Specialized metallurgical processes – compositions for use therei – Processes – Free metal or alloy reductant contains magnesium
Reexamination Certificate
1999-12-07
2002-03-12
King, Roy (Department: 1742)
Specialized metallurgical processes, compositions for use therei
Processes
Free metal or alloy reductant contains magnesium
C148S688000, C420S532000, C420S536000, C420S537000, C420S538000, C420S590000
Reexamination Certificate
active
06355090
ABSTRACT:
TECHNICAL FIELD
The present invention relates to a method of producing an aluminum alloy for wrought material, and also to an aluminum wrought alloy obtained therefrom. More particularly, the present invention relates to a method of producing an aluminum alloy for wrought material that enables aluminum alloy casting scraps to be recycled for use, for example, not only as automotive parts, such as chassis, engines, body frames, and the like, but also as aluminum wrought alloy, such as of bicycles, motorcycles, railway vehicle structure members, building members, sporting goods, and the like.
Specifically, the present invention relates to a method of producing an aluminum alloy for automotive parts, and also to automotive parts obtained from the aluminum alloy. More specifically, the present invention relates to a method of producing an aluminum alloy for wrought material useful as automotive parts, wherein it is made possible to recycle the casting scraps of an aluminum alloy as a wrought material for automotive parts, such as space frames.
BACKGROUND ART
In recent years, effective utilization has been strongly called for, such as recycling regarding resources, in all fields. Also in regard to aluminum materials, there are no exception to this, and recycling regarding the resources has been demanded.
When aluminum alloy materials are recycled, the usual practice is to use a method wherein recycling is performed from high-quality materials with a reduced amount of impurities toward low-quality materials with a greater amount of impurities. Accordingly, whenever aluminum alloy materials are recycled, they are regenerated and reused as materials of lower quality with more impurities. Finally, such materials are utilized for casting parts or the like, containing a large amount of impurities.
When such casting parts are provided as scraps, it has been usual that part thereof is utilized as a deoxidizer for steel making, and the other is again recycled as castings or is wasted as surplus scrap, due to no demand.
The present invention has as its object the provision of a method wherein a casting scrap of an aluminum alloy is regenerated, to provide an aluminum alloy that is applicable as wrought material. The present invention also has as another object the provision of a wrought material of the aluminum alloy obtained by the method. The present invention has as a further object the provision of a method for obtaining an aluminum alloy that is recycled from an aluminum alloy casting scrap and is applicable as automotive parts. The present invention has as a still further object the provision of automotive parts obtained by the above method.
Other and further objects, features, and advantages of the invention will appear more fully from the following description.
DISCLOSURE OF THE INVENTION
In view of the above object, the inventors of the present invention, having investigated intensively, have found that the above problem can be solved by adding a scrap of an aluminum wrought alloy or a pure aluminum ingot to an aluminum alloy casting scrap, melting the resultant mixture for dilution, and, if necessary, subjecting the mixture to adjustment of elements thereof after or without purification refinement. Based on the above finding, the present inventors accomplished the present invention.
That is, according to the present invention, there are provided:
(1) A method of producing an aluminum alloy for automotive parts, which is characterized by comprising adding a pure aluminum ingot (a virgin aluminum ingot) or a scrap of an aluminum wrought alloy obtained through recovery as a scrap of a wrought material, to an aluminum alloy casting scrap, obtained via recovery of a scraped vehicle, melting the mixture, to dilute impurities, and adjusting elements in the mixture, if necessary; and
(2) A method of producing an aluminum alloy for wrought material, which is characterized by comprising adding a pure aluminum ingot or a scrap of an aluminum wrought alloy obtained via recovery as a scrap of a wrought material, to an aluminum alloy casting scrap, obtained via recovery of a scraped vehicle, melting the mixture to dilute impurities, subjecting the resultant liquid metal to purification refinement according to a batch process of &agr;-phase separating treatment, wherein the aluminum alloy liquid metal obtained after the melting and dilution is cooled and pressed to get a solid phase in the same vessel, and adjusting elements of the solid phase prior to or after the purification refinement, if necessary.
In the method as stated in the above (1) or (2), it is effective if not less than 50 wt % (hereinafter referred to simply as “%”) of the aluminum alloy casting scrap is constituted of an scrap of aluminum alloy casting for automotive vehicles.
After the melting and dilution in the method as stated in the above (1), or after the purification refinement in the method as stated in the above (2), or after the adjustment of elements performed as required, it is effective if the aluminum alloy is comprising of 0.5 to 5.0 wt % of Si, 0.2 to 5.0 wt % of Mg, 0.01 to 1.2 wt % of Mn, 0.1 to 1.2 wt % of Zn, 0.2 to 1.2 wt % of Cu, 0.2 to 2.0 wt % of Fe, and one or more of 0.01 to 0.2 wt % of Cr, 0.01 to 0.2 wt % of Zr, 0.01 to 0.2 wt % of V, and 0.01 to 0.2 wt % of Ti, with the balance being made of Al and unavoidable impurities.
A first of automotive parts according to the invention is characterized by being composed of an aluminum alloy having a composition, which is obtained by adding a scrap of an aluminum wrought alloy or a pure aluminum ingot to an aluminum alloy casting scrap, melting the mixture to dilute impurities, and, if necessary, adjusting elements of the resultant, comprising 0.5 to 5.0 wt % of Si, 0.2 to 5.0 wt % of Mg, 0.01 to 1.2 wt % of Mn, 0.1 to 1.2 wt % of Zn, 0.2 to 1.2 wt % of Cu, 0.2 to 2.0 wt % of Fe, and one or more of 0.01 to 0.2 wt % of Cr, 0.01 to 0.2 wt % of Zr, 0.01 to 0.2 wt % of V, and 0.01 to 0.2 wt % of Ti, with the balance being made of Al and unavoidable impurities.
A second of automotive parts according to the invention is characterized by being composed of an aluminum alloy having a composition, which is obtained by adding a scrap of aluminum wrought alloy or a pure aluminum ingot to an aluminum alloy casting scrap containing not less than 50% of an scrap of aluminum alloy casting for automotive vehicles, melting the mixture to dilute impurities, and, if necessary, adjusting elements therein, comprising 0.5 to 5.0 wt % of Si, 0.2 to 5.0 wt % of Mg, 0.01 to 1.2 wt % of Mn, 0.1 to 1.2 wt % of Zn, 0.2 to 1.2 wt % of Cu, 0.2 to 2.0 wt % of Fe, and one or more of 0.01 to 0.2 wt % of Cr, 0.01 to 0.2 wt % of Zr, 0.01 to 0.2 wt % of V, and 0.01 to 0.2 wt % of Ti, with the balance being made of Al and unavoidable impurities.
The aluminum wrought alloy of the present invention is characterized by being composed of an aluminum alloy having a composition, which is obtained by adding a scrap of an aluminum wrought alloy or a pure aluminum ingot to an aluminum alloy casting scrap, melting the mixture to dilute impurities, subjecting the resultant aluminum alloy liquid metal obtained after the melting and dilution to purification refinement according to a batch process of &agr;-phase separating treatment, wherein the aluminum alloy liquid metal is cooled and pressed to get a solid phase in the same vessel, and, if necessary, adjusting elements of the solid phase prior to or after the purification refinement, comprising 0.5 to 5.0 wt % of Si, 0.2 to 5.0 wt % of Mg, 0.01 to 1.2 wt % of Mn, 0.1 to 1.2 wt % of Zn, 0.2 to 1.2 wt % of Cu, 0.2 to 2.0 wt % of Fe, and one or more of 0.01 to 0.2 wt % of Cr, 0.01 to 0.2 wt % of Zr, 0.01 to 0.2 wt % of V, and 0.01 to 0.2 wt % of Ti, with the balance being made of Al and unavoidable impurities.
Another type of aluminum wrought alloy according to the present invention is characterized by being composed of an aluminum alloy having a composition, which is obtained by adding a scrap of an aluminum wrought alloy or a pure aluminum ingot to an aluminum
Bekki Yoichiro
Hayashi Noboru
Ohyama Koji
King Roy
McGuthry-Banks Tima
The Furukawa Electric Co. Ltd.
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