Die casting aluminum alloy and production method thereof, and communications product

Abstract

Embodiments of the present invention provide a die casting aluminum alloy, including the following components in percentage by mass: 11.0% to 14.0% of silicon; 0.1% to 0.9% of manganese; 0.1% to 1.0% of magnesium; 0.3% to 1.4% of iron; less than or equal to 0.2% of copper; and aluminum and inevitable impurities. The die casting aluminum alloy has good formability, heat conductivity, and corrosion resistance, and certain mechanical properties, which can avoid problems of a low yield of die-casting fittings, burn-in caused by severe heat emission of a product, corrosion in a coastal environment, assembly difficulties caused by insufficient mechanical properties, severe deformation in a wind load condition, and the like, so as to satisfy requirements of global delivery of complex communications products.

Claims

1. A die casting aluminum alloy consisting of the following components in percentage by mass: 13.5% to 14.0% of silicon; 0.1% to 0.9% of manganese; 0.1% to 1.0% of magnesium; 0.3% to 1.4% of iron; and less than or equal to 0.2% of copper and greater than 0% copper, and a balance being aluminum and inevitable impurities.

2. The die casting aluminum alloy according to claim 1, wherein a mass percentage of copper is less than or equal to 0.15% and greater than 0%.

3. The die casting aluminum alloy according to claim 2, wherein the mass percentage of copper is less than or equal to 0.05% and greater than 0%.

4. The die casting aluminum alloy according to claim 3, wherein the mass percentage of copper is less than or equal to 0.01% and greater than 0%.

5. The die casting aluminum alloy according to claim 1, wherein a mass percentage of manganese is 0.3% to 0.7%.

6. The die casting aluminum alloy according to claim 5, wherein the mass percentage of manganese is 0.45%.

7. The die casting aluminum alloy according to claim 1, wherein a mass percentage of magnesium is 0.35% to 0.7%.

8. The die casting aluminum alloy according to claim 7, wherein the mass percentage of magnesium is 0.5%.

9. The die casting aluminum alloy according to claim 1, wherein a mass percentage of iron is 0.6% to 1.3%.

10. The die casting aluminum alloy according to claim 9, wherein the mass percentage of iron is 0.8%.

11. The die casting aluminum alloy according to claim 1, wherein phases in an organization structure of the die casting aluminum alloy comprise an -Al phase, an eutectic Si phase, and a second phase, and the second phase is distributed in a grain boundary location of the -Al phase.

12. The die casting aluminum alloy according to claim 11, wherein the second phase comprises an Al.sub.3Fe phase, a CuAl.sub.2 phase, an Mg.sub.2Si phase, an AlSiFeMn quaternary compound phase, and an AlSiFe ternary compound phase.

13. A production method of a die casting aluminum alloy, the method comprising the following: according to a component ratio of the die casting aluminum alloy, first adding a pure aluminum ingot to a smelting furnace, adding an aluminum silicon alloy, an aluminum copper alloy, an aluminum iron alloy, an aluminum manganese alloy, and an aluminum magnesium alloy for smelting after the aluminum ingot is smelted, and performing die-cast formation after refining and degassing processing, to obtain the die casting aluminum alloy, wherein the die casting aluminum alloy consists of the following components in percentage by mass: 13.5% to 14.0% of silicon; 0.1% to 0.9% of manganese; 0.1% to 1.0% of magnesium; 0.3% to 1.4% of iron; and less than or equal to 0.2% of copper and greater than 0% copper, and a balance being aluminum and inevitable impurities.

14. A communications product comprising a housing, and a power supply circuit and a functional circuit located in the housing, wherein the power supply circuit supplies power to the functional circuit, and the housing is obtained through die-casting by die casting an aluminum alloy, wherein the die cast aluminum alloy consists of the following components in percentage by mass: 13.5% to 14.0% of silicon; 0.1% to 0.9% of manganese; 0.1% to 1.0% of magnesium; 0.3% to 1.4% of iron; less than or equal to 0.2% of copper and greater than 0% of copper; and a balance being aluminum and inevitable impurities.

Description

DESCRIPTION OF EMBODIMENTS

(1) The following descriptions are exemplary implementation manners of the present invention. It should be noted that a person of ordinary skill in the art may make certain improvements and polishing without departing from the principle of the present invention and the improvements and polishing shall fall within the protection scope of the present invention.

(2) A first aspect of embodiments of the present invention provides a die casting aluminum alloy, which has good formability, heat-conducting property, and corrosion resistance, and certain mechanical properties, and is used to resolve a problem in the prior art that the die casting aluminum alloy cannot have good formability, heat-conducting property, corrosion resistance, and mechanical properties.

(3) According to the first aspect, an embodiment of the present invention provides a die casting aluminum alloy, including the following components in percentage by mass:

(4) 11.0% to 14.0% of silicon;

(5) 0.1% to 0.9% of manganese;

(6) 0.1% to 1.0% of magnesium;

(7) 0.3% to 1.4% of iron;

(8) less than or equal to 0.2% of copper; and aluminum and inevitable impurities.

(9) In an implementation manner of the present invention, a mass percentage of silicon is specifically 11.5% to 13.5%.

(10) In an exemplary implementation manner of the present invention, the mass percentage of silicon is specifically 13%.

(11) In an implementation manner of the present invention, a mass percentage of copper is specifically less than or equal to 0.15%.

(12) In an exemplary implementation manner of the present invention, the mass percentage of copper is specifically less than or equal to 0.05%.

(13) In an exemplary implementation manner of the present invention, the mass percentage of copper is specifically less than or equal to 0.01%.

(14) In an implementation manner of the present invention, a mass percentage of manganese is specifically 0.3% to 0.7%.

(15) In an exemplary implementation manner of the present invention, the mass percentage of manganese is specifically 0.45%.

(16) In an implementation manner of the present invention, a mass percentage of magnesium is specifically 0.35% to 0.7%.

(17) In an exemplary implementation manner of the present invention, the mass percentage of magnesium is specifically 0.5%.

(18) In an implementation manner of the present invention, a mass percentage of iron is specifically 0.6% to 1.3%.

(19) In an exemplary implementation manner of the present invention, the mass percentage of iron is specifically 0.8%.

(20) In an implementation manner of the present invention, the die casting aluminum alloy includes the following components in percentage by mass: 11.5% to 13.5% of silicon; 0.3% to 0.7% of manganese; 0.35% to 0.7% of magnesium; 0.6% to 1.3% of iron; less than or equal to 0.15% of copper; and aluminum and inevitable impurities.

(21) In an implementation manner of the present invention, the die casting aluminum alloy includes the following components in percentage by mass: 13% of silicon; 0.45% of manganese; 0.5% of magnesium; 0.8% of iron; 0.049% of copper; and aluminum and inevitable impurities.

(22) In an implementation manner of the present invention, the die casting aluminum alloy includes the following components in percentage by mass: 13% of silicon; 0.45% of manganese; 0.5% of magnesium; 0.8% of iron; 0.006% of copper; and t aluminum and inevitable impurities.

(23) In an implementation manner of the present invention, phases in an organization structure of the die casting aluminum alloy include an -Al phase, an eutectic Si phase, and a second phase, and the second phase is distributed in a grain boundary location or is separated out of the -Al phase.

(24) In an implementation manner of the present invention, the second phase includes an Al.sub.3Fe phase, a CuAl.sub.2 phase, an Mg.sub.2Si phase, an AlSiFeMn quaternary compound phase, and an AlSiFe ternary compound phase.

(25) In an implementation manner of the present invention, solution treatment is performed on some of iron, copper, magnesium, and manganese inside the -Al phase;

(26) silicon forms a binary or multi-component eutectic structure in an aluminum alloy, which improves formability of the alloy, and improves fluidity, and when silicon content is 11.0% to 14.0%, the die casting aluminum alloy is located near an eutectic point, and has good formability;

(27) adding 0.1% to 0.9% of manganese to an aluminum silicon alloy can improve corrosion resistance of the alloy, and deleterious effects of iron can be reduced by improving a form of a Fe-containing phase, so as to achieve an objective of improving strength of the alloy, and improve mechanical properties of the alloy;

(28) due to refining effects on an Si phase, adding 0.1% to 1.0% of magnesium to the aluminum silicon alloy can improve strength and rigidity of the alloy, so as to improve mechanical properties of the alloy;

(29) in the die casting aluminum alloy, iron content being 0.3% to 1.4% can avoid a mold sticking phenomenon of metal, and improve formability of the alloy; and

(30) copper content being less than or equal to 0.2% in the die casting aluminum alloy can play a role of enhancing mechanical properties, which ensures good corrosion resistance of the alloy.

(31) The die casting aluminum alloy provided in the first aspect of the embodiments of the present invention has good formability, heat conductivity, corrosion resistance, and mechanical properties. Because combined action of specific content of multiple elements, namely, silicon, manganese, magnesium, iron, and copper balances various properties, a stable crystal structure is formed, so that the die casting aluminum alloy having an excellent integrated property is obtained.

(32) According to a second aspect, an embodiment of the present invention provides a production method of a die casting aluminum alloy, including the following steps:

(33) according to a component ratio of the die casting aluminum alloy, first adding a pure aluminum ingot to a smelting furnace, adding an aluminum silicon alloy, an aluminum copper alloy, an aluminum iron alloy, an aluminum manganese alloy, and an aluminum magnesium alloy for smelting after the aluminum ingot is smelted, and performing die-cast formation after refining and degassing processing, to obtain the die casting aluminum alloy, where the die casting aluminum alloy includes the following components in percentage by mass: 11.0% to 14.0% of silicon; 0.1% to 0.9% of manganese; 0.1% to 1.0% of magnesium; 0.3% to 1.4% of iron; less than or equal to 0.2% of copper; and aluminum and inevitable impurities.

(34) The production method of the die casting aluminum alloy in the present invention uses an existing conventional process, and further includes operations such as conventional removal of impurities. Parameters of various processes are not specifically limited in the present invention.

(35) In an implementation manner of the present invention, a mass percentage of silicon is specifically 11.5% to 13.5%.

(36) In an exemplary implementation manner of the present invention, the mass percentage of silicon is specifically 13%.

(37) In an implementation manner of the present invention, a mass percentage of copper is specifically less than or equal to 0.15%.

(38) In an exemplary implementation manner of the present invention, the mass percentage of copper is specifically less than or equal to 0.05%.

(39) In an exemplary implementation manner of the present invention, the mass percentage of copper is specifically less than or equal to 0.01%.

(40) In an implementation manner of the present invention, a mass percentage of manganese is specifically 0.3% to 0.7%.

(41) In an exemplary implementation manner of the present invention, the mass percentage of manganese is specifically 0.45%.

(42) In an implementation manner of the present invention, a mass percentage of magnesium is specifically 0.35% to 0.7%.

(43) In an exemplary implementation manner of the present invention, the mass percentage of magnesium is specifically 0.5%.

(44) In an implementation manner of the present invention, a mass percentage of iron is specifically 0.6% to 1.3%.

(45) In an exemplary implementation manner of the present invention, the mass percentage of iron is specifically 0.8%.

(46) In an implementation manner of the present invention, the die casting aluminum alloy includes the following components in percentage by mass: 11.5% to 13.5% of silicon; 0.3% to 0.7% of manganese; 0.35% to 0.7% of magnesium; 0.6% to 1.3% of iron; less than or equal to 0.15% of copper; and aluminum and inevitable impurities.

(47) In an implementation manner of the present invention, the die casting aluminum alloy includes the following components in percentage by mass: 13% of silicon; 0.45% of manganese; 0.5% of magnesium; 0.8% of iron; 0.049% of copper; and the others being aluminum and inevitable impurities.

(48) In an implementation manner of the present invention, the die casting aluminum alloy includes the following components in percentage by mass: 13% of silicon; 0.45% of manganese; 0.5% of magnesium; 0.8% of iron; 0.006% of copper; and the others being aluminum and inevitable impurities.

(49) In an implementation manner of the present invention, phases in an organization structure of the die casting aluminum alloy include an -Al phase, an eutectic Si phase, and a second phase, and the second phase is distributed in a grain boundary location or is separated out of the -Al phase.

(50) In an implementation manner of the present invention, the second phase includes an Al.sub.3Fe phase, a CuAl.sub.2 phase, an Mg.sub.2Si phase, an AlSiFeMn quaternary compound phase, and an AlSiFe ternary compound phase.

(51) In an implementation manner of the present invention, solution treatment is performed on some of iron, copper, magnesium, and manganese inside the -Al phase.

(52) The production method of the die casting aluminum alloy provided in the second aspect of the embodiments of the present invention has a simple process, and the die casting aluminum alloy obtained through production has good formability, heat conductivity, and corrosion resistance, and certain mechanical properties.

(53) A third aspect of the embodiments of the present invention provides a communications product, including a housing, and a power supply circuit and a functional circuit that are located in the housing, where the power supply circuit supplies power to the functional circuit, and the housing is obtained through die-casting by using the die casting aluminum alloy provided in the first aspect of the embodiments of the present invention.

(54) In the communications product, other components that can be made of an aluminum alloy may also be obtained through die-casting by using the die casting aluminum alloy in the embodiments of the present invention, such as a handle, a maintenance cavity cover, a slide rail, a rotating shaft, and a supporting piece.

(55) The communications product provided in the third aspect of the embodiments of the present invention has good formability, heat conductivity, and corrosion resistance, and certain mechanical properties, and high stability, which can satisfy requirements of global delivery.

(56) The embodiments of the present invention are further described below by using multiple embodiments. The embodiments of the present invention are not limited to the following specific embodiments. Implementation may be appropriately modified without changing the scope of the independent claims.

Embodiment 1

(57) A die casting aluminum alloy includes the following components in percentage by mass: 11.0% to 14.0% of silicon; 0.1% to 0.9% of manganese; 0.1% to 1.0% of magnesium; 0.3% to 1.4% of iron; less than or equal to 0.2% of copper; and the others being aluminum and inevitable impurities.

(58) The die casting aluminum alloy having composition in this embodiment is die-cast into a complex thin-wall communications housing, and a production method of the housing includes the following steps:

(59) according to a component ratio of the die casting aluminum alloy, first adding a pure aluminum ingot to a smelting furnace, adding an aluminum silicon alloy, an aluminum copper alloy, an aluminum iron alloy, an aluminum manganese alloy, and an aluminum magnesium alloy for smelting after the aluminum ingot is smelted, and performing die-cast formation after refining and degassing processing, to obtain the thin-wall communications housing.

(60) The interior of the die casting aluminum alloy includes an -Al phase, an eutectic Si phase, and a second phase, the second phase is distributed in a grain boundary location or is separated out of the -Al phase, and the second phase includes an Al.sub.3Fe phase, a CuAl.sub.2 phase, an Mg.sub.2Si phase, an AlSiFeMn quaternary compound phase, and an AlSiFe ternary compound phase. In addition, solution treatment is performed on some of iron, copper, magnesium, and manganese inside the -Al phase.

(61) Adding 11.0% to 14.0% of silicon can improve the formability of the alloy and improve fluidity. Adding 0.1% to 0.9% of manganese can improve corrosion resistance of the alloy, and deleterious effects of iron can be reduced by improving a form of a Fe-containing phase, so as to achieve an objective of improving strength of the alloy, and reduce occurrence of a mold sticking phenomenon. Because of refining effects on an Si phase, adding 0.1% to 1.0% of magnesium can improve strength and rigidity of the alloy. In the die casting aluminum alloy, iron content being 0.3% to 1.4% can avoid a mold sticking phenomenon of metal. Adding less than or equal to 0.2% of copper can play a role of enhancing mechanical properties.

Embodiment 2

(62) A die casting aluminum alloy includes the following components in percentage by mass: 13% of silicon; 0.45% of manganese; 0.5% of magnesium; 0.8% of iron; 0.049% of copper; and the others being aluminum and inevitable impurities.

(63) The die casting aluminum alloy having composition in this embodiment is die-cast into a complex thin-wall communications housing according to the method of Embodiment 1.

Embodiment 3

(64) A die casting aluminum alloy includes the following components in percentage by mass: 13% of silicon; 0.45% of manganese; 0.5% of magnesium; 0.8% of iron; 0.006% of copper; and the others being aluminum and inevitable impurities.

(65) The die casting aluminum alloy having composition in this embodiment is die-cast into a complex thin-wall communications housing according to the method of Embodiment 1.

Embodiment 4

(66) A die casting aluminum alloy includes the following components in percentage by mass: 13% of silicon; 0.45% of manganese; 0.5% of magnesium; 0.8% of iron; 0.19% of copper; and the others being aluminum and inevitable impurities.

(67) The die casting aluminum alloy having composition in this embodiment is die-cast into a complex thin-wall communications housing according to the method of Embodiment 1.

Embodiment 5

(68) A die casting aluminum alloy includes the following components in percentage by mass: 11% of silicon; 0.1% of manganese; 0.1% of magnesium; 0.3% of iron; 0.05% of copper; and the others being aluminum and inevitable impurities.

(69) The die casting aluminum alloy having composition in this embodiment is die-cast into a complex thin-wall communications housing according to the method of Embodiment 1.

Embodiment 6

(70) A die casting aluminum alloy includes the following components in percentage by mass: 13% of silicon; 0.45% of manganese; 0.5% of magnesium; 0.8% of iron; 0.15% of copper; and the others being aluminum and inevitable impurities.

(71) The die casting aluminum alloy having composition in this embodiment is die-cast into a complex thin-wall communications housing according to the method of Embodiment 1.

Embodiment 7

(72) A die casting aluminum alloy includes the following components in percentage by mass: 14% of silicon; 0.9% of manganese; 1.0% of magnesium; 1.4% of iron; 0.01% of copper; and the others being aluminum and inevitable impurities.

(73) The die casting aluminum alloy having composition in this embodiment is die-cast into a complex thin-wall communications housing according to the method of Embodiment 1.

(74) Effect embodiments: To effectively support beneficial effects of the embodiments of the present invention, effect embodiments are provided as follows, which are used to evaluate properties of the product provided in the embodiments of the present invention.

(75) 1. Formability

(76) A complex thin-wall communications housing is obtained by die-casting each of the following three alloys: the alloy in Embodiment 1 of the present invention, a 43400 alloy, and an ADC12 alloy. When formability of the alloy is not good, a defect of a short shot easily occur in a thin-wall heat sink fin. According to existing statistics, 30 die-casting fittings are continuously manufactured by using each alloy, and a statistics result of a largest three-dimensional size of each short shot feature on 25 heat sink fins is shown in Table 1. The largest three-dimensional size is described in three types: 0.5 mm, 1.0 mm; >1.0 mm, 3 mm; >3 mm.

(77) TABLE-US-00001 TABLE 1 Statistics of short shot features of die-casting fittings made of different materials Short shot Short shot Total Ratio of a total quantity of that is 0.5 mm that is >1.0 mm Short shot quantity of defects between each alloy and 1.0 mm and 3 mm that is >3 mm Material defects and 43400 alloy Quantity Quantity Quantity 43400 243 75 138 30 ADC12 201 17% 90 90 21 Embodiment 1 171 30% 63 81 27

(78) The statistics result of Table 1 indicates that, formability of the alloy in Embodiment 1 of the present invention is not lower than that of the widely used die casting aluminum alloy ADC12, and is superior to that of the European Union standard die casting aluminum alloy 43400.

(79) 2. Heat Conductivity

(80) Heat conductivity of the alloy in Embodiment 2 of the present invention is tested, differences between heat conductivity of the alloy in Embodiment 2 of the present invention and heat conductivity of an existing alloy are compared, and results are shown in Table 2. Heat conductivity is tested by using a hot disk thermal analyzer according to a hot disk principle, and a sample size is 505025 mm.

(81) TABLE-US-00002 TABLE 2 Comparison of heat conductivity of various alloys Alloy designation Heat conductivity (w/mk) ADC12 92 YL102 126 43400 148 Embodiment 2 144

(82) 3. Corrosion Resistance

(83) Corrosion resistance of the alloys in Embodiment 2 to Embodiment 4 of the present invention is tested, differences between corrosion resistance of the alloys in Embodiment 2 to Embodiment 4 of the present invention and corrosion resistance of an existing alloy are compared, and results are shown in Table 3. Corrosion resistance of an alloy is indicated by using a corrosion rate, a testing method of the corrosion rate is based on the standard GB/T19292.4 and the standard GB/T 16545, and a sample size is 1201005 mm. To eliminate impact of fringe effects, periphery edges of a testing sample for testing the corrosion rate are covered by adhesive tapes. After neutral salt spray test is performed for 300 h, an average corrosion rate is calculated according to a change of weights of the salt spray before and after the test.

(84) TABLE-US-00003 TABLE 3 Comparison of corrosion rates of various alloys Alloy designation Corrosion rate (mg/(dm.sup.2 d)) ADC12 34.0 YL102 25.0 43400 10.6 Embodiment 2 9.5 Embodiment 3 3.7 Embodiment 4 16.2

(85) The result of Table 3 indicates that heat conductivity and the corrosion rate of the alloy in the embodiments of the present invention are equivalent to those of the 43400 alloy, and are superior to those of the ADC12 alloy and the YL102 alloy.

(86) 4. Mechanical Properties

(87) A communications housing product is obtained by die-casting each of the following alloys: the alloys in Embodiment 5 to Embodiment 7 of the present invention, the ADC12 alloy, the YL102 alloy, and the 43400 alloy, a standard tensile mechanical test piece is cut from the product according to requirements of GB/T 228, and mechanical properties are tested on a tensile mechanical testing machine, and results are shown in Table 4.

(88) TABLE-US-00004 TABLE 4 Mechanical properties of various alloys Alloy Tensile Elongation Rigidity designation strength (MPa) rate (%) (HBW) ADC12 260 1.8 92 YL102 235 2.3 70 43400 242 2.2 85 Embodiment 5 226 2.4 78 Embodiment 6 239 1.9 85 Embodiment 7 246 1.3 87

(89) The results of Table 4 indicate that, compared with a commonly used die casting aluminum alloy, the die casting aluminum alloy of the present invention has certain mechanical properties. Rigidity of the die casting aluminum alloy of the present invention is higher than that of the YL102 alloy, which can effectively prevent threads of a die-casting fitting from malfunctioning in a life cycle.

(90) It can be learned from the foregoing that, formability, heat conductivity, and corrosion resistance of a die casting aluminum alloy obtained according to the embodiments of the present invention are excellent, and the die casting aluminum alloy has certain mechanical properties, which resolves a problem in the prior art that a die casting aluminum alloy cannot have good formability, heat-conducting property, corrosion resistance, and mechanical properties. Therefore, occurrence of problems of a low yield of die-casting fittings, burn-in caused by severe heat emission of a product, corrosion in a coastal environment, assembly difficulties caused by insufficient mechanical properties, severe deformation in a wind load condition, and the like, so as to satisfy requirements of global delivery of complex communications products.