A new energy vehicle heat pump high-strength AlNi3Fe aluminum alloy and a production process thereof

Abstract

This invention discloses a high-strength AlNi3Fe aluminum alloy for heat pumps in new energy vehicles and its production process, relating to the field of aluminum alloy technology. The alloy is composed of the following components by mass percentage: nickel: 2.9–3.1%, iron: 0.9–1.1%, silicon: ≤0.08%, copper: ≤0.03%, magnesium: ≤0.03%, manganese: 0.9–1.1%, with the remainder being aluminum and unavoidable impurities. The above components are melted and mixed to form alloy ingots or alloy plates, which are then used to manufacture corresponding heat pump components. The reduction of magnesium content minimizes its detrimental effects on the alloy's toughness and thermal stability; the adjustment of silicon content improves the alloy's casting and machinability; the addition of nickel provides high corrosion resistance and wear resistance; and the addition of manganese increases the alloy's strength. The alloy ingots produced exhibit excellent casting performance, mechanical properties, physical properties, corrosion resistance, and machinability. The production process is simple, concise, and efficient, facilitating mass production.

Description

Technical Field

[0001] This invention relates to the field of aluminum alloy technology, and more specifically, to a high-strength AlNi3Fe aluminum alloy for heat pumps in new energy vehicles and its production process. Background Technology

[0002] Aluminum alloys are a widely used alloy material in industry. Aluminum, through combination with other elements, gives rise to a variety of aluminum alloy materials, such as aluminum-silicon alloys, aluminum-magnesium alloys, and aluminum-zinc alloys. Due to their excellent performance, aluminum alloys have achieved significant development in various industries and now play an important role in aerospace, construction, and automobiles.

[0003] In the automotive industry, aluminum alloys are widely used, from car bumpers and bodies to engines. Various types of aluminum alloys are required. In the production of automotive heat pumps, aluminum alloy engines have been developed, which have the advantages of being lightweight and reducing fuel consumption. As a core component of new energy vehicles, conventional aluminum alloys cannot meet the requirements for automotive heat pumps. Therefore, a high-performance alloy material for manufacturing automotive heat pumps is proposed. Summary of the Invention

[0004] To address the shortcomings of existing technologies, the present invention aims to provide a high-strength AlNi3Fe aluminum alloy for heat pumps in new energy vehicles and its production process. The invention proposes a high-strength alloy with good mechanical properties, including high strength, light weight, and good heat resistance. Castings made from the high-strength alloy exhibit high structural strength and long service life.

[0005] The above-mentioned technical objective of the present invention is achieved through the following technical solution: a high-strength AlNi3Fe aluminum alloy for heat pumps in new energy vehicles, the alloy being composed of the following components by mass percentage: nickel: 2.9-3.1%, iron: 0.9-1.1%, silicon: ≤0.08%, copper: ≤0.03%, magnesium: ≤0.03%, manganese: 0.9-1.1%, with the remainder being aluminum and unavoidable impurities. The above components are melted and mixed to form alloy ingots or alloy plates, and the alloy ingots are used to manufacture corresponding heat pump components.

[0006] A high-strength AlNi3Fe aluminum alloy production process includes the following steps:

[0007] Step 1: Material smelting. First, nickel, iron, silicon, copper, magnesium, manganese, and aluminum are added to a metal furnace according to their mass percentages for smelting. The temperature inside the metal furnace is adjusted to melt and initially mix the above components to obtain the first metal solution.

[0008] Step 2: Homogenization. The first metal solution is stirred by ultrasonic or electromagnetic waves to achieve homogeneous mixing and obtain the second metal solution.

[0009] Step 3: Casting and shaping. The second molten metal is fed into the vacuum casting machine, and the alloy ingot is obtained by vacuum casting through the vacuum casting machine.

[0010] Step 4: Workpiece fabrication. The obtained alloy ingots are then used to manufacture high-performance automotive engine parts.

[0011] The present invention is further configured as follows: In step one, aluminum is first added to a metal furnace, the temperature of the metal furnace is raised to 800-1000℃, so that the aluminum is melted into aluminum molten metal, and then nickel, iron, silicon, copper, magnesium and manganese are added to the aluminum molten metal, and the temperature inside the metal furnace is raised to 1800-2500℃, and after melting, an aluminum alloy solution that constitutes the first metal solution is obtained.

[0012] The present invention is further configured such that: in step two, the temperature inside the metal furnace is adjusted to 760-780℃, and after standing for 10-30 minutes, the first molten metal is stirred by ultrasonic waves or electromagnetic waves to form a fully mixed second molten metal solution, wherein the frequency of the ultrasonic waves is 35kHz-80kHz.

[0013] The present invention is further configured such that: in step three, the vacuum casting device is connected to the metal furnace, and the second molten metal in the metal furnace can be directly input into the vacuum casting device. The vacuum casting device includes a base and a body installed on the base. The bottom of the base has a base plate with an extension section. The metal furnace is set on the extension section and has a feed port. The base is equipped with a PLC controller for controlling the vacuum casting device and the metal furnace.

[0014] The invention is further configured such that: the body includes an outer shell and a vacuum chamber, the vacuum chamber is located inside the outer shell, the outer shell is provided with multiple pipes communicating with the vacuum chamber, the outer shell is provided with a sealing door, one end of the sealing door is hinged to the outer shell, and the outer shell is also provided with a locking member for locking the sealing door, the locking member is hinged to the outer shell, the locking member is provided with a handwheel, and the sealing door is provided with an observation window.

[0015] The invention is further configured such that: on the surfaces of the outer shell and the sealing door opposite each other, sealing elements are respectively provided. The sealing elements are a receiving element provided on the outer shell and a plug-in element provided on the sealing door. The receiving element is annular and has a receiving groove. The receiving element is made of high-temperature resistant silicone rubber with a Shore hardness of 28-35. The plug-in element is T-shaped with its protruding part facing the receiving groove. The plug-in element is adhered to the sealing door and is made of high-temperature resistant silicone rubber with a Shore hardness of 28-35. During use, it moves synchronously with the sealing door and is then inserted into the receiving groove.

[0016] The invention is further configured such that: the pipeline includes a feed pipe, a discharge pipe, an air inlet pipe, and an air outlet pipe; the feed pipe and the discharge pipe are disposed opposite each other on both sides of the outer shell; the feed pipe is connected to a metal furnace; the discharge pipe is used to deliver alloy ingots; the air inlet pipe and the air outlet pipe are both disposed on the top of the outer shell; the air inlet pipe is used to inject inert gas into the vacuum chamber; the air outlet pipe is used to evacuate the vacuum chamber; a pressure sensor is also provided on the shell on one side of the air inlet pipe; at least a portion of the pressure sensor extends into the vacuum chamber.

[0017] In summary, the present invention has the following beneficial effects: reducing the magnesium content reduces its harmful effects on the alloy's toughness and thermal stability; adjusting the silicon content improves the alloy's casting and machinability; adding nickel gives the alloy high corrosion resistance and wear resistance; adding manganese increases the alloy's strength; the alloy ingots produced using the above methods have excellent casting performance, mechanical properties, physical properties, corrosion resistance, and machinability; and the production process is simple, concise, and efficient, which is conducive to mass production. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the vacuum casting apparatus of the present invention;

[0019] Figure 2 This is a schematic diagram of the vacuum cavity structure of the present invention;

[0020] Figure 3 This is a process flow diagram of the present invention.

[0021] In the diagram: 1. Metal furnace; 2. Vacuum casting device; 3. Machine base; 31. Base plate; 4. Machine body; 5. Vacuum chamber; 51. Forming mold; 6. Outer shell; 7. Feed pipe; 8. Discharge pipe; 9. Air inlet pipe; 10. Air outlet pipe; 11. Sealing door; 12. Observation window; 13. Locking element; 14. Handwheel; 15. Sealing element. Detailed Implementation

[0022] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0023] This invention discloses a high-strength AlNi3Fe aluminum alloy for heat pumps in new energy vehicles. It possesses excellent casting and physical properties, making it suitable for casting heat pumps in new energy vehicles. The alloy comprises the following components by mass percentage: nickel: 2.9–3.1%, iron: 0.9–1.1%, silicon: ≤0.08%, copper: ≤0.03%, magnesium: ≤0.03%, manganese: 0.9–1.1%, with the remainder being aluminum and unavoidable impurities. These components are melted and mixed to form alloy ingots or plates, which are then used to manufacture corresponding heat pump components. Magnesium in the aluminum alloy reacts with aluminum and silicon to form a strengthening phase, providing solid solution strengthening. The components of this alloy have the same effect as magnesium, thus improving the strength of aluminum alloys. Copper, in addition to forming CuAl2 for age strengthening with aluminum, also has a good solid solution strengthening effect, thereby improving the strength of aluminum alloys. Manganese, in aluminum alloys, forms MnAl6 compounds with aluminum, which can effectively prevent grain growth during recrystallization, thus significantly refining the recrystallized grains. Nickel provides high polishability and corrosion resistance. Therefore, alloy ingots made with the above-mentioned component ratio have excellent casting performance, mechanical properties, physical properties, corrosion resistance, and machinability.

[0024] like Figure 3 As shown, according to an embodiment of this application, a high-strength AlNi3Fe aluminum alloy production process is also provided. This process can be used to prepare the aluminum alloy material described above, and includes the following steps:

[0025] Step 1: Material smelting. First, nickel, iron, silicon, copper, magnesium, manganese and aluminum are added to metal furnace 1 according to the mass percentage for smelting. The temperature inside metal furnace 1 is adjusted to melt and initially mix the above components to obtain the first metal solution.

[0026] Step 2: Homogenization. The first metal solution is stirred by ultrasonic or electromagnetic waves to achieve homogeneous mixing and obtain the second metal solution.

[0027] Step 3: Casting and shaping. The second molten metal is fed into the vacuum casting machine, and the alloy ingot is obtained by vacuum casting through the vacuum casting machine.

[0028] Step 4: Workpiece fabrication. The obtained alloy ingots are then used to manufacture high-performance automotive engine parts.

[0029] The metal furnace 1 is used to melt and mix the various raw materials. During preparation, aluminum is first added to the metal furnace 1, and the temperature of the metal furnace 1 is raised to 800-1000℃, preferably 900℃, to melt the aluminum into molten aluminum. Then, nickel, iron, silicon, copper, magnesium, and manganese are added to the molten aluminum, and the temperature inside the metal furnace 1 is raised to 1800-2500℃, which melts the metals with higher melting points. After melting, an aluminum alloy solution constituting the first molten metal is obtained. The temperature inside the metal furnace 1 is then lowered to 760-780℃, preferably 750℃, and allowed to stand for 10-30 minutes, with the temperature inside the metal furnace 1 being further reduced as the standing time increases. After at least 20 minutes, the temperature inside the metal furnace 1 will reach 700℃. The aluminum-silicon-magnesium-copper alloy solution is then agitated and stirred using ultrasonic technology at a frequency of 35kHz-80kHz to ensure uniform mixing of the components, resulting in a second metal solution for casting. This uniformly mixed second metal solution is then transported to a vacuum casting device 2, where it is cast into an alloy ingot. Finally, the alloy ingot is used to manufacture automobile engines or related engine parts. The alloy ingots produced in this way are lightweight, high-strength, and possess excellent mechanical properties and high-temperature resistance, which helps to improve the service life of automobile engines.

[0030] like Figure 1 As shown, the vacuum casting apparatus 2 provided by the present invention is used to form alloy ingots from a second metal solution. The vacuum casting apparatus 2 includes a base 3 and a body 4. The base 3 has a bottom plate 31, which is used to support the base 3 and the metal furnace 1. The lower end face of the bottom plate 31 is provided with multiple support feet. The base 3 is installed on one side of the upper end face of the bottom plate 31, and the metal furnace 1 is installed opposite to it on the other side of the upper end face of the bottom plate 31. The metal furnace 1 is connected to the vacuum casting apparatus 2. Electrical equipment, such as a PLC controller for controlling the vacuum casting apparatus 2 and the metal furnace 1, is installed inside the base 3.

[0031] Specifically, such as Figure 1 , Figure 2As shown, the machine body 4 is installed on the upper end of the base 3. The machine body 4 consists of an outer shell 6 and a vacuum chamber 5 enclosed inside the outer shell 6. The outer shell 6 is provided with multiple pipes, all of which are connected to the vacuum chamber 5. Specifically, the multiple pipes are a feed pipe 7, a discharge pipe 8, an air inlet pipe 9, and an air outlet pipe 10. The feed pipe 7 and the discharge pipe 8 are arranged opposite each other on both sides of the outer shell 6. The feed pipe 7 is connected to the metal melting furnace 1. The discharge pipe 8 is used to send out alloy ingots. The air inlet pipe 9 and the air outlet pipe 10 are both located on the top of the outer shell 6. The air inlet pipe 9 is used to inject inert gas into the vacuum chamber 5, and the air outlet pipe 10 is used to evacuate the vacuum chamber 5. A pressure sensor is also provided on the shell on one side of the air inlet pipe 9. At least part of the pressure sensor extends into the vacuum chamber 5. A forming mold 51 is also provided inside the vacuum chamber 5. The vacuum chamber 5 uses the forming mold 51 to form the second metal solution into alloy ingots by vacuum casting.

[0032] like Figure 1 , Figure 2 As shown, a sealing door 11 is provided at one end of the outer casing 6. One end of the sealing door 11 is hinged to one side of the outer casing 6. The sealing door 11 is semi-circular and has an observation window 12 for observing the situation inside the vacuum chamber 5 from the outside. A locking member 13 is provided on the other side of the outer casing 6. At least part of the locking member 13 is hinged to the outer casing 6. The locking member 13 is L-shaped, and the bent part of the locking member 13 is locked onto the sealing door 11. The locking member 13 also has... A handwheel 14 extends through the thickness of the sealing door 11. When the sealing door 11 is closed, tightening the handwheel 14 causes the rod extending through the handwheel 14 to press against the sealing door 11, thus reinforcing the seal between the sealing door 11 and the outer shell 6. Sealing elements 15 are respectively provided on the opposing surfaces of the sealing door 11 and the outer shell 6. Each sealing element 15 includes a connector on the sealing door 11 and a receiving element on the outer shell 6. Both the connector and the receiving element are made of high-temperature resistant silicone rubber with a Shore hardness of 28-35. The receiving element is annular and is bonded to the outer shell 6 with high-temperature adhesive or secured with bolts. After installation, the receiving element has a recessed receiving groove on its side facing the sealing door 11. The connector is fixed to the side of the sealing door 11 facing the outer shell 6 with high-temperature adhesive or bolts. The connector is annular and has a "T"-shaped cross-section. After installation, the protruding part of the connector faces the receiving groove. In use, the connector moves synchronously with the sealing door 11. When it is necessary to seal the vacuum chamber 5... When sealing, the sealing door 11 closes, the connector is inserted into the receiving part, specifically the protruding part of the connector is inserted into the receiving groove, then the locking part 13 is rotated to the front of the sealing door 11, and the locking part 13 is fastened to one side edge of the sealing door 11 and part of the outer shell 6. Finally, the handwheel 14 is tightened, and the rod of the handwheel 14 is pressed tightly on the sealing door 11, so that the sealing door 11 and the outer shell 6 are sealed. When the sealing door 11 is open, the handwheel 14 is rotated in the opposite direction, so that the rod of the handwheel 14 is disengaged from the sealing door 11.

[0033] In summary, this invention reduces the harmful effects of magnesium on the toughness and thermal stability of the alloy by lowering its content; it improves the casting and machinability of the alloy by adjusting the silicon content; it increases the strength and toughness of the alloy by using strontium modification to give it higher density; and it enhances the strength and high-temperature resistance of the alloy by adding titanium. The alloy ingots produced using the above methods have excellent casting performance, mechanical properties, physical properties, corrosion resistance, and machinability. The production process is simple, concise, and efficient, which is conducive to mass production.

[0034] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A production process for high-strength AlNi3Fe aluminum alloy for heat pumps in new energy vehicles, characterized in that: The alloy is composed of the following components by mass percentage: nickel: 2.9-3.1%, iron: 0.9-1.1%, silicon: ≤0.08%, copper: ≤0.03%, magnesium: ≤0.03%, manganese: 0.9-1.1%, with the remainder being aluminum and unavoidable impurities. The above components are melted and mixed to form alloy ingots or alloy plates, and the alloy ingots are used to make corresponding heat pump components. The production process includes the following steps: Step 1: Material smelting. First, nickel, iron, silicon, copper, magnesium, manganese and aluminum are added to the metal furnace (1) according to the mass percentage for smelting. The temperature inside the metal furnace (1) is adjusted to melt the components and mix them initially to obtain the first metal solution. Step 2: Homogenization. The first metal solution is stirred by ultrasonic or electromagnetic waves to achieve homogeneous mixing and obtain the second metal solution. Step 3: Casting and shaping. The second molten metal is fed into the vacuum casting machine, and the alloy ingot is obtained by vacuum casting through the vacuum suction of the vacuum casting machine. Step 4: Workpiece fabrication. The obtained alloy ingots are then used to manufacture high-performance automotive engine parts. In step one, aluminum is first added to a metal furnace (1), and the temperature of the metal furnace (1) is raised to 800-1000℃ to melt the aluminum into a liquid aluminum metal. Then, nickel, iron, silicon, copper, magnesium and manganese are added to the liquid aluminum metal, and the temperature inside the metal furnace (1) is raised to 1800-2500℃. After melting, an aluminum alloy solution that makes up the first metal solution is obtained. In step two, the temperature inside the metal furnace (1) is adjusted to 760-780℃, and after standing for 10-30 minutes, the first metal liquid is stirred by ultrasonic waves or electromagnetic waves to form a fully mixed second metal solution. The frequency of the ultrasonic waves is 35kHz-80kHz.

2. The production process of a high-strength AlNi3Fe aluminum alloy for heat pumps in new energy vehicles as described in claim 1, characterized in that: In step three, the vacuum casting device (2) is connected to the metal furnace (1). The second molten metal in the metal furnace (1) can be directly input into the vacuum casting device (2). The vacuum casting device (2) includes a base (3) and a body (4) installed on the base (3). The base (3) has a bottom plate (31) at the bottom. The bottom plate (31) has an extension section. The metal furnace (1) is set on the extension section. The metal furnace (1) has a feed port. The base (3) is equipped with a PLC controller. The PLC controller is used to control the vacuum casting device (2) and the metal furnace (1).

3. The production process of a high-strength AlNi3Fe aluminum alloy for heat pumps in new energy vehicles as described in claim 2, characterized in that: The body (4) includes an outer shell (6) and a vacuum chamber (5). The vacuum chamber (5) is located inside the outer shell (6). The outer shell (6) is provided with multiple pipes communicating with the vacuum chamber (5). The outer shell (6) is provided with a sealing door (11). One end of the sealing door (11) is hinged to the outer shell (6). The outer shell (6) is also provided with a locking member (13) for locking the sealing door (11). The locking member (13) is hinged to the outer shell (6). The locking member (13) is provided with a handwheel (14). The sealing door (11) is provided with an observation window (12).

4. The production process of a high-strength AlNi3Fe aluminum alloy for heat pumps in new energy vehicles as described in claim 3, characterized in that: On the surfaces of the outer shell (6) and the sealing door (11) respectively, there are sealing elements (15). The sealing elements (15) are a receiving element provided on the outer shell (6) and a plug-in element provided on the sealing door (11). The receiving element is annular and has a receiving groove. The receiving element is made of high temperature resistant silicone rubber with a Shore hardness of 28-35. The plug-in element is T-shaped with its protruding part facing the receiving groove. The plug-in element is adhered to the sealing door (11). The plug-in element is made of high temperature resistant silicone rubber with a Shore hardness of 28-35. When in use, it moves synchronously with the sealing door (11) and is then inserted into the receiving groove.

5. The production process of a high-strength AlNi3Fe aluminum alloy for heat pumps in new energy vehicles as described in claim 3, characterized in that: The pipeline includes a feed pipe (7), a discharge pipe (8), an air inlet pipe (9), and an air outlet pipe (10). The feed pipe (7) and the discharge pipe (8) are arranged opposite each other on both sides of the outer shell (6). The feed pipe (7) is connected to the metal furnace (1). The discharge pipe (8) is used to send out alloy ingots. The air inlet pipe (9) and the air outlet pipe (10) are both arranged on the top of the outer shell (6). The air inlet pipe (9) is used to inject inert gas into the vacuum chamber (5). The air outlet pipe (10) is used to evacuate the vacuum chamber (5). A pressure sensor is also provided on the shell on one side of the air inlet pipe (9). At least part of the pressure sensor extends into the vacuum chamber (5).

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