Patent Application
20090136380
The present invention relates to magnesium alloys and, more particularly, to magnesium alloys which can be cast by high pressure die casting (HPDC).
With the increasing need to limit fuel consumption and reduce harmful emissions into the atmosphere, automobile manufacturers are seeking to develop more fuel efficient vehicles. Reducing the overall weight of vehicles is a key to achieving this goal. Major contributors to the weight of any vehicle are the engine and other components of the powertrain. The most significant component of the engine is the cylinder block, which makes up 20-25% of the total engine weight. In the past significant weight savings were made by introducing aluminium alloy cylinder blocks to replace traditional grey iron blocks, and further weight reductions of the order of 40% could be achieved if a magnesium alloy that could withstand the temperatures and stresses generated during engine operation was used. Development of such an alloy, which combines the desired elevated temperature mechanical properties with a cost effective production process, is necessary before viable magnesium engine block manufacturing can be considered.
HPDC is a highly productive process for mass production of light alloy components. While the casting integrity of sand casting and low pressure/gravity permanent mould castings is generally higher than HPDC, HPDC is a less expensive technology for higher volume mass production. HPDC is gaining popularity among automobile manufacturers in North America and is the predominant process used for casting aluminium alloy engine blocks in Europe and Asia. In recent years, the search for an elevated temperature magnesium alloy has focused primarily on the HPDC processing route and several alloys have been developed. HPDC is considered to be a good option for achieving high productivity rates and thus reducing the cost of manufacture.
In a first aspect the invention provides a magnesium-based alloy consisting of, by weight:
1.5-4.0% rare earth element(s),
0.3-0.8% zinc,
0.02-0.1% aluminium,
4-25 ppm beryllium,
0-0.2% zirconium,
0-0.3% manganese,
0-0.5% yttrium,
0-0.1% calcium, and
the remainder being magnesium except for incidental impurities.
Throughout this specification the expression “rare earth” is to be understood to mean any element or combination of elements with atomic numbers 57 to 71, ie. lanthanum (La) to lutetium (Lu).
Preferably, alloys according to the present invention contain at least 95.5% magnesium, more preferably 95.5-97% magnesium, and most preferably about 96.1% magnesium.
The neodymium content is preferably 1.0-2.5% by weight. In one embodiment, the neodymium content is 1.4-2.1% by weight. In another embodiment, the neodymium content is greater than 1.7%, more preferably greater than 1.8%, more preferably 1.8-2.0% and most preferably about 1.9%. In another embodiment, the neodymium content is 1.7-1.9% by weight. The neodymium content may be derived from pure neodymium, neodymium contained within a mixture of rare earths such as a misch metal, or a combination thereof.
Preferably, the content of rare earth(s) other than neodymium is 0.5-1.5%, more preferably 0.8-1.2%, more preferably 0.9-1.2%, such as about 1.1%. Preferably, the rare earth(s) other than neodymium are cerium (Ce), lanthanum (La), or a mixture thereof. Preferably, cerium 5 comprises over half the weight of the rare earth elements other than neodymium, more preferably 60-80%, especially about 70% with lanthanum comprising substantially the balance. The rare earth(s) other than neodymium may be derived from pure rare earths, a mixture of rare earths such as a misch metal or a combination thereof. Preferably, the rare earths other than neodymium are derived from a cerium misch metal containing cerium, lanthanum, optionally neodymium, a modest amount of praseodymium (Pr) and trace amounts of other rare earths.
In a preferred embodiment, the neodymium, cerium and lanthanum contents are 1.7-2.1%, more preferably 1.7-1.9% by weight; 0.5-0.7%, more preferably 0.55-0.65% by weight; and 0.3-0.5% by weight respectively.
The zinc content is 0.3-0.8% by weight, preferably 0.4-0.7%, more preferably 0.5-0.6%.
The aluminium content is 0.02-0.1% by weight, preferably 0.03-0.09% by weight, more preferably 0.04-0.08% by weight, such as 0.05-0.07% by weight. Without wishing to be bound by theory, the inclusion of these small amounts of aluminium in the alloys of the present invention is believed to improve the creep properties of the alloys.
The beryllium content is 4-25 ppm, more preferably 4-20 ppm, more preferably 4-15 ppm, more preferably 6-13 ppm, such as 8-12 ppm. Beryllium would typically be introduced by way of an aluminium-beryllium master alloy, such as an Al-5% Be alloy. Without wishing to be bound by theory, the inclusion of beryllium is believed to improve the die castability of the alloy. Again, without wishing to be bound by theory, the inclusion of beryllium is also believed to improve the retention of the rare earth element(s) in the alloys against oxidation losses.
Reduction in iron content can be achieved by addition of zirconium which precipitates iron from the molten alloy. Accordingly, the zirconium contents specified herein are residual zirconium contents. However, it is to be noted that zirconium may be incorporated at two different stages. Firstly, on manufacture of the alloy and secondly, following melting of the alloy just prior to casting. Preferably, the zirconium content will be the minimum amount required to achieve satisfactory iron removal. Typically, the zirconium content will be less than 0.1%.
Manganese is an optional component of the alloy. When present, the manganese content will typically be about 0.1%.
Calcium (Ca) is an optional component which may be included, especially in circumstances where adequate melt protection through cover gas atmosphere control is not possible. This is particularly the case when the casting process does not involve a closed system.
Yttrium is an optional component which may be included. Without wishing to be bound by theory, the inclusion of yttrium is believed to beneficial to melt protection, ductility and creep resistance. When present, the yttrium content is preferably 0.1-0.4% by weight, more preferably 0.1-0.3% by weight.
Ideally, the incidental impurity content is zero but it is to be appreciated that this is essentially impossible. Accordingly, it is preferred that the incidental impurity content is less than 0.15%, more preferably less than 0.1%, more preferably less than 0.01%, and still more preferably less than 0.001%.
In a second aspect, the present invention provides a magnesium-based alloy consisting of 1.7-2.1% by weight neodymium, 0.5-0.7% by weight cerium, 0.3-0.5% by weight lanthanum, 0.03-0.09% by weight aluminium, 4-15 ppm beryllium; the remainder being magnesium except for incidental impurities and, optionally, trace amounts of rare earth elements other than neodymium, cerium and lanthanum.
In a third aspect, the present invention provides an engine block for an internal combustion engine produced by high pressure die casting an alloy according to the first or second aspects of the present invention.
In a fourth aspect, the present invention provides a component of an internal combustion engine formed from an alloy according to the first or second aspects of the present invention. The component of an internal combustion engine may be the engine block or a portion thereof such as a shroud.
Specific reference is made above to engine blocks but it is to be noted that alloys of the present invention may find use in other elevated temperature applications such as may be found in automotive powertrains as well as in low temperature applications. Specific reference is also made above to HPDC but it is to be noted that alloys of the present invention may be cast by techniques other than HPDC including thixomoulding, thixocasting, permanent moulding and sand casting.
Three alloys were prepared and chemical analyses of the alloys are set out in Table 1 below. The rare earths other than neodymium were added as a Ce-based misch metal which contained cerium, lanthanum and some neodymium. The extra neodymium and the zinc were added in their elemental forms. The zirconium was added through a proprietary Mg-Zr master alloy known as AM-cast. Aluminium and beryllium were added through an aluminium-beryllium master alloy which contained 5% by weight of beryllium. Standard melt handling procedures were used throughout preparation of the alloys.
Alloys A, B and C were high pressure die cast and 5 creep tests were carried out at a constant load of 90 MPa and at a temperature of 177° C. An additional creep test at 100 MPa and 177° C. was carried out for Alloy B. The steady state creep rates are listed in Table 2.
The stress to give a value of 0.1% creep strain after 100 hours is often quoted when comparing various creep resistant magnesium alloys. Neither Alloy B nor Alloy C had creep strains of this order after 100 hours at 177° C. and 90 MPa, although creep strains in excess of that were reached at much longer test times. At 177° C. Alloy B and Alloy C would be acceptable for most automotive powertrain applications in terms of their creep behaviour.
The tensile properties were measured in accordance with ASTM E8 at 20, 100, 150 and 177° C. in air using an Instron Universal Testing Machine. Samples were held at temperature for 10 minutes prior to testing. The test specimens had a circular cross section (5.6 mm diameter), with a gauge length of 25 mm.
Tensile test results for Alloys A, B and C are set out in Table 3 and
Alloys B and C and commercial alloy AZ91D were die cast in a triangular shaped die which had oil heating/cooling in both the fixed and moving halves of the mould. A thermocouple was present in the centre of the moving half.
The die was designed to provide both diverging and converging flow paths (see
Referring to
Finally the die had three strips of varying surface finish parallel to the flow direction. The surface finishes are full polish, semi-matt and full matt (EDM finish). These strips give an indication of the ease with which an alloy will form these surfaces. Accordingly, the die was designed to rigorously test the performance of any alloy cast in it by HPDC. A part cast from the die is illustrated in
Particulars of the HPDC conditions for the die are set out below.
AZ91D was cast with a molten metal temperature of 700° C. and an estimated die temperature of 200° C.; whereas, Alloys B and C were cast with a molten metal temperature of 740° C. and an estimated die temperature of 250° C.
Castings made with both AZ91D and Alloys B and C had a high quality surface finish although the AZ91D castings did have some surface cold shuts which may indicate that the oil temperature, and hence die temperature, should have been slightly higher. The molten metal temperature for AZ91D was in the upper region for normal HPDC casting of AZ91D. The surface finishes on both sides of the castings from Alloys B and C were good which demonstrated that both alloys can flow reasonable distances.
All alloys cast with equivalent castability although Alloys B and C did have a more rapid reduction in quality at the limit of their operating windows. For example, if insufficient metal was dosed into the shot sleeve, which led to a reduction in the molten metal temperature entering the cavity, then surface quality diminished rapidly.
For all alloys, the holding time in the die was varied so that some idea of the cracking propensity could be determined. The casting has many thick and thin sections with sharp corners at the changes in section thickness, which should have meant that the resultant castings should exhibit cracks. In the castings of Alloys B and C there were no signs of cracking while in the AZ91D castings there were some signs of hot tearing in one section of the large rib.
The die casting trial demonstrated that Alloys B and C have excellent die castability approximately equivalent to AZ91D although the melt temperature and die temperature required for Alloys B and C were higher than that required for AZ91D.
A series of alloys were produced and their compositions are listed in Table 4 below. In each of Alloys D-Y, except for any incidental impurities, the balance of the alloy was magnesium.
For the purposes of mechanical property evaluation, test specimens were produced by the high pressure die casting (HPDC) of the alloys on a 250 tonne Toshiba cold chamber machine. Two dies were designed with magnesium alloys in mind to cast tensile/creep specimens and bolt load retention bosses. The alloy properties that were evaluated included casting quality, as-cast microstructure, tensile strength at room temperature and 177° C., creep behaviour at 150° C. and 177° C., and bolt load retention (BLR) behaviour at 150° C. and 177° C.
A typical example of the microstructure of an alloy according to the present invention (Alloy G) in the as-cast condition, is shown in
A summary of the tensile test data for various of the alloys is given in Table 5 below and it can be seen that the tensile behaviour of alloys according to the present invention is very good at both of the test temperatures considered.
A summary of the secondary creep rates under the same conditions of 177° C. and 90 MPa for various of the alloys are contained in Table 6 below. These test conditions were chosen specifically to provide a stringent test that would identify magnesium alloys with creep properties suitable for demanding automotive powertrain applications.
These results can be divided into three groups depending on the observed creep behaviour and the Al content of the alloy. The first group contains those alloys which have an Al content of less than 0.03 wt. % (Alloys D and F) and it can be seen that these compositions display a relatively high secondary creep rate. The second group contains those alloys which have an Al content of more than 0.02 wt. % and less than 0.11 wt. % (Alloys E, G, H, I, N, O, R, S, T, U, V and W) and it can be seen that these alloys display secondary creep rates that are very low, in the range of 10−10-10−11 s−1, and therefore these compositions would be classified as very creep resistant under these test conditions. This is illustrated by the comparison of the creep behaviour, at 177° C. and 90 MPa, of Alloys E and F in
The BLR behaviour for Alloy Y was measured at 150° C. and 177° C., with loads of 8 kN and 11 kN. The results are presented in two charts:
| Number | Date | Country | Kind |
|---|---|---|---|
| 2005901623 | Apr 2005 | AU | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/AU06/00447 | 4/4/2006 | WO | 00 | 11/26/2007 |
