Patent Application
20130307383
The present invention relates in general to a high electrical resistance aluminum alloy, more specifically to a high electrical resistance aluminum alloy casting excelling in toughness and corrosion resistance, suitable for use in the production of housings for electric motors, and a method for production thereof.
AC electric motors are often used as motive power sources. AC electric motors consist of a stator and a rotor, and can be largely divided between induction motors using electromagnets in both the stator and the rotor, and synchronous motors using an electromagnet in either the stator or the rotor, and a permanent magnet in the other.
The stator and rotor in an induction motor are constituted by coil elements that both generate magnetic flux and a core element that concentrates the magnetic flux generated by the coil elements. When a current is supplied to at least one of the coil elements of the stator and rotor, a magnetic field is created in accordance with the laws of electromagnetic induction, setting up a magnetic flux between the stator and the rotor, and generating a rotational force on the rotor.
While the stators or rotors with the electromagnets in synchronous motors have the same structure as those of induction motors, the stators or rotors with the permanent magnets are constituted by a magnet element that generates magnetic flux and a core element for concentrating the magnetic flux generated by the magnet element. In the case of synchronous motors as well, when a current is supplied to a coil element of a stator or rotor using an electromagnet, a magnetic field is created in accordance with the laws of electromagnetic induction, setting up a magnetic flux between the stator and the rotor, and generating a rotational force on the rotor.
In the case of both the induction motor and the synchronous motor, the magnetic flux created by the magnetic field generated in accordance with the laws of electromagnetic induction is not limited to being between the stator and the rotor, and some leaks to the periphery thereof. For this reason, if the housing of the motor has good electroconductivity, eddy currents will be generated at the housing, resulting in eddy current loss and the housing being heated to high temperatures.
In view of these circumstances, Patent Document 1, for example, discloses art to improve the heat dissipation by using an aluminum alloy of high thermal conductivity in the housing. On the other hand, Patent Document 2 proposes art for reducing generated eddy currents by providing apertures at the portions of the housing where eddy currents occur or using a ceramic or resin that is non-magnetic and of high electrical resistivity as the housing. Additionally, Patent Document 3 proposes an aluminum alloy of high electrical resistivity capable of being used as the housing of an electric motor.
However, while the aluminum alloy disclosed in Patent Document 1 excels in heat dissipation, no measures are taken against eddy current loss, so the problem of reduced output of the electric motor accompanying the generation of eddy currents is not resolved.
Additionally, of the inventions disclosed in Patent Document 2, those having apertures at the portions where the eddy currents are generated have the problems that extra steps are required to make the apertures and the presence of the apertures reduces the rigidity of the housing. On the other hand, those using a ceramic or resin that is non-magnetic and having a high electrical resistivity cannot easily achieve toughness.
Furthermore, while the aluminum alloy disclosed in Patent Document 3 has sufficiently high electrical resistivity and is capable of solving the problem remaining in the invention of Patent Document 2, research by the present inventors etc. has revealed that it has insufficient strength, toughness and corrosion resistance for use as housings for electric motors, and presents economical problems for containing large quantities of expensive Mn, Mg and Cu.
The present invention was conceived in order to solve the above-described problems, and has the main purpose of offering a high electrical resistance aluminum alloy casting capable of being favorably used for the production of an electric motor housing, and a method for production thereof.
Additionally, the present invention offers an electric motor housing formed by the above-described aluminum alloy casting.
In one aspect of the present invention, a high electrical resistance aluminum alloy casting with excellent toughness and corrosion resistance, characterized by comprising 11.0 to 13.0 mass % of Si, 0.2 to 1.0 mass % of Fe, 0.2 to 2.2 mass % of Mn, 0.7 to 1.3 mass % of Mg, 0.5 to 1.3 mass % of Cr and 0.1 to 0.5 mass % of Ti, the balance consisting of Al and unavoidable impurities, wherein the amount of Cu as an unavoidable impurity is restricted to 0.2 mass % or less is offered. Additionally, in another aspect, an electric motor housing formed by the aluminum alloy casting is offered.
In this case, the aluminum alloy casting is preferably cast by any process among gravity casting, low-pressure casting, die casting and squeeze casting. The aluminum alloy casting may be presented for use without subjecting to a heat treatment after casting, or may be subjected to a heat treatment after casting. In one embodiment, the high electrical resistance aluminum alloy casting of the present invention is subjected after casting to a solution heat treatment at 510 to 530° C. for 2 to 5 hours, followed by artificial ageing at 160 to 200° C. for 4 to 8 hours.
In a further aspect of the present invention, a method for producing a high electrical resistance aluminum alloy casting with excellent toughness and corrosion resistance, characterized by casting an aluminum alloy melt comprising 11.0 to 13.0 mass % of Si, 0.2 to 1.0 mass % of Fe, 0.2 to 2.2 mass % of Mn, 0.7 to 1.3 mass % of Mg, 0.5 to 1.3 mass % of Cr and 0.1 to 0.5 mass % of Ti, the balance consisting of Al and unavoidable impurities, wherein the amount of Cu as an unavoidable impurity is restricted to 0.2 mass % or less is offered.
In this case, the casting is preferably cast by any process among gravity casting, low-pressure casting, die casting and squeeze casting. Additionally, the aluminum alloy casting may be followed by a heat treatment, or not followed by a heat treatment. In one embodiment, the method includes steps, after casting, of performing a solution heat treatment at 510 to 530° C. for 2 to 5 hours, followed by artificial ageing at 160 to 200° C. for 4 to 8 hours. In one example, the aluminum alloy casting to be produced is a housing for electric motors.
The aluminum alloy casting of the present invention has a high electrical resistivity and excels in toughness, and can therefore be favorably used as a housing for electric motors.
The present inventors performed diligent research into means for cheaply raising the electrical resistivity of high strength, high toughness, high corrosion resistance aluminum alloys capable of being favorably used as housings for electric motors. In the process of doing so, they found that an aluminum alloy with high corrosion resistance and high electrical resistivity can be obtained by adding an appropriate amount of Fe and Mn to an Al—Si type alloy. Furthermore, they discovered that by adding Mg, Cr or Ti, the electrical resistance can be further increased, the strength and toughness can be improved, and the corrosion resistance can be improved due to refinement of the crystal grains, thereby achieving the present invention.
One embodiment of the present invention relates to a high electrical resistance Al—Si type alloy with excellent toughness and corrosion resistance, comprising 11.0 to 13.0 mass % of Si, 0.2 to 1.0 mass % of Fe, 0.2 to 2.2 mass % of Mn, 0.7 to 1.3 mass % of Mg, 0.5 to 1.3 mass % of Cr and 0.1 to 0.5 mass % of Ti, the balance consisting of Al and unavoidable impurities, wherein the amount of Cu as an unavoidable impurity is restricted to 0.2 mass % or less. Additionally, another embodiment of the present invention relates to a high electrical resistance Al—Si type alloy casting with excellent toughness and corrosion resistance, comprising 11.0 to 13.0 mass % of Si, 0.2 to 1.0 mass % of Fe, 0.2 to 2.2 mass % of Mn, 0.7 to 1.3 mass % of Mg, 0.5 to 1.3 mass % of Cr and 0.1 to 0.5 mass % of Ti, the balance consisting of Al and unavoidable impurities, wherein the amount of Cu as an unavoidable impurity is restricted to 0.2 mass % or less.
Another embodiment of the present invention relates to the use of an alloy comprising 11.0 to 13.0 mass % of Si, 0.2 to 1.0 mass % of Fe, 0.2 to 2.2 mass % of Mn, 0.7 to 1.3 mass % of Mg, 0.5 to 1.3 mass % of Cr and 0.1 to 0.5 mass % of Ti, the balance consisting of Al and unavoidable impurities, wherein the amount of Cu as an unavoidable impurity is restricted to 0.2 mass % or less, or a casting of said alloy, as a high electrical resistance material with excellent toughness and corrosion resistance. Furthermore, another embodiment of the present invention relates to the use of an alloy comprising 11.0 to 13.0 mass % of Si, 0.2 to 1.0 mass % of Fe, 0.2 to 2.2 mass % of Mn, 0.7 to 1.3 mass % of Mg, 0.5 to 1.3 mass % of Cr and 0.1 to 0.5 mass % of Ti, the balance consisting of Al and unavoidable impurities, wherein the amount of Cu as an unavoidable impurity is restricted to 0.2 mass % or less, or a casting of said alloy, for producing a high electrical resistance material with excellent toughness and corrosion resistance.
First, the functions of each component element constituting the aluminum alloy will be discussed briefly.
The addition of Si up to the eutectic point in the Al—Si system has the effects of improving the strength, toughness, and castability without detracting from the corrosion resistance, so in the present invention, it is added within the range up to the eutectic point. In an Al—Si two-element equilibrium diagram, the eutectic composition is Al-12.6 mass % Si, but the alloy of the present invention includes 0.7 to 1.3 mass % of Mg. When 0.7 mass % of Mg is added, the eutectic point is Al-13.1 mass % Si, and when 1.3 mass % of Mg is added, the eutectic point is Al-13.8 mass % Si, so the amount of Si added to the alloy of the present invention, 11.0 to 13.0 mass %, is less than that of the eutectic point. When the amount of Si added is less than 11.0 mass %, the effect of improving the strength, toughness and castability is insufficient and therefore undesirable. On the other hand, the addition of Si past the eutectic point reduces castability due to increases in the liquidus temperature and also reduces toughness since the primary crystals are of Si, which is undesirable.
In an Al-based cast alloy, the addition of 0.2 to 1.0 mass % of Fe has an effect of preventing burning to the cast when casting, as well as raising the strength and increasing the electrical resistance, so it is added within that range to the present invention. If the amount of Fe added is less than 0.2 mass %, the effect of preventing burning to the cast when casting is insufficient, and no significant strength increasing effect is observed, which is undesirable. On the other hand, if the amount of Fe in the Al—Si type alloy exceeds 1.0 mass %, crude intermetallic compounds are generated in the Al—Fe—Si system, making it brittle and reducing toughness, which is undesirable.
In Al-based alloys, the addition of 0.2 to 2.2 mass % of Mn maintains the corrosion resistance, improves strength and increases electrical resistance. Additionally, the addition of 0.2 to 2.2 mass % of Mn to an Al—Si type alloy containing 0.2 to 1.0 mass % of Fe contributes to improved toughness, but the addition of Mn in excess of 2.2 mass % causes brittleness along with the creation of crude intermetallic compounds in the Al—Mn—Si system, thereby reducing the toughness, so in the present invention, the amount of Mn added is in the range of 0.2 to 2.2 mass %. If the amount of Mn added is less than 0.2 mass %, significant strength improving effects, toughness improving effects and electrical resistance increasing effects are not observed, which is undesirable. On the other hand, as mentioned previously, if the amount of Mn added exceeds 2.2 mass %, the toughness is reduced, which is undesirable.
In an Al—Si type alloy, the addition of 0.7 to 1.3 mass % of Mg has a strength improving effect with the addition, and an even greater strength improving effect and electrical resistance increasing effect due to a heat treatment for artificial ageing to be described in detail below, so it is added to the present invention in the indicated range. If the amount of Mg added is less than 0.7 mass %, the aforementioned effects are insufficient, which is undesirable. On the other hand, if the amount of Mg added exceeds 1.3 mass %, the aforementioned effects reach saturation, while further addition is a factor in reducing castability due to the formation of oxides (in the melt) during casting, as well as raising the cost, which is undesirable.
The addition of Cr and Ti to an Al-based alloy has the effect of increasing electrical resistance, improving the strength and toughness due to crystal grain refinement, and improving corrosion resistance. Therefore, in the present invention, Cr is added in the range of 0.5 to 1.3 mass % and Ti is added in the range of 0.1 to 0.5 mass %. If the amount of Cr added is less than 0.5 mass %, or the amount of Ti added is less than 0.1 mass %, then a significant toughness improving effect, strength improving effect and corrosion resistance improving effect is not observed, which is undesirable. On the other hand, if the amount of Cr added exceeds 1.3 mass %, the formation of crude Al—Cr type intermetallic compounds reduces the toughness, which is undesirable. Additionally, if the amount of Ti added exceeds 0.5 mass %, the toughness improving effect, strength improving effect and corrosion resistance improving effect are saturated, and further addition results in increased cost, which is undesirable.
While Cu conventionally has been added to Al—Si type alloys for the purpose of improving strength, the addition of Cu, while effective in improving strength, reduces the toughness and the corrosion resistance. For this reason, in the present invention, various types of melt raw materials such as ingots, scrap and added alloys are selected, and the content of Cu as an impurity is held to 0.2 mass % or less, preferably 0.1 mass % or less, more preferably 0.05 mass % or less, and most preferably 0.01 mass % or less. Thus, the lower the Cu content the better, but on the other hand, the use of aluminum ingots of low Cu content raises the cost, so the melt raw material should be chosen in consideration of the effects and the cost.
While other elements may be included as unavoidable impurities in aluminum ingots, they will not detract from the effects of the present invention if only present up to 0.1 mass % individually and 0.3 mass % in total, so their presence in this range is tolerable.
Another embodiment of the present invention relates to an aluminum alloy casting production method characterized by casting an aluminum alloy melt comprising 11.0 to 13.0 mass % of Si, 0.2 to 1.0 mass % of Fe, 0.2 to 2.2 mass % of Mn, 0.7 to 1.3 mass % of Mg, 0.5 to 1.3 mass % of Cr and 0.1 to 0.5 mass % of Ti, with the balance consisting of Al and unavoidable impurities, wherein the content of Cu as an unavoidable impurity is 0.2 mass % or less. As disclosed in the above-identified Patent Document 1 and Patent Document 3, electric motor housings of aluminum alloy have conventionally been produced by known casting methods such as gravity casting, low-pressure casting, die casting and squeeze casting, and these casting methods can also be favorably used in carrying out the present invention.
The aluminum alloy casting of the present invention has high strength, high toughness and high corrosion resistance, as well as high electrical resistance, even directly as cast, so it can be favorably used as a housing for an electric motor, but by performing heat treatments for artificial ageing, the strength and corrosion resistance can be further improved, which is favorable.
The heat treatment for artificial ageing should preferably be for 4 to 8 hours at 160 to 200° C. If the heat treatment temperature is less than 160° C. or the heat treatment time is less than 4 hours, there is little precipitation of fine intermetallic compounds during the heat treatment, so the improvement in strength due to the artificial ageing treatment is inadequate, and there is little significant difference from the case where a heat treatment for artificial ageing is not performed. On the other hand, if the heat treatment temperature exceeds 200° C. or the heat treatment time exceeds 8 hours, the precipitated intermetallic compounds can grow too large, resulting in so-called over-ageing, thereby reducing the strength improving effect and reducing the electrical resistivity, which is undesirable.
Furthermore, in the present invention, it is preferable to carry out a heat treatment for solutionization after casting and before said artificial ageing. By carrying out a heat treatment for solutionization, the variability in properties can be reduced. The heat treatment for solutionization should preferably be performed for 2 to 5 hours at 510 to 530° C. If the heat treatment temperature is less than 510° C. or the heat treatment time is less than 2 hours, the solutionization effect is insufficient, and there is little significant difference from the case where a heat treatment is not carried out for solutionization, which is undesirable. On the other hand, the heat treatment for solutionization is adequate if carried out for 5 hours at 530° C., and it is meaningless to carry out the heat treatment in excess of this temperature and time, which is undesirable.
Additionally, when producing a housing for an electric motor, it is preferable to perform machining after casting, but when carrying out a heat treatment for ageing as described above, the machining should precede the ageing step.
Aside for use in housings for electric motors, the aluminum alloy casting of the present invention can be favorably used in any application requiring a material of high strength, high toughness and high corrosion resistance, while also having high electrical resistivity.
While the present invention will be explained by way of examples in detail below, the present invention is not to be construed as being limited by these examples.
The respective properties in the examples were evaluated by the following methods.
The strength was evaluated by a so-called tension testing method. That is, tension testing pieces in the shape shown in
The toughness was evaluated by a so-called Charpy impact test. That is, a testing piece having a notch shape forming a V-notch as shown in
The corrosion resistance was evaluated in accordance with the so-called salt spray test. That is, the test was performed by preparing a 65×145×1.0 mm test piece as shown in
The electrical resistivity was obtained by preparing a 180×150×6 mm test piece as shown in
As shown in Table 1 below, aluminum alloy test materials of Alloy Nos. 1-6 (Present Invention Examples) which are aluminum alloy castings with compositions within the scope of the present invention, aluminum alloy test materials of Alloy Nos. 7-18 (Comparative Examples) which are aluminum alloy castings with compositions not within the scope of the present invention, and an aluminum alloy test material of Alloy No. 19 (Conventional Example) which is an aluminum alloy casting with a composition in the scope disclosed in Patent Document 3 were cast by a die casting method. The aluminum alloy test materials of Alloy Nos. 3-7 are present invention examples and comparative examples in which the Cu content is changed. The aluminum alloy test materials of Alloy Nos. 8-9 are comparative examples wherein Si is outside the scope of the present invention. The aluminum alloy test materials of Alloy Nos. 10-11 are comparative examples wherein Fe lies outside the scope of the present invention. The aluminum alloy test materials of Alloy Nos. 12-13 are comparative examples wherein Mn lies outside the scope of the present invention. The aluminum alloy test materials of Alloy Nos. 14-15 are comparative examples wherein Mg lies outside the scope of the present invention. The aluminum alloy test materials of Alloy Nos. 16-17 are comparative examples wherein Cr lies outside the scope of the present invention. The aluminum alloy test material of Alloy No. 18 is a comparative example wherein Ti lies outside the scope of the present invention.
0.60
10.3
14.1
0.12
1.20
0.14
3.10
0.35
1.80
0.25
1.90
0.04
10.8
0.15
4.81
2.36
5.12
—
—
For each of these nineteen different aluminum alloy test materials, samples were produced (a) directly as cast, and (b) subjected to a solution heat treatment at 520° C. for 3 hours, then water-cooled, followed by an artificial ageing treatment at 180° C. for 6 hours.
The above-described aluminum alloy test materials were each evaluated for the properties of strength, toughness, corrosion resistance and electrical resistivity in accordance with the evaluation methods described above.
Of these results, comparisons of Alloy No. 3 which is a representative of the present invention and Alloy No. 19 which is a conventional example are summarized in the following Tables 2-3.
According to the results shown in Tables 2 and 3, the aluminum alloy test materials of the present invention examples, whether (a) as cast, or (b) after subjecting to a solution heat treatment at 520° C. for 3 hours, then water-cooled and artificially aged at 180° C. for 6 hours, had slightly lower electrical resistivity but excellent strength, toughness and corrosion resistance compared to aluminum alloy test materials of conventional examples subjected to the same treatments. In other words, the aluminum alloy test material of the present invention had significantly high break elongation and Charpy values, as well as high tensile strength, and little mass change in the test material before and after neutral salt spray testing. An aluminum alloy casting having such properties can be favorably used as a housing for an electric motor.
Next, Alloy Nos. 1, 2 and 4-18 which are present invention examples and comparative examples when changing the Cu content and comparative examples where the Si, Fe, Ti, Mn, Mg or Cr is outside the range of the present invention are summarized in the following Tables 4-5.
0.80
1.14
0.98
0.81
0.98
0.77
1.01
0.99
0.82
0.98
1.08
0.79
0.98
0.76
0.99
0.79
1.16
58.9
1.02
58.9
0.82
0.98
1.00
57.5
0.78
1.00
1.02
55.6
0.80
0.99
1.10
52.6
0.80
52.1
0.79
54.7
According to the results shown in these tables, when used (a) as cast, the aluminum alloy test materials of the present invention satisfied all the conditions of a Charpy impact value of at least 0.90, a mass change before and after salt spray of 0.97 μg or less, and an electrical resistivity of at least 59.0 mΩm, while the aluminum alloy test materials of the comparative examples had one of these properties outside the desired values, and when used (b) after subjecting to a solution heat treatment at 520° C. for 3 hours, then water-cooled and artificially aged at 180° C. for 6 hours, the aluminum alloy test materials of the present invention satisfied all the conditions of a Charpy impact value of at least 0.90, a mass change before and after salt spray of 0.97 μg or less, and an electrical resistivity of at least 59.0 mΩm, while the aluminum alloy test materials of the comparative examples had one of these properties outside the desired values. In other words, the aluminum alloy test materials of the present invention have a harmonious balance of the properties of strength, toughness, corrosion resistance and electrical resistivity. The aluminum castings having these properties are capable of being used favorably as housings for electric motors.
Additionally, the aluminum alloy test materials according to the present invention, when used directly as cast, have an electrical resistivity of at least 71.0 mΩm, and when subjected to solutionization and artificial ageing after casting, have a lower electrical resistivity than directly as cast, but have a tensile strength of at least 360 MPa, and a mass change before and after salt spray of 0.9 μg or less.
Of the above test materials, the metal structures of the aluminum alloy test material of Alloy No. 3 according to the present invention (b) after subjecting to solutionization, water-cooling and artificial ageing, and the aluminum alloy test material of Alloy No. 19 according to a conventional example after likewise subjecting to solutionization, water-cooling and artificial ageing, were observed by microscope.
The aluminum alloy castings of the present invention have high electrical resistivity, high toughness and high corrosion resistance, and are also lightweight, and can therefore be favorably used as housings in electric motors.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP11/51615 | 1/27/2011 | WO | 00 | 7/26/2013 |
