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

Abstract

An aluminum-based alloy having the general formula Al100−(a+b)QaMb (wherein Q is V, Mo, Fe, W, Nb, and/or Pd; M is Mn, Fe, Co, Ni, and/or Cu; and a and b, representing a composition ratio in atomic percentages, satisfy the relationships 1≦a≦8, 0

Description

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 1 X with a special composition ratio (wherein M 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, he 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 100−(a+b) Q a M 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≦a≦8, 0<b<5, and 3≦a+b≦8) having a metallographic structure comprising a quasi-crystalline phase, wherein the difference in the atomic radii between Q and M exceeds 0.01 Å, 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 94 V 4 Fe 2 .

FIG. 3 shows the analysis result of the X-ray diffraction of an alloy having the composition of Al 95 Mo 3 Ni 2 .

FIG. 4 shows the thermal properties of an alloy having the composition of Al 94 V 4 Ni 2 .

FIG. 5 shows the thermal properties of an alloy having the composition of Al 94 V 4 Mn 2 .

FIG. 6 shows the thermal properties of an alloy having the composition of Al 95 Nb 3 Co 2 .

FIG. 7 shows the thermal properties of an alloy having the composition of Al 95 Mo 3 Ni 2 .

FIG. 8 shows the thermal properties of an alloy having the composition of Al 97 Fe 3 .

FIG. 9 shows the thermal properties of an alloy having the composition of Al97Fe 5 Co 3 .

FIG. 10 shows the thermal properties of an alloy having the composition of Al 97 Fe 1 Ni 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 100−(a+b) Q a M 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≦a≦8, 0<b<5, and 3≦a+b≦8), comprising a quasi-crystalline phase in the alloy, wherein the difference in the atomic radii between Q and M exceeds 0.01 Å, 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≦Al≦97, preferably in the range of 94≦Al≦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 84%; 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 Å. 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 atmic radii for each combination are as shown in Table 1.

Q: V=1.32 Å, Mo=1.36 Å, Fe=1.24 Å, W=1.37 Å, Nb=1.43 Å, Pd=1.37 Å

M: Mn=1.12 Å or 1.50 Å, Fe=1.24 Å, Ni=1.25 Å, Co=1.25 Å, Cu=1.28 Å

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: Å
ELEMENT	Mn	Fe	Co	Ni	Cu
V	0.20 0r 0.18	0.08	0.07	0.07	0.04
Nb	0.31 0r 0.07	0.19	0.18	0.18	0.15
Mo	0.24 0r 0.14	0.12	0.11	0.11	0.08
Pd	0.25 0r 0.13	0.13	0.12	0.12	0.09
W	0.25 0r 0.13	0.13	0.12	0.12	0.09
Fe	0.12 0r 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 Å, 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 4 to 10 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 μm 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 an 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 μm.

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≧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° 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° 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 (α-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 −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 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 μm) of the compositions (atomic percentages) shown in Tables 2 and 3 were formed. The hardness (Hv) and tensile rupture strength (σ 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° contact bending test was conducted by bending each sample 180° 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	σf	Hv	Bending
No.	(at %)	(MPa)	(DPN)	test
1	Al 95 V 3 Ni 2	880	320	Duc	Example
2	Al 94 V 4 Ni 2	1230	365	Duc	Example
3	Al 93 V 5 Ni 2	1060	325	Duc	Example
4	Al 95 V 3 Fe 2	630	300	Duc	Example
5	Al 94 V 4 Fe 2	1350	370	Duc	Example
6	Al 93 V 5 Fe 2	790	305	Duc	Example
7	Al 95 V 3 Co 2	840	310	Duc	Example
8	Al 94 V 4 Co 2	1230	355	Duc	Example
9	Al 93 V 5 Co 2	1090	350	Duc	Example
10	Al 94 V 4 Mn 2	1210	355	Duc	Example
11	Al 93 V 4 Mn 3	800	310	Duc	Example
12	Al 94 V 4 Cu 2	1010	310	Duc	Example
14	Al 92 V 5 Ni 3	1110	330	Duc	Example
15	Al 93 V 4 Fe 3	1200	340	Duc	Example
16	Al 93 V 6 Fe 1	1210	345	Duc	Example
17	Al 92 V 7 Co 1	1010	310	Duc	Example
18	Al 93 V 4 Co 3	1110	310	Duc	Example
19	Al 94 Mo 4 Ni 2	1200	300	Duc	Example
20	Al 95 Mo 3 Ni 2	1250	305	Duc	Example
21	Al 93 Mo 5 Ni 2	1300	320	Duc	Example
22	Al 94 Mo 4 Co 2	1010	300	Duc	Example
23	Al 95 Mo 3 Co 2	1210	330	Duc	Example
24	Al 93 Mo 5 Fe 2	990	310	Duc	Example
25	Al 94 Mo 4 Fe 2	1320	375	Duc	Example
26	Al 94 Mo 4 Mn 2	1220	360	Duc	Example
27	Al 92 Mo 5 Mn 3	1100	345	Duc	Example
28	Al 95 Mo 3 Mn 2	1020	330	Duc	Example
29	Al 97 Mo 1 Cu 2	880	305	Duc	Example
30	Al 94 Fe 4 Mn 2	1320	370	Duc	Example
31	Al 94 Fe 3 Mn 3	1100	345	Duc	Example
33	Al 94 Fe 4 Cu 2	890	285	Duc	Example
34	Al 95 Fe 4 Cu 1	880	300	Duc	Example
35	Al 94 W 4 Ni 2	1010	340	Duc	Example
36	Al 94 W 3 Ni 3	1000	300	Duc	Example
37	Al 93 W 5 Co 2	1110	315	Duc	Example
38	Al 95 W 2 Co 3	1210	365	Duc	Example
39	Al 94 W 4 Fe 2	1090	305	Duc	Example
40	Al 93 W 6 Fe 1	1100	360	Duc	Example
41	Al 94 W 2 Mn 4	1210	350	Duc	Example
42	Al 92 Nb 6 Mn 2	1230	330	Duc	Example
43	Al 94 Nb 4 Fe 2	1040	320	Duc	Example
44	Al 94 Nb 4 Ni 2	1300	370	Duc	Example
45	Al 93 Nb 3 Ni 4	1210	360	Duc	Example
46	Al 95 Nb 3 Ni 2	1100	360	Duc	Example
47	Al 94 Nb 4 Co 2	1150	365	Duc	Example
50	Al 94 Pd 4 Fe 2	1010	315	Duc	Example
51	Al 96 Pd 3 Fe 1	990	310	Duc	Example
52	Al 94 Pd 4 Ni 2	1210	365	Duc	Example
53	Al 92 Pd 5 Ni 3	1230	365	Duc	Example
54	Al 94 Pd 3 Co 3	1100	335	Duc	Example

TABLE 3
	Alloy
Sample	composition	σf	Hv	Bending
No.	(at %)	(MPa)	(DPN)	test
55	Al 94 Fe 4 Co 2	1310	370	Duc	Comparative
					Example
56	Al 94 Fe 5 Co 1	1110	335	Duc	Comparative
					Example
57	Al 96 Fe 3 Co 1	1010	320	Duc	Comparative
					Example
58	Al 90 Fe 8 Ni 2	1100	340	Duc	Comparative
					Example
59	Al 88 Fe 10 Ni 2	1300	375	Duc	Comparative
					Example
60	Al 88 Fe 9 Ni 3	1280	360	Duc	Comparative
					Example
61	Al 96.5 V 0.5 Mn 3	460	95	Duc	Comparative
					Example
62	Al 86 V 12 Mn 2	600	450	Bri	Comparative
					Example
63	Al 97 V 3	400	120	Duc	Comparative
					Example
64	Al 90 V 4 Mn 6	550	410	Bri	Comparative
					Example
65	Al 98 V 1 Mn 1	430	95	Duc	Comparative
					Example
66	Al 87 V 10 Mn 3	510	410	Bri	Comparative
					Example
67	Al 96.5 V 0.5 Fe 3	410	120	Duc	Comparative
					Example
68	Al 85 V 13 Fe 2	505	405	Bri	Comparative
					Example
69	Al 98 V 1 Fe 1	400	110	Duc	Comparative
					Example
70	Al 87 V 10 Fe 3	490	410	Bri	Comparative
					Example
71	Al 90 V 4 Fe 6	450	430	Bri	Comparative
					Example
72	Al 95.5 V 0.5 Ni 4	390	95	Duc	Comparative
					Example
73	Al 86 V 11 Ni 3	410	430	Bri	Comparative
					Example
74	Al 89 V 4 Ni 7	405	425	Bri	Comparative
					Example
75	Al 98 V 1 Ni 1	290	80	Duc	Comparative
					Example
76	Al 85 V 11 Ni 4	500	420	Bri	Comparative
					Example
77	Al 94.5 V 0.5 Co 5	410	125	Duc	Comparative
					Example
78	Al 83 V 15 Co 2	490	480	Bri	Comparative
					Example
79	Al 90 V 2 Co 8	480	410	Bri	Comparative
					Example
80	Al 98.5 V 0.5 Co 1	210	90	Duc	Comparative
					Example
81	Al 85 V 11 Co 4	410	430	Bri	Comparative
					Example
82	Al 94.5 V 0.5 Cu 5	340	105	Duc	Comparative
					Example
83	Al 88 V 11 Cu 1	490	420	Bri	Comparative
					Example
84	Al 89 V 3 Cu 8	480	410	Bri	Comparative
					Example
85	Al 98 V 1 Cu 1	410	95	Duc	Comparative
					Example
86	Al 85 V 12 Cu 3	550	420	Bri	Comparative
					Example
87	Al 96.5 Mo 0.5 Mn 3	430	125	Duc	Comparative
					Example
88	Al 86 Mo 12 Mn 2	510	430	Bri	Comparative
					Example
89	Al 97 Mo 3	370	130	Duc	Comparative
					Example
90	Al 90 Mo 4 Mn 6	480	410	Bri	Comparative
					Example
91	Al 98 Mo 1 Mn 1	380	100	Duc	Comparative
					Example
92	Al 87 Mo 10 Mn 3	490	420	Bri	Comparative
					Example
93	Al 96.5 Mo 0.5 Fe 3	360	125	Duc	Comparative
					Example
94	Al 85 Mo 13 Fe 2	500	460	Bri	Comparative
					Example
95	Al 98 Mo 1 Fe 1	210	80	Duc	Comparative
					Example
96	Al 87 Mo 10 Fe 3	510	450	Bri	Comparative
					Example
97	Al 90 Mo 4 Fe 6	490	435	Bri	Comparative
					Example
98	Al 95.5 Mo 0.5 Ni 4	310	95	Duc	Comparative
					Example
99	Al 86 Mo 11 Ni 3	500	430	Bri	Comparative
					Example
100	Al 89 Mo 4 Ni 7	465	410	Bri	Comparative
					Example
101	Al 98 Mo 1 Ni 1	200	95	Duc	Comparative
					Example
102	Al 85 Mo 11 Ni 4	460	450	Bri	Comparative
					Example
103	Al 94.5 Mo 0.5 Co 5	380	100	Duc	Comparative
					Example
104	Al 83 Mo 15 Co 2	510	410	Bri	Comparative
					Example
105	Al 90 Mo 2 Co 8	490	420	Bri	Comparative
					Example
106	Al 98.5 Mo 0.5 Co 1	360	105	Duc	Comparative
					Example
107	Al 85 Mo 11 Co 4	460	430	Bri	Comparative
					Example
108	Al 94.5 Mo 0.5 Cu 5	340	105	Duc	Comparative
					Example
109	Al 88 Mo 11 Cu 1	490	430	Bri	Comparative
					Example
110	Al 89 Mo 3 Cu 8	510	410	Bri	Comparative
					Example
111	Al 98 Mo 1 Cu 1	410	95	Duc	Comparative
					Example
112	Al 85 Mo 12 Cu 3	550	420	Bri	Comparative
					Example
113	Al 96.5 Fe 0.5 Mn 3	420	130	Duc	Comparative
					Example
114	Al 86 Fe 12 Mn 2	510	430	Bri	Comparative
					Example
115	Al 97 Fe 3	480	160	Duc	Comparative
					Example
116	Al 90 Fe 4 Mn 6	530	425	Bri	Comparative
					Example
117	Al 98 Fe 1 Mn 1	480	95	Duc	Comparative
					Example
118	Al 87 Fe 10 Mn 3	510	420	Bri	Comparative
					Example
119	Al 95.5 Fe 0.5 Ni 4	470	105	Duc	Comparative
					Example
120	Al 86 Fe 11 Ni 3	510	420	Bri	Comparative
					Example
121	Al 89 Fe 4 Ni 7	505	425	Bri	Comparative
					Example
122	Al 98 Fe 1 Ni 1	380	95	Duc	Comparative
					Example
123	Al 85 Fe 11 Ni 4	500	410	Bri	Comparative
					Example
124	Al 94.5 Fe 0.5 Co 5	380	125	Duc	Comparative
					Example
125	Al 83 Fe 15 Co 2	200	480	Bri	Comparative
					Example
126	Al 90 Fe 2 Co 8	490	425	Bri	Comparative
					Example
127	Al 98.5 Fe 0.5 Co 1	380	95	Duc	Comparative
					Example
128	Al 85 Fe 11 Co 4	350	435	Bri	Comparative
					Example
129	Al 94.5 Fe 0.5 Cu 5	340	105	Duc	Comparative
					Example
130	Al 88 Fe 11 Cu 1	410	435	Bri	Comparative
					Example
131	Al 89 Fe 3 Cu 8	480	410	Bri	Comparative
					Example
132	Al 98 Fe 1 Cu 1	410	95	Duc	Comparative
					Example
133	AL 85 Fe 12 Cu 3	550	420	Bri	Comparative
					Example
134	Al 96.5 W 0.5 Mn 3	380	120	Duc	Comparative
					Example
135	Al 86 W 12 Mn 2	420	435	Bri	Comparative
					Example
136	Al 97 W 3	280	95	Duc	Comparative
					Example
137	Al 90 W 4 Mn 6	490	440	Bri	Comparative
					Example
138	Al 98 W 1 Mn 1	280	95	Duc	Comparative
					Example
139	Al 87 W 10 Mn 3	290	475	Bri	Comparative
					Example
140	Al 96.5 W 0.5 Fe 3	385	105	DUC	Comparative
					Example
141	Al 85 W 13 Fe 2	310	480	Bri	Comparative
					Example
142	Al 98 W 1 Fe 1	320	105	Duc	Comparative
					Example
143	Al 87 W 10 Fe 3	500	475	Bri	Comparative
					Example
144	Al 90 W 4 Fe 6	510	460	Bri	Comparative
					Example
145	Al 95.5 W 0.5 Ni 4	380	95	Duc	Comparative
					Example
146	Al 86 W 11 Ni 13	520	470	Bri	Comparative
					Example
147	Al 89 W 4 Ni 7	500	435	Bri	Comparative
					Example
148	Al 98 W 1 Ni 1	280	80	Duc	Comparative
					Example
149	Al 85 W 11 Ni 4	460	435	Bri	Comparative
					Example
150	Al 94.5 W 0.5 Co 5	275	105	Duc	Comparative
					Example
151	Al 83 W 15 Co 2	500	460	Bri	Comparative
					Example
152	Al 90 W 2 Co 8	410	445	Bri	Comparative
					Example
153	Al 98.5 W 0.5 Co 1	270	85	Duc	Comparative
					Example
184	Al 85 W 11 Co 4	290	470	Bri	Comparative
					Example
155	Al 94.5 W 0.5 Cu 5	340	105	Duc	Comparative
					Example
156	Al 88 W 11 Cu 1	310	435	Bri	Comparative
					Example
157	Al 89 W 3 Cu 8	380	410	Bri	Comparative
					Example
158	Al 98 W 1 Cu 1	410	95	Duc	Comparative
					Example
159	Al 85 W 12 Cu 3	550	420	Bri	Comparative
					Example
160	Al 96.5 Nb 0.5 Mn 3	430	120	Duc	Comparative
					Example
161	Al 86 Nb 12 Mn 2	510	475	Bri	Comparative
					Example
162	Al 97 Nb 3	430	105	Duc	Comparative
					Example
163	Al 90 Nb 4 Mn 6	490	430	Bri	Comparative
					Example
164	Al 98 Nb 1 Mn 1	380	95	Duc	Comparative
					Example
165	Al 87 Nb 10 Mn 3	390	465	Bri	Comparative
					Example
166	Al 96.5 Nb 0.5 Fe 3	400	95	Duc	Comparative
					Example
167	Al 85 Nb 13 Fe 2	390	480	Bri	Comparative
					Example
168	Al 98 Nb 1 Fe 1	430	100	Duc	Comparative
					Example
169	Al 87 Nb 10 Fe 3	510	435	Bri	Comparative
					Example
170	Al 90 Nb 4 Fe 6	420	80	Bri	Comparative
					Example
171	Al 95.5 Nb 0.5 Ni 4	380	110	Duc	Comparative
					Example
172	Al 86 Nb 11 Ni 3	510	440	Bri	Comparative
					Example
173	Al 89 Nb 4 Ni 7	490	435	Bri	Comparative
					Example
174	Al 98 Nb 1 Ni 1	230	80	Duc	Comparative
					Example
175	Al 85 Nb 11 Ni 4	430	475	Bri	Comparative
					Example
176	Al 94.5 Nb 0.5 Co 5	280	95	Duc	Comparative
					Example
177	Al 83 Nb 15 Co 2	410	470	Bri	Comparative
					Example
178	Al 90 Nb 2 Co 8	510	430	Bri	Comparative
					Example
179	Al 98.5 Nb 0.5 Co 1	270	90	Duc	Comparative
					Example
180	Al 85 Nb 11 Co 4	510	475	Bri	Comparative
					Example
181	Al 94.5 Nb 0.5 Cu 5	340	105	Duc	Comparative
					Example
182	Al 88 Nb 11 Cu 1	490	445	Bri	Comparative
					Example
183	Al 89 Nb 3 Cu 8	475	410	Bri	Comparative
					Example
184	Al 98 Nb 1 Cu 1	410	95	Duc	Comparative
					Example
185	Al 85 Nb 12 Cu 3	550	420	Bri	Comparative
					Example
186	Al 96.5 Pd 0.5 Mn 3	380	105	Duc	Comparative
					Example
187	Al 86 Pd 12 Mn 2	400	435	Bri	Comparative
					Example
188	Al 97 Pd 3	410	95	Duc	Comparative
					Example
189	Al 90 Pd 4 Mn 6	510	420	Bri	Comparative
					Example
190	Al 98 Pd 1 Mn 1	390	80	Duc	Comparative
					Example
191	Al 87 Pd 10 Mn 3	490	465	Bri	Comparative
					Example
192	Al 96.5 Pd 0.5 Fe 3	300	95	Duc	Comparative
					Example
193	Al 85 Pd 13 Fe 2	210	480	Bri	Comparative
					Example
194	Al 98 Pd 1 Fe 1	290	105	Duc	Comparative
					Example
195	Al 87 Pd 10 Fe 3	460	435	Bri	Comparative
					Example
196	Al 90 Pd 4 Fe 6	475	430	Bri	Comparative
					Example
197	Al 95.5 Pd 0.5 Ni 4	310	90	Duc	Comparative
					Example
198	Al 86 Pd 11 Ni 3	410	465	Bri	Comparative
					Example
199	Al 89 Pd 4 Ni 7	460	450	Bri	Comparative
					Example
200	Al 98 Pd 1 Ni 1	280	85	Duc	Comparative
					Example
201	Al 85 Pd 11 Ni 4	410	460	Bri	Comparative
					Example
202	Al 94.5 Pd 0.5 Co 5	430	120	Duc	Comparative
					Example
203	Al 83 Pd 15 Co 2	290	485	Bri	Comparative
					Example
204	Al 90 Pd 2 Co 8	425	430	Bri	Comparative
					Example
205	Al 98.5 Pd 0.5 Co 1	290	95	Duc	Comparative
					Example
206	Al 85 Pd 11 Co 4	460	465	Bri	Comparative
					Example
207	Al 94.5 Pd 0.5 Cu 5	340	105	Duc	Comparative
					Example
208	Al 88 Pd 11 Cu 1	475	435	Bri	Comparative
					Example
209	Al 89 Pd 3 Cu 8	490	410	Bri	Comparative
					Example
210	Al 98 Pd 1 Cu 1	410	95	Duc	Comparative
					Example
211	Al 85 Pd 12 Cu 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 balance Q a M b , 1≦a≦8, 0<b<5, 3≦a+b ≦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 Å 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 (σ 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 94 V 4 Fe 2 . FIG. 3 shows an X-ray diffraction pattern possessed by an alloy sample having the composition of Al 95 Mo 3 Ni 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 94 V 4 Ni 2 is heated at rate of 0.67 K/s, FIG. 5 shows the same for Al 94 V 4 Mn 2 , FIG. 6 shows the same for Al 95 Nb 3 Co 2 , and FIG. 7 shows the same for Al 95 Mo 3 Ni 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° C.

FIG. 8 shows the DSC curve in the case when an alloy having the composition of Al 97 Fe 3 is heated at a rate of 0.67 K/s, FIG. 9 shows the same for Al 92 Fe 5 Co 3 , and FIG. 10 shows the same for Al 96 Fe 1 Ni 3 , each of which has an atomic radius difference between Q and M or 0.01 Å 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° 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 μm 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 greed of 5 mm/s and a push-out temperature of 573 K. Using these bulk samples, a Charpy impact test was performed. The results are shown in Table 4.

TABLE 4
                                 Units: kgf-m/cm                                                                        2
Composition                      Charpy Impact Value
Al                                                                        94                                                                    V                                                                        4                                                                    Mn                                                                        2 1.2
Al                                                                        95                                                                    Nb                                                                        3                                                                    Co                                                                        2 1.1
Al                                                                        95                                                                    Mo                                                                        3                                                                    Ni                                                                        2 1.2
Al                                                                        95                                                                    W                                                                        4                                                                    Cu                                                                        1 1.2
Al                                                                        93                                                                    V                                                                        5                                                                    Fe                                                                        2 1
Al                                                                        95                                                                    Nb                                                                        3                                                                    Cu                                                                        2 1.5
Al                                                                        93                                                                    V                                                                        4                                                                    Ni                                                                        2 1.2
Al                                                                        93                                                                    Mo                                                                        4                                                                    Cu                                                                        3 1.2
Al                                                                        93                                                                    W                                                                        5                                                                    Mn                                                                        2 1
Al                                                                        92                                                                    Nb                                                                        4                                                                    Ni                                                                        4 1.5
Al                                                                        97                                                                    Fe                                                                        3 0.3
Al                                                                        92                                                                    Fe                                                                        5                                                                    Co                                                                        3 0.2
Al                                                                        96                                                                    Fe                                                                        1                                                                    Ni                                                                        3 0.3

According to the results of Table 4, Al 97 Fe 3 , Al 92 Fe 5 Co 3 and Al 96 Fe 1 Ni 3 wherein the atomic radius difference between Q and M is less than 0.01 Å all have Charpy impact values of less than 1, while Al 94 V 4 Mn 2 , Al 95 Nb 3 Co 2 , Al 95 Mo 3 Ni 2 , Al 95 W 4 Cu 1 , Al 93 V 5 Fe 2 , Al 95 Nb 3 Cu 2 , Al 93 V 4 Ni 2 , Al 93 Mo 4 Cu 3 , Al 93 W 5 Mn 2 and Al 92 Nb 4 Ni 4 wherein the atomic radius difference between Q and M is greater than 0.01 Å 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.

Claims

1. A production method for an aluminum-based alloy comprising the steps of:a) selecting an element Q, which is at least one element selected from the group consisting of V, Mo, Fe, W, Nb, and Pd; b) selecting an element M, which is at least one element having an atomic radius which is more than 0.01 Å larger or smaller than the atomic radius of said element Q and which is selected from the group consisting of Mn, Fe, Co, Ni, and Cu; c) preparing a liquid-melt consisting essentially of Al having an amount in atomic percentage of 100−(a+b), said element Q having an amount in atomic percentage of a and said element M having an amount in atomic percentage of b, wherein said a and b satisfy the relationships 1≦a≦8, 0<b<5, and 3≦a+b≦8, said liquid-melt not containing rare earth elements; and d) quick-quenching said liquid-melt to obtain a solidified aluminum-based alloy having a metallographic structure incorporating a quasi-crystalline phase.

2. A production method for an aluminum-based alloy according to claim 1, wherein said solidified aluminum-based alloy has a metallographic structure incorporating a quasi-crystalline phase.

3. A production method for an aluminum-based alloy according to claim 1, wherein said step d) further comprises the steps of:e) pouring said liquid-melt onto a rotating roll; and f) quick-quenching said liquid-melt to form a thin layer of the aluminum-based alloy.

4. A production method for an aluminum-based alloy according to claim 1, wherein said step d) further comprises the steps of:g) atomizing said liquid-melt; and h) quick-quenching said liquid-melt to form a powder of the aluminum-based alloy.

5. A production method for an aluminum-based alloy according to claim 1, wherein said step d) further comprises the steps of:g) spraying said liquid-melt; and h) quick-quenching said liquid-melt to form a powder of the aluminum-based alloy.