MAGNESIUM ALLOY FOR LASER CLADDING

Description

[0001] The invention relates to a use of a magnesium alloy. Furthermore, the invention relates to a welding filler material for, in particular, wire-based laser cladding and a method for producing a, preferably metallic, component.

[0002] Magnesium alloys are well known. They are characterized by a good strength-to-density ratio. Furthermore, magnesium alloys are easy to machine.

[0003] DE 11 2007 002 016 T5 discloses a high-strength, non-combustible magnesium alloy. The alloy is prepared by adding at least one additional additive selected from carbon (C), molybdenum (Mo), niobium (Nb), silicon (Si), tungsten (W), aluminum oxide (Al 2 O 3 ), magnesium silicide (Mg 2 Si), and silicon carbide (SiC) to a non-combustible magnesium alloy, and by adding 0.5 to 5.0 mass % of calcium.

[0004] Furthermore, EP 1 400 605 B1 describes a wire made of a magnesium alloy and a manufacturing method therefor.

[0005] EP 1 418 248 A1 also discloses a heat-resistant magnesium alloy with 1 to 6 wt.% aluminum (Al), 0.5 to 3 wt.% calcium (Ca) and 0.2 to 1 wt.% manganese (Mn).

[0006] In addition, the article by HM Fu, et al., "Grain refinement by AIN Particles in Mg-Al based alloys", Journal of Alloys and Compounds 478 (2009), pages 809 to 812, describes the grain refinement of magnesium-aluminum alloys by the addition of aluminum nitride (AIN).

[0007] An object of the invention is to provide a magnesium alloy which is non-flammable or only flame-resistant, wherein in particular the magnesium alloy is to be suitable, for example, for use in laser deposition welding and the production of components in laser deposition welding is to be improved.

[0008] This object is achieved by a welding filler material for, in particular, wire-based, laser cladding, wherein the welding filler material is made of a magnesium alloy, wherein the magnesium alloy consists of the following components based on the total weight of the alloy: 3.0 wt% to 9.0 wt% aluminum (Al), 0.2 wt% to 2.0 wt% calcium (Ca), 0.1 wt% to 0.8 wt% manganese (Mn), 0.2 wt% to 2.0 wt% aluminum nitride (AlN), and magnesium and unavoidable impurities, especially those caused by manufacturing, as the remainder.

[0009] The advantage of the magnesium alloy according to the invention is, among other things, that the addition or alloying of calcium (Ca) to the raw magnesium alloy significantly reduces or prevents the alloy's flammability. Furthermore, the additional addition of aluminum nitride (AIN), preferably in the form of nanoparticles, achieves significant grain refinement in the produced alloy. A particular advantage of aluminum nitride or the aluminum nitride nanoparticles in the magnesium alloy is that the grain refinement of the alloy persists or is present even after remelting and resolidification of the alloy.

[0010] The inventive combination of the components of the magnesium alloy or the alloying of the components results in the flammability of the magnesium alloy according to the invention being reduced and, in addition, grain refinement being achieved. Due to these properties of the magnesium alloy, it is particularly suitable for use as a welding material or as a laser welding wire for laser cladding, since the magnesium alloy does not ignite when the magnesium alloy is melted as a welding filler material by a high-energy laser beam from a laser cladding device. Furthermore, during or after the application of the welding material to a component, in particular a metallic component, the mechanical properties of a component provided with a surface coated with the magnesium alloy are improved.

[0011] As components, for example, metallic components are provided with a magnesium alloy structure on their surface by means of laser deposition welding. In one embodiment, the structures can be formed either flatly or in a three-dimensional form on the surface by melting the magnesium alloy. In a further development, the components can be, among other things, preferably metallic components or semi-finished products from the fields of mechanical engineering, automobiles, engines, ships, and / or aircraft. Other, preferably metallic, components provided with the magnesium alloy from other fields and industries are also possible within the scope of the invention.

[0012] According to the state of the art, magnesium alloys are rarely or never used for laser cladding processes because of their high fire hazard. This fire hazard during laser cladding is avoided by the alloy according to the invention. The mechanical properties of the component are significantly improved by the fine grain of the welding material made of or manufactured from the magnesium alloy, thereby increasing the application possibilities for magnesium materials in laser cladding.

[0013] Preferably, in the magnesium alloy, the lower limit of the proportion of aluminum (Al) in wt.% is selected from the group of the following values {3.0; 3.1; 3.2; 3.3; 3.4; 3.5; 3.6; 3.7; 3.8; 3.9; 4.0; 4.1; 4.2; 4.3; 4.4; 4.5; 4.6; 4.7; 4.8; 4.9; 5.0; 5.1; 5.2; 5.3; 5.4; 5.5; 5.6; 5.7; 5.8; 5.9; 6.0; 6.1; 6.2; 6.3; 6.4; 6.5; 6.6; 6.7; 6.8; 6.9; 7.0; 7.1; 7.2; 7.3; 7.4; 7.5; 7.6; 7.7; 7.8; 7.9; 8.0; 8.1; 8.2; 8.3; 8.4; 8.5; 8.6; 8.7; 8.8; 8.9; 9.0} and the upper limit of aluminum (AI) of the proportion in wt.% is selected from the group of the following values {3.0; 3.1; 3.2; 3.3; 3.4; 3.5; 3.6; 3.7; 3.8; 3.9; 4.0; 4.1; 4.2; 4.3; 4.4; 4.5; 4.6; 4.7; 4.8; 4.9; 5.0; 5.1; 5.2; 5.3; 5.4; 5.5; 5.6; 5.7; 5.8; 5.9; 6.0; 6.1; 6.2; 6.3; 6.4; 6.5; 6.6; 6.7; 6.8; 6.9; 7.0; 7.1; 7.2; 7.3; 7.4; 7.5; 7.6; 7.7; 7.8; 7.9; 8.0; 8.1; 8.2; 8.3; 8.4; 8.5; 8.6; 8.7; 8.8; 8.9; 9.0}, where the lower limit of the aluminum (AI) content is less than the upper limit of the content or the lower limit of the content is equal to the upper limit of the content.

[0014] Preferably, in the magnesium alloy, the lower limit of the calcium (Ca) content in wt.% is selected from the group of the following values {0.2; 0.3; 0.4; 0.5; 0.6; 0.7; 0.8; 0.9; 1.0; 1.1; 1.2; 1.3; 1.4; 1.5; 1.6; 1.7; 1.8; 1.9; 2.0} and the upper limit of calcium (Ca) of the content in wt.% is selected from the group of the following values {0.2; 0.3; 0.4; 0.5; 0.6; 0.7; 0.8; 0.9; 1.0; 1.1; 1.2; 1.3; 1.4; 1.5; 1.6; 1.7; 1.8; 1.9; 2.0}, where the lower limit of the calcium (Ca) content does not exceed the upper limit of the content or the lower limit of the content is equal to the upper limit of the content.

[0015] Preferably, in the magnesium alloy, the lower limit of the proportion of manganese (Mn) in wt.% is selected from the group of the following values {0.1; 0.2; 0.3; 0.4; 0.5; 0.6; 0.7; 0.8} and the upper limit of manganese (Mn) of the proportion in wt.% is selected from the group of the following values {0.1; 0.2; 0.3; 0.4; 0.5; 0.6; 0.7; 0.8}, wherein the lower limit of the proportion of manganese (Mn) is less than the upper limit of the proportion or the lower limit of the proportion is equal to the upper limit of the proportion.

[0016] Preferably, in the magnesium alloy, the lower limit of the proportion of aluminum nitride (AIN) in wt.% is selected from the group of the following values {0.2; 0.3; 0.4; 0.5; 0.6; 0.7; 0.8; 0.9; 1.0; 1.1; 1.2; 1.3; 1.4; 1.5; 1.6; 1.7; 1.8; 1.9; 2.0} and the upper limit of aluminum nitride (AIN) of the proportion in wt.% is selected from the group of the following values {0.2; 0.3; 0.4; 0.5; 0.6; 0.7; 0.8; 0.9; 1.0; 1.1; 1.2; 1.3; 1.4; 1.5; 1.6; 1.7; 1.8; 1.9; 2.0}, where the lower limit of the proportion of aluminum nitride (Al) is less than the upper limit of the proportion or the lower limit of the proportion is equal to the upper limit of the proportion.

[0017] According to a further development of the welding filler, it is provided that aluminum nitride is present as nanoparticles with a particle size of 80 nm (nanometers) to 400 nm (nanometers), preferably from 80 nm to 250 nm, in, preferably maximum, diameter.

[0018] In laser cladding, the welding filler, which is designed as a laser welding wire, for example, is melted by means of the high-energy radiation of a laser in the area of a surface, in particular a metallic surface, of a component, whereby at the same time the surface of the component is also melted locally, whereby the molten welding material consisting of the magnesium alloy bonds with the metallic surface of the component at the molten point, whereby the magnesium alloy is applied to the surface of the component.

[0019] For this purpose, in one embodiment of the welding filler material, it is provided that the welding filler material is or will be formed as a wire with a diameter of 0.5 mm (millimeters) to 2.0 mm (millimeters) or as a strip with a diameter of 0.5 mm to 2.0 mm.

[0020] According to one aspect, the welding filler material is further characterized in that the welding filler material is produced according to an extrusion process. Within the scope of the invention, it is possible for the welding filler material to be extruded using an extrusion device, wherein the extrusion device is or is operated according to a direct or indirect or hydrostatic extrusion process.

[0021] In direct extrusion, for example, a punch presses a magnesium alloy block along the inner surface of a container towards a die. The indirect extrusion process is characterized by the container being closed on one side, while the die is pressed onto the magnesium alloy block from the other side of the container, which is located at the head of a hollow punch. During extrusion, the strand is forced through a punch bore. The hydrostatic extrusion process is realized in that the pressing force is not applied directly to the block by the punch, but via an active medium (oil).

[0022] A further solution to the problem is achieved by using a welding filler material for producing a welding filler material, in particular in the form of a wire or strip, for, in particular, wire-based, laser deposition welding, wherein the magnesium alloy consists of the following components based on the total weight of the alloy: 3.0 wt% to 9.0 wt% aluminum (Al), 0.2 wt% to 2.0 wt% calcium (Ca), 0.1 wt% to 0.8 wt% manganese (Mn), 0.2 wt% to 2.0 wt% aluminum nitride (AlN), and magnesium and unavoidable impurities, particularly those caused by manufacturing, as the remainder.

[0023] Preferably, aluminum nitride is present as nanoparticles with a particle size of 80 nm to 400 nm, preferably 80 nm to 250 nm, in, preferably maximum, diameter.

[0024] In a further development, it is provided that the welding filler material is or will be formed as a wire, in particular with a diameter of 0.5 mm to 2.0 mm, or as a strip, in particular with a diameter of 0.5 mm to 2.0 mm.

[0025] In particular, the welding consumable is or is produced by an extrusion process.

[0026] One embodiment of the use of the magnesium alloy is characterized in that the magnesium alloy is or is applied as a structure to a, preferably metallic, surface of a, preferably metallic, component, in particular by melting.

[0027] Furthermore, the object is achieved by a method for producing a, preferably metallic, component, wherein a structure made of a magnesium alloy, as described above, is applied to a, preferably metallic, surface of the component by means of, preferably wire-based, laser deposition welding using a laser deposition welding device, in particular by melting, wherein the magnesium alloy consists of the following components based on the total weight of the alloy: 3.0 wt% to 9.0 wt% aluminum (Al), 0.2 wt% to 2.0 wt% calcium (Ca), 0.1 wt% to 0.8 wt% manganese (Mn), 0.2 wt% to 2.0 wt% aluminum nitride (AlN), and magnesium and unavoidable impurities, especially those caused by manufacturing, as the remainder.

[0028] For this purpose, it is specifically provided that a welding filler material made of the magnesium alloy is applied to the surface of the component using the laser cladding device. The welding filler material is melted by a laser of the laser cladding device and applied to the component.

[0029] The welding filler material is preferably in the form of wire or strip.

Claims

1. A welding consumable for, in particular wire-based, laser deposition welding, wherein the welding consumable is produced from a magnesium alloy, wherein the magnesium alloy the magnesium alloy consists of the following constituent substances with regard to the total weight of the alloy: 3.0% by weight to 9.0% by weight of aluminum (Al), 0.2% by weight to 2.0% by weight of calcium (Ca), 0.1% by weight to 0.8% by weight of manganese (Mn), 0.2% by weight to 2.0% by weight of aluminum nitride (AIN), and magnesium and unavoidable, in particular production-related, contaminants as the rest.

2. The welding consumable according to claim 1, characterized in that aluminum nitride is present as nanoparticles with a particle size of 80 nm to 400 nm, preferably from 80 nm to 250 nm, in, preferably maximum, diameter.

3. The welding consumable according to claim 1 or 2, characterized in that the welding consumable is designed as a wire with a diameter of 0.5 mm to 2.0 mm or as a band with a diameter of 0.5 mm to 2.0 mm.

4. The welding consumable according to any of the claims 1 to 3, characterized in that the welding consumable is produced according to an extrusion method.

5. A use of a magnesium alloy for producing an, in particular wire-shaped or band-shaped, welding consumable for, in particular wire-based, laser deposition welding, wherein the magnesium alloy the magnesium alloy consists of the following constituent substances with regard to the total weight of the alloy: 3.0% by weight to 9.0% by weight of aluminum (Al), 0.2% by weight to 2.0% by weight of calcium (Ca), 0.1% by weight to 0.8% by weight of manganese (Mn), 0.2% by weight to 2.0% by weight of aluminum nitride (AIN), and magnesium and unavoidable, in particular production-related, contaminants as the rest.

6. The welding consumable according to claim 5, characterized in that aluminum nitride is present as nanoparticles with a particle size of 80 nm to 400 nm, preferably from 80 nm to 250 nm, in, preferably maximum, diameter7. The use according to claim 5 or 6, characterized in that the welding consumable is designed as a wire, in particular with a diameter of 0.5 mm to 2.0 mm, or as a band, in particular with a diameter of 0.5 mm to 2.0 mm.

8. The use according to any of the claims 5 to 7, characterized in that the welding consumable is produced according to an extrusion method.

9. The use according to any of the claims 5 to 8, characterized in that the magnesium alloy is applied as a structure to a, preferably metal, surface of a, preferably metal, component, in particular by fusing.

10. A method for producing a, preferably metal, component, wherein a structure made of a magnesium alloy is applied to a, preferably metal, surface of the component by means of, preferably wire-based, laser deposition welding using a laser deposition welding device, in particular by fusing, wherein the magnesium alloy the magnesium alloy consists of the following constituent substances with regard to the total weight of the alloy: 3.0% by weight to 9.0% by weight of aluminum (Al), 0.2% by weight to 2.0% by weight of calcium (Ca), 0.1% by weight to 0.8% by weight of manganese (Mn), 0.2% by weight to 2.0% by weight of aluminum nitride (AIN), and magnesium and unavoidable, in particular production-related, contaminants as the rest.

11. The method according to claim 10, characterized in that aluminum nitride is present as nanoparticles, in particular with a particle size of 80 nm to 400 nm, preferably from 80 nm to 250 nm, in, preferably maximum, diameter.

12. The method according to claim 10 or 11, characterized in that a welding consumable according to any of the claims 1 to 4 produced from the magnesium alloy is applied to the surface of the component by means of the laser deposition welding device.

13. The method according to any of the claims 10 to 12, characterized in that the welding consumable is designed as a wire or band.