Aluminum alloy containing copper and zinc

Abstract

Disclosed is an elementally mixed Al—Cu—Zn base powder blend for a sintered Al base alloy. The powder blend includes more than 5.6 wt % and less than 9 wt % Cu, 1˜5 wt % Zn, and a balance Al. With the powder blend, an article of a sintered Al base alloy having higher wear resistance as well as higher tensile strength can be fabricated.

1 . An aluminum alloy comprising Al, Cu and Zn, 
 wherein a portion of the alloy comprises: 
 Cu in an amount over 5.6 wt % and less than about 9 wt % with reference to  
   the weight of the portion; and 
 Zn in an amount from about 1 wt % to about 5 wt % with reference to the weight of the portion.  
   
     
     
         2 . The alloy of  claim 1 , wherein the portion comprises Al-containing grains and an intergrain material disposed between and interconnecting neighboring grains, wherein a substantial amount of Cu is present in the intergrain material, and wherein a substantial amount of Zn is present in central areas of the Al-containing grains.  
     
     
         3 . The alloy of  claim 2 , wherein a substantial amount of Cu present in the intergrain material is in the form of CuAl 2 .  
     
     
         4 . The alloy of  claim 3 , wherein substantially the entire amount of Cu present in the intergrain material is in the form of CuAl 2 .  
     
     
         5 . The alloy of  claim 2 , wherein the intergrain material comprises a portion which comprises Cu in an amount from about 20 wt % to about 60 wt % with reference to the weight of the portion of the intergrain material.  
     
     
         6 . The alloy of  claim 2 , wherein substantially the entire amount of Zn is present in the Al-containing grains.  
     
     
         7 . The alloy of  claim 1 , wherein the portion of the alloy comprises Cu in an amount from about 6 wt % to about 8 wt % with reference to the weight of the portion.  
     
     
         8 . The alloy of  claim 1 , wherein the portion of the alloy contains Sn in an amount from about 0.01 wt % to about 0.05 wt % with reference to the weight of the portion.  
     
     
         9 . The alloy of  claim 1 , wherein the portion of the alloy contains Mg in an amount less than about 0.03 wt % with reference to the weight of the portion.  
     
     
         10 . The alloy of  claim 1 , wherein the alloy is produced by a method, which comprises: 
 providing a powder mixture comprising Al, Cu and Zn; and    heating the powder mixture to a temperature sufficient to melt at least part of the powder mixture.    
     
     
         11 . A method of making an aluminum alloy, comprising: 
 providing a powder mixture comprising Al, Cu and Zn, wherein Cu is in an amount over 5.6 wt % and less than about 9 wt % with reference to the weight of the powder mixture, and wherein Zn is in an amount from about I wt % to about 5 wt % with reference to the weight of the powder mixture; and    heating the powder mixture to a temperature sufficient to melt at least part of the powder mixture.    
     
     
         12 . The method of  claim 11 , wherein the powder mixture comprises Al-containing particles, and wherein a substantial amount of Zn is dissolved into at least part of the Al-containing particles.  
     
     
         13 . The method of  claim 11 , wherein upon heating at least part of the powder mixture is melt to form a liquefied state, and wherein a substantial amount of Cu is present in the liquefied state.  
     
     
         14 . The method of  claim 11 , further comprising cooling the heated powder mixture thereby forming an alloy comprising a portion which comprises Al-containing grains and an intergrain material disposed between and interconnecting neighboring grains, wherein a substantial amount of Cu is present in the intergrain material.  
     
     
         15 . An aluminum alloy produced by the method of  claim 11 , wherein a portion of the alloy comprises Al-containing grains and an intergrain material disposed between and interconnecting neighboring grains, wherein a substantial amount of Cu is present in the intergrain material, and wherein a substantial amount of Zn is present in central areas of the Al-containing grains.  
     
     
         16 . The alloy of  claim 15 , wherein a substantial amount of Cu in the intergrain material is present in the form of CuAl 2 .  
     
     
         17 . The alloy of  claim 16 , wherein substantially the entire amount of Cu in the intergrain material is present in the form of CuAl 2 .  
     
     
         18 . The alloy of  claim 15 , wherein a substantial amount of Zn is present in the Al-containing grains.  
     
     
         19 . The alloy of  claim 18 , wherein substantially the entire portion of Zn is present in the Al-containing grains.  
     
     
         20 . A powder blend for use in making an aluminum alloy, the powder blend comprising Al, Cu and Zn, wherein the powder blend comprises: 
 Cu in an amount over 5.6 wt % and less than about 9 wt % with reference to the weight of the powder blend; and    Zn in an amount from about 1 wt % to about 5 wt % with reference to the weight of the powder blend.    
     
     
         21 . The powder blend of  claim 20 , wherein the powder blend comprises Cu in an amount from about 6 wt % to about 8 wt % with reference to the weight of the powder blend.  
     
     
         22 . The powder blend of  claim 20 , wherein the powder blend comprises Sn in an amount from about 0.01 wt % to about 0.05 wt % with reference to the weight of the powder blend.  
     
     
         23 . The powder blend of  claim 20 , wherein the powder blend comprises Mg in an amount less than about 0.03 wt % with reference to the weight of the powder blend.