High strength and high rigidity aluminum-based alloy and production method therefor

BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an aluminum-based alloy for use in a wide range of applications such as in a structural material for aircraft, vehicles, and ships, and for engine parts. In addition, the present invention may be employed in sashes, roofing materials, and exterior materials for use in construction, or as material for use in marine equipment, nuclear reactors, and the like.
2. Description of Related Art
As prior art aluminum-based alloys, alloys incorporating various components such as Al--Cu, Al--Si, Al--Mg, Al--Cu--Si, Al--Cu--Mg, and Al--Zn--Mg are known. In all of the aforementioned, superior anti-corrosive properties are obtained at a light weight, and thus the aforementioned alloys are being widely used as structural material for machines in vehicles, ships, and aircraft, in addition to being employed in sashes, roofing materials, exterior materials for use in construction, structural material for use in LNG tanks, and the like.
However, the prior art aluminum-based alloys generally exhibit disadvantages such as a low hardness and poor heat resistance when compared to material incorporating Fe. In addition, although some materials have incorporated elements such as Cu, Mg, and Zn for increased hardness, disadvantages remain such as low anti-corrosive properties.
On the other hand, recently, experiments have been conducted in which a fine metallographic structure of aluminum-based alloys is obtained by means of performing quick-quench solidification from a liquid-melt state, resulting in the production of superior mechanical strength and anti-corrosive properties.
In Japanese Patent Application, First Publication No. 1-275732, an aluminum-based alloy comprising a composition AlM.sub.1 X with a special composition ratio (wherein M.sub.1 represents an element such as V, Cr, Mn, Fe, Co, Ni, Cu, Zr and the like, and X represents a rare earth element such as La, Ce, Sm, and Nd, or an element such as Y, Nb, Ta, Mm (misch metal) and the like), and having an amorphous or a combined amorphous/fine crystalline structure, is disclosed.
This aluminum-based alloy can be utilized as material with a high hardness, high strength, high electrical resistance, anti-abrasion properties, or as soldering material. In addition, the disclosed aluminum-based alloy has a superior heat resistance, and may undergo extruding or press processing by utilizing the superplastic phenomenon observed near crystallization temperatures.
However, the aforementioned aluminum-based alloy is disadvantageous in that high costs result from the incorporation of large amounts of expensive rare earth elements and/or metal elements with a high activity such as Y. Namely, in addition to the aforementioned use of expensive raw materials, problems also arise such as increased consumption and labor costs due to the large scale of the manufacturing facilities required to treat materials with high activities. Furthermore, this aluminum-based alloy having the aforementioned composition tends to display insufficient resistance to oxidation and corrosion.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an aluminum-based alloy, possessing superior strength, rigidity, and anti-corrosive properties, which comprises a composition in which rare earth elements or high activity elements such as Y are not incorporated, thereby effectively reducing the cost, as well as, the activity described in the aforementioned.
In order to solve the aforementioned problems, the present invention provides a high strength and high rigidity aluminum-based alloy consisting essentially of a composition represented by the general formula Al.sub.100-(a+b) Q.sub.a M.sub.b (wherein Q is at least one metal element selected from the group consisting of V, Mo, Fe, W, Nb, and Pd; M is at least one metal element selected from the group consisting of Mn, Fe, Co, Ni, and Cu; and a and b, which represent a composition ratio in atomic percentages, satisfy the relationships 1.ltoreq.a.ltoreq.8, 0<b<5, and 3.ltoreq.a+b.ltoreq.8) having a metallographic structure comprising a quasi-crystalline phase, wherein the difference in the atomic radii between Q and M exceeds 0.01 .ANG., and said alloy does not contain rare earths.
According to the present invention, by adding a predetermined amount of V, Mo, Fe, W, Nb, and/or Pd to Al, the ability of the alloy to form a quasi-crystalline phase is improved, and the strength, hardness, and toughness of the alloy is also improved. Moreover, by adding a predetermined amount of Mn, Fe, Co, Ni, and/or Cu, the effects of quick-quenching are enhanced, the thermal stability of the overall metallographic structure is improved, and the strength and hardness of the resulting alloy are also increased. Fe has both quasi-crystalline phase forming effects and alloy strengthening effects.
The aluminum-based alloy according to the present invention is useful as materials with a high hardness, strength, and rigidity. Furthermore, this alloy also stands up well to bending, and thus possesses superior properties such as the ability to be mechanically processed.
Accordingly, the aluminum-based alloys according to the present invention can be used in a wide range of applications such as in the structural material for aircraft, vehicles, and ships, as well as for engine parts. In addition, the aluminum-based alloys of the present invention may be employed in sashes, roofing materials, and exterior materials for use in construction, or as materials for use in marine equipment, nuclear reactors, and the like.

BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a construction of an example of a single roll apparatus used at the time of manufacturing a tape of an alloy of the present invention following quick-quench solidification.
FIG. 2 shows the analysis result of the X-ray diffraction of an alloy having the composition of Al.sub.94 V.sub.4 Fe.sub.2.
FIG. 3 shows the analysis result of the X-ray diffraction of an alloy having the composition of Al.sub.95 Mo.sub.3 Ni.sub.2.
FIG. 4 shows the thermal properties of an alloy having the composition of Al.sub.94 V.sub.4 Ni.sub.2.
FIG. 5 shows the thermal properties of an alloy having the composition of Al.sub.94 V.sub.4 Mn.sub.2.
FIG. 6 shows the thermal properties of an alloy having the composition of Al.sub.95 Nb.sub.3 Co.sub.2.
FIG. 7 shows the thermal properties of an alloy having the composition of Al.sub.95 Mo.sub.3 Ni.sub.2.
FIG. 8 shows the thermal properties of an alloy having the composition of Al.sub.97 Fe.sub.3.
FIG. 9 shows the thermal properties of an alloy having the composition of Al.sub.97 Fe.sub.5 Co.sub.3.
FIG. 10 shows the thermal properties of an alloy having the composition of Al.sub.97 Fe.sub.1 Ni.sub.3.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiment of the present invention provides a high strength and high rigidity aluminum-based alloy consisting essentially of a composition represented by the general formula Al.sub.100-(a+b) Q.sub.a M.sub.b (wherein Q is at least one metal element selected from the group consisting of V, Mo, Fe, W, Nb, and Pd; M is at least one metal element selected from the group consisting of Mn, Fe, Co, Ni, and Cu; and a and b, which represent a composition ratio in atomic percentages, satisfy the relationships 1.ltoreq.a.ltoreq.8, 0<b<5, and 3.ltoreq.a+b.ltoreq.8), comprising a quasi-crystalline phase in the alloy, wherein the difference in the atomic radii between Q and M exceeds 0.01 .ANG., and said alloy does not contain rare earths.
In the following, the reasons for limiting the composition ratio of each component in the alloy according to the present invention are explained.
The atomic percentage of Al (aluminum) is in the range of 92.ltoreq.Al.ltoreq.97, preferably in the range of 94.ltoreq.Al.ltoreq.97. An atomic percentage for Al of less than 92% results in embrittlement of the alloy. On the other hand, an atomic percentage for Al exceeding 97% results in reduction of the strength and hardness of the alloy.
The amount of at least one metal element selected from the group consisting of V (vanadium), Mo (molybdenum), Fe (iron), W (tungsten), Nb (niobium), and Pd (palladium) in atomic percentage is at least 1% and does not exceed 8%; preferably, the amount is at least 2% and does not exceed 8%; more preferably, the amount is at least 2% and does not exceed 6%. If the amount is less than 1%, a quasi-crystalline phase cannot be obtained, and the strength is markedly reduced. On the other hand, if the amount exceeds 10%, coarsening (the diameter of particles is 500 nm or more) of a quasi-crystalline phase occurs, and this results in remarkable embrittlement of the alloy and reduction of (rupture) strength of the alloy.
The amount of at least one metal element selected from the group consisting of Mn (manganese), Fe (iron), Co (cobalt), Ni (nickel), and Cu (copper) in atomic percentage is less than 5%; preferably, the amount is at least 1% and does not exceed 3%; more preferably, the amount is at least 1% and does not exceed 2%. If the amount is 5% or more, forming and coarsening (the diameter of particles is 500 nm or more) of intermetallic compounds occur, and these result in remarkable embrittlement and reduction of toughness of the alloy.
Furthermore, with the present invention, the difference in radii between the atom selected from the above-mentioned group Q and the atom selected from the above-mentioned group M must exceed 0.01 .ANG.. According to the Metals Databook (Nippon Metals Society Edition, 1984, published by Maruzen K. K.), the radii of the atoms contained in groups Q and M are as follows, and the differences in atomic radii for each combination are as shown in Table 1.
Q: V=1.32 .ANG., Mo=1.36 .ANG., Fe=1.24 .ANG., W=1.37 .ANG., Nb=1.43 .ANG., Pd=1.37 .ANG.
M: Mn=1.12 .ANG. or 1.50 .ANG., Fe=1.24 .ANG., Ni=1.25 .ANG., Co=1.25 .ANG., Cu=1.28 .ANG.
Table 1 shows the differences in radii between atoms selected from group Q and atoms selected from group M for all combinations, as calculated from the above-listed atomic radius values.
TABLE 1______________________________________Units: .ANG.ELEMENT Mn Fe Co Ni Cu______________________________________V 0.20 or 0.18 0.08 0.07 0.07 0.04Nb 0.31 or 0.07 0.19 0.18 0.18 0.15Mo 0.24 or 0.14 0.12 0.11 0.11 0.08Pd 0.25 or 0.13 0.13 0.12 0.12 0.09W 0.25 or 0.13 0.13 0.12 0.12 0.09Fe 0.12 or 0.26 0 0.01 0.01 0.04______________________________________
Therefore, of the combinations of Q and M expressed by the above-given general formula, the three combinations of:
Q=Fe, M=Fe
Q=Fe, M=Co
Q=Fe, M=Ni are excluded from the scope of the present invention.
If the difference in radii of the atom selected from group Q and the atom selected from group M is not more than 0.01 .ANG., then they tend to form thermodynamically stable intermetallic compounds which are undesirable for tending to become brittle upon solidification. For example, when forming bulk-shaped samples by solidifying ultra-quick-quenching tape, the intermetallic compounds leave prominent deposits so as to make the samples extremely brittle.
The formation of thermodynamically stable intermetallic compounds can be detected, for example, as decreases in the crystallization temperature by means of differential scanning calorimetry (DSC).
Additionally, brittleness can appear as reductions in the Charpy impact values.
Furthermore, the total amount of unavoidable impurities, such as Fe, Si, Cu, Zn, Ti, O, C, or N, does not exceed 0.3% by weight; preferably, the amount does not exceed 0.15% by weight; and more preferably, the amount does not exceed 0.10% by weight. If the amount exceeds 0.3% by weight, the effects of quick-quenching is lowered, and this results in reduction of the formability of a quasi-crystalline phase. Among the unavoidable impurities, particularly, it is preferable that the amount of O does not exceed 0.1% by weight and that the amount of C or N does not exceed 0.03% by weight.
The aforementioned aluminum-based alloys can be manufactured by quick-quench solidification of the alloy liquid-melts having the aforementioned compositions using a liquid quick-quenching method. This liquid quick-quenching method essentially entails rapid cooling of the melted alloy. For example, single roll, double roll, and submerged rotational spin methods have proved to be particularly effective. In these aforementioned methods, a cooling rate of 10.sup.4 to 10.sup.6 K/sec is easily obtainable.
In order to manufacture a thin tape using the aforementioned single or double roll methods, the liquid-melt is first poured into a storage vessel such as a silica tube, and is then discharged, via a nozzle aperture at the tip of the silica tube, towards a copper or copper alloy roll of diameter 30 to 300 mm, which is rotating at a fixed velocity in the range of 300 to 1000 rpm. In this manner, various types of thin tapes of thickness 5-500 .mu.m and width 1-300 mm can be easily obtained.
On the other hand, fine wire-thin material can be easily obtained through the submerged rotational spin method by discharging the liquid-melt via the nozzle aperture, into a refrigerant solution layer of depth 1 to 10 cm, maintained by means of centrifugal force inside an air drum rotating at 50 to 500 rpm, under argon gas back pressure. In this case, the angle between the liquid-melt discharged from the nozzle, and the refrigerant surface is preferably 60 to 90 degrees, and the relative velocity ratio of the liquid-melt and the refrigerant surface is preferably 0.7 to 0.9.
In addition, thin layers of aluminum-based alloy of the aforementioned compositions can also be obtained without using the above methods, by employing layer formation processes such as the sputtering method. In addition, aluminum alloy powder of the aforementioned compositions can be obtained by quick-quenching the liquid-melt using various atomizer and spray methods such as a high pressure gas spray method.
In the following, examples of metallographic-structural states of the aluminum-based alloy obtained using the aforementioned methods are listed:
(1) Multiphase structure incorporating a quasi-crystalline phase and an aluminum phase;
(2) Multiphase structure incorporating a quasi-crystalline phase and a metal solid solution having an aluminum matrix;
(3) Multiphase structure incorporating a quasi-crystalline phase and a stable or metastable intermetallic compound phase; and
(4) Multiphase structure incorporating a quasi-crystalline phase, an amorphous phase, and a metal solid solution having am aluminum matrix.
The fine crystalline phase of the present invention represents a crystalline phase in which the crystal particles have an average maximum diameter of 1 .mu.m.
By regulating the cooling rate of the alloy liquid-melt, any of the metallographic-structural states described in (1) to (4) above can be obtained.
The properties of the alloys possessing the aforementioned metallographic-structural states are described in the following.
An alloy of the multiphase structural state described in (1) and (2) above has a high strength and an excellent bending ductility.
An alloy of the multiphase structural state described in (3) above has a higher strength and lower ductility than the alloys of the multiphase structural state described in (1) and (2). However, the lower ductility does not hinder its high strength.
An alloy of the multiphase structural state described in (4) has a high strength, high toughness and a high ductility.
Each of the aforementioned metallographic-structural states can be easily determined by a normal X-ray diffraction method or by observation using a transmission electron microscope. In the case when a quasi-crystal exists, a dull peak, which is characteristic of a quasi-crystalline phase, is exhibited.
By regulating the cooling rate of the alloy liquid-melt, any of the multiphase structural states described in (1) to (3) above can be obtained.
By quick-quenching the alloy liquid-melt of the Al-rich composition (e.g., composition with Al.gtoreq.92 atomic %), any of the metallographic-structural states described in (4) can be obtained.
The aluminum-based alloy of the present invention displays superplasticity at temperatures near the crystallization temperature (crystallization temperature .+-.50.degree. C.), as well as, at the high temperatures within the fine crystalline stable temperature range, and thus processes such as extruding, pressing, and hot forging can easily be performed. Consequently, aluminum-based alloys of the above-mentioned compositions obtained in the aforementioned thin tape, wire, plate, and/or powder states can be easily formed into bulk materials by means of extruding, pressing and hot forging processes at the aforementioned temperatures. Furthermore, the aluminum-based alloys of the aforementioned compositions possess a high ductility, thus bending of 180.degree. is also possible.
Additionally, the aforementioned aluminum-based alloys having multiphase structure composed of a pure-aluminum phase, a quasi-crystalline phase, a metal solid solution, and/or an amorphous phase, and the like, do not display structural or chemical non-uniformity of crystal grain boundary, segregation and the like, as seen in crystalline alloys. These alloys cause passivation due to formation of an aluminum oxide layer, and thus display a high resistance to corrosion. Furthermore, disadvantages exist when incorporating rare earth elements: due to the activity of these rare earth elements, non-uniformity occurs easily in the passive layer on the alloy surface resulting in the progress of corrosion from this portion towards the interior. However, since the alloys of the aforementioned compositions do not incorporate rare earth elements, these aforementioned problems are effectively circumvented.
In regards to the aluminum-based alloy of the aforementioned compositions, the manufacturing of bulk-shaped (mass) material will now be explained.
When heating the aluminum-based alloy according to the present invention, precipitation and crystallization of the fine crystalline phase is accompanied by precipitation of the aluminum matrix (.alpha.-phase), and when further heating beyond this temperature, the intermetallic compound also precipitates. Utilizing this property, bulk material possessing a high strength and ductility can be obtained.
Concretely, the tape alloy manufactured by means of the aforementioned quick-quenching process is pulverized in a ball mill, and then powder pressed in a vacuum hot press under vacuum (e.g. 10.sup.-3 Torr) at a temperature slightly below the crystallization temperature (e.g. approximately 470K), thereby forming a billet for use in extruding with a diameter and length of several centimeters. This billet is set inside a container of an extruder, and is maintained at a temperature slightly greater than the crystallization temperature for several tens of minutes. Extruded materials can then be obtained in desired shapes such as round bars, etc., by extruding.
EXAMPLES
(Hardness and Tensile Rupture Strength)
A molten alloy having a predetermined composition was manufactured using a high frequency melting furnace. Then, as shown in FIG. 1, this melt was poured into a silica tube 1 with a small aperture 5 (aperture diameter: 0.2 to 0.5 mm) at the tip, and then heated to melt, after which the aforementioned silica tube 1 was positioned directly above copper roll 2. This roll 2 was then rotated at a high speed of 4000 rpm, and argon gas pressure (0.7 kg/cm.sup.3) was applied to silica tube 1. Quick-quench solidification was subsequently performed by quick-quenching the liquid-melt by means of discharging the liquid-melt from small aperture 5 of silica tube 1 onto the surface of roll 2 and quick-quenching to yield an alloy tape 4.
Under these manufacturing conditions, the numerous alloy tape samples (width: 1 mm, thickness: 20 .mu.m) of the compositions (atomic percentages) shown in Tables 2 and 3 were formed. The hardness (Hv) and tensile rupture strength (.sigma..sub.f : MPa) of each alloy tape sample were measured. These results are also shown in Tables 2 and 3. The hardness is expressed in the value measured according to the minute Vickers hardness scale (DPN: Diamond Pyramid Number).
Additionally, a 180.degree. contact bending test was conducted by bending each sample 180.degree. and contacting the ends thereby forming a U-shape. The results of these tests are also shown in Tables 2 and 3: those samples which displayed ductility and did not rupture are designated Duc (ductile), while those which ruptured are designated Bri (brittle).
TABLE 2______________________________________Sample Alloy composition of Hv BendingNo. (at %) (MPa) (DPN) test______________________________________1 Al.sub.95 V.sub.3 Ni.sub.2 880 320 Duc Example2 Al.sub.94 V.sub.4 Ni.sub.2 1230 365 Duc Example3 Al.sub.93 V.sub.5 Ni.sub.2 1060 325 Duc Example4 Al.sub.95 V.sub.3 Fe.sub.2 630 300 Duc Example5 Al.sub.94 V.sub.4 Fe.sub.2 1350 370 Duc Example6 Al.sub.93 V.sub.5 Fe.sub.2 790 305 Duc Example7 Al.sub.95 V.sub.3 Co.sub.2 840 310 Duc Example8 Al.sub.94 V.sub.4 Co.sub.2 1230 355 Duc Example9 Al.sub.93 V.sub.5 Co.sub.2 1090 350 Duc Example10 Al.sub.94 V.sub.4 Mn.sub.2 1210 355 Duc Example11 Al.sub.93 V.sub.4 Mn.sub.3 800 310 Duc Example12 Al.sub.94 V.sub.4 Cu.sub.2 1010 310 Duc Example14 Al.sub..sub.92 V.sub.5 Ni.sub.3 1110 330 Duc Example15 Al.sub.93 V.sub.4 Fe.sub.3 1200 340 Duc Example19 Al.sub.93 V.sub.6 Fe.sub.1 1210 345 Duc Example17 Al.sub.92 V.sub.7 Co.sub.1 1010 310 Duc Example18 Al.sub.93 V.sub.4 Co.sub.3 1110 310 Duc Example19 Al.sub.94 Mo.sub.4 Ni.sub.2 1200 300 Duc Example20 Al.sub.95 Mo.sub.3 Ni.sub.2 1250 305 Duc Example21 Al.sub.93 Mo.sub.5 Ni.sub..sub.2 1300 320 Duc Example22 Al.sub.94 Mo.sub.4 Co.sub.2 1010 300 Duc Example23 Al.sub.95 Mo.sub.3 Co.sub.2 1210 330 Duc Example24 Al.sub.93 Mo.sub.5 Fe.sub..sub.2 990 310 Duc Example25 Al.sub.94 Mo.sub.4 Fe.sub.2 1320 375 Duc Example26 Al.sub.94 Mo.sub.4 Mn.sub.2 1220 360 Duc Example27 Al.sub.92 Mo.sub.5 Mn.sub.3 1100 345 Duc Example28 Al.sub.95 Mo.sub.3 Mn.sub.2 1020 330 Duc Example29 Al.sub.97 Mo.sub.1 Cu.sub.2 880 305 Duc Example30 Al.sub.94 Fe.sub.4 Mn.sub.2 1320 370 Duc Exam31 Al.sub.94 Fe.sub.3 Mn.sub.3 1100 345 Duc Exam33 Al.sub.94 Fe.sub.4 Cu.sub.2 890 285 Duc Example34 Al.sub.95 Fe.sub.4 Cu.sub.1 880 300 Duc Example35 Al.sub.94 W.sub.4 Ni.sub..sub.2 1010 340 Duc Example36 Al.sub.94 W.sub.3 Ni.sub.3 1000 300 Duc Example37 Al.sub.93 W.sub.5 Co.sub.2 1110 315 Duc Example38 Al.sub.95 W.sub.2 Co.sub.3 1210 365 Duc Example39 Al.sub.94 W.sub.4 Fe.sub..sub.2 1090 305 Duc Example40 Al.sub.93 W.sub.6 Fe.sub.1 1100 360 Duc Example41 Al.sub.94 W.sub.2 Mn.sub.4 1210 350 Duc Example42 Al.sub.92 Nb.sub.6 Mn.sub.2 1230 330 Duc Example43 Al.sub.94 Nb.sub.4 Fe.sub.2 1040 320 Duc Example44 Al.sub.94 Nb.sub.4 Ni.sub.2 1300 370 Duc Example45 Al.sub.93 Nb.sub.3 Ni.sub.4 1210 360 Duc Example46 Al.sub.95 Nb.sub.3 Ni.sub.2 1100 360 Duc Example47 Al.sub.94 Nb.sub.4 Co.sub.2 1150 365 Duc Example50 Al.sub.94 Pd.sub.4 Fe.sub.2 1010 315 Duc Example51 Al.sub.96 Pd.sub.3 Fe.sub.1 990 310 Duc Example52 Al.sub.94 Pd.sub.4 Ni.sub.2 1210 365 Duc Example53 Al.sub.92 Pd.sub.5 Ni.sub.3 1230 365 Duc Example54 Al.sub.94 Pd.sub.3 Co.sub.3 1100 335 Duc Example______________________________________
TABLE 3______________________________________Sample Alloy composition of Hv BendingNo (at %) (MPa) (DPN) test______________________________________55 Al.sub.94 Fe.sub.4 Co.sub.2 1310 370 Duc Comparative Example56 Al.sub.94 Fe.sub.5 Co.sub.1 1110 335 Duc Comparative Example57 Al.sub.96 Fe.sub.3 Co.sub.1 1010 320 Duc Comparative Example58 Al.sub.90 Fe.sub.8 Ni.sub.2 1100 340 Duc Comparative Example59 Al.sub.88 Fe.sub.10 Ni.sub.2 1300 375 Duc Comparative Example60 Al.sub.88 Fe.sub.9 Ni.sub.3 1280 360 Duc Comparative Example61 Al.sub.96.5 V.sub.0.5 Mn.sub.3 460 95 Duc Comparative Example62 Al.sub.86 V.sub.12 Mn.sub.2 600 450 Bri Comparative Example63 Al.sub.97 V.sub.3 400 120 Duc Comparative Example64 Al.sub.90 V.sub.4 Mn.sub.6 550 410 Bri Comparative Example65 Al.sub.98 V.sub.1 Mn.sub.1 430 95 Duc comparative Example66 Al.sub.87 V.sub.10 Mn.sub.3 510 410 Bri Comparative Example67 Al.sub.96.5 V.sub.0.5 Fe.sub.3 410 120 Duc Comparative Example68 Al.sub.85 V.sub.13 Fe.sub.2 505 405 Bri Comparative Example69 Al.sub.98 V.sub.1 Fe.sub.1 400 110 Duc Comparative Example70 Al.sub.87 V.sub.10 Fe.sub.3 490 410 Bri Comparative Example71 Al.sub.90 V.sub.4 Fe.sub.6 450 430 Bri Comparative Example72 Al.sub.95.5 V.sub.0.5 Ni.sub.4 390 95 Duc Comparative Example73 Al.sub.86 V.sub.11 Ni.sub.3 410 430 Bri Comparative Example74 Al.sub.89 V.sub.4 Ni.sub.7 405 425 Bri Comparative Example75 Al.sub.98 V.sub.1 Ni.sub.1 290 80 Duc Comparative Example76 Al.sub.85 V.sub.11 Ni.sub.4 500 420 Bri Comparative Example77 Al.sub.94.5 V.sub.0.5 Co.sub.5 410 125 Duc Comparative Example78 Al.sub.83 V.sub.15 Co.sub.2 490 480 Bri Comparative Example79 Al.sub.90 V.sub.2 Co.sub.8 480 410 Bri Comparative Example80 Al.sub.98.5 V.sub.0.5 Co.sub.1 210 90 Duc Comparative Example81 Al.sub.85 V.sub.11 Co.sub.4 410 430 Bri Comparative Example82 Al.sub.94.5 V.sub.0.5 Cu.sub.5 340 105 Duc Comparative Example83 Al.sub.88 V.sub.11 Cu.sub.1 490 420 Bri Comparative Example84 Al.sub.89 V.sub.3 Cu.sub.8 480 410 Bri Comparative Example85 Al.sub.98 V.sub.1 Cu.sub.1 410 95 Duc Comparative Example86 Al.sub.85 V.sub.12 Cu.sub.3 550 420 Bri Comparative Example87 Al.sub.96.5 Mo.sub.0.5 Mn.sub.3 430 125 Duc Comparative Example88 Al.sub.86 Mo.sub.12 Mn.sub.2 510 430 Bri Comparative Example89 Al.sub.97 Mo.sub.3 370 130 Duc Comparative Example90 Al.sub.90 Mo.sub.4 Mn.sub.6 480 410 Bri Comparative Example91 Al.sub.98 Mo.sub.1 Mn.sub.1 380 100 Duc Comparative Example92 Al.sub.87 Mo.sub.10 Mn.sub.3 490 420 Bri Comparative Example93 Al.sub.96.5 Mo.sub.0.5 Fe.sub.3 360 125 Duc Comparative Example94 Al.sub.85 Mo.sub.13 Fe.sub.2 500 460 Bri Comparative Example95 Al.sub.98 Mo.sub.1 Fe.sub.1 210 80 Duc Comparative Example96 Al.sub.87 Mo.sub.10 Fe.sub.3 510 450 Bri Comparative Example97 Al.sub.90 Mo.sub.4 Fe.sub.6 490 435 Bri Comparative Example98 Al.sub.95.5 Mo.sub.0.5 Ni.sub.4 310 95 Duc Comparative Example99 Al.sub.86 Mo.sub.11 Ni.sub.3 500 430 Bri Comparative Example100 Al.sub.89 Mo.sub.4 Ni.sub.7 465 410 Bri Comparative Example101 Al.sub.98 Mo.sub.1 Ni.sub.1 200 95 Duc Comparative Example102 Al.sub.85 Mo.sub.11 Ni.sub.4 460 450 Bri Comparative Example103 Al.sub.94 5 Mo.sub.0.5 Co.sub.5 380 100 Duc Comparative Example104 Al.sub.83 Mo.sub.15 Co.sub.2 510 410 Bri Comparative Example105 Al.sub.90 Mo.sub.2 Co.sub.8 490 420 Bri Comparative Example106 Al.sub.98.5 Mo.sub.0.5 Co.sub.1 360 105 Duc Comparative Example107 Al.sub.85 Mo.sub.11 Co.sub.4 460 430 Bri Comparative Example108 Al.sub.94.5 Mo.sub.0.5 Cu.sub.5 340 105 Duc Comparative Example109 Al.sub.88 Mo.sub.11 Cu.sub.1 490 430 Bri Comparative Example110 Al.sub.89 Mo.sub.3 Cu.sub.8 510 410 Bri Comparative Example111 Al.sub.98 Mo.sub.1 Cu.sub.1 410 95 Duc Comparative Example112 Al.sub.85 Mo.sub.12 Cu.sub.3 550 420 Bri Comparative Example113 Al.sub.96.5 Fe.sub.0.5 Mn.sub.3 420 130 Duc Comparative Example114 Al.sub.86 Fe.sub.12 Mn.sub.2 510 430 Bri Comparative Example115 Al.sub.97 Fe.sub.3 480 160 Duc Comparative Example116 Al.sub.90 Fe.sub.4 Mn.sub.6 530 425 Bri Comparative Example117 Al.sub.96 Fe.sub.1 Mn.sub.1 480 95 Duc Comparative Example118 Al.sub.87 Fe.sub.10 Mn.sub.3 510 420 Bri Comparative Example119 Al.sub.95.5 Fe.sub.0.5 Ni.sub.4 470 105 Duc Comparative Example120 Al.sub.86 Fe.sub.11 Ni.sub.3 510 420 Bri Comparative Example121 Al.sub.89 Fe.sub.4 Ni.sub.7 505 425 Bri Comparative Example122 Al.sub.98 Fe.sub.1 Ni.sub.1 380 95 Duc Comparative Example123 Al.sub.85 Fe.sub.11 Ni.sub.4 500 410 Bri Comparative Example124 Al.sub.94.5 Fe.sub.0.5 Co.sub.5 380 125 Duc Comparative Example125 Al.sub.83 Fe.sub.15 Co.sub.2 200 480 Bri Comparative Example126 Al.sub.90 Fe.sub.2 Co.sub.8 490 425 Bri Comparative Example127 Al.sub.98.5 Fe.sub.0.5 Co.sub.1 380 95 Duc Comparative Example128 Al.sub.85 Fe.sub.11 Co.sub.4 350 435 Bri Comparative Example129 Al.sub.94.5 Fe.sub.0.5 Cu.sub.5 340 105 Duc Comparative Example130 Al.sub.88 Fe.sub.11 Cu.sub.1 410 435 Bri Comparative Example131 Al.sub.89 Fe.sub.3 Cu.sub.8 480 410 Bri Comparative Example132 Al.sub.98 Fe.sub.1 Cu.sub.1 410 95 Duc Comparative Example133 Al.sub.85 Fe.sub.12 Cu.sub.3 550 420 Bri Comparative Example134 Al.sub.96.5 W.sub.0.5 Mn.sub.3 380 120 Duc Comparative Example135 Al.sub.86 W.sub.12 Mn.sub.2 420 435 Bri Comparative Example136 Al.sub.97 W.sub.3 280 95 Duc Comparative Example137 Al.sub.90 W.sub.4 Mn.sub.6 490 440 Bri Comparative Example138 Al.sub.98 W.sub.1 Mn.sub.1 280 95 Duc Comparative Example139 Al.sub.87 W.sub.10 Mn.sub.3 290 475 Bri Comparative Example140 Al.sub.96.5 W.sub.0.5 Fe.sub.3 385 105 Duc Comparative Example141 Al.sub.85 W.sub.13 Fe.sub.2 310 480 Bri Comparative Example142 Al.sub.98 W.sub.1 Fe.sub.1 320 105 Duc Comparative Example143 Al.sub.87 W.sub.10 Fe.sub.3 500 475 Bri Comparative Example144 Al.sub.90 W.sub.4 Fe.sub.6 510 460 Bri Comparative Example145 Al.sub.95.5 W.sub.0.5 Ni.sub.4 380 95 Duc Comparative Example146 Al.sub.86 W.sub.11 Ni.sub.13 520 470 Bri Comparative Example147 Al.sub.89 W.sub.4 Ni.sub.7 500 435 Bri Comparative Example148 Al.sub.98 W.sub.1 Ni.sub.1 280 80 Duc Comparative Example149 Al.sub.85 W.sub.11 Ni.sub.4 460 435 Bri Comparative Example150 Al.sub.94.5 W.sub.0.5 Co.sub.5 275 105 Duc Comparative Example151 Al.sub.83 W.sub.15 Co.sub.2 500 460 Bri Comparative Example152 Al.sub.90 W.sub.2 Co.sub.8 410 445 Bri Comparative Example153 Al.sub.98.5 W.sub.0.5 Co.sub.1 270 85 Duc Comparative Example154 Al.sub.85 W.sub.11 Co.sub.4 290 470 Bri Comparative Example155 Al.sub.94.5 W.sub.0.5 Cu.sub.5 340 105 Duc Comparative Example156 Al.sub.88 W.sub.11 Cu.sub.1 310 435 Bri Comparative Example157 Al.sub.89 W.sub.3 Cu.sub.8 380 410 Bri Comparative Example158 Al.sub.98 W.sub.1 Cu.sub.1 410 95 Duc Comparative Example159 Al.sub.85 W.sub.12 Cu.sub.3 550 420 Bri Comparative Example160 Al.sub.96.5 Nb.sub.0.5 Mn.sub.3 430 120 Duc Comparative Example161 Al.sub.86 Nb.sub.12 Mn.sub.2 510 475 Bri Comparative Example162 Al.sub.97 Nb.sub.3 430 105 Duc Comparative Example163 Al.sub.90 Nb.sub.4 Mn.sub.6 490 430 Bri Comparative Example164 Al.sub.98 Nb.sub.1 Mn.sub.1 380 95 Duc Comparative Example165 Al.sub.87 Nb.sub.10 Mn.sub.3 390 465 Bri Comparative Example166 Al.sub.96.5 Nb.sub.0.5 Fe.sub.3 400 95 Duc Comparative Example167 Al.sub.85 Nb.sub.13 Fe.sub.2 390 480 Bri Comparative Example168 Al.sub.98 Nb.sub.1 Fe.sub.1 430 100 Duc Comparative Example169 Al.sub.87 Nb.sub.10 Fe.sub.3 510 435 Bri Comparative Example170 Al.sub.90 Nb.sub.4 Fe.sub.6 420 80 Bri Comparative Example171 Al.sub.95.5 Nb.sub.0.5 Ni.sub.4 380 110 Duc Comparative Example172 Al.sub.86 Nb.sub.11 Ni.sub.3 510 440 Bri Comparative Example173 Al.sub.69 Nb.sub.4 Ni.sub.7 490 435 Bri Comparative Example174 Al.sub.98 Nb.sub.1 Ni.sub.1 230 80 Duc Comparative Example175 Al.sub.85 Nb.sub.11 Ni.sub.4 430 475 Bri Comparative Example176 Al.sub.94.5 Nb.sub.0.5 Co.sub.5 280 95 Duc Comparative Example177 Al.sub.83 Nb.sub.15 Co.sub.2 410 470 Bri Comparative Example178 Al.sub.90 Nb.sub.2 Co.sub.8 510 430 Bri Comparative Example179 Al.sub.98.5 Nb.sub.0.5 Co.sub.1 270 90 Duc Comparative Example180 Al.sub.85 Nb.sub.11 Co.sub.4 510 475 Bri Comparative Example181 Al.sub.94.5 Nb.sub.0.5 Cu.sub.5 340 105 Duc Comparative Example182 Al.sub.88 Nb.sub.11 Cu.sub.1 490 445 Bri Comparative Example183 Al.sub.89 Nb.sub.3 Cu.sub.8 475 410 Bri Comparative Example184 Al.sub.98 Nb.sub.1 Cu.sub.1 410 95 Duc Comparative Example185 Al.sub.85 Nb.sub.12 Cu.sub.3 550 420 Bri Comparative Example186 Al.sub.96.5 Pd.sub.0.5 Mn.sub.3 380 105 Duc Comparative Example187 Al.sub.86 Pd.sub.12 Mn.sub.2 400 435 Bri Comparative Example188 Al.sub.97 Pd.sub.3 410 95 Duc Comparative Example189 Al.sub.90 Pd.sub.4 Mn.sub.6 510 420 Bri Comparative Example190 Al.sub.98 Pd.sub.1 Mn.sub.1 390 80 Duc Comparative Example191 Al.sub.87 Pd.sub.10 Mn.sub.3 490 465 Bri Comparative Example192 Al.sub.96.5 Pd.sub.0.5 Fe.sub.3 300 95 Duc Comparative Example193 Al.sub.85 Pd.sub.13 Fe.sub.2 210 480 Bri Comparative Example194 Al.sub.98 Pd.sub.1 Fe.sub.1 290 105 Duc Comparative Example195 Al.sub.87 Pd.sub.10 Fe.sub.3 460 435 Bri Comparative Example196 Al.sub.90 Pd.sub.4 Fe.sub.6 475 430 Bri Comparative Example197 Al.sub.95.5 Pd.sub.0.5 Ni.sub.4 310 90 Duc Comparative Example198 Al.sub.86 Pd.sub.11 Ni.sub.3 410 465 Bri Comparative Example199 Al.sub.89 Pd.sub.4 Ni.sub.7 460 450 Bri Comparative Example200 Al.sub.96 Pd.sub.1 Ni.sub.1 280 85 Duc Comparative Example201 Al.sub.65 Pd.sub.11 Ni.sub.4 410 460 Bri Comparative Example202 Al.sub.94.5 Pd.sub.0.5 Co.sub.5 430 120 Duc Comparative Example203 Al.sub.83 Pd.sub.15 Co.sub.2 290 485 Bri Comparative Example204 Al.sub.90 Pd.sub.2 Co.sub.8 425 430 Bri Comparative Example205 Al.sub.98.5 Pd.sub.0.5 Co.sub.1 290 95 Duc Comparative Example206 Al.sub.85 Pd.sub.11 Co.sub.4 460 465 Bri Comparative Example207 Al.sub.94.5 Pd.sub.0.5 Cu.sub.5 340 105 Duc Comparative Example208 Al.sub.88 Pd.sub.11 Cu.sub.1 475 435 Bri Comparative Example209 Al.sub.89 Pd.sub.3 Cu.sub.8 490 410 Bri Comparative Example210 Al.sub.98 Pd.sub.1 Cu.sub.1 410 95 Duc Comparative Example211 Al.sub.85 Pd.sub.12 Cu.sub.3 550 420 Bri Comparative Example______________________________________
It is clear from the results shown in Tables 2 and 3 that an aluminum-based alloy possessing a high bearing force and hardness, which endured bending and could undergo processing, was obtainable when the alloy comprising at least one of Mn, Fe, Co, Ni, and Cu, as element M, in addition to an Al--V, Al--Mo, Al--W, Al--Fe, Al--Nb, or Al--Pd two-component alloy has the atomic percentages satisfying the relationships Al.sub.balance Q.sub.a M.sub.b, 1.ltoreq.a.ltoreq.8, 0<b<5, 3.ltoreq.a+b.ltoreq.8, Q=V, Mo, Fe, W, Nb, and/or Pd, and M=Mn, Fe, Co, Ni, and/or Cu, wherein the difference in the atomic radii between Q and M exceeds 0.01 .ANG. and the alloy does not contain rare-earths.
In contrast to normal aluminum-based alloys which possess an Hv of approximately 50 to 100 DPN, the samples according to the present invention, shown in Table 2, display an extremely high hardness from 295 to 375 DPN.
In addition, in regards to the tensile rupture strength (.sigma..sub.f), normal age hardened type aluminum-based alloys (Al--Si--Fe type) possess values from 200 to 600 MPa; however, the samples according to the present invention have clearly superior values in the range from 630 to 1350 MPa.
Furthermore, when considering that the tensile strengths of aluminum-based alloys of the AA6000 series (alloy name according to the Aluminum Association (U.S.A.)) and AA7000 series which lie in the range from 250 to 300 MPa, Fe-type structural steel sheets which possess a value of approximately 400 MPa, and high tensile strength steel sheets of Fe-type which range from 800 to 980 MPa, it is clear that the aluminum-based alloys according to the present invention display superior values.
(X-ray Diffraction)
FIG. 2 shows an X-ray diffraction pattern possessed by an alloy sample having the composition of Al.sub.94 V.sub.4 Fe.sub.2. FIG. 3 shows an X-ray diffraction pattern possessed by an alloy sample having the composition of Al.sub.95 Mo.sub.3 Ni.sub.2. According to these patterns, each of these three alloy samples has a multiphase structure comprising a fine Al-crystalline phase having an fcc structure and a fine regular-icosahedral quasi-crystalline phase. In these patterns, peaks expressed as (111), (200), (220), and (311) are crystalline peaks of Al having an fcc structure, while peaks expressed as (211111) and (221001) are dull peaks of regular-icosahedral quasi crystals.
(Crystallization Temperature Measurement)
FIG. 4 shows the DSC (Differential Scanning Calorimetry) curve in the case when an alloy having the composition of Al.sub.94 V.sub.4 Ni.sub.2 is heated at rate of 0.67 K/s, FIG. 5 shows the same for Al.sub.94 V.sub.4 Mn.sub.2, FIG. 6 shows the same for Al.sub.95 Nb.sub.3 Co.sub.2, and FIG. 7 shows the same for Al.sub.95 Mo.sub.3 Ni.sub.2. In these figures, a dull exothermal peak, which is obtained when a quasi-crystalline phase is changed to a stable crystalline phase, is seen in the high temperature region exceeding 300.degree. C.
FIG. 8 shows the DSC curve in the case when an alloy having the composition of Al.sub.97 Fe.sub.3 is heated at a rate of 0.67 K/s, FIG. 9 shows the same for Al.sub.92 Fe.sub.5 Co.sub.3, and FIG. 10 shows the same for Al.sub.96 Fe.sub.1 Ni.sub.3, each of which has an atomic radius difference between Q and M or 0.01 .ANG. or less. In the DSC curves of these samples, the crystallization temperature which is indicated by the temperature at the starting end of the exothermal peak is each 300.degree. C. or less, which is comparatively low in comparison to the results of FIGS. 4-7, thereby suggesting that thermodynamically stable intermetallic compounds are formed.
(Charpy Impact Values)
Alloy samples having the compositions indicated below were prepared, and their Charpy impact values were measured. That is, after preparing a rapidly hardened powder by means of high-pressure atomization, a powder having a grain size of 25 .mu.m or less was separated out, filled into a copper container and formed into a billet, then bulk samples were made using a 100-ton warm press with a cross-sectional reduction rate of 80%, a push-out speed of 5 mm/s and a push-out temperature of 573K. Using these bulk samples, a Charpy impact test was performed. The results are shown in Table 4.
TABLE 4______________________________________ Units: kgf-m/cm.sup.2Composition Charpy Impact Value______________________________________Al.sub.94 V.sub.4 Mn.sub.2 1.2Al.sub.95 Nb.sub.3 Co.sub.2 1.1Al.sub.95 Mo.sub.3 Ni.sub.2 1.2Al.sub.95 W.sub.4 Cu.sub.1 1.2Al.sub.93 V.sub.5 Fe.sub.2 1Al.sub.95 Nb.sub.3 Cu.sub.2 1.5Al.sub.93 V.sub.4 Ni.sub.2 1.2Al.sub.93 Mo.sub.4 Cu.sub.3 1.2Al.sub.93 W.sub.5 Mn.sub.2 1Al.sub.92 Nb.sub.4 Ni.sub.4 1.5Al.sub.97 Fe.sub.3 0.3Al.sub.92 Fe.sub.5 Co.sub.3 0.2Al.sub.96 Fe.sub.1 Ni.sub.3 0.3______________________________________
According to the results of Table 4, Al.sub.97 Fe.sub.3, Al.sub.92 Fe.sub.5 Co.sub.3 and Al.sub.96 Fe.sub.1 Ni.sub.3 wherein the atomic radius difference between Q and M is less than 0.01 .ANG. all have Charpy impact values of less than 1, while Al.sub.94 V.sub.4 Mn.sub.2, Al.sub.95 Nb.sub.3 Co.sub.2, Al.sub.95 Mo.sub.3 Ni.sub.2, Al.sub.95 W.sub.4 Cu.sub.1, Al.sub.93 V.sub.5 Fe.sub.2, Al.sub.95 Nb.sub.3 Cu.sub.2, Al.sub.93 V.sub.4 Ni.sub.2, Al.sub.93 Mo.sub.4 Cu.sub.3, Al.sub.93 W.sub.5 Mn.sub.2 and Al.sub.92 Nb.sub.4 Ni.sub.4 wherein the atomic radius difference between Q and M is greater than 0.01 .ANG. all have Charpy impact values greater than 1, which is a level suitable for practical applications.
Although the invention has been described in detail herein with reference to its preferred embodiments and certain described alternatives, it is to be understood that this description is by way of example only, and it is not to be construed in a limiting sense. It is further understood that numerous changes in the details of the embodiments of the invention, and additional embodiments of the invention, will be apparent to, and may be made by persons of ordinary skill in the art having reference to this description. It is contemplated that all such changes and additional embodiments are within the spirit and true scope of the invention as claimed below.

Number	Name	Date	Kind
5458700	Masumoto et al.	Oct 1995
5593515	Masumoto et al.	Jan 1997

High strength and high rigidity aluminum-based alloy and production method therefor

Information

Patent Number

Date Filed

Date Issued

Inventors

Original Assignees

Examiners

Agents

CPC

US Classifications

Field of Search

US

International Classifications

Abstract

Description

Claims

Priority Claims (1)

CROSS-REFERENCE TO RELATED APPLICATION

US Referenced Citations (2)

Foreign Referenced Citations (1)

Continuation in Parts (1)