Be)+(0.1-1.25% Mg)+(0<X<5.5%)+(0<Y<4%)+(0<Z<0.75%)=100, wherein X is at least one element selected from the group consisting of nickel, cobalt and copper; Y is at least one element selected from the group consisting of silicon and silver; and Z is at least one element selected from the group consisting of iron, titanium, zirconium, boron, antimony, strontium, germanium, scandium and the rare earth elements.
According to another aspect of the present invention is an investment cast net shape article comprised of an aluminum-beryllium alloy containing magnesium represented by the formula, (25-60% Al)+(40-75% Be)+(0.1-1.25% Mg)+(0<X<5%)+(0<Y<4%)+(0<Z<0.75%)=100, where X=nickel, cobalt and/or copper, Y=silicon and/or silver, and Z=iron, titanium, zirconium, boron, antimony, strontium, germanium, scandium and/or a rare earth element.
In accordance with a further aspect of the present invention is an avionics box consisting essentially of an aluminum-beryllium alloy containing magnesium represented by the formula (25-60% Al)+(40-75% Be)+(0.1-1.25% Mg)+(0<X<5%)+(0<Y<4%)+(0<Z<0.75%)=100, where X=nickel, cobalt and/or copper, Y=silicon and/or silver, and Z=iron, titanium, zirconium, boron, antimony, strontium, germanium, scandium and/or a rare earth element.
According to still another aspect of the invention is a rotatable armset of an actuator consisting essentially of an aluminum-beryllium alloy containing magnesium represented by the formula (25-60% Al)+(40-75% Be)+(0.1-1.25% Mg)+(0<X<5%)+(0<Y<4%)+(0<Z<0.75%)=100, where X=nickel, cobalt and/or copper, Y=silicon and/or silver, and Z=iron, titanium, zirconium, boron, antimony, strontium, germanium, scandium and/or a rare earth element.
In accordance with yet a further aspect of the invention is a rotatable armset of an actuator, the armset comprising a bore for rotating about a shaft of a disk drive for positioning a head radially across a disk of the disk drive, wherein the armset is a one piece unit consisting essentially of an aluminum-beryllium-copper alloy containing magnesium.
According to yet another aspect of the present invention is a rotatable armset of an actuator, the armset comprising a bore for rotating about a shaft of a disk drive for positioning a head radially across a disk of the disk drive, wherein the armset is a one piece unit consisting essentially of an aluminum-beryllium-cobalt alloy containing magnesium.
According to a further aspect of the invention is an aluminum-beryllium-nickel alloy containing magnesium, the alloy having a first phase consisting of a primary solid solution based on the Be—&bgr;-phase with a microhardness H
&mgr;
of about 285 KSI, a second phase consisting of a solid solution based on the Al—&agr;-phase with a microhardness H
&mgr;
of about 85 KSI, and a phase of unknown nature having a microhardness H
&mgr;
of about 714 KSI.
In accordance with still a further aspect of the present invention is a beryllium-aluminum-copper alloy system, the system structure being characterized by the presence of a Be phase (&bgr;-phase) and a slightly alloyed solid solution of beryllium in aluminum.
In accordance with yet another aspect of the present invention is a beryllium-aluminum-nickel alloy system, the system structure being characterized by the presence of a Be phase (&bgr;-phase) and a slightly alloyed solid solution of beryllium in aluminum.
According to another aspect is an end effector for a robot arm consisting essentially of an aluminum-beryllium alloy containing magnesium represented by the formula (25-60% Al)+(40-75% Be)+(0.1-1.25% Mg)+(0<X<5%)+(0<Y<4%)+(0<Z<0.75%)=100, where X=nickel, cobalt and/or copper, Y=silicon and/or silver, and Z=iron, titanium, zirconium, boron, antimony, strontium, germanium, scandium and/or a rare earth element.
In accordance with a further aspect of the invention is a piston for an automobile engine, the piston consisting essentially of an aluminum-beryllium alloy containing magnesium represented by the formula (25-60% Al)+(40-75% Be)+(0.1-1.25% Mg)+(0<X<5%)+(0<Y<4%)+(0<Z<0.75%)=100, where X=nickel, cobalt and/or copper, Y=silicon and/or silver, and Z=iron, titanium, zirconium, boron, antimony, strontium, germanium, scandium and/or a rare earth element.
According to another aspect of the present invention is a method of producing a high strength cast aluminum-beryllium alloy containing magnesium. The method comprises the steps of initially melting charges of aluminum-beryllium under vacuum, then pressuring the melt with an inert gas. Magnesium is added at a selected pressure to retard boiling. The resulting material is then cast also under a selected pressure, and cooled in an inert gas atmosphere. Alternatively or concurrently therewith, the material is cooled, again under a selected pressure.
Altho
Brush Wellman Inc.
Calfee Halter & Griswold LLP
Kastler Scott
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