Patent Grant
9802273
This application is being filed under §371 as a National Phase Application of International Application No. PCT/JP2011/075348, filed Nov. 2, 2011.
The present disclosure relates to a method for manufacturing an aluminum alloy cladding material used in the structural members and components of automobiles, ships, aircraft, and the like.
A method for manufacturing an aluminum alloy cladding material has been conventionally carried out by, for example, hot rolling for joining as described below. First, a core material and a skin material are prepared according to a clad rate of interest. In general, for the core material, an ingot is faced to have a predetermined thickness. For the skin material, an ingot is faced, hot-rolled, rolled to have a predetermined plate thickness, and cut in accordance with the length of the core material alloy. Homogenization treatment of the core material is carried out if necessary, and the skin material and the core material are then joined, heated prior to hot rolling, and is rolled for joining by a reverse-type hot rolling machine. The core material and the skin material are press-fitted by the rolling for joining and rolled to have a thickness of interest after the press-fitting in such a manner that a usual aluminum alloy ingot is hot-rolled.
However, the hot rolling for joining requires rolling under low pressure for suppression of peeling and warpage of a plate until press-fitting strength becomes sufficient and is inferior in productivity to usual rolling. In addition, it is necessary for press-fitting aluminum alloy materials or pure aluminum materials (hereinafter uniformly referred to as aluminum alloy materials) to each other to mechanically demolish an oxide film on a press-fitted interface by deformation and to allow a newly formed surface to appear. Therefore, it is necessary to apply a load, sufficient for demolishing the oxide film on the press-fitted interface, to a portion that is farther from the contact surface of a roll when a clad rate is high, and there are also rolling machine facility limits. Thus, it is considerably difficult to manufacture a material with a high clad rate of more than 20% in the method for manufacturing a clad material by the press-fitting rolling. The degree of difficulty is also high for multilayered materials. For example, there is a method in which press-fitting rolling is divided into two or more processes, which are carried out. However, there are considerable troubles in the method.
Against the problems of the manufacture of a clad material as described above, Patent Literature 1 proposes a manufacturing method in which when a clad material of an aluminum alloy is manufactured, only the surface layers of joining materials are heated, and press-fitting rolling can be carried out at high rolling reduction rate while preventing a clad interface from peeling in rolling for joining. However, in Patent Literature 1, when press-fitting rolling is carried out under unexpected high pressure, since joining surfaces are not bonded to each other, warpage occurs, a press-fitted surface is peeled, and it can be impossible to manufacture a clad material.
A method for obtaining a clad material at a high clad rate is considered to be enabled by a method described in Patent Literature 2. Patent Literature 2 proposes, as a method for bonding metallic materials, a method of heating and pressurizing metal joining materials to be bonded, with an intermediate material, in which an element that is not melted into a parent phase in a solid state is scattered in a soft metal such as aluminum, therebetween, by rolling, extrusion, drawing, and/or the like. In the method, there are manufacture limits that it is necessary to apply strong downward pressurization in a temperature range in which the intermediate material melts. In addition, an element that has a low melting point and does not become a solid solution in a solid state is added to the intermediate material, and it is presumed that only a low-melting-point metal that exists on a surface can be used for bonding. Therefore, there is apprehension that an addition amount for obtaining sufficient bonding strength is considerably increased, a large amount of low-melting-point metal component remains in a bonded interface after bonding, and the characteristics of a metal base material are adversely affected.
There is also a method for manufacturing a clad material by face bonding by solid phase diffusion bonding or liquid phase diffusion bonding. In the solid phase diffusion bonding, long time is needed for bonding compared to welding, brazing, and the like since a diffusion phenomenon is utilized. In general, retention at predetermined temperature is needed for time of around 30 minutes or more. In addition, since pressurization is needed for bonding, complication of a bonding operation and increase in cost are inevitable. Further, in the case of an aluminum alloy material, since a stable, firm oxide film exists on the surface thereof and diffusion is inhibited thereby, it is difficult to apply the solid phase diffusion bonding. When the liquid phase diffusion bonding is used particularly in a large-scale industrial product, it is difficult to optimally control the amount of a remaining insert material to be a liquid phase after bonding the insert material, and it is also difficult to suppress the growth of an intermetallic compound generated in a portion to be bonded. Thus, it is difficult to keep favorable bondability in the liquid phase diffusion bonding.
Patent Literature 1: Unexamined Japanese Patent Application Kokai Publication No. 2008-264825
Patent Literature 2: Unexamined Japanese Patent Application Kokai Publication No. H8-318381
In the case of carrying out hot rolling for joining for manufacturing an aluminum alloy clad material, high manufacture technologies have been required, and further, there have been limits based on the capacities of hot rolling machines and manufacture limits based on clad rates, multilayered materials, and the like. Further, there have been problems that hot rolling for joining has been poor in productivity due to prevention of bonded interfaces from peeling and suppression of warpage of plates. Therefore, a method for manufacturing an aluminum alloy clad material, which is easier, has the high degree of the freedom of the formation of a clad material, and is excellent in productivity, has been desired.
The present disclosure was accomplished with respect to the above-described problems, and an objective thereof is to provide a method for manufacturing an aluminum alloy clad material, capable of easily manufacturing a clad material and forming the multilayered clad material at a high clad rate.
In order to achieve the above-described objective, a method for manufacturing an aluminum alloy clad material according to the present disclosure comprises layering plural aluminum alloy materials (including a pure aluminum material) with an intermediate layer therebetween, heating and bonding a layered body at a temperature, at which a ratio of a mass of a liquid phase generated from the intermediate layer is 5% or more and 35% or less, and rolling the body.
A material of the intermediate layer may be an aluminum alloy comprising 0.5 mass % or less (including 0 mass %) of Mg and 0.4-4.5 mass % of Si, and bonding may be carried out in a non-oxidizing atmosphere in a state in which a fluoride-based flux is coated between bonding members.
A material of the intermediate layer may be an aluminum alloy comprising 0.5 mass % or less (including 0 mass %) of Mg and 0.7-10 mass % of Cu, and bonding may be carried out in a non-oxidizing atmosphere in a state in which a fluoride-based flux is coated between bonding members.
A material of the intermediate layer may be an aluminum alloy comprising 0.5 mass % or less (including 0 mass %) of Mg, 0.4-10 mass % of Cu, and 0.3-4.5 mass % of Si, and bonding may be carried out in a non-oxidizing atmosphere in a state in which a fluoride-based flux is coated between bonding members.
A material of the intermediate layer may be an aluminum alloy comprising 0.5 mass % or less (including 0 mass %) of Mg, 0.3-4.5 mass % of Si, 0.5-20 mass % of Zn, and 0.3-10 mass % of Cu, and bonding may be carried out in a non-oxidizing atmosphere in a state in which a fluoride-based flux is coated between bonding members.
A material of the intermediate layer may be an aluminum alloy comprising 0.2-2.0 mass % of Mg and 0.3-5.0 mass % of Si, and bonding may be carried out in atmospheric air, in a non-oxidizing atmosphere, or in a vacuum.
A material of the intermediate layer may be an aluminum alloy comprising 0.2-2.0 mass % of Mg and 0.1-10 mass % of Cu, and bonding may be carried out in atmospheric air, in a non-oxidizing atmosphere, or in a vacuum.
A material of the intermediate layer may be an aluminum alloy comprising 0.2-2.0 mass % of Mg, 0.15-10 mass % of Cu, and 0.1-4.5 mass % of Si, and bonding may be carried out in atmospheric air, in a non-oxidizing atmosphere, or in a vacuum.
A material of the intermediate layer may be an aluminum alloy comprising 0.2-2.0 mass % of Mg, 0.1-4.5 mass % of Si, 0.1-20 mass % of Zn, and 0.1-10 mass % of Cu, and bonding may be carried out in atmospheric air, in a non-oxidizing atmosphere, or in a vacuum.
The aluminum alloy of the intermediate layer may further comprise one or two or more selected from 0.05-1.0 mass % of Si, 0.05-0.5 mass % of Cu, 0.05-1.0 mass % of Fe, 0.05-3.0 mass % of Zn, 0.1-1.8 mass % of Mn, 0.01-0.3 mass % of Ti, and 0.01-0.3 mass % of Zr.
In the above-described method for manufacturing an aluminum alloy clad material, heat treatment in the bonding may be carried out in an atmosphere in which a dew point is 0° C. or less.
In accordance with the present disclosure, there can be obtained a method for manufacturing an aluminum alloy clad material, capable of easily manufacturing a clad material and forming the multilayered clad material at a high clad rate.
The embodiments of the present disclosure will be specifically explained below.
The method for manufacturing an aluminum alloy clad material of the present disclosure comprises layering plural aluminum alloy materials with an intermediate layer therebetween, heating a layered body to a temperature that is lower than the solidus temperature of the aluminum alloy material and at which the ratio of the mass of a liquid phase generated from the intermediate layer (hereinafter referred to as a “liquid phase rate”) is 5.0% or more and 35% or less, to thereby overall or partially bond the bond surfaces of the layered layers, and then rolling the body. The bonding results in overall or partial bonding of the bond surfaces of the layered layers and facilitates the subsequent rolling.
When the liquid phase rate is more than 35%, the amount of the generated liquid phase is excessively large, it becomes impossible to maintain the shape of the aluminum alloy material, and the aluminum alloy material is highly deformed. Therefore, the bonding is not uniformly carried out, and the bonding rate is decreased. In contrast, when the liquid phase rate is less than 5.0%, the bonding becomes difficult. It is preferable that the liquid phase rate is 5.0-30%, and it is more preferable that the liquid phase rate is 10-20%.
It is very difficult to measure a real liquid phase rate during heating. Thus, a liquid phase rate stipulated according to the present disclosure is calculated by an equilibrium calculation. Specifically, a liquid phase rate is calculated from alloy composition and the maximum end-point temperature during heating by using thermodynamic equilibrium calculation software such as Thermo-Calc.
In order to reliably carrying out the bonding, a temperature at which the liquid phase rate of the intermediate layer is 5.0% or more is desirably kept for 10 minutes or more. In the present disclosure, the reliability of the bonding is increased with increasing bonding time.
<Behavior of Metal Structure in Bonding>
A liquid phase generation mechanism will be explained.
Subsequently, as indicated in
<Demolition of Oxide Film>
An oxide film is formed on a surface layer of an aluminum alloy material, and is an obstacle to bonding. Accordingly, it is necessary to demolish the oxide film in the bonding. In the method for manufacturing a clad material according to the present disclosure, one of the methods stated in the following “D-1” and “D-2” is adopted for the demolition of the oxide film in the bonding.
D-1. Demolition of Oxide Film with Flux
In the method, a portion to be bonded is at least coated with a flux for the demolition of the oxide film. For the flux, it is possible to use a fluoride-based flux such as KAlF4 or CsAlF4, and a chloride-based flux such as KCl or NaCl, which are used in brazing of an aluminum alloy. Before the liquid phases are melted or before the bonding temperature is attained, each of the fluxes is melted so as to react with the oxide film, resulting in demolition of the oxide film.
Further, in the method, in order to suppress formation of the oxide film, the bonding is carried out in a non-oxidizing atmosphere such as a nitrogen gas or an argon gas. Especially, when the fluoride-based flux is used, it is preferable that the bonding is carried out in the non-oxidizing atmosphere in which an oxygen concentration is 250 ppm or less, and in which a dew point is −25° C. or less.
In addition, when the fluoride-based flux is used, and when the aluminum alloy materials of the one and other members to be bonded contain Mg exceeding 0.50 mass % in the aluminum alloys, the flux and Mg react with each other so that the action of demolishing the oxide film of the flux is diminished. Accordingly, in the present disclosure, the aluminum alloy that generates a liquid phase contains 0.50 mass % or less of Mg.
D-2. Demolition of Oxide Film by Gettering Action of Mg
In a case where a given content of Mg is added to an aluminum alloy material, even when a portion to be bonded is not coated with a flux, the oxide film can be demolished so that it is possible to carry out bonding. In the case, similarly to the case of vacuum fluxless brazing, when the aluminum alloy is melted so that liquid phases appear on the surface thereof, the oxide film is demolished by the gettering action of Mg evaporated from the inside of the aluminum alloy. In the case where the oxide film is demolished by the gettering action of Mg, in order to suppress formation of the oxide film, the bonding is carried out in a vacuum or the above-described non-oxidizing atmosphere. However, since face bonding is carried out in the case of the present disclosure, the bonding can be carried out even in a dried atmosphere. In order that the oxide film is demolished by the gettering action of Mg, in the present disclosure, the aluminum alloy material that generates a liquid phase contains Mg falling within a range from 0.20 mass % to 2.0 mass %. When the Mg content is less than 0.20 mass %, a sufficient gettering action cannot be obtained so that a superior bonding is not attained. On the other hand, when the Mg content exceeds 2.0 mass %, Mg reacts with oxygen in the atmosphere on the surface, and much oxide MgO is generated, resulting in diminution of the bonding.
<Components (Other than Mg) of Aluminum Alloy that Generates Liquid Phase>
Al—Si Alloy:
An Al—Si alloy of which the content of Si is 0.40-4.5 mass % is preferably used. In the case of less than 0.40 mass %, a temperature range in which a liquid phase rate is 5.0% to 35% becomes narrow, so that stable bonding may be difficult. On the other hand, in the case of more than 4.5 mass %, the amount of a liquid phase generated at the solidus temperature=the eutectic temperature is almost 35%, so that a temperature range becomes narrow at a liquid phase rate of 35% from the solidus temperature, and stable bonding may be difficult. It is more preferable that the content of Si is 1.2-3.0 mass %.
Al—Cu Alloy:
An Al—Cu alloy of which the content of Cu is 0.70-10 mass % is preferably used. In the case of less than 0.70 mass %, a temperature range in which a liquid phase rate is 5.0% to 35% becomes narrow, so that stable bonding may be difficult. On the other hand, in the case of more than 10 mass %, strength is increased, so that cracking occurs in rolling, and manufacturing cannot be carried out. It is more preferable that the content of Cu is 1.5-6.0 mass %.
Al—Cu—Si Alloy:
An Al—Cu—Si alloy of which the content of Cu is 0.40-10 mass % and the content of Si is 0.30-4.5 mass % is preferably used. In a case in which the content of Cu is less than 0.40 mass %, a temperature range in which a liquid phase rate is 5.0% to 35% becomes narrow, so that stable bonding may be difficult. On the other hand, in the case of more than 10 mass %, strength is increased, so that cracking occurs in rolling, and manufacturing cannot be carried out. In a case in which the content of Si is less than 0.30 mass %, a temperature range in which a liquid phase rate is 5.0% to 35% becomes narrow, so that stable bonding may be difficult. On the other hand, in the case of more than 4.5 mass %, the amount of a liquid phase generated at the solidus temperature=the eutectic temperature is almost 35%, so that a temperature range becomes narrow at a liquid phase rate of 35% from the solidus temperature, and stable bonding may be difficult. It is more preferable that the content of Cu is 1.5-6.0 mass %, and it is more preferable that the content of Si is 1.2-3.0 mass %.
Al—Si—Zn—Cu Alloy:
An Al—Si—Zn—Cu alloy of which the content of Si is 0.30-4.5 mass %, the content of Zn is 0.50-20 mass %, and the content of Cu is 0.30-10 mass % is preferably used. In a case in which the content of Si is less than 0.30 mass %, a temperature range in which a liquid phase rate is 5.0% to 35% becomes narrow, so that stable bonding may be difficult. On the other hand, in the case of more than 4.5 mass %, the amount of a liquid phase generated at the solidus temperature=the eutectic temperature is almost 35%, so that a temperature range becomes narrow at a liquid phase rate of 35% from the solidus temperature, and stable bonding may be difficult. In a case in which the content of Zn is less than 0.50 mass %, a temperature range in which a liquid phase rate is 5.0% to 35% becomes narrow, so that stable bonding may be difficult. On the other hand, in the case of more than 20 mass %, an aluminum matrix becomes brittle, so that cracking occurs in rolling, and manufacturing cannot be carried out. In a case in which the content of Cu is less than 0.30 mass %, a temperature range in which a liquid phase rate is 5.0% to 35% becomes narrow, so that stable bonding may be difficult. On the other hand, in the case of more than 10 mass %, strength is increased, so that cracking occurs in rolling, and manufacturing cannot be carried out.
Al—Si—Mg Alloy:
An Al—Si—Mg alloy of which the content of Si is 0.30-5.0 mass % is preferably used. In the case of less than 0.40 mass %, a temperature range in which a liquid phase rate is 5.0% to 35% becomes narrow, so that stable bonding may be difficult. On the other hand, in the case of more than 4.5 mass %, the amount of a liquid phase generated at the solidus temperature=the eutectic temperature is almost 35%, so that a temperature range becomes narrow at a liquid phase rate of 35% from the solidus temperature, and stable bonding may be difficult. It is more preferable that the content of Si is 1.2-3.0 mass %.
Al—Cu—Mg Alloy:
An Al—Cu—Mg alloy of which the content of Cu is 0.10-10 mass % is preferably used. In the case of less than 0.70 mass %, a temperature range in which a liquid phase rate is 5.0% to 35% becomes narrow, so that stable bonding may be difficult. On the other hand, in the case of more than 10 mass %, strength is increased, so that cracking occurs in rolling, and manufacturing cannot be carried out. It is more preferable that the content of Cu is 1.5-6.0 mass %.
Al—Cu—Si—Mg Alloy:
An Al—Cu—Si—Mg alloy of which the content of Cu is 0.15-10 mass % and the content of Si is 0.10-4.5 mass % is preferably used. In a case in which the content of Cu is less than 0.15 mass %, a temperature range in which a liquid phase rate is 5.0% to 35% becomes narrow, so that stable bonding may be difficult. On the other hand, in the case of more than 10 mass %, strength is increased, so that cracking occurs in rolling, and manufacturing cannot be carried out. In a case in which the content of Si is less than 0.10 mass %, a temperature range in which a liquid phase rate is 5.0% to 35% becomes narrow, so that stable bonding may be difficult. On the other hand, in the case of more than 4.5 mass %, the amount of a liquid phase generated at the solidus temperature=the eutectic temperature is almost 35%, so that a temperature range becomes narrow at a liquid phase rate of 35% from the solidus temperature, and stable bonding may be difficult.
Al—Si—Zn—Cu—Mg Alloy:
An Al—Si—Zn—Cu—Mg alloy of which the content of Si is 0.10-4.5 mass %, the content of Zn is 0.10-20 mass %, and the content of Cu is 0.10-10 mass % is preferably used. In a case in which the content of Si is less than 0.10 mass %, a temperature range in which a liquid phase rate is 5.0% to 35% becomes narrow, so that stable bonding may be difficult. On the other hand, in a case in which the content of Si is more than 4.5 mass %, the amount of a liquid phase generated at the solidus temperature=the eutectic temperature is almost 35%, so that a temperature range becomes narrow at a liquid phase rate of 35% from the solidus temperature, and stable bonding may be difficult. In a case in which the content of Zn is less than 0.10 mass %, a temperature range in which a liquid phase rate is 5.0% to 35% becomes narrow, so that stable bonding may be difficult. On the other hand, in a case in which the content of Zn is more than 20 mass %, an aluminum matrix becomes brittle, so that cracking occurs in rolling, and manufacturing cannot be carried out. In a case in which the content of Cu is less than 0.10 mass %, a temperature range in which a liquid phase rate is 5.0% to 35% becomes narrow, so that stable bonding may be difficult. On the other hand, in a case in which the content of Cu is more than 10 mass %, strength is increased, so that cracking occurs in rolling, and manufacturing cannot be carried out.
Also, each of the above-described alloys may further contain one or two or more selected from 0.05-1.0 mass % of Si, 0.05-0.50 mass % of Cu, 0.05-1.0 mass % of Fe, 0.05-3.0 mass % of Zn, 0.10-1.8 mass % of Mn, 0.01-0.30 mass % of Ti, and 0.01-0.30 mass % of Zr.
In the method for manufacturing an aluminum alloy clad material of the present disclosure, the difference between the solidus and liquidus temperatures of the aluminum alloy material that generates a liquid phase is preferably 10° C. or more. When a temperature exceeds the solidus temperature, generation of the liquid phase begins. Nevertheless, when the temperature between the solidus temperature and the liquidus temperature is small, a temperature range, in which the solid and the liquid can coexist, becomes narrower, so that it is difficult to control the amount of a liquid phase to be generated.
As the difference between the solidus temperature and the liquidus temperature becomes larger, it is possible to more easily and suitably control the amount of the liquid phase. Accordingly, the upper limit of the difference between the solidus temperature and the liquidus temperature is not especially set. In the aluminum alloy that generates a liquid phase, it is more preferable to set the temperature, at which the liquid phase rate is from 5.0% to 35%, to be 10° C. or more, and it is still more preferable to set the temperature, at which the liquid phase rate is from 5.0 to 35%, to be 20° C. or more.
In the heat treatment for bonding, it is desirable to use a furnace in which a dew point is controlled to 0° C. or less. The concentration of oxygen in the furnace is preferably 5.0% or less.
In the method for manufacturing an aluminum alloy clad material of the present disclosure, rolling is carried out after the bonding at high temperature. The rolling may be any of hot rolling and cold rolling, and the hot rolling is carried out when the plate thickness of the aluminum alloy material is large before the bonding. The rolling is effective in compensating for insufficient bonding by a liquid phase, and the aluminum alloy clad material with higher reliability can be manufactured by the rolling.
For reliably carrying out the bonding, it is desirable to prevent a gap from being formed in the bonded interface as much as possible, for example, by carrying out fixation with an iron band or mounting a weight during the heat treatment. However, when the thickness of an ingot to be bonded is large, the gap on the bonded surfaces is reduced by the self-weight thereof, and therefore pressurization is not always necessary. As a bonding rate (described below) is higher, it is possible to more easily carrying out rolling. However, even when the bonding rate is low, press-fitting is carried out during the rolling, resulting in bonding. The bonding rate is preferably 10-100%, more desirably 20-100%. When the bonding rate is less than 10%, it is more likely to separate each layer during the rolling.
For the material to be bonded, an ingot is faced depending on a clad rate or is previously prepared to have a predetermined thickness by hot rolling. The bonded interface can also be washed with an acid or an alkali in order to enhance the bonding rate.
It is necessary that the solidus temperature (eutectic temperature) of the aluminum alloy material bonded with the aluminum alloy material that generates a liquid phase is higher than the solidus temperature (eutectic temperature) of the aluminum alloy material that generates the liquid phase. In other words, it is necessary to choose the component of the aluminum alloy material that generates the liquid phase depending on an aluminum alloy to be bonded. For example, when the bonding is carried out using a fluoride-based flux in a non-oxidizing atmosphere, it is necessary that the amount of Mg in the aluminum alloy to be bonded is also set to 0.50 mass % or less. When more than 0.50 mass % of Mg is contained, a flux reacts with Mg, resulting in deterioration of the action of demolishing an oxide film of the flux.
In addition, when bonding is carried out utilizing the gettering action of Mg in atmospheric air, a non-oxidizing atmosphere, or a vacuum, it is necessary to set the amount of Mg in an aluminum alloy to be bonded to 2.0 mass % or less. When the Mg amount exceeds 2.0 mass %, Mg reacts with oxygen in the atmosphere on the surface, and much oxide MgO is generated, resulting in diminution of the bonding. However, since the bonding in the case is face bonding, the bonding can be carried out even when the amount of Mg is increased to 6.0 mass % in a case in which the atmosphere in a furnace is a non-oxidizing atmosphere or a vacuum.
As the bonding rate after the heat treatment, it is preferable to carrying out the bonding at 15% or more. When the bonding rate is less than 15%, peeling occurs in rolling, and a clad material cannot be manufactured.
The thickness of a layer that generates a liquid phase is preferably 0.10-10 mm. In the case of less than 0.10 mm, the amount of the generated liquid phase is not sufficient, and bonding becomes insufficient. The thickness of more than 10 mm results in the fear of the excessively large amount of the generated liquid phase, resulting in flowing of the liquid phase in a furnace, and is unfavorable. As illustrated in
As explained above, as a result of diligent examination with respect to the above-described problems, the present inventors found a method in which aluminum alloy material layers to be cladded are pre-bonded to each other before hot rolling, the need of hot rolling for joining is eliminated or the hot rolling for joining is simplified, and a multilayered aluminum material at a high clad rate can be manufactured. When the manufacturing method is used, hot rolling for joining can be carried out at high rolling reduction rate, and therefore excellent productivity is exhibited.
In the method for manufacturing an aluminum alloy clad material of the present disclosure, materials to be cladded are overall or partially pre-bonded before hot rolling, resulting in simplification of a manufacturing process that generally requires hot rolling for joining. The bonding is carried out by heat treatment at a temperature at which only the aluminum alloy layer having the lowest solidus temperature is partially melted. In the manufacturing method of the present disclosure, the need of rolling for joining, which generally requires a high manufacturing technology, is eliminated, or a load on hot rolling for joining is greatly reduced. Therefore, limits based on the capacity of a hot rolling machine are reduced. In addition, even in the case of a high clad rate and the case of a multilayered material that is a material based on three or more layers, in which it is generally difficult to make a clad material, the clad material can be relatively easily made. Further, since rolling can be carried out in a state similar to the case of rolling a usual ingot, the stability region of a clad rate is expanded in a width direction and a longitudinal direction, so that yield can be improved. Further, when both of heat treatment in the bonding and homogenization heat treatment of a core material can be carried out, the manufacturing method can be simplified without increasing the number of steps, so that a cost can be reduced.
Examples of the disclosure will be described together with comparative examples. The examples below are intended to explain the effect of the disclosure, and the processes and conditions described in the examples are not limited to the technical scope of the disclosure.
The components of aluminum alloy materials (hereinafter also referred to as “intermediate layers” in Examples and Tables) functioning as generation of liquid phases used for manufacturing clad materials in bonding are listed in Tables 1 and 2. The components of aluminum alloy materials to be bonded (hereinafter also referred to as “main layers” in Examples and Tables) are listed in Table 3. The solidus temperature of each alloy was listed together in Tables 1-3. The solidus temperature is a value calculated based on the thermodynamic calculation software Thermo-Calc. In addition, “-” in each component in Tables 1-3 means that the element concerned is not contained (less than the detection limit).
Each alloy ingot of the components listed in Tables 1 and 2 was prepared, then faced, and hot-rolled. In addition, each alloy ingot listed in Table 3 was prepared, then subjected to facing processing, and hot-rolled and cold-rolled as needed, to thereby obtain a rolled plate having a predetermined thickness. Two ingots of main layers selected from each alloy material listed in Table 3 were layered to sandwich an alloy material of each intermediate layer listed in Tables 1 and 2 therebetween, gently fixed with an iron band, and then subjected to heat treatment for bonding. The bonded surface of each clad material to be coated with a flux and bonded was coated with a noncorrosive flux based on potassium fluoride or cesium fluoride. The presence or absence and kind of flux coating are listed in Tables 4 and 5. In the tables, “K” represents a potassium fluoride-based noncorrosive flux (KAlF4), “Cs” represents a cesium fluoride-based noncorrosive flux (CsAlF4), and “Absent” represents a case in which a flux was not coated.
The combinations of alloys to be layered, bonding conditions, and results after bonding are listed in Tables 4 and 5. Each size of the ingots was set to 1000 mm in width×2000 mm in length, and the thicknesses thereof were set to respective values listed in Tables 4 and 5. A batch-type furnace was used for bonding, heating was carried out until each heating temperature in bonding listed in Tables 4 and 5 was reached, and retention time was set to 3 hours. Cooling was carried out after bonding heating, cooling was carried out from a bonding heating temperature, and the hot rolling began from each temperature listed in Tables 4 and 5. The rolling was carried out on a condition that a rolling rate in each pass was 5-50%. As the results after the bonding, examination of bonding rates and structure observation after the heat treatment, and results after the rolling are listed. The bonding rate was the average of values measured at three points (center and both ends) in the width direction at the middle position of the length. As a measurement method, a bonded portion was cut out, the cross section thereof was observed with an optical microscope, and a bonding rate was obtained by calculating a bonding percentage with respect to a measurement length. In the structure observation after the bonding, a case in which melting occurred in the aluminum alloy material to be bonded was estimated by symbol “x”, and a case in which melting did not occur in the aluminum alloy material to be bonded was estimated by symbol “∘”. For the results after the rolling, an alloy material in which cracking occurred in rolling in a case in which an alloy material that generates a liquid phase was produced was estimated by symbol “x”, and an alloy material that was able to be produced without cracking was estimated by symbol “∘”. In addition, a clad material that was able to be rolled without peeling a bonded interface in the rolling after the bonding was estimated by symbol “∘”, and a clad material in which peeling occurred during the rolling was estimated by symbol “x”.
In each of Examples 1-72, the bonding in the heat treatment was sufficiently carried out, and therefore the clad material was able to be produced without peeling in the subsequent rolling.
In each of Comparative Examples 1, 3, 5, 7, 11, 12, 13, 15, 17, 18, and 23, the liquid phase generated from the intermediate layer was less than 5.0% and sufficient, therefore, the bonding was not sufficiently carried out, and the layer was peeled after the rolling, resulting in an insufficient result. In addition, when a temperature was excessively increased for the purpose of generating the liquid phase necessary for the bonding, the first layer or the second layer was melted.
In each of Comparative Examples 2 and 24, the liquid phase generated from the intermediate layer was more than 35%, therefore, the bonding was not sufficiently carried out, and the layer was peeled after the rolling, resulting in an insufficient result.
In Comparative Example 10, the amount of added Mg in the intermediate layer in the case of using the flux was out of the scope of the present disclosure, the oxide film on the surface was not demolished during the bonding, the bonding was not sufficiently carried out, and the layer was peeled after the rolling, resulting in an insufficient result.
In each of Comparative Examples 21 and 22, the amount of added Mg in the intermediate layer in the case of using no flux was out of the scope of the present disclosure, the oxide film on the surface was not demolished during the bonding, bonding was not sufficiently carried out, and the layer was peeled after the rolling, resulting in an insufficient result.
In each of Comparative Examples 4, 6, 8, 9, 14, 16, 19, and 20, cracking occurred during hot-rolling the aluminum alloy material (intermediate layer) that generates the liquid phase, and therefore the clad material was not able to be produced. In Table 5, “-” was indicated in each of the items other than the items of the intermediate layers in themselves in the comparative examples concerned.
Next, Examples 73-77 of multilayered materials based on three or more layers will be described. In Table 6, bonding conditions and bonding rates are listed. In each of the examples, the aluminum alloy material to be bonded was not melted, each layer was not peeled during the rolling, and the rolling was able to be favorably carried out.
The present disclosure is applicable to an aluminum alloy clad material that is formed by layering aluminum alloy materials with two layers or three or more layers.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2011/075348 | 11/2/2011 | WO | 00 | 8/26/2014 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
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