High strength and high rigidity aluminium based alloy and production method therefor

Abstract: An aluminum-based alloy having the general formula Al 100-(a+b) Q a M b (wherein Q is V, Mo, Fe, W, Nb, and/or Pd; M is Mn, Fe, Co, Ni, and/or Cu; and a and b, representing a composition ratio in atomic percentages, satisfy the relationships 1 ≦ a ≦ 10, 0 < b < 5, and 3 ≦ a+b ≦ 12 ) having a metallographic structure comprising a quasi-crystalline phase possesses high strength and high rigidity. The aluminum-based alloy is useful as a structural material for aircraft, vehicles and ships, and for engine parts; as material for sashes, roofing materials, and exterior materials for use in construction; or as materials for use in marine equipment, nuclear reactors, and the like.

Description: BACKGROUND OF THE INVENTION Field of the Invention The present invention relates to an aluminum-based alloy for use in a wide range of applications such as in a structural material for aircraft, vehicles, and ships, and for engine parts. In addition, the present invention may be employed in sashes, roofing materials, and exterior materials for use in construction, or as material for use in marine equipment, nuclear reactors, and the like. Description of Related Art As prior art aluminum-based alloys, alloys incorporating various components such as Al-Cu, Al-Si, Al-Mg, Al-Cu-Si, Al-Cu-Mg, and Al-Zn-Mg are known. In all of the aforementioned, superior anti-corrosive properties are obtained at a light weight, and thus the aforementioned alloys are being widely used as structural material for machines in vehicles, ships, and aircraft, in addition to being employed in sashes, roofing materials, exterior materials for use in construction, structural material for use in LNG tanks, and the like. However, the prior art aluminum-based alloys generally exhibit disadvantages such as a low hardness and poor heat resistance when compared to material incorporating Fe. In addition, although some materials have incorporated elements such as Cu, Mg, and Zn for increased hardness, disadvantages remain such as low anti-corrosive properties. On the other hand, recently, experiments have been conducted in which a fine metallographic structure of aluminum-based alloys is obtained by means of performing quick-quench solidification from a liquid-melt state, resulting in the production of superior mechanical strength and anti-corrosive properties. In Japanese Patent Application, First Publication No. 1-275732, an aluminum-based alloy comprising a composition AlM 1 X with a special composition ratio (wherein M 1 represents an element such as V, Cr, Mn, Fe, Co, Ni, Cu, Zr and the like, and X represents a rare earth element such as La, Ce, Sm, and Nd, or an element such as Y, Nb, Ta, Mm (misch metal) and the like), and having an amorphous or a combined amorphous/fine crystalline structure, is disclosed. This aluminum-based alloy can be utilized as material with a high hardness, high strength, high electrical resistance, anti-abrasion properties, or as soldering material. In addition, the disclosed aluminum-based alloy has a superior heat resistance, and may undergo extruding or press processing by utilizing the superplastic phenomenon observed near crystallization temperatures. However, the aforementioned aluminum-based alloy is disadvantageous in that high costs result from the incorporation of large amounts of expensive rare earth elements and/or metal elements with a high activity such as Y. Namely, in addition to the aforementioned use of expensive raw materials, problems also arise such as increased consumption and labor costs due to the large scale of the manufacturing facilities required to treat materials with high activities. Furthermore, this aluminum-based alloy having the aforementioned composition tends to display insufficient resistance to oxidation and corrosion. EP-A-584 596 relates to a high strength aluminum-based alloy essentially consisting of an amorphous structure or a multiphase amorphous/fine crystalline structure. Further, Skinner et al. in "Stability of Quasicrystalline Phases in Al-Fe-V Alloys," Mat. Sci. and Eng., 99, 1988, pp. 407-411, disclose Al-V-Fe quasi-crystalline alloys produced by melt spinning techniques, and thermal stability and microstructures thereof. Dunlap et al. in "Physical properties of a rapidly quenched Al-Fe alloys", J. Phys. F, Met. Phys., July 1988, UK, pp. 1329-1341, and Kim et al. in "Microstructural characteristics of rapidly solidified Al-Fe alloys. II. Quaiscrystalline and related crystalline phase," J. Korean Inst. Met. (South Korea), Sept. 1991, South Korea, pp. 976-982, disclose binary Al-Fe quasi-crystalline alloys. SUMMARY OF THE INVENTION It is an object of the present invention to provide an aluminum-based alloy, possessing superior strength, rigidity, and anti-corrosive properties, which comprises a composition in which rare earth elements or high activity elements such as Y are not incorporated, thereby effectively reducing the cost, as well as, the activity described in the aforementioned. In order to solve the aforementioned problems, the present invention provides a high strength and high rigidity aluminum-based alloy according the features of claim 1. According to the present invention, by adding a predetermined amount of V, Mo, Fe, W, Nb, and/or Pd to Al, the ability of the alloy to form a quasi-crystalline phase is improved, and the strength, hardness, and toughness of the alloy is also improved. Moreover, by adding a predetermined amount of Mn, Fe, Co, Ni, and/or Cu, the effects of quick-quenching are enhanced, the thermal stability of the overall metallographic structure is improved, and the strength and hardness of the resulting alloy are also increased. The aluminum-based alloy according to the present invention is useful as materials with a high hardness, strength, and rigidity. Furthermore, this alloy also stands up well to bending, and thus possesses superior properties such as the ability to be mechanically processed. Accordingly, the aluminum-based alloys according to the present invention can be used in a wide range of applications such as in the structural material for aircraft, vehicles, and ships, as well as for engine parts. In addition, the aluminum-based alloys of the present invention may be employed in sashes, roofing materials, and exterior materials for use in construction, or as materials for use in marine equipment, nuclear reactors, and the like. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 shows a construction of an example of a single roll apparatus used at the time of manufacturing a tape of an alloy of the present invention following quick-quench solidification. Fig. 2 shows the analysis result of the x-ray diffraction of an alloy having the composition of Al 94 V 4 Fe 2 . Fig. 3 shows the analysis result of the X-ray diffraction of an alloy having the composition of Al 95 Mo 3 Ni 2 . Fig. 4 shows the analysis result of the X-ray diffraction of an alloy having the composition of Al 91 Nb 6 Co 3 . Fig. 5 shows the thermal properties of an alloy having the composition of Al 94 V 4 Ni 2 . DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The first preferred embodiment of the present invention provides a high strength and high rigidity aluminum-based alloy consisting essentially of a composition represented by the general formula Al 100-(a+b) Q a M b (wherein Q is at least one metal element selected from the group consisting of V, Mo, Fe, W, Nb, and Pd; M is at least one metal element selected from the group consisting of Mn, Fe, Co, Ni, and Cu; and a and b, which represent a composition ratio in atomic percentages, satisfy the relationships 1 ≤ a ≤ 10, 0 < b < 5, and 3 ≤ a+b ≤ 12), comprising a quasi-crystalline phase in the alloy. In the following, the reasons for limiting the composition ratio of each component in the alloy according to the present invention are explained. The atomic percentage of Al (aluminum) is in the range of 88 ≤ Al ≤ 97, preferably in the range of 92 ≤ Al ≤ 97, and more preferably in the range of 94 ≤ Al ≤ 97. An atomic percentage for Al of less than 88% results in embrittlement of the alloy. On the other hand, an atomic percentage for Al exceeding 97% results in reduction of the strength and hardness of the alloy. The amount of at least one metal element selected from the group consisting of V (vanadium), Mo (molybdenum), Fe (iron), W (tungsten), Nb (niobium), and Pd (palladium) in atomic percentage is at least 1% and does not exceed 10%; preferably, the amount is at least 2% and does not exceed 8%; more prefarably, the amount is at least 2% and does not exceed 6%. If the amount is less than 1%, a quasi-crystalline phase cannot be obtained, and the strength is markedly reduced. On the other hand, if the amount exceeds 10%, coarsening (the diameter of particles is 500 nm or more) of a quasi-crystalline phase occurs, and this results in remarkable embrittlement of the alloy and reduction of (rupture) strength of the alloy. The amount of at least one metal element selected from the group consisting of Mn (manganese), Fe (iron), Co (cobalt), Ni (nickel), and Cu (copper) in atomic percentage is less than 5%; preferably, the amount is at least 1% and does not exceed 3%; more preferably, the amount is at least 1% and does not exceed 2%. If the amount is 5% or more, forming and coarsening (the diameter of particles is 500 nm or more) of intermetallic compounds occur, and these result in remarkable embrittlement and reduction of toughness of the alloy. Furthermore, the total amount of unavoidable impurities, such as Fe (if not a selected metal element), Si, Cu (if not a selected metal element), Zn, Ti, O, C, or N, does not exceed 0.3% by weight; preferably, the amount does not exceed 0.15% by weight; and more preferably, the amount does not exceed 0.10% by weight. If the amount exceeds 0.3% by weight, the effects of quick-quenching is lowered, and this results in reduction of the formability of a quasi-crystalline phase. Among the unavoidable impurities, particularly, it is preferable that the amount of O does not exceed 0.1% by weight and that the amount of C or N does not exceed 0.03% by weight. The aforementioned aluminum-based alloys can be manufactured by quick-quench solidification of the alloy liquid-melts having the aforementioned compositions using a liquid quick-quenching method. This liquid quick-quenching method essentially entails rapid cooling of the melted alloy. For example, single roll, double roll, and submerged rotational spin methods have proved to be particularly effective. In these aforementioned methods, a cooling rate of 10 4 to 10 6 K/sec is easily obtainable. In order to manufacture a thin tape using the aforementioned single or double roll methods, the liquid-melt is first poured into a storage vessel such as a silica tube, and is then discharged, via a nozzle aperture at the tip of the silica tube, towards a copper or copper alloy roll of diameter 30 to 300 mm, which is rotating at a fixed velocity in the range of 300 to 1000 rpm. In this manner, various types of thin tapes of thickness 5 - 500 µm and width 1 - 300 mm can be easily obtained. On the other hand, fine wire-thin material can be easily obtained through the submerged rotational spin method by discharging the liquid-melt via the nozzle aperture, into a refrigerant solution layer of depth 1 to 10 cm, maintained by means of centrifugal force inside an air drum rotating at 50 to 500 rpm, under argon gas back pressure. In this case, the angle between the liquid-melt discharged from the nozzle, and the refrigerant surface is preferably 60 to 90 degrees, and the relative velocity ratio of the liquid-melt and the refrigerant surface is preferably 0.7 to 0.9. In addition, thin layers of aluminum-based alloy of the aforementioned compositions can also be obtained without using the above methods, by employing layer formation processes such as the sputtering method. In addition, aluminum alloy powder of the aforementioned compositions can be obtained by quick-quenching the liquid-melt using various atomizer and spray methods such as a high pressure gas spray method. In the following, examples of metallographic-structural states of the aluminum-based alloy obtained using the aforementioned methods are listed: (1) Multiphase structure incorporating a quasi-crystalline phase and an aluminum phase; (2) Multiphase structure incorporating a quasi-crystalline phase and a metal solid solution having an aluminum matrix; (3) Multiphase structure incorporating a quasi-crystalline phase and a stable or metastable intermetallic compound phase; and (4) Multiphase structure incorporating a quasi-crystalline phase, an amorphous phase, and a metal solid solution having an aluminum matrix. A widely-recognized definition of "quasi-crystalline" is given for a structure satisfying the following three conditions with respect to the reciprocal lattice or diffraction pattern: (A) the diffraction pattern consists of a set of δ-functions (or points); (B) the number of fundamental unit vectors describing the distribution of the reciprocal lattice points (diffraction particles) must be greater than the number of dimensions (i.e., equal to or greater than four for an actual quasi-crystal); and (C) the structure has a rotation symmetry which is not permitted for a crystal. (It should be noted that a crystal has only one-, two-, three-, four-, or six-folded rotation symmetry.) Condition (A) may be satisfied by a crystal. In the case of a crystal, when three short, independent diffraction vectors a*, b* , and c* are chosen as the fundamental vectors as in Condition (B), all diffraction points can be formulated as a linear combination of the three vectors, namely, the formula la* + mb* + nc* . However, since more than three fundamental unit vectors are necessary for an incommensurate crystal, a material cannot be identified as a quasi-crystal by merely satisfying Conditions (A) and (B). Thus, a quasi-crystal must meet also Condition (C). (When a lattice is modulated by a period a' which differs from the natural period a , if the value a '/ a is an irrational number, such a crystal is called an "incommensurate crystal". Such a modulation occurs when re-distribution of electrons, such as charge density wave, affects the lattice.) The above definition of quasi-crystal relates to reciprocal lattices. Therefore, examination of diffraction patterns in detail allows experimental judgement as to whether or not a material is a quasi-crystal. Specifically, quasi-crystals having a five-fold rotation symmetry are known. As quasi-crystalline phases defined in the above, regular icosahedral phase, regular decagonal phase, regular dodecagonal phase, and regular octagonal phase have been found. A quasi-crystal was first discovered by Shechtmann, et al., of Israel in 1984. This quasi-crystal was of the regular icosahedral phase (D. Shechtmann, I. A. Blech, D. Gratias, and J. W. Cahn; Phys. Rev. Lett., 53 (1984), 1951). The fine crystalline phase of the present invention represents a crystalline phase in which the crystal particles have an average maximum diameter of 1 µm. By regulating the cooling rate of the alloy liquid-melt, any of the metallographic-structural states described in (1) to (4) above can be obtained. The properties of the alloys possessing the aforementioned metallographic-structural states are described in the following. An alloy of the multiphase structural state described in (1) and (2) above has a high strength and an excellent bending ductility. An alloy of the multiphase structural state described in (3) above has a higher strength and lower ductility than the alloys of the multiphase structural state described in (1) and (2). However, the lower ductility does not hinder its high strength. An alloy of the multiphase structural state described in (4) has a high strength, high toughness and a high ductility. Each of the aforementioned metallographic-structural states can be easily determined by a normal X-ray diffraction method or by observation using a transmission electron microscope. In the case when a quasi-crystal exists, a dull peak, which is characteristic of a quasi-crystalline phase, is exhibited. By regulating the cooling rate of the alloy liquid-melt, any of the multiphase structural states described in (1) to (3) above can be obtained. By quick-quenching the alloy liquid-melt of the Alrich composition (e.g., composition with Al ≥ 92 atomic %), any of the metallographic-structural states described in (4) can be obtained. The aluminum-based alloy of the present invention displays superplasticity at temperatures near the crystallization temperature (crystallization temperature ±50°C), as well as, at the high temperatures within the fine crystalline stable temperature range, and thus processes such as extruding, pressing, and hot forging can easily be performed. Consequently, aluminum-based alloys of the above-mentioned compositions obtained in the aforementioned thin tape, wire, plate, and/or powder states can be easily formed into bulk materials by means of extruding, pressing and hot forging processes at the aforementioned temperatures. Furthermore, the aluminum-based alloys of the aforementioned compositions possess a high ductility, thus bending of 180° is also possible. Additionally, the aforementioned aluminum-based alloys having multiphase structure composed of a pure-aluminum phase, a quasi-crystalline phase, a metal solid solution, and/or an amorphous phase, and the like, do not display structural or chemical non-uniformity of crystal grain boundary, segregation and the like, as seen in crystalline alloys. These alloys cause passivation due to formation of an aluminum oxide layer, and thus display a high resistance to corrosion. Furthermore, disadvantages exist when incorporating rare earth elements: due to the activity of these rare earth elements, non-uniformity occurs easily in the passive layer on the alloy surface resulting in the progress of corrosion from this portion towards the interior. However, since the alloys of the aforementioned compositions do not incorporate rare earth elements, these aforementioned problems are effectively circumvented. In regards to the aluminum-based alloy of the aforementioned compositions, the manufacturing of bulk-shaped (mass) material will now be explained. When heating the aluminum-based alloy according to the present invention, precipitation and crystallization of the fine crystalline phase is accompanied by precipitation of the aluminum matrix (α-phase), and when further heating beyond this temperature, the intermetallic compound also precipitates. Utilizing this property, bulk material possessing a high strength and ductility can be obtained. Concretely, the tape alloy manufactured by means of the aforementioned quick-quenching process is pulverized in a ball mill, and then powder pressed in a vacuum hot press under vacuum (e.g. 10 -3 Torr) at a temperature slightly below the crystallization temperature (e.g. approximately 470K), thereby forming a billet for use in extruding with a diameter and length of several centimeters. This billet is set inside a container of an extruder, and is maintained at a temperature slightly greater than the crystallization temperature for several tens of minutes. Extruded materials can then be obtained in desired shapes such as round bars, etc., by extruding. Examples A molten alloy having a predetermined composition was manufactured using a high frequency melting furnace. Then, as shown in Fig. 1, this melt was poured into a silica tube 1 with a small aperture 5 (aperture diameter: 0.2 to 0.5 mm) at the tip, and then heated to melt, after which the aforementioned silica tube 1 was positioned directly above copper roll 2. This roll 2 was then rotated at a high speed of 4000 rpm, and argon gas pressure (0.7 kg/cm 3 ) was applied to silica tube 1. Quick-quench solidification was subsequently performed by quick-quenching the liquid-melt by means of discharging the liquid-melt from small aperture 5 of silica tube 1 onto the surface of roll 2 and quick-quenching to yield an alloy tape 4. Under these manufacturing conditions, the numerous alloy tape samples (width: 1 mm, thickness: 20 µm) of the compositions (atomic percentages) shown in Tables 1 and 2 were formed. The hardness (Hv) and tensile rupture strength (σ f : MPa) of each alloy tape sample were measured. These results are also shown in Tables 1 and 2. The hardness is expressed in the value measured according to the minute Vickers hardness scale (DPN: Diamond Pyramid Number). Additionally, a 180° contact bending test was conducted by bending each sample 180° and contacting the ends thereby forming a U-shape. The results of these tests are also shown in Tables 1 and 2: those samples which displayed ductility and did not rupture are designated Duc (ductile), while those which ruptured are designated Bri (brittle). Sample No. Alloy composition (at%) σf (MPa) Hv (DPN) Bending test 1 Al 95 V 3 Ni 2 880 320 Duc Example 2 Al 94 V 4 Ni 2 1230 365 Duc Example 3 Al 93 V 5 Ni 2 1060 325 Duc Example 4 Al 95 V 3 Fe 2 630 300 Duc Example 5 Al 94 V 4 Fe 2 1350 370 Duc Example 6 Al 93 V 5 Fe 2 790 305 Duc Example 7 Al 95 V 3 Co 2 840 310 Duc Example 8 Al 94 V 4 Co 2 1230 355 Duc Example 9 Al 93 V 5 Co 2 1090 350 Duc Example 10 Al 94 V 4 Mn 2 1210 355 Duc Example 11 Al 91 V 8 Mn 2 1010 345 Duc Example 12 Al 93 V 4 Mn 3 800 310 Duc Example 13 Al 94 V 4 Cu 2 1010 310 Duc Example 14 Al 88 V 10 Cu 2 810 305 Duc Example 15 Al 88 V 8 Cu 4 650 295 Duc Example 16 Al 89 V 10 Ni 1 840 310 Duc Example 17 Al 92 V 5 Ni 3 1110 330 Duc Example 18 Al 93 V 4 Fe 3 1200 340 Duc Example 19 Al 93 V 6 Fe 1 1210 345 Duc Example 20 Al 92 V 7 Co 1 1010 310 Duc Example 21 Al 93 V 4 Co 3 1110 310 Duc Example 22 Al 94 Mo 4 Ni 2 1200 300 Duc Example 23 Al 95 Mo 3 Ni 2 1250 305 Duc Example 24 Al 93 Mo 5 Ni 2 1300 320 Duc Example 25 Al 94 Mo 4 Co 2 1010 300 Duc Example 26 Al 89 Mo 8 Co 3 1010 305 Duc Example 27 Al 95 Mo 3 Co 2 1210 330 Duc Example 28 Al 93 Mo 5 Fe 2 990 310 Duc Example 29 Al 90 Mo 7 Fe 3 1110 320 Duc Example 30 Al 94 Mo 4 Fe 2 1320 375 Duc Example 31 Al 94 Mo 4 Mn 2 1220 360 Duc Example 32 Al 92 Mo 5 Mn 3 1100 345 Duc Example 33 Al 95 Mo 3 Mn 2 1020 330 Duc Example 34 Al 97 Mo 1 Cu 2 880 305 Duc Example 35 Al 89 Mo 10 Cu 1 890 300 Duc Example 36 Al 90 Mo 7 Cu 3 880 300 Duc Example 37 Al 94 Fe 4 Mn 2 1320 370 Duc Example 38 Al 94 Fe 3 Mn 3 1100 345 Duc Example 39 Al 91 Fe 8 Mn 1 1210 365 Duc Example 40 Al 94 Fe 4 Co 2 1310 370 Duc Example 41 Al 94 Fe 5 Co 1 1110 335 Duc Example 42 Al 96 Fe 3 Co 1 1010 320 Duc Example 43 Al 90 Fe 8 Ni 2 1100 340 Duc Example 44 Al 88 Fe 10 Ni 2 1300 375 Duc Example 45 Al 88 Fe 9 Ni 3 1280 360 Duc Example 46 Al 94 Fe 4 Cu 2 890 285 Duc Example 47 Al 95 Fe 4 Cu 1 880 300 Duc Example 48 Al 88 Fe 8 Cu 3 930 295 Duc Example 49 Al 94 W 4 Ni 2 1010 340 Duc Example 50 Al 89 W 8 Ni 3 990 310 Duc Example 51 Al 94 W 3 Ni 3 1000 300 Duc Example 52 Al 93 W 5 Co 2 1110 315 Duc Example 53 Al 95 W 2 Co 3 1210 365 Duc Example 54 Al 94 W 4 Fe 2 1090 305 Duc Example 55 Al 93 W 6 Fe 1 1100 360 Duc Example 56 Al 90 W 8 Fe 2 1060 340 Duc Example 57 Al 91 W 5 Mn 4 1130 345 Duc Example 58 Al 94 W 2 Mn 4 1210 350 Duc Example 59 Al 90 W 8 Cu 2 910 310 Duc Example 60 Al 90 W 7 Cu 3 890 305 Duc Example 61 Al 90 Nb 6 Mn 4 1160 335 Duc Example 62 Al 90 Nb 7 Mn 3 1070 320 Duc Example 63 Al 92 Nb 6 Mn 2 1230 330 Duc Example 64 Al 94 Nb 4 Fe 2 1040 320 Duc Example 65 Al 91 Nb 8 Fe 1 1110 340 Duc Example 66 Al 90 Nb 7 Fe 3 890 305 Duc Example 67 Al 94 Nb 4 Ni 2 1300 370 Duc Example 68 Al 93 Nb 3 Ni 4 1210 360 Duc Example 69 Al 95 Nb 3 Ni 2 1100 360 Duc Example 70 Al 94 Nb 4 Co 2 1150 365 Duc Example 71 Al 90 Nb 7 Co 3 1160 345 Duc Example 72 Al 91 Nb 6 Co 3 1020 335 Duc Example 73 Al 90 Nb 8 Cu 2 990 320 Duc Example 74 Al 20 Nb 6 Cu 4 900 300 Duc Example 75 Al 90 Nb 8 Cu 2 930 305 Duc Example 76 Al 91 Pd 6 Mn 3 1020 320 Duc Example 77 Al 91 Pd 7 Mn 2 1270 345 Duc Example 78 Al 90 Pd 8 Mn 2 1190 320 Duc Example 79 Al 94 Pd 4 Fe 2 1010 315 Duc Example 80 Al 6 Pd 3 Fe 1 990 310 Duc Example 81 Al 90 Pd 6 Fe 4 1010 325 Duc Example 82 Al 90 Pd 8 Ni 2 1100 340 Duc Example 83 Al 94 Pd 4 Ni 2 1210 365 Duc Example 84 Al 92 Pd 5 Ni 3 1230 365 Duc Example 85 Al 94 Pd 3 Co 3 1100 335 Duc Example 86 Al 91 Pd 6 Co 3 1260 360 Duc Example 87 Al 89 Pd 8 Co 3 1000 340 Duc Example 88 Al 91 Pd 7 Cu 1 980 300 Duc Example 89 Al 88 Pd 9 Cu 3 970 295 Duc Example 90 Al 90 Pd 8 Cu 2 990 300 Duc Example Sample No. Alloy composition (at%) σf (MPa) Hv (DPN) Bending test 91 Al 96.5 V 0.5 Mn 3 460 95 Duc Comparative Example 92 Al 86 V 12 Mn 2 600 450 Bri Comparative Example 93 Al 97 V 3 400 120 Duc Comparative Example 94 Al 90 V 4 Mn 6 550 410 Bri Comparative Example 95 Al 98 V 1 Mn 1 430 95 Duc Comparative Example 96 Al 87 V 10 Mn 3 510 410 Bri Comparative Example 97 Al 96.5 V 0.5 Fe 3 410 120 Duc Comparative Example 98 Al 85 V 13 Fe 2 505 405 Bri Comparative Example 99 Al 98 V 1 Fe 1 400 110 Duc Comparative Example 100 Al 87 V 10 Fe 3 490 410 Bri Comparative Example 101 Al 90 V 4 Fe 6 450 430 Bri Comparative Example 102 Al 95.5 V 0.5 Ni 4 390 95 Duc Comparative Example 103 Al 86 V 11 Ni 3 410 430 Bri Comparative Example 104 Al 89 V 4 Ni 7 405 425 Bri Comparative Example 105 Al 98 V 1 Ni 1 290 80 Duc Comparative Example 106 Al 85 V 11 Ni 4 500 420 Bri Comparative Example 107 Al 94.5 V 0.5 Co 5 410 125 Duc Comparative Example 108 Al 83 V 15 Co 2 490 480 Bri Comparative Example 109 Al 90 V 2 Co 6 480 410 Bri Comparative Example 110 Al 98.5 V 0.5 Co 1 210 90 Duc Comparative Example 111 Al 85 V 11 Co 4 410 430 Bri Comparative Example 112 Al 94.5 V 0.5 Cu 5 340 105 Duc Comparative Example 113 Al 88 V 11 Cu 1 490 420 Bri Comparative Example 114 Al 89 V 3 Cu 8 480 410 Bri Comparative Example 115 Al 98 V 1 Cu 1 410 95 Duc Comparative Example 116 Al 85 V 12 Cu 3 550 420 Bri Comparative Example 117 Al 96.5 Mo 0.5 Mn 3 430 125 Duc Comparative Example 118 Al 86 Mo 12 Mn 2 510 430 Bri Comparative Example 119 Al 97 Mo 3 370 130 Duc Comparative Example 120 Al 90 Mo 4 Mn 6 480 410 Bri Comparative Example 121 Al 98 Mo 1 Mn 1 380 100 Duc Comparative Example 122 Al 87 Mo 10 Mn 3 490 420 Bri Comparative Example 123 Al 96.5 Mo 0.5 Fe 3 360 125 Duc Comparative Example 124 Al 85 Mo 13 Fe 2 500 460 Bri Comparative Example 125 Al 48 Mo 1 Fe 1 210 80 Duc Comparative Example 126 Al 87 Mo 10 Fe 3 510 450 Bri Comparative Example 127 Al 90 Mo 4 Fe 6 490 435 Bri Comparative Example 128 Al 95.5 Mo 0.5 Ni 4 310 95 Duc Comparative Example 129 Al 86 Mo 11 Ni 3 500 430 Bri Comparative Example 130 Al 89 Mo 4 Ni 7 465 410 Bri Comparative Example 131 Al 98 Mo 1 Ni 1 200 95 Duc Comparative Example 132 Al 85 Mo 11 Ni 4 460 450 Bri Comparative Example 133 Al 94.5 Mo 0.5 Co 5 380 100 Duc Comparative Example 134 Al 83 Mo 15 Co 2 510 410 Bri Comparative Example 135 Al 90 Mo 2 Co 8 490 420 Bri Comparative Example 136 Al 98.5 Mo 0.5 Co 1 360 105 Duc Comparative Example 137 Al 85 Mo 11 Co 4 460 430 Bri Comparative Example 138 Al 94.5 Mo 0.5 Cu 5 340 105 Duc Comparative Example 139 Al 88 Mo 11 Cu 1 490 430 Bri Comparative Example 140 Al 89 Mo 3 Cu 8 510 410 Bri Comparative Example 141 Al 98 Mo 1 Cu 1 410 95 Duc Comparative Example 142 Al 85 Mo 12 Cu 3 550 420 Bri Comparative Example 143 Al 96.5 Fe 0.5 Mn 3 420 130 Duc Comparative Example 144 Al 86 Fe 12 Mn 2 510 430 Bri Comparative Example 145 Al 97 Fe 3 480 160 Duc Comparative Example 146 Al 90 Fe 4 Mn 6 530 425 Bri Comparative Example 147 Al 98 Fe 1 Mn 1 480 95 Duc Comparative Example 148 Al 87 Fe 10 Mn 3 510 420 Bri Comparative Example 149 Al 95.5 Fe 0.5 Ni 4 470 105 Duc Comparative Example 150 Al 86 Fe 11 Ni 3 510 420 Bri Comparative Example 151 Al 89 Fe 4 Ni 7 505 425 Bri Comparative Example 152 Al 98 Fe 1 Ni 1 380 95 Duc Comparative Example 153 Al 85 Fe 11 Ni 4 500 410 Bri Comparative Example 154 Al 94.5 Fe 0.5 Co 5 380 125 Duc Comparative Example 155 Al 83 Fe 15 Co 2 200 480 Bri Comparative Example 156 Al 90 Fe 2 Co 8 490 425 Bri Comparative Example 157 Al 98.5 Fe 0.5 Co 1 380 95 Duc Comparative Example 158 Al 85 Fe 11 Co 4 350 435 Bri Comparative Example 159 Al 94.5 Fe 0.5 Cu 5 340 105 Duc Comparative Example 160 Al 88 Fe 11 Cu 1 410 435 Bri Comparative Example 161 Al 89 Fe 3 Cu 8 480 410 Bri Comparative Example 162 Al 98 Fe 1 Cu 1 410 95 Duc Comparative Example 163 Al 85 Fe 12 Cu 3 550 420 Bri Comparative Example 164 Al 96.5 W 0.5 Mn 3 380 120 Duc Comparative Example 165 Al 86 W 12 Mn 2 420 435 Bri Comparative Example 166 Al 97 W 3 280 95 Duc Comparative Example 167 Al 90 W 4 Mn 6 490 440 Bri Comparative Example 168 Al 98 W 1 Mn 1 280 95 Duc Comparative Example 169 Al 87 W 10 Mn 3 290 475 Bri Comparative Example 170 Al 96.5 W 0.5 Fe 3 385 105 Duc Comparative Example 171 Al 85 W 13 Fe 2 310 480 Bri Comparative Example 172 Al 98 W 1 Fe 1 320 105 Duc Comparative Example 173 Al 87 W 10 Fe 3 500 475 Bri Comparative Example 174 Al 90 W 4 Fe 6 510 460 Bri Comparative Example 175 Al 95.5 W 0.5 Ni 4 380 95 Duc Comparative Example 176 Al 86 W 11 Ni 13 520 470 Bri Comparative Example 177 Al 89 W 4 Ni 7 500 435 Bri Comparative Example 178 Al 98 W 1 Ni 1 280 80 Duc Comparative Example 179 Al 85 W 11 Ni 4 460 435 Bri Comparative Example 180 Al 94.5 W 0.5 Co 5 275 105 Duc Comparative Example 181 Al 83 W 15 Co 2 500 460 Bri Comparative Example 182 Al 90 W 2 Co 8 410 445 Bri Comparative Example 183 Al 98.5 W 0.5 Co 1 270 85 Duc Comparative Example 184 Al 85 W 11 Co 4 290 470 Bri Comparative Example 185 Al 94.5 W 0.5 Cu 5 340 105 Duc Comparative Example 186 Al 88 W 11 Cu 1 310 435 Bri Comparative Example 187 Al 89 W 3 Cu 8 380 410 Bri Comparative Example 188 Al 98 W 1 Cu 1 410 95 Duc Comparative Example 189 Al 85 W 12 Cu 3 550 420 Bri Comparative Example 190 Al 96.5 Nb 0.5 Mn 3 430 120 Duc Comparative Example 191 Al 86 Nb 12 Mn 2 510 475 Bri Comparative Example 192 Al 97 Nb 3 430 105 Duc Comparative Example 193 Al 90 Nb 4 Mn 6 490 430 Bri Comparative Example 194 Al 98 Nb 1 Mn 1 380 95 Duc Comparative Example 195 Al 87 Nb 10 Mn 3 390 465 Bri Comparative Example 196 Al 96.5 Nb 0.5 Fe 3 400 95 Duc Comparative Example 197 Al 85 Nb 13 Fe 2 390 480 Bri Comparative Example 198 Al 98 Nb 1 Fe 1 430 100 Duc Comparative Example 199 Al 87 Nb 10 Fe 3 510 435 Bri Comparative Example 200 Al 90 Nb 4 Fe 6 420 80 Bri Comparative Example 201 Al 95.5 Nb 0.5 Ni 4 380 110 Duc Comparative Example 202 Al 86 Nb 11 Ni 3 510 440 Bri Comparative Example 203 Al 89 Nb 4 Ni 7 490 435 Bri Comparative Example 204 Al 98 Nb 1 Ni 1 230 80 Duc Comparative Example 205 Al 85 Nb 11 Ni 4 430 475 Bri Comparative Example 206 Al 94.5 Nb 0.5 Co 5 280 95 Duc Comparative Example 207 Al 83 Nb 15 Co 2 410 470 Bri Comparative Example 208 Al 90 Nb 2 Co 8 510 430 Bri Comparative Example 209 Al 98.5 Nb 0.5 Co 1 270 90 Duc Comparative Example 210 Al 85 Nb 11 Co 4 510 475 Bri Comparative Example 211 Al 94.5 Nb 0.5 Cu 5 340 105 Duc Comparative Example 212 Al 88 Nb 11 Cu 1 490 445 Bri Comparative Example 213 Al 89 Nb 3 Cu 8 475 410 Bri Comparative Example 214 Al 98 Nb 1 Cu 1 410 95 Duc Comparative Example 215 Al 85 Nb 12 Cu 3 550 420 Bri Comparative Example 216 Al 96.5 Pd 0.5 Mn 3 380 105 Duc Comparative Example 217 Al 86 Pd 12 Mn 2 400 435 Bri Comparative Example 218 Al 97 Pd 3 410 95 Duc Comparative Example 219 Al 90 Pd 4 Mn 6 510 420 Bri Comparative Example 220 Al 98 Pd 1 Mn 1 390 80 Duc Comparative Example 221 Al 87 Pd 10 Mn 3 490 465 Bri Comparative Example 222 Al 96.5 Pd 0.5 Fe 3 300 95 Duc Comparative Example 223 Al 83 Pd 13 Fe 2 210 480 Bri Comparative Example 224 Al 98 Pd 1 Fe 1 290 105 Duc Comparative Example 225 Al 87 Pd 10 Fe 3 460 435 Bri Comparative Example 226 Al 90 Pd 4 Fe 6 475 430 Bri Comparative Example 227 Al 95.5 Pd 0.5 Ni 4 310 90 Duc Comparative Example 228 Al 86 Pd 11 Ni 3 410 465 Bri Comparative Example 229 Al 89 Pd 4 Ni 7 460 450 Bri Comparative Example 230 Al 98 Pd 1 Ni 1 280 85 Duc Comparative Example 231 Al 85 Pd 11 Ni 4 410 460 Bri Comparative Example 232 Al 94.5 Pd 0.5 Co 5 430 120 Duc Comparative Example 233 Al 83 Pd 15 Co 2 290 485 Bri Comparative Example 234 Al 90 Pd 2 Co 8 425 430 Bri Comparative Example 235 Al 98.5 Pd 0.5 Co 1 290 95 DuC Comparative Example 236 Al 85 Pd 11 Co 4 460 465 Bri Comparative Example 237 Al 94.5 Pd 0.5 Cu 5 340 105 Duc Comparative Example 238 Al 88 Pd 11 Cu 1 475 435 Bri Comparative Example 239 Al 89 Pd 3 Cu 8 490 410 Bri Comparative Example 240 Al 98 Pd 1 Cu 1 410 95 Duc Comparative Example 241 Al 85 Pd 12 Cu 3 550 420 Bri Comparative Example Samples No. 4, 5, 6, 18 and 19 of Table 1 do not form part of the invention. It is clear from the results shown in Tables 1 and 2 that an aluminum-based alloy possessing a high bearing force and hardness, which endured bending and could undergo processing, was obtainable when the alloy comprising at least one of Mn, Fe, Co, Ni, and Cu, as element M, in addition to an Al-V, Al-Mo, Al-W, Al-Fe, Al-Nb, or Al-Pd two-component alloy has the atomic percentages satisfied the relationships Al balance Q a M b , 1 ≤ a ≤ 10, 0 < b < 5, 3 ≤ a+b ≤ 12, Q = V, Mo, Fe, W, Nb, and/or Pd, and M = Mn, Fe, Co, Ni, and/or Cu. In contrast to normal aluminum-based alloys which possess an Hv of approximately 50 to 100 DPN, the samples according to the present invention, shown in Table 1, with exception of alloys wherein M is Fe when Q is V or Fe, display an extremely high hardness from 295 to 375 DPN. In addition, in regards to the tensile rupture strength (σ f ), normal age hardened type aluminum-based alloys (Al-Si-Fe type) possess values from 200 to 600 MPa; however, the samples according to the present invention have clearly superior values in the range from 630 to 1350 MPa. Furthermore, when considering that the tensile strengths of aluminum-based alloys of the AA6000 series (alloy name according to the Aluminum Association (U.S.A.)) and AA7000 series which lie in the range from 250 to 300 MPa, Fe-type structural steel sheets which possess a value of approximately 400 MPa, and high tensile strength steel sheets of Fe-type which range from 800 to 980 MPa, it is clear that the aluminum-based alloys according to the present invention display superior values. Fig. 2 shows an X-ray diffraction pattern possessed by an alloy sample having the composition of Al 94 V 4 Fe 2 . Fig. 3 shows an X-ray diffraction pattern possessed by an alloy sample having the composition of Al 95 Mo 3 Ni 2 . Fig. 4 shows an X-ray diffraction pattern possessed by an alloy sample having the composition of Al 91 Nb 6 Co 3 . According to these patterns, each of these three alloy samples has a multiphase structure comprising a fine Al-crystalline phase having an fcc structure and a fine regular-icosahedral quasi-crystalline phase. In these patterns, peaks expressed as (111), (200), (220), and (311) are crystalline peaks of Al having an fcc structure, while peaks expressed as (211111) and (221001) are dull peaks of regular-icosahedral quasi crystals. Fig. 5 shows the DSC (Differential Scanning Calorimetry) curve in the case when an alloy having the composition of Al 94 V 4 Ni 2 is heated at rate of 0.67 K/s. In this figure, a dull exothermal peak, which is obtained when a quasi-crystalline phase is changed to a stable crystalline phase, is seen in the high temperature region.

Claims: An aluminum-based alloy of high strength and high rigidity characterized by consisting of a composition represented by the general formula Al 100-(a+b) Q a M b ; wherein Q is at least one metal element selected from the group consisting of V, Mo, Fe, W, Nb, and Pd; M is at least one metal element selected from the group consisting of Mn, Fe, Co, Ni, and Cu; wherein M is not Fe when Q is V or Fe; and a and b, which represent a composition ratio in atomic percentages, satisfy the relationships 1 ≤ a ≤ 10, 1 ≤ b < 5, and 3 ≤ a+b ≤ 12; said aluminum-based alloy having a metallographic structure comprising a quasi-crystalline phase. An aluminum-based alloy of high strength and high rigidity according to Claim 1, characterized in that said metallographic structure is a multiphase structure comprising a quasi-crystalline phase and an aluminum phase. An aluminum-based alloy of high strength and high rigidity according to Claim 1, characterized in that said metallographic structure is a multiphase structure comprising a quasi-crystalline phase and a metal solid solution having an aluminum matrix. An aluminum-based alloy of high strength and high rigidity according to Claim 1, characterized in that said metallographic structure is a multiphase structure comprising a quasi-crystalline phase and a stable or metastable intermetallic compound phase. An aluminum-based alloy of high strength and high rigidity according to Claim 1, characterized in that said metallographic structure is a multiphase structure comprising a quasi-crystalline phase, an amorphous phase, and a metal solid solution having an aluminum matrix. An aluminum-based alloy of high strength and high rigidity according to one of Claims 1 to 5, characterized in that a+b is not more than 8. An aluminum-based alloy of high strength and high rigidity according to one of Claims 1 to 5, characterized in that a+b is not more than 6. An aluminum-based alloy of high strength and high rigidity according to one of Claims 1 to 7, characterized in that a is not less than 2. An aluminum-based alloy of high strength and high rigidity according to one of Claims 1 to 8, characterized in that a is not more than 8. An aluminum-based alloy of high strength and high rigidity according to one of Claims 1 to 8, characterized in that a is not more than 6. An aluminum-based alloy of high strength and high rigidity according to one of Claims 1 to 11, characterized in that b is not more than 3. An aluminum-based alloy of high strength and high rigidity according to one of Claims 1 to 11, characterized in that b is not more than 2. A production method for an aluminium-based alloy of high strength and high rigidity having a metallographic structure incorporating a quasi-crystalline phase, said production method characterized by comprising a step selected from the group of: the step of performing quick-quench solidification of an alloy liquid-melt, by means of a liquid quick-quenching method; the step of forming a thin layer by using an alloy liquid-melt; the step of quick-quenching an alloy liquid-melt by means of an atomizer method; and the step of quick-quenching an alloy liquid-melt by means of a spray method; said alloy liquid-melt consisting of Al having an amount in atomic percentage of 100-(a+b), element Q having an amount in atomic percentage of a, and element M having an amount in atomic percentage of b; wherein said element Q is at least one metal element selected from the group consisting of V, Mo, Fe, W, Nb, and Pd; element M is at least one metal element selected from the group consisting of Mn, Fe, Co, Ni, and Cu; wherein M is not Fe when Q is V or Fe; and a and b satisfy the relationships 1 ≤ a ≤ 10, 1 ≤ b < 5, and 3 ≤ a+b ≤ 12.

Inventors: HORIO YUMA, INOUE AKIHISA, KIMURA HISAMICHI, HORIO, YUMA, INOUE, AKIHISA, KIMURA, HISAMICHI, Horio, Yuma, c/o Yamaha Corp.
Applicants: INOE AKIHISA, MASUMOTO TSUYOSHI, YAMAHA CORP, INOUE, AKIHISA, MASUMOTO, TSUYOSHI, YAMAHA CORPORATION
Application year: 1995
Main classification: C22C21
IPC codes: C22C21, C23C26, C22C1, C23C6, B22F9