New light-weight aluminum alloys with high Mg2Si-content by spray forming∗

O. Stelling; A. Irretier; O. Keßler; P. Krug; B. Commandeur

doi:10.3139/105.100394

Artikel

New light-weight aluminum alloys with high Mg₂Si-content by spray forming∗

O. Stelling , A. Irretier , O. Keßler , P. Krug und B. Commandeur

Veröffentlicht/Copyright: 11. Mai 2013

Veröffentlicht von

Veröffentlichen auch Sie bei De Gruyter Brill

Manuskript einreichen Informationen für Autor*innen

Aus der Zeitschrift HTM Journal of Heat Treatment and Materials Band 61 Heft 5

Abstract

Aluminum alloys with high Mg₂Si-content (> 10%) offer the possibility of a significant decrease in density and an increase in stiffness at the same time. But these alloys can hardly be produced in casting processes, due to an oxidation and a generation of pores by high hydrogen solubility in the melt. Furthermore, the usual solidification rate is not sufficient for a fine microstructure morphology. A fine distribution of Mg₂Si is possible by spray forming, where a coarsening of the particles can be avoided due to a higher solidification rate. Different aluminum alloys with high Mg₂Si-content (> 10%) have successfully been produced by spray forming, extrusion and age hardening. Mg-excess as well as Si-excess has been investigated. An additional alloying with copper leads to a further increase in strength by the precipitation sequence of Al₂Cu. The new light-weight aluminum alloys have been investigated regarding age hardening, physical and mechanical properties. Densities of 2.5–2.6 g/cm³ and Young's modulus of approx. 80,000 MPa have been found. Microstructures were dense, homogeneous and of fine morphology. The yield strength of these alloys reached values of approx. 400 MPa after artificial aging, whereby only a slight decrease in the hot yield strength was observed up to a temperature of 200 °C. Applications of the new light-weight aluminum alloys can be expected where a reduced density together with a high hot yield strength would lead to a more compact design in high temperature environments, e.g. in combustion engines.

Kurzfassung

Aluminiumlegierungen mit hohem Mg₂Si-Anteil (> 10%) bieten die Möglichkeit einer signifikanten Dichteverringerung bei gleichzeitiger Festigkeitssteigerung. Derartige Legierungen lassen sich mittels gängiger Gießtechnik nur schwer realisieren. Die Abkühlraten während des Gießprozesses reichen nicht aus, um die angestrebte, feine Verteilung der Mg₂Si-Ausscheidungen im feinkörnigen Gefüge zu erzielen. Durch den Sprühkompaktierprozess ist es möglich, eine Vergröberung der Ausscheidungen durch hohe Abkühlraten zu unterdrücken. Aluminiumlegierungen mit unterschiedlichen Mg₂Si-Gehalten (> 10%) konnten erfolgreich sprühkompaktiert werden. Sie wurden anschließend stranggepresst und wärmebehandelt. Es wurden sowohl Legierungen mit Mg-als auch mit Si-Überschuss untersucht. Die Zugabe von Kupfer führt durch die Ausscheidungssequenz der Al₂Cu-Phase zu einer zusätzlichen Steigerung der Festigkeit. Die Materialien wurden bezüglich Auslagerungsverhalten sowie ihrer physikalischen und mechanischen Eigenschaften untersucht. Dichten von 2,5–2,6 g/cm³ und ein Elastizitätsmodul von ca. 80000 MPa konnten erzielt werden. Das Gefüge war homogen und zeichnete sich durch eine feine Morphologie aus. Nach der Warmauslagerung konnten Zugfestigkeiten von ca. 400 MPa erreicht werden. Untersuchungen zur Warmfestigkeit zeigten lediglich einen leichten Abfall im Temperaturbereich bis 200 °C. Anwendungen für diese neuartigen Aluminiumlegierungen sind in Bereichen zu erwarten, in denen geringe Dichten in Verbindung mit hoher Warmfestigkeit gefordert sind, z.B. in Verbrennungsmotoren.

Dipl.-Ing. Olaf Stelling, born in 1978, has studied Production Engineering at the University Bremen, Germany. Afterwards he was working as Research Engineer at the Materials Testing Institute University Stuttgart (MPA Stuttgart). Since 2006 he works as Research Engineer at the Foundation Institute for Materials Science (IWT) in Bremen.

Dipl.-Ing. Andree Irretier, born in 1972, has studied Production Engineering at the University of Bremen, Germany. Since 2000 he was working as Research Engineer at the Foundation Institute for Materials Science (IWT) in Bremen. Since 2006 he is the Leader of the department Metallic Materials and Structures at the Bremen Institute for Materials Testing (MPA Bremen, a devision of IWT).

PD Dr.-Ing. Olaf Keßler, born in 1965, studied Production Engineering at the University Bremen. He finished his dissertation in 1995 and his postdoctoral lecture qualification in 2003. Since 2006 he is Head of the department “Light Weight Materials”.

Dr.-Ing. Peter Krug, born in 1965, has studied Materials Science at the University Erlangen, Germany. There he earned his Doctor's degree in the field of directional solidification of turbine blades by liquid metal cooling. He started in 1998 in the industry at AUDI AG, Ingolstadt, Germany, at the Department “Materials, Processes and Recycling”. In 1999 he became the Head of the Casting Laboratory at “Aluminium Rheinfelden GmbH, Rheinfelden, Germany. Since 2001 he is the responsible for the R&D-Department of PEAK Werkstoff GmbH, Velbert, Germany.

Dipl.-Ing. Bernd Commandeur, born in 1961, studied Mechanical Engineering at the FH Aachen in Jülich, Germany, and received his degree in 1987. His first practical work experience focused on thermal spraying at the „Innovation Center for Welding and Surface Treatments“ in Dortmund. He acceded a development position in 1989 within the R&D Department of Erbslöh Aluminium in Velbert, Germany. In 1990 he changed to PEAK Werkstoff GmbH and since 2002 he is the Managing Director of PEAK Werkstoff GmbH.

∗

Revised lecture held by O. Stelling at the Int. Conf. Aluminium Alloy 2006, ICAA10, July 9^th–13^th, 2006 in Vancouver/Ca. The original lecture version is published in Materials Science Forum Vols. 519–521 (2006).

References

1. Fujii, H.; Sugamata, M.; Kaneko, J.; Ohkubo, M.: Structures and mechanical properties of rapidly solidified Al-5∼13 % Mg-2∼13% Si ternary alloys. Proc. 6^th Int. Conf. on Aluminum Alloys, ICAA-6, Toyohashi/Japan, 1998, pp. 1805–1810Suche in Google Scholar

2. Zhang, J.; Wang, Y.-Q.; Zhou, B.-L.: Microstructure and tensile properties of graded Al-Mg₂Si in situ composites fabricated by centrifugal casting. Mater. Sci. Technol.15 (1999), pp. 1236–1240Suche in Google Scholar

3. Frommeyer, G.; Beer, S.; von Oldenburg, K.: Microstructure and mechanical properties of mechanically alloyed intermetallic Mg₂Si-Al Alloys. Z. Metallkd.85 (1994), pp. 372–377Suche in Google Scholar

4. Hummert, K.; Frech, W.; Schwagereit, M.: Industriell hergestellte sprühkompaktierte Aluminiumlegierungen. Metall9 (1999), pp. 496–500Suche in Google Scholar

5. Stocker, P.; Rückert, F.; Hummert, K.: Die neue Aluminium-Silizium-Zylinderlaufbahn-Technologie für Kurbelgehäuse aus Aluminium-Druckguß. Motorentechn. Z.58 (1997), pp. 502–518Suche in Google Scholar

6. Vetters, H.; Schulz, A.; Schimanski, K.; Spangel, S.; Uhlenwinkel, V.; Bauckhage, K.: Spray forming of cast alloys, an innovative alternative. Proc. 65^th World Foundry Congr., Gyeongju/Korea, 2002, pp. 1089–1093Suche in Google Scholar

7. Zhang, J.; Fan, Z.; Wang, Y.-Q.; Zhou, B.-L.: Microstructure and mechanical properties of in situ Al-Mg₂Si composites. Mater. Sci. Technol.16 (2000), pp. 913–91810.1179/026708300101508685Suche in Google Scholar

Published Online: 2013-05-11

Published in Print: 2006-09-01

Sie haben derzeit keinen Zugang zu diesem Inhalt.

Artikel in diesem Heft

https://doi.org/10.3139/105.100394