Aluminum alloy compositions and methods of making and using the same

Patent metadata

Field	Value
Publication number	US-11242587-B2
Application number	US-201715594434-A
Country	US
Kind code	B2
Filing date	May 12, 2017
Priority date	May 12, 2017
Publication date	Feb 8, 2022
Grant date	Feb 8, 2022

Abstract

The present disclosure concerns embodiments of aluminum alloy compositions exhibiting superior microstructural stability and strength at high temperatures. The disclosed aluminum alloy compositions comprise particular combinations of components that contribute the ability of the alloys to exhibit improved microstructural stability and hot tearing resistance as compared to conventional alloys. Also disclosed herein are embodiments of methods of making and using the alloys.

First claim

We claim:

1. An aluminum alloy, comprising:
>8 wt % to 15 wt % copper;
0.05 wt % to 0.3 wt % zirconium;
0.2 wt % to 0.5 wt % manganese;
0 wt % to 0.2 wt % titanium;
0 wt % to 0.1 wt % silicon;
0 wt % to 0.1 wt % iron;
0 wt % to 0.01 wt % magnesium;
0 wt % vanadium; and
aluminum,
wherein the alloy exhibits an average hot tearing value ranging from 0.5 to 2.

2. The aluminum alloy of claim 1 , wherein the alloy comprises 0 wt % to less than 0.05 wt % titanium.

3. The aluminum alloy of claim 1 , further comprising a grain refiner comprising (i) titanium, boron, aluminum, or a combination thereof, or (ii) titanium and carbon, wherein the grain refiner provides 0.02 wt % to 0.2 wt % titanium to the alloy.

4. The aluminum alloy of claim 3 , wherein the alloy further comprises:
(i) boron in an amount of from 0.15×the amount of titanium present to 0.4×the amount of titanium present; or
(ii) carbon in an amount of from 0.2×the amount of titanium present to 0.3×the amount of titanium present.

5. The aluminum alloy of claim 1 , further comprising nickel, cobalt, antimony, or a combination thereof.

6. The aluminum alloy of claim 5 , wherein:
the nickel is present in an amount ranging from greater than 0 wt % to 0.01 wt %; or
the cobalt is present in an amount ranging from greater than 0 wt % to 0.1 wt %; or
the antimony is present in an amount ranging from greater than 0 wt % to 0.1 wt %; or
any combination thereof.

7. The aluminum alloy of claim 1 , wherein:
the manganese is present in an amount greater than 3 times the amount of silicon.

8. The aluminum alloy of claim 1 , wherein the alloy comprises:
>8 wt % to 15 wt % copper;
0.4 wt % to 0.5 wt % manganese;
0.15 wt % to 0.25 wt % zirconium;
greater than 0.05 wt % and up to 0.2 wt % titanium; and
aluminum.

9. The aluminum alloy of claim 1 , wherein the alloy comprises strengthening precipitates having an aspect ratio≥20.

10. A component made with the aluminum alloy of claim 1 .

11. An aluminum alloy, consisting essentially of:
8 wt % to 15 wt % copper;
0.15 wt % to 0.25 wt % zirconium;
0.4 wt % to 0.5 wt % manganese;
0 wt % to 0.1 wt % silicon;
0.02 to 0.2 wt % titanium;
0 wt % to 0.1 wt % iron;
0 wt % to 0.01 wt % nickel;
0 wt % to 0.01 wt % magnesium;
0 wt % to 0.1 wt % cobalt;
0 wt % to 0.1 wt % antimony;
0 wt % vanadium;
0.004 wt % to 0.067 wt % boron; and
aluminum,
wherein the alloy exhibits an average hot tearing value ranging from 0.5 to 2.5.

12. A component made with the aluminum alloy of claim 11 .

13. The aluminum alloy of claim 4 , consisting essentially of:
>8 wt % to 15 wt % copper;
0.05 wt % to 0.3 wt % zirconium;
0.2 wt % to 0.5 wt % manganese;
0 wt % to 0.1 wt % iron;
0 wt % to 0.1 wt % silicon;
0 wt % to 0.01 wt % magnesium;
0 wt % vanadium;
0.02 wt % to 0.2 wt % titanium provided by the grain refiner;
boron in an amount of from 0.15×the amount of titanium present to 0.4×the amount of titanium present, or carbon in an amount of from 0.2×the amount of titanium present to 0.3×the amount of titanium present; and
aluminum.

14. A method for making an aluminum alloy according to claim 1 , comprising:
combining >8 wt % to 15 wt % copper, 0.05 wt % to 0.3 wt % zirconium, 0.2 wt % to 0.5 wt % manganese, 0 wt % to 0.1 wt % silicon, 0 wt % to 0.1 wt % iron, 0 wt % to 0.01 wt % magnesium, 0 wt % vanadium, and aluminum to form a composition;
solution treating the composition at a temperature ranging from 525° C. to 550° C.; and
age treating the composition at a temperature ranging from 150° C. to 300° C. to provide the alloy.

15. The method of claim 14 , wherein:
age treating is performed at a temperature ranging from 150° C. to less than 210° C. to provide a low-temperature alloy; or
age treating is performed at a temperature ranging from 210° C. to 300° C. to provide a high-temperature alloy.

16. The method of claim 14 , further comprising:
adding a grain refiner comprising titanium to the composition to provide a mixture;
pouring the mixture into a pre-heated mold within 5 minutes of adding the grain refiner.

17. A method for making an aluminum alloy according to claim 11 , comprising:
combining 8 wt % to 15 wt % copper, 0.15 wt % to 0.25 wt % zirconium, 0.4 wt % to 0.5 wt % manganese, 0 wt % to 0.1 wt % silicon, 0 wt % to 0.045 wt % titanium, 0 wt % to 0.1 wt % iron, 0 wt % to 0.01 wt % nickel, 0 wt % to 0.01 wt % magnesium, 0 wt % to 0.1 wt % cobalt, 0 wt % to 0.1 wt % antimony, 0.004 wt % to 0.067 wt % boron, and aluminum to form a composition;
solution treating the composition at a temperature ranging from 525° C. to 550° C.;
age treating the composition at a temperature ranging from 150° C. to 300° C.; and
pouring the composition into a pre-heated mold.

Assignees

• Ut Battelle Llc
• Fca Us Llc
• Nemak Usa Inc

Inventors

• Shyam Amit
• Haynes James A
• Sabau Adrian S
• Shin Dongwon
• Yamamoto Yukinori
• Glaspie Christopher R
• Gonzalez-Villarreal Jose A
• Mirmiran Seyed
• Rodriguez-Jasso Andres F

Classifications

• C22C21/14

  with silicon · CPC title

• C22C1/06

  with the use of special agents for refining or deoxidising · CPC title

• C22C21/16

  with magnesium · CPC title

• B22D21/007

  with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C · CPC title

• C22F1/057 Primary

  of alloys with copper as the next major constituent · CPC title