Reinforced aluminum alloy with high electrical and thermal conductivity and its manufaturing process thereof

Abstract

A reinforced aluminum alloy with high electric and thermal conductivity of the present invention has the weight percentage below: Mg 0.61˜0.65%, Si 0.4˜0.45%, rare earth elements 0.21˜0.3%, B 0.03˜0.10% and the balances essentially Al and unavoidable impurities. The reinforced aluminum alloy enhanced the containing of Mg and Si elements compared to the conventional aluminum alloy such as 6063, and controlled the containing of the Mg and Si in a certain relatively narrower range so as to control the desired quality of the aluminum alloy. At the same time, a Ce of the rare earth elements and B element are added into the aluminum alloy and completely solid melted the added alloys to the aluminum alloy. It is not only remaining the strength of the aluminum alloy, but also increasing the electric and thermal conductivity.

1 . A reinforced aluminum alloy, having essentially 0.61 to 0.65% of Magnesium (Mg) by weight, 0.4 to 0.45% of Silicon (Si) by weight, 0.21 to 0.3% of rare earth element by weight, 0.03 to 0.10% of Boron (B) by weight, and the rest are Aluminum (AI) and unavoidable impurities. 
     
     
         2 . The reinforced aluminum alloy, as recited in  claim 1 , wherein said rare earth element comprises Cerium (Ce) and Lanthanum (La) as major elements. 
     
     
         3 . The reinforced aluminum alloy, as recited in  claim 1 , further comprising elements of Manganese (Mn), Ferrum (Fe) Vanadium (V), Chromium, Titanium (Ti), and Zirconium (Zr). 
     
     
         4 . The reinforced aluminum alloy, as recited in  claim 2 , further comprising elements of Manganese (Mn), Ferrum (Fe) Vanadium (V), Chromium, Titanium (Ti), and Zirconium (Zr). 
     
     
         5 . The reinforced aluminum alloy, as recited in  claim 3 , wherein ratio of said elements are Mn≦0.03% by weight, Fe≦0.12% by weight, V≦0.03% by weight, Cr≦0.03% by weight, Ti≦0.03% by weight, and Zr≦0.03% by weight. 
     
     
         6 . The reinforced aluminum alloy, as recited in  claim 4 , wherein ratio of said elements are Mn≦0.03% by weight, Fe≦0.12% by weight, V≦0.03% by weight, Cr≦0.03% by weight, Ti≦0.03% by weight, and Zr≦0.03% by weight. 
     
     
         7 . The reinforced aluminum alloy, as recited in  claim 1 , having a tensile strength (δb)≧172 MP, a yield strength (δ80.2)≧112 MPa, a percentage elongation rate (δ)≧8.0%, an electrical conductivity≧58.8% IACS, and a thermal conductivity≧220 w/m·k. 
     
     
         8 . The reinforced aluminum alloy, as recited in  claim 4 , having a tensile strength (δb)≧172 MP, a yield strength (δ0.2)≧112 MPa, a percentage elongation rate (δ)≧8.0%, an electrical conductivity≧58.8% IACS, and a thermal conductivity≧220 w/m·k. 
     
     
         9 . The reinforced aluminum alloy, as recited in  claim 6 , having a tensile strength (δb)≧172 MP, a yield strength (60.2)≧112 MPa, a percentage elongation rate (δ)≧8.0%, an electrical conductivity≧58.8% IACS, and a thermal conductivity≧220 w/m·k. 
     
     
         10 . The reinforced aluminum alloy, as recited in  claim 1 , wherein said impurities are controlled under 0.15% by weight. 
     
     
         11 . The reinforced aluminum alloy, as recited in  claim 6 , wherein said impurities are controlled under 0.15% by weight. 
     
     
         12 . The reinforced aluminum alloy, as recited in  claim 9 , wherein said impurities are controlled under 0.15% by weight. 
     
     
         13 . The reinforced aluminum alloy, as recited in  claim 1 , further comprising a refiner added into said Magnesium (Mg), Silicon (Si), rare earth element, Boron (B), and Aluminum (AI) to proceed a refining process thereof, wherein said refiner is arranged for ensuring a homogenous structure of said reinforced aluminum alloy. 
     
     
         14 . The reinforced aluminum alloy, as recited in  claim 9 , further comprising a refiner added into said Magnesium (Mg), Silicon (Si), rare earth element, Boron (B), and Aluminum (AI) to proceed a refining process thereof, wherein said refiner is arranged for ensuring a homogenous structure of said reinforced aluminum alloy. 
     
     
         15 . The reinforced aluminum alloy, as recited in  claim 12 , further comprising a refiner added into said Magnesium (Mg), Silicon (Si), rare earth element, Boron (B), and Aluminum (AI) to proceed a refining process thereof, wherein said refiner is arranged for ensuring a homogenous structure of said reinforced aluminum alloy. 
     
     
         16 . The reinforced aluminum alloy, as recited in  claim 13 , wherein said refiner is one of Al—Ti—C and Al—Ti—B. 
     
     
         17 . The reinforced aluminum alloy, as recited in  claim 14 , wherein said refiner is one of Al—Ti—C and Al—Ti—B. 
     
     
         18 . The reinforced aluminum alloy, as recited in  claim 15 , wherein said refiner is one of Al—Ti—C and Al—Ti—B. 
     
     
         19 . The reinforced aluminum alloy, as recited in  claim 13 , which is manufactured by a casting step and a dispersing step,
 wherein said casting step comprises the steps of:   (a) adding 3˜3.5% by weight of Al—Si alloy, with 95˜97% by weight of aluminum (Al), wherein said Al—Si alloy has 12 to 14% of Si element by weight;   (b) melting said Al—Si alloy with said aluminum at a temperature with a range between 700° C. and 800° C.;   (c) adding 1.9˜3.3% by weight of Al-Rare Earth Elements and 0.03˜0.10% of Boron (B) with said melted Al—Si alloy and aluminum, wherein said Al-Rare Earth Elements has a 9 to 11% of Re by weight;   (d) adding 0.63˜0.68% by weight of Magnesium (Mg),   (e) adding 1.5˜2% by weight of said refiner under a temperature between 720 and 740° C. with a refining time between 15 and 20 minutes to proceed said refining process, wherein one of liquefied nitrogen and 99.99% nitrogen gas is mixing with a refining agent in said refining process, wherein said refining agent is consisted of 40% Cryolite (Na 3 AlF 6 ), 30% NaCl, and 30% KCl; and   (f) placing said materials at a temperature between 680° C. and 710° C. for 13 to 15 minutes;   wherein said dispersing step comprises the step of:   (g) keeping a temperature of said materials from said casting step at a temperature between 560 and 580° C. for 3.5 to 4.5 Hr;   (h) cooling down said materials at a cooling rate of 180˜220° C./Hr to form said reinforced aluminum alloy.   
     
     
         20 . The reinforced aluminum alloy, as recited in  claim 18 , which is manufactured by a casting step and a dispersing step,
 wherein said casting step comprises the steps of:   (a) adding 3˜3.5% by weight of Al—Si alloy, with 95˜97% by weight of aluminum (Al), wherein said Al—Si alloy has 12 to 14% of Si element by weight;   (b) melting said Al—Si alloy with said aluminum at a temperature with a range between 700° C. and 800° C.;   (c) adding 1.9˜3.3% by weight of Al-Rare Earth Elements and 0.03˜0.10% of Boron (B) with said melted Al—Si alloy and aluminum, wherein said Al-Rare Earth Elements has a 9 to 11% of Re by weight;   (d) adding 0.63˜0.68% by weight of Magnesium (Mg),   (e) adding 1.5˜2% by weight of said refiner under a temperature between 720 and 740° C. with a refining time between 15 and 20 minutes to proceed said refining process, wherein one of liquefied nitrogen and 99.99% nitrogen gas is mixing with a refining agent in said refining process, wherein said refining agent is consisted of 40% Cryolite (Na 3 AlF 6 ), 30% NaCl, and 30% KCl; and   (f) placing said materials at a temperature between 680° C. and 710° C. for 13 to 15 minutes;   wherein said dispersing step comprises the step of:   (g) keeping a temperature of said materials from said casting step at a temperature between 560 and 580° C. for 3.5 to 4.5 Hr;   (h) cooling down said materials at a cooling rate of 180˜220° C./Hr to form said reinforced aluminum alloy.