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Hypereutectic aluminum-silicon cast alloy with unique micro-structure

An aluminum-silicon alloy and hypereutectic technology, which is applied in the field of hypereutectic aluminum-silicon casting alloys with unique microstructure, and can solve problems such as unproven

Pending Publication Date: 2018-03-20
BRUNSWICK CORPORATION
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

All of the above discussion does not imply that die casting alloys with or without nickel cannot be made more machinable if the primary silicon grain size is small and the eutectic is modified, this has not been proven so far

Method used

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  • Hypereutectic aluminum-silicon cast alloy with unique micro-structure
  • Hypereutectic aluminum-silicon cast alloy with unique micro-structure
  • Hypereutectic aluminum-silicon cast alloy with unique micro-structure

Examples

Experimental program
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Effect test

Embodiment 1

[0117] The internal combustion engine piston is cast with the alloy of the present invention, and has the following specific components by weight percentage: 19% silicon, 0.6% magnesium, 4% nickel, and the balance is aluminum. The piston is cast using traditional sand casting methods. Piston castings are heat treated and subsequently machined.

[0118] The machining of the pistons proceeded so well that it was suspected that the alloy was not a hypereutectic AlSi alloy. The machining results are so amazing that high speed steel is sufficient to machine the pistons without the use of carbide or diamond tools. Additionally, in comparative testing with pistons cast from AA B391, pistons using the alloys of the present invention provided lower discharge numbers than pistons cast from AA B391. The lower emission numbers are attributable to the higher temperature strength of the alloys of the invention, as well as the lower coefficient of thermal expansion of the alloys of the inv...

Embodiment 2

[0120] The twin-barrel engine cylinder is cast using pressure lost foam casting, where ten atmospheres of pressure are used in the curing process. The twin barrel engine cylinder was cast using the alloy of the present invention, specifically comprising: 19.1% silicon, 0.65% manganese and 5.2% nickel. After casting, the porosity level of the twin cylinder block was tested at 0.11%.

[0121] The porosity of 0.11% is significantly lower than the best porosity (about 0.35%) measured in the copper-containing hypereutectic silicon-aluminum alloy solidified in the same lost foam cylinder under the same pressure at 10 atmospheres. The tensile strength of samples obtained from cylinder block casting of the alloy of the present invention had a tensile strength of 10.5 ksi when tested at 700°F. The machining results for the 100 engine block machining trials were as surprising as those for the pistons in Example 1 and, accordingly, allow high speed steel machining.

[0122]The examples...

Embodiment 3

[0124] Three "as cast" tensile specimens were extracted from a high pressure die cast engine block with the following composition: 19.2% by weight Si, 0.05% by weight Sr, 0.7% by weight Fe, and 0.46% Mg, the balance is Al, and its microstructure is shown in Figure 8 middle. Standard testing revealed that the alloy had an average ultimate tensile strength (UTS) of 263 MPa (or 38.1 ksi), a yield strength of 207 MPa (or 30.0 ksi) and an elongation of 2.1%. The elongation is four times higher than the 0.5% elongation of a typical hypereutectic Al-Si alloy and higher than that of a fully annealed conventional hypereutectic Al-Si alloy.

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PUM

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Abstract

The present invention discloses a hypereutectic aluminum-silicon high-pressure cast alloy comprising: 16% to 23% of silicon by weight, 0.01% to 1.5% of iron by weight, 0.01% to 0.6% of manganese by weight, 0.01% to 1.3% of magnesium by weight, 0.05% to 0.20% of strontium by weight, and the balance aluminum, the composition of iron can be adjusted to 0.01% to 0.7% of iron by weight, or 0.01% to 0.2% of iron by weight, the composition of manganese can be adjusted to 0.01% to 0.5% of manganese by weight, the composition of strontium can be adjusted to 0.05% to 0.1% of strontium by weight, the alloy has an elongation rate of at least 2%, an average ultimate tensile strength higher than 250 MPa and a yield strength higher than 200 MPa, and a microstructure has primary silicon with a volume content of greater than 10% and metamorphic eutectic aluminum-silicon with a volume content of 45% to 90%.

Description

[0001] Cross References to Related Applications [0002] This application is a continuation-in-part of U.S. Patent Application No. 14 / 791,646, filed July 6, 2015, which is a continuation-in-part of U.S. Patent Application No. 14 / 791,646, filed March 14, 2013 Continuation Application No. 13 / 828,765, which is hereby incorporated by reference in its entirety. [0003] Statement Regarding Federally Funded Research and Development Areas [0004] Not applicable. [0005] Cited References Submitted on CD-ROM [0006] Not applicable. Background technique [0007] The eutectic structure of aluminum silicon alloys has long been studied to determine the mechanical properties of the alloy, see US Patent Nos. 1,387,900 and 1,410,461. After studying this eutectic structure for more than 80 years, those skilled in the art now understand that the addition of sodium or strontium to the eutectic melt at a concentration of as little as 100 ppm changes the size and morphology of the eutectic ...

Claims

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Application Information

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IPC IPC(8): C22C21/02
CPCC22C21/02B22D17/00B22D21/007
Inventor 雷蒙德·J·多纳休凯文·R·安德森特伦斯·M·克利亚历山大·K·门罗
Owner BRUNSWICK CORPORATION
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