Aluminum-alloy clad member, method for producing same, and heat exchanger using aluminum-alloy clad member

Abstract

An aluminum alloy clad material having a core material and a sacrificial anode material clad on at least one surface of the core material, wherein the core material comprises an aluminum alloy comprising 0.050 to 1.5 mass % (referred to as “%” below) Si, 0.050 to 2.0% Fe and 0.50 to 2.00% Mn; the sacrificial anode material includes an aluminum alloy containing 0.50 to 8.00% Zn, 0.05 to 1.50% Si and 0.050 to 2.00% Fe; the grain size of the sacrificial anode material is 60 μm or more; and a ratio R1/R2 is 0.30 or less, wherein R1 (μm) is a grain size in a thickness direction and R2 (μm) is a grain size in a rolling direction in a cross section of the core material along the rolling direction; a production method thereof; and a heat exchanger using the clad.

1 . An aluminum alloy clad material having an aluminum alloy core material and a sacrificial anode material clad on at least one surface of the core material,
 wherein the core material comprises an aluminum alloy comprising 0.05 to 1.50 mass % Si, 0.05 to 2.00 mass % Fe, 0.50 to 2.00 mass % Mn and a balance of Al and unavoidable impurities,   the sacrificial anode material comprises an aluminum alloy comprising 0.50 to 8.00 mass % Zn, 0.05 to 1.50 mass % Si, 0.05 to 2.00 mass % Fe and a balance of Al and unavoidable impurities,   a grain size of the sacrificial anode material is 60 μm or more, and   a ratio R1/R2 is 0.30 or less, when R1 (μm) is a grain size in a thickness direction and R2 (μm) is a grain size in a rolling direction in a cross section of the core material along the rolling direction.   
     
     
         2 . The aluminum alloy clad material according to  claim 1 , wherein the core material comprises the aluminum alloy further comprising one or, two or more selected from 0.05 to 1.50 mass % Cu, 0.05 to 0.50 mass % Mg, 0.05 to 0.30 mass % Ti, 0.05 to 0.30 mass % Zr, 0.05 to 0.30 mass % Cr and 0.05 to 0.30 mass % V. 
     
     
         3 . The aluminum alloy clad material according to  claim 1 , wherein the sacrificial anode material comprises the aluminum alloy further comprising one or, two or more selected from 0.05 to 2.00 mass % Ni, 0.05 to 2.00 mass % Mn, 0.05 to 3.00 mass % Mg, 0.05 to 0.30 mass % Ti, 0.05 to 0.30 mass % Zr, 0.05 to 0.30 mass % Cr and 0.05 to 0.30 mass % V. 
     
     
         4 . An aluminum alloy clad material having an aluminum alloy core material, a sacrificial anode material clad on one surface of the core material and a brazing filler metal clad on the other surface of the core material,
 wherein the core material comprises an aluminum alloy comprising 0.05 to 1.50 mass % Si, 0.05 to 2.00 mass % Fe, 0.50 to 2.00 mass % Mn and a balance of Al and unavoidable impurities,   the sacrificial anode material comprises an aluminum alloy comprising 0.50 to 8.00 mass % Zn, 0.05 to 1.50 mass % Si, 0.05 to 2.00 mass % Fe and a balance of Al and unavoidable impurities,   the brazing filler metal comprises an aluminum alloy comprising 2.50 to 13.00 mass % Si, 0.05 to 1.20 mass % Fe and a balance of Al and unavoidable impurities, a grain size of the sacrificial anode material is 60 μm or more, and   a ratio R1/R2 is 0.30 or less, wherein R1 (μm) is a grain size in a thickness direction and R2 (μm) is a grain size in a rolling direction in a cross section of the core material along the rolling direction.   
     
     
         5 . The aluminum alloy clad material according to  claim 4 , wherein the brazing filler metal comprises the aluminum alloy further comprising one or, two or more selected from 0.50 to 8.00 mass % Zn, 0.05 to 1.50 mass % Cu, 0.05 to 2.00 mass % Mn, 0.05 to 0.30 mass % Ti, 0.05 to 0.30 mass % Zr, 0.05 to 0.30 mass % Cr, 0.05 to 0.30 mass % V, 0.001 to 0.050 mass % Na and 0.001 to 0.050 mass % Sr. 
     
     
         6 . The aluminum alloy clad material according to  claim 4 , wherein the core material comprises the aluminum alloy further comprising one or, two or more selected from 0.05 to 1.50 mass % Cu, 0.05 to 0.50 mass % Mg, 0.05 to 0.30 mass % Ti, 0.05 to 0.30 mass % Zr, 0.05 to 0.30 mass % Cr and 0.05 to 0.30 mass % V. 
     
     
         7 . The aluminum alloy clad material according to  claim 4 , wherein the sacrificial anode material comprises the aluminum alloy further comprising one or, two or more selected from 0.05 to 2.00 mass % Ni, 0.05 to 2.00 mass % Mn, 0.05 to 3.00 mass % Mg, 0.05 to 0.30 mass % Ti, 0.05 to 0.30 mass % Zr, 0.05 to 0.30 mass % Cr and 0.05 to 0.30 mass % V. 
     
     
         8 . An aluminum alloy clad material having an aluminum alloy core material, an intermediate layer material clad on one surface of the core material, a brazing filler metal clad on a surface of the intermediate layer material such that the surface is not the core material side, and a sacrificial anode material clad on the other surface of the core material,
 wherein the core material comprises an aluminum alloy comprising 0.05 to 1.50 mass % Si, 0.05 to 2.00 mass % Fe, 0.50 to 2.00 mass % Mn, 0.05 to 0.50 mass % Mg and a balance of Al and unavoidable impurities,   the intermediate layer material comprises an aluminum alloy comprising 0.05 to 1.50 mass % Si, 0.05 to 2.00 mass % Fe and a balance of Al and unavoidable impurities,   the sacrificial anode material comprises an aluminum alloy comprising 0.50 to 8.00 mass % Zn, 0.05 to 1.50 mass % Si, 0.05 to 2.00 mass % Fe and a balance of Al and unavoidable impurities,   the brazing filler metal comprises an aluminum alloy comprising 2.50 to 13.00 mass % Si, 0.05 to 1.20 mass % Fe and a balance of Al and unavoidable impurities,   a grain size of the sacrificial anode material is 60 μm or more, and   a ratio R1/R2 is 0.30 or less, wherein R1 (μm) is a grain size in a thickness direction and R2 (μm) is a grain size in a rolling direction in a cross section of the core material along the rolling direction.   
     
     
         9 . The aluminum alloy clad material according to  claim 8 , wherein the brazing filler metal comprises the aluminum alloy further comprising one or, two or more selected from 0.50 to 8.00 mass % Zn, 0.05 to 1.50 mass % Cu, 0.05 to 2.00 mass % Mn, 0.05 to 0.30 mass % Ti, 0.05 to 0.30 mass % Zr, 0.05 to 0.30 mass % Cr, 0.05 to 0.30 mass % V, 0.001 to 0.050 mass % Na and 0.001 to 0.050 mass % Sr. 
     
     
         10 . The aluminum alloy clad material according to  claim 8 , wherein the core material comprises the aluminum alloy further comprising one or, two or more selected from 0.05 to 1.50 mass % Cu, 0.05 to 0.30 mass % Ti, 0.05 to 0.30 mass % Zr, 0.05 to 0.30 mass % Cr and 0.05 to 0.30 mass % V. 
     
     
         11 . The aluminum alloy clad material according to  claim 8 , wherein the sacrificial anode material comprises the aluminum alloy further comprising one or, two or more selected from 0.05 to 2.00 mass % Ni, 0.05 to 2.00 mass % Mn, 0.05 to 3.00 mass % Mg, 0.05 to 0.30 mass % Ti, 0.05 to 0.30 mass % Zr, 0.05 to 0.30 mass % Cr and 0.05 to 0.30 mass % V. 
     
     
         12 . The aluminum alloy clad material according to  claim 8 , wherein the intermediate layer material comprises the aluminum alloy further comprising one or, two or more selected from 0.50 to 8.00 mass % Zn, 0.05 to 2.00 mass % Mn, 0.05 to 1.50 mass % Cu, 0.05 to 0.30 mass % Ti, 0.05 to 0.30 mass % Zr, 0.05 to 0.30 mass % Cr and 0.05 to 0.30 mass % V. 
     
     
         13 . An aluminum alloy clad material having an aluminum alloy core material, an intermediate layer material clad on one surface of the core material, a brazing filler metal clad on the surface of the intermediate layer material such that the surface is not the core material side, and a sacrificial anode material clad on the other surface of the core material,
 wherein the core material comprises an aluminum alloy comprising 0.05 to 1.50 mass % Si, 0.05 to 2.00 mass % Fe, 0.50 to 2.00 mass % Mn and a balance of Al and unavoidable impurities,   the intermediate layer material comprises an aluminum alloy comprising 0.05 to 1.50 mass % Si, 0.05 to 2.00 mass % Fe, 0.50 to 8.00 mass % Zn and a balance of Al and unavoidable impurities,   the sacrificial anode material comprises an aluminum alloy comprising 0.50 to 8.00 mass % Zn, 0.05 to 1.50 mass % Si, 0.05 to 2.00 mass % Fe and a balance of Al and unavoidable impurities,   the brazing filler metal comprises an aluminum alloy comprising 2.50 to 13.00 mass % Si, 0.05 to 1.20 mass % Fe and a balance of Al and unavoidable impurities,   a grain size of the sacrificial anode material is 60 μm or more, and   a ratio R1/R2 is 0.30 or less, wherein R1 (μm) is a grain size in a thickness direction and R2 (μm) is a grain size in a rolling direction in a cross section of the core material along the rolling direction.   
     
     
         14 . The aluminum alloy clad material according to  claim 13 , wherein the brazing filler metal comprises the aluminum alloy further comprising one or, two or more selected from 0.50 to 8.00 mass % Zn, 0.05 to 1.50 mass % Cu, 0.05 to 2.00 mass % Mn, 0.05 to 0.30 mass % Ti, 0.05 to 0.30 mass % Zr, 0.05 to 0.30 mass % Cr, 0.05 to 0.30 mass % V, 0.001 to 0.050 mass % Na and 0.001 to 0.050 mass % Sr. 
     
     
         15 . The aluminum alloy clad material according to  claim 13 , wherein the core material comprises the aluminum alloy further comprising one or, two or more selected from 0.05 to 1.50 mass % Cu, 0.05 to 0.50 mass % Mg, 0.05 to 0.30 mass % Ti, 0.05 to 0.30 mass % Zr, 0.05 to 0.30 mass % Cr and 0.05 to 0.30 mass % V. 
     
     
         16 . The aluminum alloy clad material according to  claim 13 , wherein the sacrificial anode material comprises the aluminum alloy further comprising one or, two or more selected from 0.05 to 2.00 mass % Ni, 0.05 to 2.00 mass % Mn, 0.05 to 3.00 mass % Mg, 0.05 to 0.30 mass % Ti, 0.05 to 0.30 mass % Zr, 0.05 to 0.30 mass % Cr and 0.05 to 0.30 mass % V. 
     
     
         17 . The aluminum alloy clad material according to  claim 13 , wherein the intermediate layer material comprises the aluminum alloy further comprising one or, two or more selected from 0.05 to 2.00 mass % Mn, 0.05 to 1.50 mass % Cu, 0.05 to 0.30 mass % Ti, 0.05 to 0.30 mass % Zr, 0.05 to 0.30 mass % Cr and 0.05 to 0.30 mass % V. 
     
     
         18 . A method for producing the aluminum alloy clad material according to  claim 1 , comprising:
 a step of casting the aluminum alloys for the core material and the sacrificial anode material, respectively,   a hot rolling step of hot rolling the cast sacrificial anode material ingot to a predetermined thickness,   a cladding step of cladding the sacrificial anode material rolled to the predetermined thickness on at least one surface of the core material ingot and thus obtaining a clad material,   a hot clad rolling step of hot rolling the clad material,   a cold rolling step of cold rolling the hot-rolled clad material, and   one or more annealing steps of annealing the clad material either during or after the cold rolling step or both during and after the cold rolling step:   wherein in the hot clad rolling step, the rolling start temperature is 400 to 520° C., and the number of rolling passes each with a rolling reduction of 30% or more is restricted to five or less while the temperature of the clad material is 200 to 400° C., and   the clad material is held at 200 to 560° C. for 1 to 10 hours in the annealing steps.   
     
     
         19 . A method for producing the aluminum alloy clad material according to  claim 4 , comprising:
 a step of casting the aluminum alloys for the core material, the sacrificial anode material and the brazing filler metal, respectively,   a hot rolling step of hot rolling the cast sacrificial anode material ingot and the cast brazing filler metal ingot to predetermined thicknesses, respectively,   a cladding step of cladding the sacrificial anode material rolled to the predetermined thickness on one surface of the core material ingot, cladding the brazing filler metal rolled to the predetermined thickness on the other surface and thus obtaining a clad material,   a hot clad rolling step of hot rolling the clad material,   a cold rolling step of cold rolling the hot-rolled clad material, and   one or more annealing steps of annealing the clad material either during or after the cold rolling step or both during and after the cold rolling step:   wherein in the hot clad rolling step, the rolling start temperature is 400 to 520° C., and the number of rolling passes each with a rolling reduction of 30% or more is restricted to five or less while the temperature of the clad material is 200 to 400° C., and   the clad material is held at 200 to 560° C. for 1 to 10 hours in the annealing steps.   
     
     
         20 . A method for producing the aluminum alloy clad material according to  claim 8 , comprising:
 a step of casting the aluminum alloys for the core material, the intermediate layer material, the brazing filler metal and the sacrificial anode material, respectively,   a hot rolling step of hot rolling the cast intermediate layer material ingot, the cast brazing filler metal ingot and the cast sacrificial anode material ingot to predetermined thicknesses, respectively,   a cladding step of cladding the intermediate layer material rolled to the predetermined thickness on one surface of the core material ingot, cladding the brazing filler metal rolled to the predetermined thickness on a surface of the intermediate layer material such that the surface is not the core material side, cladding the sacrificial anode material rolled to the predetermined thickness on the other surface of the core material ingot and thus obtaining a clad material,   a hot clad rolling step of hot rolling the clad material,   a cold rolling step of cold rolling the hot-rolled clad material, and   one or more annealing steps of annealing the clad material either during or after the cold rolling step or both during and after the cold rolling step:   wherein in the hot clad rolling step, the rolling start temperature is 400 to 520° C., and the number of rolling passes each with a rolling reduction of 30% or more is restricted to five or less while the temperature of the clad material is 200 to 400° C., and   the clad material is held at 200 to 560° C. for 1 to 10 hours in the annealing steps.   
     
     
         21 . A heat exchanger using the aluminum alloy clad material according to  claim 1 , wherein the grain size of the sacrificial anode material after braze heating is 100 μm or more. 
     
     
         22 . A method for producing the aluminum alloy clad material according to  claim 13 , comprising:
 a step of casting the aluminum alloys for the core material, the intermediate layer material, the brazing filler metal and the sacrificial anode material, respectively,   a hot rolling step of hot rolling the cast intermediate layer material ingot, the cast brazing filler metal ingot and the cast sacrificial anode material ingot to predetermined thicknesses, respectively,   a cladding step of cladding the intermediate layer material rolled to the predetermined thickness on one surface of the core material ingot, cladding the brazing filler metal rolled to the predetermined thickness on a surface of the intermediate layer material such that the surface is not the core material side, cladding the sacrificial anode material rolled to the predetermined thickness on the other surface of the core material ingot and thus obtaining a clad material,   a hot clad rolling step of hot rolling the clad material,   a cold rolling step of cold rolling the hot-rolled clad material, and   one or more annealing steps of annealing the clad material either during or after the cold rolling step or both during and after the cold rolling step:   wherein in the hot clad rolling step, the rolling start temperature is 400 to 520° C., and the number of rolling passes each with a rolling reduction of 30% or more is restricted to five or less while the temperature of the clad material is 200 to 400° C., and   the clad material is held at 200 to 560° C. for 1 to 10 hours in the annealing steps.   
     
     
         23 . A heat exchanger using the aluminum alloy clad material according to  claim 4 , wherein the grain size of the sacrificial anode material after braze heating is 100 μm or more. 
     
     
         24 . A heat exchanger using the aluminum alloy clad material according to  claim 8 , wherein the grain size of the sacrificial anode material after braze heating is 100 μm or more. 
     
     
         25 . A heat exchanger using the aluminum alloy clad material according to  claim 13 , wherein the grain size of the sacrificial anode material after braze heating is 100 μm or more.