Light weight, high strength beryllium-aluminum alloy

FIELD OF INVENTION
This invention relates to a light weight, high strength beryllium-aluminum alloy suitable for the manufacture of precision castings or wrought material produced from ingot castings.
BACKGROUND OF INVENTION
Beryllium is a high strength, light weight, high stiffness metal that has extremely low ductility which prevents it from being cast and also creates a very low resistance to impact and fatigue, making the cast metal or metal produced from castings relatively useless for most applications.
To increase the ductility of beryllium, much work has been done with beryllium-aluminum alloys to make a ductile, two phase, composite of aluminum and beryllium. Aluminum does not react with the reactive beryllium, is ductile, and is relatively lightweight, making it a suitable candidate for improving the ductility of beryllium, while keeping the density low. However, beryllium-aluminum alloys are inherently difficult to cast due to the mutual insolubility of beryllium and aluminum in the solid phase and the wide solidification temperature range typical in this alloy system. An alloy of 60 weight % beryllium and 40 weight % aluminum has a liquidus temperature (temperature at which solidification begins) of nearly 1250.degree. C. and a solidus temperature (temperature of complete solidification) of 645 .degree. C. During the initial stages of solidification, primary beryllium dendrites form in the liquid to make a two phase solid-liquid mixture. The beryllium dendrites produce a tortuous channel for the liquid to flow and fill during the last stages of solidification. As a result, shrinkage cavities develop, and these alloys typically exhibit a large amount of microporosity in the as-cast condition. This feature greatly affects the properties and integrity of the casting. Porosity leads to low strength and premature failure at relatively low ductilities. In addition, castings have a relatively coarse microstructure of beryllium distributed in an aluminum matrix, and such coarse microstructures generally result in low strength and low ductility. To overcome the problems associated with cast structures, a powder metallurgical approach has been used to produce useful materials from beryllium-aluminum alloys.
There have also been proposed ternary beryllium-aluminum alloys made by powder metallurgical approaches. For example, U.S. Pat. No. 3,322,512, Krock et al., May 30, 1967, discloses a beryllium-aluminum-silver composite containing 50 to 85 weight % beryllium, 10.5 to 35 weight % aluminum, and 4.5 to 15 weight % silver. The composite is prepared by compacting a powder mixture having the desired composition, including a fluxing agent of alkali and alkaline earth halogenide agents such as lithium fluoride-lithium chloride, and then sintering the compact at a temperature below the 1277.degree. C. melting point of beryllium but above the 620.degree. C. melting point of the aluminum-silver alloy so that the aluminum-silver alloy liquifies and partially dissolves the small beryllium particles to envelope the brittle beryllium in a more ductile aluminum-silver-beryllium alloy. U.S. Pat. No. 3,438,75 1, issued to Krock et al. on Apr. 15, 1969, discloses a beryllium-aluminum-silicon composite containing 50 to 85 weight % beryllium, 13 to 50 weight % aluminum, and a trace to 6.6 weight % silicon, also made by the above-described powder metallurgical liquid sintering technique. However, high silicon content reduces ductility to unacceptably low levels, and high silver content increases alloy density.
Other ternary, quaternary and more complex beryllium-aluminum alloys made by powder metallurgical approaches have also been proposed. See, for example, McCarthy et al., U.S. Pat. No. 3,664,889. That patent discloses preparing the alloys by atomizing a binary beryllium-aluminum alloy to create a powder that then has mixed into it fine elemental metallic powders of the desired alloying elements. The powders are then mixed together thoroughly to achieve good distribution, and the powder blend is consolidated by a suitable hot or cold operation, carried on without any melting.
It is known, however, that beryllium-aluminum alloys tend to separate or segregate when cast and generally have a porous cast structure. Accordingly, previous attempts to produce beryllium-aluminum alloys by casting resulted in low strength, low ductility, and coarse microstructures with poor internal quality.
SUMMARY OF INVENTION
It is therefore an object of this invention to provide an improved light weight, high strength beryllium-aluminum alloy suitable for casting.
It is a further object of this invention to provide such an alloy that can be cast without segregation.
It is a further object of this invention to provide such an alloy that can be cast without microporosity.
It is a further object of this invention to provide such an alloy that has a relatively fine as-cast microstructure.
It is a further object of this invention to provide such an alloy that has a higher strength than has previously been attained for other cast beryllium-aluminum alloys.
It is a further object of this invention to provide such an alloy that has a higher ductility than has previously been attained for other cast beryllium-aluminum alloys.
It is a further object of this invention to provide such an alloy that has a density of less than 2.2 grams per cubic centimeter (0.079 pounds per cubic inch).
It is a further object of this invention to provide such an alloy that has an elastic modulus (stiffness) greater than 28 million psi.
This invention results from the realization that a light weight, high strength and ductile beryllium-aluminum alloy capable of being cast with virtually no segregation and microporosity may be accomplished with approximately 60 to 70 weight % beryllium, one or both of approximately 0.5 to 4 weight % silicon and approximately a 0.2 to 4.25 weight % silver, and aluminum. It has been found that including both silicon and silver creates an as-cast alloy having very desirable properties which can be further improved by heat or mechanical treatment thereafter, thereby allowing the alloy to be used to cast intricate shapes that accomplish strong, lightweight stiff metal parts or cast ingots that can be rolled, extruded or otherwise mechanically worked.
This invention features a ternary or higher-order cast beryllium-aluminum alloy, comprising approximately 60 to 70 weight % beryllium; at least one of from approximately 0.5 to 4 weight % silicon and from 0.2 to approximately 4.25 weight % silver; and aluminum. Ternary alloys include only one of silicon or silver in the stated amount, with the balance aluminum. The quaternary alloy may contain both silver and silicon in the stated amounts. For alloys including silver, silicon, or silver and silicon, the beryllium may be strengthened by adding copper, nickel or cobalt in the amount of approximately 0.1 to 0.75 weight % of the alloy. For alloys to be used in the cast condition ductility may be improved by the addition of 0.0050 to 0.10000 weight % Sr, Na or Sb when Si is used in the alloy. The alloy may be wrought after casting to increase ductility and strength, or heat treated to increase strength.

BRIEF DESCRIPTIONS OF THE DRAWINGS
Other objects, features and advantages will occur to those skilled in the art from the following description of preferred embodiments and the accompanying drawings in which:
FIG. 1A is a photomicrograph of cast microstructure typical of prior art alloys;
FIGS. 1B through 1D are photomicrographs of cast microstructures of examples of the alloy of this invention; and
FIGS. 2A through 2D are photomicrographs of a microstructure from an extruded alloy of this invention.

DISCLOSURE OF THE PREFERRED EMBODIMENTS
This invention may consist essentially of a ternary or higher-order cast beryllium-aluminum alloy comprising approximately 60 to 70 weight % beryllium, silicon and/or silver, with the silicon present in approximately 0.5 to 4 weight %, and silver from approximately 0.2 weight % to approximately 4.25 weight % and aluminum. Further strengthening can be achieved by the addition of an element selected from the group consisting of copper, nickel, and cobalt, present as approximately 0.1 to 0.75 weight % of the alloy. When the alloy is to be used in the cast condition, an element such as Sr, Na or Sb can be added in quantities from approximately 0.005 to 0.10 weight % to improve ductility. The alloy is lightweight and has high stiffness. The density is no more than 2.2 g/cc, and the elastic modulus is greater than 28 million pounds per square inch (mpsi).
As described above, beryllium-aluminum alloys have not been successfully cast without segregation and microporosity. Accordingly, it has to date been impossible to make precision cast parts by processes such as investment casting, die casting or permanent mold casting from beryllium-aluminum alloys. However, there is a great need for this technology particularly for intricate parts for aircraft and spacecraft, in which light weight, strength and stiffness are uniformly required.
The beryllium-aluminum alloys of this invention include at least one of silicon and silver. The silver increases the strength and ductility of the alloy in compositions of from 0.2 to 4.25 weight % of the alloy. Silicon at from approximately 0.5 to 4 weight % promotes strength and aids in the castability of the alloy by greatly decreasing porosity. Without silicon, the alloy has more microporosity in the cast condition, which lowers the strength. Without silver, the strength of the alloy is reduced by 25 % to 50% over the alloy containing silver. Silver also makes the alloy heat treatable such that additional strengthening can be achieved without loss of ductility through a heat treatment consisting of solutionizing and aging at suitable temperature. The addition of small amounts of Sr, Na or Sb modify the Si structure in the alloy which results in increased ductility as-cast.
For a wrought alloy whose size and shape is reduced by mechanical deformation after casting, it may not be necessary to have silicon in the composition, as the microporosity is eliminated by compressive forces that are developed during extrusion, rolling, swaging and forging. However, adding silicon even to a wrought alloy greatly increases the strength of the alloy. In either case, with or without Si, wrought alloys do not benefit from the addition of Si modifiers Sr, Na or Sb so that the addition of these elements is not essential to achieving high ductility.
It has also been found that the beryllium phase can be strengthened by including copper, nickel or cobalt at from approximately 0.1 to 0.75 weight % of the alloy. The strengthening element goes into the beryllium phase to increase the yield strength of the alloy by up to 25 % without a real effect on the ductility of the alloy. Greater additions of the strengthening element cause the alloy to become more brittle.
For applications in which cast shapes are not required, it has been found that cast and wrought alloys may be accomplished by ternary beryllium-aluminum alloys including either silicon or silver in the stated amount. As cast and wrought, these alloys have superior properties to previously fabricated powder metallurgical wrought beryllium-aluminum alloys.
The following are examples of nine alloys made in accordance with the subject invention:
EXAMPLE I
A 725.75 gram charge with elements in the proportion of weight percent) 65Be, 31A1, 2Si, 2Ag, and 0.04Sr was palced in a crucible and melted in a vacuum induction furnace. The molten metal was poured into a 1.625 inch diameter cylindrical mold, cooled to room temperature, and removed from the mold. Tensile properties were measured on this material in the as-cast condition. As-cast properties were 22.4 ksi tensile yield strength, 30.6 ksi ultimate tensile strength, and 2.5 % elongation. The density of this ingot was 2.13 g/cc and the elastic modulus was 33.0 mpsi. These properties can be compared to the properties of a binary alloy (60 weight % Be, 40 weight % Al, with total charge weight of 853.3 grams) that was melted in a vacuum induction furnace and cast into a mold with a rectangular cross section measuring 3 inches by 3/8 inches. The properties of the binary alloy were 10.9 ksi tensile yield strength, 12.1 ksi ultimate tensile strength, 1% elongation, 30.7 mpsi elastic modulus, and 2.15 g/cc density. The strontium modifies the silicon phase contained within the aluminum. This helps to improve the ductility of the alloy.
EXAMPLE II
A 725.75 gram charge with elements in the proportion of (by weight percent) 65Be, 33A1, and 2Ag was placed in a crucible and melted in a vacuum induction furnace. The molten metal was poured into a 1.625 inch diameter cylindrical mold, cooled to room temperature, and removed from the mold. Tensile properties were measured on this material in the as-cast condition. As-cast properties were 19.3 ksi tensile strength, 27.3 ksi ultimate tensile strength, and 5.0% elongation. The density of this ingot was 2.13 g/cc and the elastic modulus was 32.9 mpsi.
EXAMPLE III
A 853.3 gram charge with elements in the proportion of (by weight percent) 60Be, 39Al, and 1Si was placed in a crucible and melted in a vacuum induction furnace. The molten metal was poured into a mold with a rectangular cross section measuring 3 inches by 3/8 inches, cooled to room temperature, and removed from the mold. Tensile properties were measured on this material in the as-cast condition. As-cast properties were 14.4 ksi tensile strength, 15.9 ksi ultimate tensile strength, and 1.0% elongation. The density of this ingot was 2.18 g/cc and the elastic modulus was 23.5 mpsi.
EXAMPLE IV
A 725.75 gram charge with elements in the proportion of (by weight percent) 65Be, 31Al, 2Si, 2Ag, and 0.04Sr was placed in a crucible and melted in a vacuum induction furnace. The molten metal was poured into a 1.625 inch diameter cylindrical mold, cooled to room temperature, and removed from the mold. Tensile properties were measured on this material in the as-cast condition. As-cast properties were 20.1 ksi tensile yield strength, 27.6 ksi ultimate tensile strength, and 2.3% elongation. The density of this ingot was 2.10 g/cc and the elastic modulus was 33.0 mpsi.
A section of the cast ingot was solution heat treated for 2 hours at 550.degree. C. and water quenched, then aged 16 hours at 190.degree. C. and air cooled. Tensile properties of this heat treated material were 23.0 ksi tensile yield strength, 31.6 ksi ultimate tensile strength, and 2.5% elongation. The elastic modulus was 32.7 mpsi.
EXAMPLE V
A 725.75 gram charge with elements in the proportion of (by weight percent) 65Be, 31Al, 2Si, 2Ag, 0.25Cu and 0.04Sr was placed in a crucible and melted in a vacuum induction furnace. The molten metal was poured into a 1.625 inch diameter cylindrical mold, cooled to room temperature, and removed from the mold. Tensile properties were measured on this material in the as-cast condition. As-cast properties were 21.8 ksi tensile yield strength, 30.2 ksi ultimate tensile strength, and 2.4% elongation. The density of this ingot was 2.13 g/cc and the elastic modulus was 33.0 mpsi.
A section of the cast ingot was solution heat treated for 2 hours at 550.degree. C. and water quenched, then aged 16 hours at 190.degree. C. and air cooled. Tensile properties of this heat treated material were 25.8 ksi tensile yield strength, 34.9 ksi ultimate tensile strength, and 2.5% elongation. The elastic modulus was 32.4 mpsi.
EXAMPLE VI
A 725.75 gram charge with elements in the proportion of (by weight percent) 65Be, 31Al, 2Si, 2Ag, 0.25 Ni and 0.04Sr was placed in a crucible and melted in a vacuum induction furnace. The molten metal was poured into a 1.625 inch diameter cylindrical mold, cooled to room temperature, and removed from the mold. Tensile properties were measured on this material in the as-cast condition. As-cast properties were 21.6 ksi tensile yield strength, 27.8 ksi ultimate tensile strength, and 1.3 % elongation. The density of this ingot was 2.13 g/cc and the elastic modulus was 32.9 mpsi.
A section of the cast ingot was solution heat treated for 2 hours at 550.degree. C. and water quenched, then aged 16 hours at 190.degree. C. and air cooled. Tensile properties of this heat treated material were 26.1 ksi tensile yield strength, 31.9 ksi ultimate tensile strength, 1.8% elongation. The elastic modulus was 32.3 mpsi.
EXAMPLE VII
A 725.75 gram charge with elements in the proportion of (by weight percent) 65Be, 31Al, 2Si, 2Ag, 0.25Co and 0.04 Sr was placed in a crucible and melted in a vacuum induction furnace. The molten metal was poured into a 1.625 inch diameter cylindrical mold, cooled to room temperature, and removed from the mold. Tensile properties were measured on this material in the as-cast condition. As-cast properties were 22.7 ksi tensile yield strength, 31.2 ksi ultimate tensile strength, and 2.5 % elongation. The density of this ingot was 2.14 g/cc and the elastic modulus was 32.7 mpsi.
A section of the cast ingot was solution heat treated for 2 hours at 550.degree. C. and water quenched, then aged 16 hours at 190.degree. C. and air cooled. Tensile properties of this heat treated material were 24.6 ksi tensile yield strength, 32.1 ksi ultimate tensile strength, 1.9% elongation. The elastic modulus was 31.9 mpsi.
EXAMPLE VIII
A 725.75 gram charge with elements in the proportion of (by weight percent) 65Be, 33Al, and 2Ag was placed in a crucible and melted in a vacuum induction furnace. The molten metal was poured into a 1.625 inch diameter cylindrical mold, cooled to room temperature, and removed from the mold. The resulting ingot was canned in copper, heated to 426.degree. C., and extruded to a 0.55 inch diameter rod. Tensile properties were measured on this material in the extruded condition. Extruded properties were 49.7 ksi tensile yield strength, 63.9 ksi ultimate tensile strength, and 12.6% elongation. The density of this extruded rod was 2.13 g/cc and the elastic modulus was 34.4 mpsi.
A section of the extruded rod was then annealed 24 hours at 550.degree. C. Properties of the rod were 46.7 ksi tensile yield strength, 64.9 ksi ultimate tensile strength, 16.7% elongation. The elastic modulus was 33.5 mpsi.
EXAMPLE IX
A 725.75 gram charge with elements in the proportion of (by weight percent) 65Be, 32Al, 1Si and 2Ag was placed in a crucible and melted in a vacuum induction furnace. The molten metal was poured into a 1.625 inch diameter cylindrical mold, cooled to room temperature, and removed from the mold. The resulting ingot was canned in copper, heated to 426.degree. C., and extruded to a 0.55 inch diameter rod. Tensile properties were measured on this material in the as-extruded condition. As-extruded properties were 53.0 ksi tensile yield strength, 67.9 ksi ultimate tensile strength, and 12.5% elongation. The density of this extruded rod was 2.13 g/cc and the elastic modulus was 34.8 mpsi.
A section of the extruded rod was then annealed 24 hours at 550.degree. C. Properties of the rod were 51.0 ksi tensile yield strength, 70.4 ksi ultimate tensile strength, 12.5 % elongation. The elastic modulus was 35.3 mpsi.
The properties of the alloys presented in the preceding examples are summarized in Table I.
TABLE I__________________________________________________________________________ 0.2% YS % E Density Elastic ModulusNo. Composition Condition (ksi) UTS (ksi) (in 1") (lb/ci) (Mpsi)__________________________________________________________________________ 60-Be--40Al as-cast 10.9 12.1 1.0 .078 30.7I 65Be--31Al--2Si--2Ag--0.04Sr as-cast 22.4 30.6 2.5 .077 33.0II 65Be--33Al--2Ag as-cast 19.3 27.3 5.0 .077 32.9III 60Be--39Al--1Si as-cast 14.4 15.9 1.0 .079 23.5IV 65Be--31Al--2Si--2Ag--0.04Sr as-cast 20.1 27.6 2.3 .076 33.0 heat treated 23.0 31.6 2.5 .076 32.7V 65Be--31Al--2Si--2Ag--0.25Cu--0.04Sr as-east 21.8 30.2 2.4 .077 33.0 heat treated 25.8 34.9 2.5 .077 32.4VI 65Be--31Al--2Si--2Ag--0.25Ni--0.04Sr as-cast 21.6 27.8 1.3 .077 32.9 heat treated 26.1 31.9 1.8 .077 32.3VII 65Be--31Al--2Si--2Ag--0.25Co--0.04Sr as-cast 22.7 31.2 2.5 .077 32.7 heat treated 24.6 32.1 1.9 .077 31.9VIII 65Be--33Al--2Ag as extruded 49.7 63.9 12.6 .077 34.4 annealed 46.7 64.9 16.7 .077 33.5IX 65Be--32Al--1Si--2Ag as extruded 53.0 67.9 12.5 .077 34.8 annealed 51.0 70.4 12.5 .077 35.3__________________________________________________________________________
FIG. 1 shows a comparison of cast microstructure for some of the various alloys. In these photomicrographs, the dark phase is beryllium and the light phase (matrix phase) is aluminum. Note the coarse features of the binary alloy compared to 65Be--31Al--2Si--2Ag--0.04 Sr alloy. Additions of Ni or Co cause slight coarsening compared to 65Be31Al--2Si--2Ag--0.04 Sr, but the structure is still finer than the binary alloy.
FIG. 2 shows microstructures from extruded 65Be--32Al--1Si--2Ag alloy. As-extruded structure shows uniform distribution and deformation of phases. Annealed structure shows coarsening of aluminum phase as a result of heat treatment. This annealed structure has improved ductility.
Although specific features of the invention are shown in some drawings and not others, this is for convenience only as some feature may be combined with any or all of the other features in accordance with the invention.
Other embodiments will occur to those skilled in the art and are within the following claims:

Number	Name	Date
3322512	Krock et al.	May 1967
3322514	Krock et al.	May 1967
3323880	Krock et al.	Jun 1967
3438751	Krock et al.	Apr 1969
3490959	Krock et al.	Jan 1970
3548948	Richmond et al.	Dec 1970
3664889	McCarthy et al.	May 1972
3687737	Krock et al.	Aug 1972

Light weight, high strength beryllium-aluminum alloy

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