DE102019118944A1 - HYPEREUTECTIC ALLOY WITH IMPROVED EXPANSION AND IMPACT RESISTANCE - Google Patents

Abstract

Hypereutectic alloy with improved elongation and impact resistance, a composition of the hypereutectic alloy related to the generation of an intermolecular compound phase and primary Si. The hypereutectic alloy has: 1.0 to 3.0% by weight copper (Cu), 0.1 to 0.3% by weight magnesium (Mg), 13.5 to 15.5% by weight silicon (Si), 0.1% by weight or less nickel (Ni), and a balance by aluminum (Al). Therefore, it is possible to have an improved abrasion resistance compared to an ADC12 alloy and to have an improved elongation and an improved impact resistance compared to a K14 alloy.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority from Korean Patent Application No. 10-2018-0160172 filed on December 12, 2018 with the Korean Intellectual Property Office, the entirety of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to a composition of a hypereutectic (e.g. a hypereutectic) alloy, and more particularly to a composition related to the generation of an intermolecular compound phase and primary Si.

Description of related technology

Currently, an ADC12 alloy and a K14 alloy, which are commercially available aluminum alloys, have a problem in that these alloys are difficult to use with thin-walled gear parts that require abrasion resistance and elongation. The reason for this is that in the case of an ADC12 alloy which is a eutectic alloy, abrasion resistance is poor. As a result, the phenomenon of wear due to an opposing steel part is apparent when the alloy is used in thin-walled clutch parts of a transmission. In the case of a K14 alloy, which is a hypereutectic alloy that has excellent abrasion resistance, elongation and breaking strength are reduced by primary Si, which serves as an abrasion-resistant particle. In addition, there have been various efforts to improve abrasion resistance characteristics of an ADC12 alloy, such as by shot peening or heat treatment, but there is a problem that these efforts are not effective to improve abrasion resistance. To improve characteristics.

EXPLANATION OF THE INVENTION

An object of the present invention is to simultaneously improve elongation (e.g. elongation) and impact resistance in an alloy compared to a K14 alloy, while improving abrasion resistance compared to an ADC12 alloy.

To achieve the goal, the present invention provides a hypereutectic (eg, hypereutectic) alloy comprising: 1.0 to 3.0 wt% copper (Cu), 0.1 to 0.3 wt% magnesium (Mg), 13.5 to 15.5% by weight silicon (Si), 0.1% by weight or less nickel (Ni), and a compensation by (e.g. a remainder, e.g. a remainder) aluminum (Al ).

In one embodiment, the hypereutectic alloy may further comprise: 0.5 wt% or less iron (Fe).

In one embodiment, the hypereutectic alloy may further comprise: 0.1 wt% or less manganese (Mn).

In one embodiment, the hypereutectic alloy may further comprise: 0.1 wt% or less zinc (Zn).

In one embodiment, primary Si particles can have an average size of 30 µm or less.

According to the present invention, it is possible in an alloy to have improved abrasion resistance compared to an ADC12 alloy, and to have improved extensibility (e.g. improved elongation) and improved impact resistance compared to a K14 alloy.

Figure list

• 1A and 1B respectively represent intermetallic compound phases in Examples 1 and 2 of the present invention.
• 2A and 2 B respectively represent intermetallic compound phases in Comparative Examples 1 and 2 of the present invention.
• 3rd represents an intermetallic compound phase in Comparative Example 3 of the present invention.
• 4A FIG. 10 is an image of an intermetallic compound phase of a hypereutectic (eg, hypereutectic) alloy having 2.5% by weight of copper (Cu) as an example of the present invention, and 4B FIG. 14 is an image of an intermetallic compound phase of a hypereutectic (eg, hypereutectic) alloy containing 3.5% by weight of copper (Cu) as a comparative example of the present invention.
• 5A-5D are pictures showing sizes of primary Si according to the content of magnesium (Mg) and in 5A-5D contain 0.2% by weight, 0.3% by weight, 0.5% by weight, and 0.8% by weight of magnesium (Mg) respectively (assigned).
• 6 represents average particle sizes of primary Si according to the content of magnesium (Mg).
• 7A is a picture of the structure when the content of silicon (Si) is higher than 15.5% by weight, and 7B is a picture of the structure when the content of silicon (Si) is less than 13.5% by weight.
• 8th represents breaking strengths of conditions 1 to 5.

DETAILED DESCRIPTION

Embodiments of the present invention will be described in detail below. However, the present invention is not limited or limited by the disclosed embodiments. Objects and effects of the present invention are naturally understood or will be apparent from the following description, and the objects and effects of the present invention are not limited by the following description only. Further, in the description of the present invention, when it is determined that the detailed description of the well-known technology related to the present invention may unnecessarily obscure the gist of the present invention, the detailed description thereof has been omitted. [Table 1] Assignment Cu Mg Si Fe Mn Zn Ni Al The present invention 1.0 ~ 3.0 0.1∼ 0.3 13.5 ~ 15.5 Max. 0.5 Max. 0.1 Max. 0.1 Max. 0.1 rest Eutectic alloy (ADC12) 1.5-3.5 Max. 0.30 9.6 ~ 12.0 Max. 1.3 Max. 0.5 Max. 1.0 - rest Hypereutectic alloy (K14) 4.0 ~ 5.0 Max. 0.5 13.5 ~ 15.5 Max. 1.3 Max. 0.5 Max. 0.1 Max. 0.5 rest

Table 1 shows the main compositions of the hypereutectic alloy according to the present invention (hereinafter referred to as “present hypereutectic alloy”), an ADC12 alloy which is a eutectic alloy, and a K14 alloy which is a hypereutectic alloy. Referring to Table 1, the present hypereutectic alloy has: 1.0 to 3.0 wt% copper (Cu), 0.1 to 0.3 wt% magnesium (Mg), 13.5 to 15.5 % By weight silicon (Si), 0.1% by weight or less nickel (Ni), and a compensation by (for example a remainder, for example a remainder) aluminum (Al). In addition, the present hypereutectic alloy may further include: 0.5 wt% or less iron (Fe), 0.1 wt% or less manganese (Mn), and 0.1 wt% or less zinc ( Zn).

The characteristics of the present hypereutectic alloy are said to have copper (Cu) in a smaller amount than the copper (Cu) content in the eutectic alloy (ADC12) and the hypereutectic alloy (K14), the smaller amount being 1.0 to 3.0 Is wt .-%, and should the content from magnesium (Mg) to 0.1 to 0.3% by weight in contrast to the eutectic alloy (ADC12) and the hypereutectic alloy (K14).

Copper (Cu) is used to increase the strength of the alloy by forming an Al-Cu-based intermetallic compound during aluminum molten metal solidification. However, when the content of copper (Cu) in the alloy is high, an Al ₂ Cu phase is generated, and magnesium (Mg) forms an Al ₅ Cu ₂ Mg ₈ Si ₆ phase, and the phase is consumed, so that β-Al ₅ FeSi phase is generated. This needle-like (eg needle-shaped) β-Al ₅ FeSi phase causes a considerable reduction in an extensibility (eg an elongation). In contrast, when the content of copper (Cu) is low, a small amount of an Al ₅ Cu ₂ Mg ₈ Si ₆ phase is formed due to a low content of copper (Cu) and Al ₈ Mg ₃ FeSi ₆ is / is crystallized rather than the β-Al ₅ FeSi phase by means of the remaining magnesium (Mg). At the same time, a relatively small amount of a needle-like (eg needle-shaped) β-Al ₅ FeSi phase is formed, which improves the stretchability.

In summary, the present hypereutectic alloy intends to improve the low elongation characteristics of the hypereutectic alloy in the related art by limiting the copper (Cu) content to 1.0 to 3.0% by weight, taking into account that primary Si Particles and a plurality of intermetallic compounds are present in the hypereutectic alloy in the related art, and therefore the stretchability deteriorates.

Magnesium (Mg) is used to control the sizes of primary Si particles, which (e.g. which ones) affect the stretchability. If the content of magnesium (Mg) is less than 0.1% by weight or higher than 0.3% by weight, an average size of primary Si particles may be larger than 30 µm, and therefore the Deterioration in stretchability. Accordingly, in one embodiment to control the average size of primary Si particles to 30 µm or less or smaller, 0.1 to 0.3% by weight of magnesium (Mg) is added.

Silicon (Si) serves to induce primary Si within a range of the eutectic point or more (eg, in a larger range of the eutectic point) and allows the primary Si to improve abrasion resistance than an abrasion-resistant particle . If the content of silicon (Si) in the alloy is less than 13.5% by weight, primary Si is not produced. If the content (of silicon (Si)) is higher than 15.5% by weight, platelet-like (e.g. platelet-shaped) primary Si is crystallized in a large amount. As a result, brittleness (e.g., fragility) is increased. Accordingly, in one embodiment, 13.5 to 15.5 weight percent silicon (Si) is added.

Iron (Fe) is used to prevent the mold from being soldered (eg to prevent a casting from being soldered (eg welded) to the mold) during a casting. When iron (Fe) is added in an amount of more than 0.5% by weight, a plurality of β-Al ₅ FeSi phases are generated. As a result, the stretchability deteriorates. Therefore, in one embodiment, 0.5 wt% or less iron (Fe) is added.

Manganese (Mn) is used to improve the stretchability by suppressing iron (Fe), to produce needle-like (e.g. needle-shaped) β-Al ₅ FeSi due to the (e.g. due to) formation of the Al ₁₅ ( Mn, Fe) Si ₂ phase. If manganese (Mn) is added in an amount of more than 0.1% by weight, an intermetallic compound such as Al ₂₀ Mn ₃ Cu _{2 is} produced. As a result, the stretchability deteriorates. Therefore, in one embodiment, 0.1 wt% or less of manganese (Mn) is added.

Zinc (Zn) is dissolved in aluminum (Al) with a high strength, and therefore it serves to improve the mechanical properties by means of solid solution strengthening (from the English: solid-solution strengthening). If zinc (Zn) is added in an amount of more than 0.1% by weight, the stretchability may deteriorate. Therefore, in one embodiment, 0.1 wt% or less zinc (Zn) is added.

Nickel (Ni) is used to improve heat resistance and abrasion resistance. If nickel (Ni) is added in an amount of more than 0.1% by weight, the elongation may deteriorate because the Al ₃ Ni ₂ and Al ₇ Cu ₄ Ni phases are generated. Therefore, in one embodiment, 0.1 wt% or less nickel (Ni) is added.

[Table 2] Assignment Cu Mg Si Fe Mn Zn Ni example 1 1.19 0.28 14.02 0.022 0.008 0.006 0.013 Example 2 2.51 0.29 14.01 0.024 0.009 0.003 0.014 Comparative Example 1 3.23 0.26 13.75 0.021 0.008 0.004 0.012 Comparative Example 2 4.16 0.22 13.77 0.023 0.012 0.003 0.014 Comparative Example 3 2.50 0.21 13.78 0.023 0.012 0.003 0.31 Comparative Example 4 2.40 0.23 14.21 0.78 0.012 0.002 0.014 Comparative Example 5 2.69 0.66 13.65 0.021 0.009 0.005 0.013 Comparative Example 6 2.54 0.20 15.68 0.023 0.008 0.003 0.014 Comparative Example 7 2.11 0.23 10.55 0.89 0.18 0.74 -

Table 2 shows the compositions of Examples 1 and 2 and Comparative Examples 1 to 7 of the present invention. Referring to Table 2, Comparative Examples 1 and 2 (each assigned) have 3.23 wt% and 4.16 wt% copper (Cu), which is (each) more than the highest copper (Cu) content of the present invention. Comparative Example 3 has 0.31 wt% nickel, which is more than the highest nickel (Ni) content of the present invention. Comparative Example 4 has more than the highest iron (Fe) content. Comparative Example 5 has more than the highest content of magnesium (Mg). Comparative example 6 has more than the highest content of silicon (Si). The composition of Comparative Example 7 is included in the composition of the eutectic alloy, ADC12 alloy, in Table 1.

[Table 3] Assignment Tensile strength (MPa) Yield strength (MPa) Strain (%) Impact strength (J / cm ² ) Amount of wear (g) example 1 249 216 1.13 1.34 0.0093 Example 2 275 234 1.24 1.19 0.008 Comparative Example 1 280 242 0.96 0.90 0.0085 Comparative Example 2 277 254 0.77 0.85 0.0075 Comparative Example 3 291 262 0.54 0.92 0.008 Comparative Example 4 299 247 0.96 0.87 0.006 Comparative Example 5 260 251 0.58 0.78 0.0081 Comparative Example 6 281 271 0.61 0.74 0.003 Comparative Example 7 265 225 1.03 1.17 0.057

Table 3 shows the tensile strength, the yield strength, the elongation, the impact resistance, and the amount of wear in Examples 1 and 2 and Comparative Examples 1 to 7 of the present invention. The tensile strength, the yield strength and the elongation were measured under the condition of 1 mm / min in accordance with ASTM E8M. For the evaluation of an abrasion resistance, the vibration wear test (from the English: reciprocating friction wear test, e.g. back and forth friction wear test) was measured (e.g. carried out) under the conditions of a condition load of 500 N, a temperature of 150 ° C, a frequency of 2.5 Hz, and a time (eg a duration) of 2000 s by selecting a counterpart material (SCr420HB, case hardening). Izod impact strength (e.g., Izod impact strength) was measured in accordance with ASTM E23.

Referring to Table 3, it can be seen that the elongation and elongation and impact resistance in Examples 1 and 2 are better than those in Comparative Examples 1 to 6 and are at a (respective) level that is equivalent to or is higher than the elongation or the extensibility and the impact resistance in Comparative Example 7, which is the composition of the eutectic Alloy. The wear resistance in Examples 1 and 2 is much better than that in Comparative Example 7.

1 (e.g. 1A and 1B) Figure 3 illustrates intermetallic compound phases in Examples 1 and 2 of the present invention 1A and 1B In Examples 1 and 2, primary Si (1), eutectic Si (2), Al ₈ Mg ₃ FeSi ₆ (3), Mg ₂ Si (4), and Al ₅ Cu ₂ Mg ₈ Si ₆ (5) perceived (eg determined), but the β-Al ₅ FeSi phase (4 ') was not perceived (eg determined). From this result, it can be seen that when the copper (Cu) content is 3 wt% or less, the crystallization of the β-Al ₅ FeSi phase is significantly reduced. As a result, the stretchability and the impact resistance are increased.

In contrast, it can be seen that the extensibility and the impact resistance in comparative examples 1 and 2 are lower than the extensibility and the impact resistance in examples 1 and 2. 2A and 2 B represent intermetallic compound phases in Comparative Examples 1 and 2 of the present invention. Referring to FIG 2A and 2 B not only primary Si (1), eutectic Si (2), Al ₂ Cu (3 '), and Al ₅ Cu ₂ Mg ₈ Si ₆ (5), but also β-Al ₅ FeSi (4') were observed ( eg found). From this result, it can be seen that when the copper (Cu) content is higher than 3% by weight, the β-Al ₅ FeSi phase is crystallized. As a result, the stretchability and the impact resistance are reduced.

Comparative Example 3 is a comparative example for evaluating the effectiveness (for example, mode of action) of the nickel (Ni) content added to a commercially available hypereutectic alloy. 3rd represents an intermetallic compound phase in Comparative Example 3 of the present invention. Referring to the stretchability in Comparative Example 3 of FIG 3rd and Table 3 can be seen that the Al ₃ Ni ₂ - (6) and the Al ₇ Cu ₄ Ni phase (7) were perceived (eg found). The elasticity is therefore significantly deteriorated.

Comparative Example 4 is a comparative example for evaluating elongation-deterioration characteristics according to the content of iron (Fe). It can be seen that when the iron (Fe) content is higher than 0.5% by weight, the elongation deteriorates compared to Example 2 because a plurality of the β-Al ₅ FeSi phases are generated .

Comparative Example 5 is a comparative example for evaluating elongation-deterioration characteristics according to the content of magnesium (Mg). It can be seen that if the content of magnesium (Mg) is higher than 0.3% by weight, the particle sizes of primary Si are increased (eg larger) than 30 µm (eg the particle sizes of primary Si are so enlarged that they are over 30 µm in size). As a result, the stretchability deteriorates.

In the case of Comparative Example 6, it can be seen that since the content of silicon (Si) is increased, the amount of primary Si is also increased, and as a result, the stretchability deteriorates. In the case of Comparative Example 7, it can be seen that primary Si serving as an abrasion-resistant particle is not crystallized. As a result, the abrasion resistance deteriorates significantly.

4A Fig. 12 is an image of an intermetallic compound phase of an alloy having 2.5% by weight of copper (Cu) as an example of the present invention. 4B Fig. 10 is an image of an intermetallic compound phase of an alloy having 3.5% by weight of copper (Cu) as a comparative example of the present invention. Referring to 4A and 4B can be confirmed again that it has been determined that the β-Al ₅ FeSi phase (4 ') is crystallized according to (for example in connection) that the content of copper (Cu) is higher than 3% by weight.

5A-5D are pictures showing the sizes of primary Si according to the content of magnesium (Mg). In 5A-5D each contain (assigned) 0.2% by weight, 0.3% by weight, 0.5% by weight, and 0.8% by weight of magnesium. 6 represents an average particle size of primary Si according to the content of magnesium (Mg).

Referring to 5A-5D and 6 it can be confirmed that since the content of magnesium (Mg) is increased, the particle size of primary Si is increased. It can also be seen that when the content of magnesium (Mg) is higher than 0.3 wt%, the average size of the primary Si particles is more (eg, larger) than 30 µm. In contrast, it can be seen that if the content of Magnesium (Mg) is reduced to less than 0.1% by weight, the average size of the primary Si particles is increased and the average size can be more (for example larger) than 30 μm.

7A is a picture of the structure when the content of silicon (Si) is higher than 15.5% by weight, and 7B is a picture of the structure when the content of silicon (Si) is less than 13.5% by weight. Referring to 7A and 7B it can be confirmed that the extensibility and the impact resistance in Comparative Examples 6 and 7 in Table 3 are interrelated (for example, correlate) with a large amount of crystallization and non-crystallization of primary Si.

[Table 4] Assignment ADC14 alloy K14 alloy ADC12-T5 alloy The present invention Strain (%) 0.61 0.74 1.03 1.24 Impact strength (J / cm ² ) 0, 68 0.87 1.17 1.34 Torsional breaking strength (e.g. torsional fatigue strength) (Nm) [kp.m (in English: kgf.m)] ~ 2863.54 [292] ~ 3010.64 [307] ~ 4089.37 [417] ~ 3932.47 [401] (evaluation of a torsional breaking strength meets 1,000,000 cycles) Amount of wear (g) 0.003 0.004 0.057 0.008

[Table 5] Assignment Condition -1 Condition -2 Condition -3 Condition -4 Condition -5 Condition of changing an outside diameter outer diameter Ψ146.7 Ψ147.16 Ψ147.76 Ψ148.36 Ψ148.96 Condition of changing a tooth thickness (e.g. a tooth thickness) Overall wall thickness (e.g. overall wall thickness) 2.17 2.4 2.7 3.0 3.3 Amount of a thickness (e.g. thickness) that is / is increased 0.0 +0.23 +0.53 +0.83 +1.13 Breaking strength (Nm) [kp.m (English: kgf.m)] average ~ 2994.95 [305.4] ~ 3247.96 [331.2] ~ 3777.52 [385.3] ~ 3946.2 [402.4] ~ 4030.53 [411] Minimum value ~ 2617.39 [266.9] ~ 2933.17 [299.1] ~ 3447.04 [351.5] ~ 3687.3 [376] ~ 3472.53 [354.1]

Table 4 is a table of comparing and summarizing the strains, impact strengths, torsional fracture strengths, and amounts of wear of an ADC14 alloy and a K14 alloy, which are hypereutectic alloys, an ADC12-T5 alloy, which is a eutectic alloy , and the present hypereutectic alloy. Table 5 is a table of a summary of average breaking strengths and minimum breaking strengths from Condition-1 to Condition-5, in which the thickness (e.g. thickness) of the present commercial hypereutectic alloy is varied. 8th represents breaking strengths from condition-1 to condition-5.

The present commercial eutectic alloy, such as an ADC12 alloy, has insufficient abrasion resistance and therefore additionally requires a surface treatment method to ensure abrasion resistance when used on parts (e.g. components) that are subject to abrasion - Require resilience. However, abrasion resistance is insufficiently ensured even when the surface treatment method is used, so a present commercial hypereutectic alloy having abrasion resistance is also used. However, when parts (eg components) are manufactured and evaluated by using (e.g. inserting) the present commercial hypereutectic alloy, the stretchability and the impact resistance are insufficient compared to an ADC12 alloy, so that it can be confirmed that the torsional breaking strength is significantly reduced and ~ 3040.06 Nm [310 kp.m] cannot be met. In order to compensate for the disadvantage, the disadvantage can be solved by increasing the thickness of a product (for example a component). In this case, it can be experimentally confirmed that the deterioration of breaking strength can only be corrected if the present thickness is increased by at least 40% or more.

In this case, due to an increase in weight associated with an increase in the thickness of the part (e.g., component), the weight reduction effect is reduced according to the use of an aluminum material. However, when the present hypereutectic alloy is used, it is possible to ensure elongation and impact resistance at a level (e.g. level) that is equivalent to or more (e.g. larger) than that of an ADC12 alloy. Therefore, it is possible to ensure the torsional breaking strength of a product (e.g., a component) that is equivalent to or more (e.g., larger) than that of an ADC12 alloy, and it is possible to provide a level of abrasion resistance (e.g. Level), which is equivalent to that of the commercially available hypereutectic alloy. Accordingly, it can be seen that it is possible to directly use (e.g., use) the present hypereutectic alloy on existing parts (e.g. components) without an additional increase in thickness (e.g. thickness) and without modifying the shape as in the present one commercial hypereutectic alloy. The fatigue life of a part (e.g. a component) can be / be achieved by evaluating the torsional breaking strength of the part.

Aspects of the present invention have been described in detail by the representative examples. However, it will be understood by those skilled in the art to which the present invention pertains that various modifications are possible in the examples described above within the scope that does not depart from the scope of the present invention. Therefore, the scope of the present invention should not be limited to the examples described above, but should be determined not only by means of the claims described below, but also by means of all the changes or modified embodiments, that of the claims and the equivalent concepts thereof are derived.

QUOTES INCLUDE IN THE DESCRIPTION

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Patent literature cited

• KR 1020180160172 [0001]

Claims (14)

Hypereutectic alloy with improved extensibility and impact strength, the hypereutectic alloy comprising: 1.0 to 3.0% by weight copper (Cu), 0.1 to 0.3% by weight of magnesium (Mg), 13.5 to 15.5% by weight of silicon (Si), 0.1 wt% or less nickel (Ni), and a balance aluminum (Al). Hypereutectic alloy according to Claim 1 , further comprising: 0.5% by weight or less of iron (Fe). Hypereutectic alloy according to Claim 1 or 2nd , further comprising: 0.1% by weight or less of manganese (Mn). Hypereutectic alloy according to any of the Claims 1 - 3rd further comprising: 0.1 wt% or less zinc (Zn). Hypereutectic alloy according to any of the Claims 1 - 4th , with primary Si particles having an average size of 30 µm or smaller. Hypereutectic alloy according to any of the Claims 1 - 5 , wherein an elongation of the alloy is higher than that of a K14 alloy. Hypereutectic alloy according to Claim 6 , the elongation of the alloy being 1.13 to 1.24%. Hypereutectic alloy according to any of the Claims 1 - 7 , the wear amount of the alloy is lower than that of an ADC12 alloy. Hypereutectic alloy according to Claim 8 , the wear amount of the alloy being 0.008 to 0.0093g. Hypereutectic alloy according to any of the Claims 1 - 9 , wherein a torsional breaking strength of the alloy is higher than that of a K14 alloy. Hypereutectic alloy according to any of the Claims 1 - 10th , the impact strength of the hypereutectic alloy being higher than that of an ADC14, a K14 and an ADC12 alloy. Hypereutectic alloy according to Claim 11 , the impact strength of the hypereutectic alloy being 1.19 to 1.34J / cm ² . Hypereutectic alloy according to any of the Claims 1 - 12 , wherein the hypereutectic alloy has no β-Al ₅ FeSi phase (4 '). Hypereutectic alloy with improved extensibility and impact strength, the hypereutectic alloy consisting of: 1.0 to 3.0% by weight copper (Cu), 0.1 to 0.3% by weight of magnesium (Mg), 13.5 to 15.5% by weight of silicon (Si), 0.1% by weight or less nickel (Ni), 0.5% by weight or less iron (Fe), 0.1% by weight or less of manganese (Mn), 0.1% by weight or less zinc (Zn), and a balance aluminum (Al).

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