Al-Si系合金の引け形態変化

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Shinkage Morphology in Al-Si System Casting Alloys Yoji Awano, Kazufumi Morimoto, Yoshihiro Shimizu, Hiroyuki Takamiya Abstract For making sound aluminum castings it is an important problem to clarify the shrinkage morphology of various raw ingots The aim of this study is to clarify the main factors affecting the shrinkage morphology of Al Si system casting alloys by examining their shrinkage behavior Examination of the shrinkage cavities in the cylindrical castings for secondary diecasting alloy ingots showed that the soluble gas in the melt as well as the alloying elements remarkably affected the change in shrinkage morphology By using the method newly developed for evaluating the shrinkage morphology of hypoeutictic alloys quantitatively the effects of silicon content and gas amount were investigated It was clarlfied that the total amount of three kinds of shrinkages that is porosity interior and exterior shrinkages was constant in the alloys with the same composition although each kind of shrinkage was affected by the gas in the melt It was also confirmed that the relations among the three kinds of shrinkages were varied with the silicon content Furthermore the change in the ratio of the shrinkages with the amount of gas was found to be dependent on the pore formation Al-Si,,,,, R&D Vol. 27 No. 1 ( 1992. 3 )

52 ターモールドなどにより合金元素２ ５ 不純物元素５ ６ 1 まえがき や微量元素７ の影響が研究されてきたが 再生地金に 凝固時に引け巣がどのような形状に発生するかを知 ついての研究は少ない６ ガス量については ポロシ ８ ９ １０ や 気泡生成挙動 は明らかに ることは 鋳造方案を決定する上でも 耐圧性に優れ ティ量に及ぼす影響 た鋳物を作るのにも 大変重要である その一つとし されているが 引け形態変化との関係を調べた研究は て 最近は凝固シミュレーションにより 引け巣の発 比較的少なく１１ 規格化もされていない また 引け 生位置を予測して健全な鋳物を得る方案を作成する試 性についての研究は それぞれ引け試験の方案 評価 方法が異なり 大半が定性的な把握に止まっている １ みが盛んに行われている 一方 アルミニウム合金鋳物製造においては オイ そこで本研究では 引け性の明確化を目的として ルショックによりアルミニウム製錬が壊滅したことに Al-Si系合金の引け形態変化の主要 因を明らかにする 伴い 原料の大半を再生地金に依存せざるを得なくな とともに 定量性の高い引け試験法を考案して 引け った ところが 再生地金を主体にした多種多様の原 形態に及ぼすけい素量 ガス量の影響を明らかにし 材料から作られているアルミニウム合金鋳物において さらには気泡生成と引けの発生割合 生成挙動との関 は 溶湯の化学成分は規格を満たしており通常となん 連を明らかにしようとした ら違いがなく 同一方案で同じように鋳込みを行った にもかかわらず 引け欠陥による不良が多発すること 2 引け形態変化の主要因 がある また 引け欠陥による慢性的不良も大きな問 Fig. 1は Table 1に示すメーカー 溶解ロットの異 題であり その低減にも試行錯誤で対処せざるを得な なる十銘柄A Jの再生地金D12S を1023Ｋで溶解して い場合が多い 何も溶湯処理を施さずにFig. 2に示す円柱状の砂型に 鋳造用アルミニウム合金の引け性については テー Fig. 1 973Ｋで鋳込んで得たADC12合金鋳物の断面のマクロ Shape of shrinkage cavities in JIS ADC12 alloy castings made from secondary alloy ingots without molten metal treatment. 豊田中央研究所 R&D レビュー Vol. 27 No. 1 ( 1992. 3 )

Chemical composition of JIS D12S secondary alloy ingots (mass%). Schematic view of cylindrical (a) and conical shell mold (b) for testing shrinkage behavior. 570s JISD12S ( ) JIS 2 ( NaCl+25%AlF 3 ) 0.3% Fig. 1 D12S JIS 9 12%D 12S 2% 3% 2% 3% 2% 9 12% Fig. 1ADC12 R&D Vol. 27 No. 1 ( 1992. 3 )

Shape of shrinkage cavities in Al-9 12%Si-2%Cu alloy castings made from virgin alloy ingots without molten metal treatment. Shape of shrinkage cavities in JIS ADC12 alloy castings made from secondary alloy ingots after vacuum-degassed treatment. ρ ρ R&D Vol. 27 No. 1 ( 1992. 3 )

ρ ρ Al-Si JIS 2 1023K973K 6.7 Classification of shrinkage in conical casting. 13.3Pa0.2% 1 10-3 kg 0.1kg ( ) ( ) 1 Al-4%Si 1 0.7 10-5 m 3 /kg Al-7%Si Al-4%Si Effect of silicon content on the amount of shrinkage in conical castings for Al-Si alloys. Relations between interior or/and exterior shrinkage, surface sink and porosity in conical castings for Al- 4%Si alloy. R&D Vol. 27 No. 1 ( 1992. 3 )

Al-10%Si Al-4%Si Al-7%Si Al- 10%Si Al-7%Si Al-10%Si Al-4%Si Al-7%Si Al-10%Si Al-4%Si Al-7%Si Al-4%Si Al-7%Si Al-4%Si ( ) Fig. 7 Relations between interior or/and exterior shrinkage and porosity in conical castings for Al-10%Si alloy. Relations between porosity and gas content of conical castings for Al- 7% Si and Al-10%Si alloys. R&D Vol. 27 No. 1 ( 1992. 3 )

57 外引け量から面引け量を減じた値を示す鎖線とで挟ま ス含有処理した鋳物では 深さは変わらないが細くな れた量であり 低ポロシティ域ではポロシティの増加 っている とともに減少し 高ポロシティ域ではポロシティ量が Al-10%Si合金の真空脱ガス処理をした鋳物では 内 上昇してもほとんど変化していない このことは Al 引け直下にざく巣が生成している 無処理の鋳物では -4%Si合金やAl-7%Si合金では 凝固殻の形成にポロ 真空脱ガス処理の場合に比べて 内引けの深さは浅く シティの生成が関与していることを示唆している て ポロシティが多い ガス含有処理をした場合には 純アルミニウムでは いずれの鋳物においても柱状 晶がよく発達している 内引けの大きさは 真空脱ガ ス処理と無処理とではほとんど差がない しかし ガ ポロシティはさらに多く 内引けはわずかしか生じて いない 純アルミニウムとAl-10%Si合金の場合は 面引けは Fig. 10 Macrostructures of longitudinal sections of conical castings for Al-Si alloys. ( ): porosity, 10-5m3/kg 豊田中央研究所 R&D レビュー Vol. 27 No. 1 ( 1992. 3 )

Relations between exterior shrinkage and surface sink in conical castings for Al-4%Si and Al-7%Si alloys. Al-10%Si Al-4 %Si Al-7%Si Cooling curve and change in depth of interior shrinkage for JIS AC4C alloy. Al-7%Si AC4C Al-Si Fig. 12 Al-4%Si Al-7%Si R&D Vol. 27 No. 1 ( 1992. 3 )

Al-7% Si Al-4%Si Al-4%Si Al-7% Si Fig. 13 Al-7%Si 54s 50s Al-4%Si 1023 Table 1 D12S ( ADC12 ) K, L, N Effect of silicon content on the ending time of interior shrinkage formation in the conical castings made after vacuumdegassed(a) and gas-enriched treatment(b) for Al-Si alloys. Change in bottom surface shape of each conical casting obtained by taking off a part of the mold bottom during solidification for Al-7%Si alloy. (a): [48s], just before the end of interior shrinkage (b): [55s], just after the end of interior shrinkage [ ]: time from the start of solidification R&D Vol. 27 No. 1 ( 1992. 3 )

Relations between interior or/and exterior shrinkage and porosity in conical castings for JIS D12S secondary alloy ingot N. Effect of quenching temperature on the density for Al-4%Si alloy. (1): ending temperature of primary crystal solidification (2): starting temperature of primary crystal solidification (3): pouring into the parmanent mold (4): quenching into water N 1023K 943K N 1 Al-10%Si Al-11%Si-3%Cu 1.8 10-5 m 3 kg Al-4%Si Al-7%Si Al-10%Si Al-12%Si Al-12%Si Al-12%Si Al-7%Si Al-10%Si 100s Al-7%Si 10% 3 4 R&D Vol. 27 No. 1 ( 1992. 3 )

Relations between gas content and porosity in conical castings for Al- 11%Si-3%Cu virgin alloy and JIS D12S secondary alloy ingots. Distribution of porosity in conical castings for Al-7%Si alloy. Al-10%Si α Al Al-Si α Al Al-Si Microstructures in the conical casting made after gas-enriching for Al-10%Si alloy. Al-10%Si α-al Si P g P s 2γ /r P a P h P g P s g rp a P h P a Al-10%Si 0.5 10-5 m 3 /kg 1.5 10-5 m 3 /kg 0.5 10-5 m 3 /kg R&D Vol. 27 No. 1 ( 1992. 3 )

1) (1981) 674 2) (1964), 670 3) (1966), 293 4) (1975), 345 5) Arbenz H. Giesserei, (1962), 105 6) Berezyanskaya, N. B., Sov. Non-Ferr. Met. Res., (1983), 59 7) (1964) 27 8) Gruzleski, J. E., et al. Br. Foundryman, (1978), 69 9) 41, (1981), 65p. 10) (1983) 508 11) Tiwari, S. N., et al. Br. Foundryman, (1986), 129 1941 1988 1990, Best Technical Paper (56th World Foundry Congress 1989) 1946 1955 1988 1990, Best Technical Paper (56th World Foundry Congress 1989) 1991 1991 1962 R&D Vol. 27 No. 1 ( 1992. 3 )

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