KR20220129568A - Die-cast aluminum alloy for structural elements - Google Patents

Abstract

An alloy composition comprising Al is disclosed, wherein the alloy comprises a yield strength of at least about 130 MPa and a bend angle of at least about 20° at a cross-sectional thickness of 3 mm without further processing in the as-cast state. Methods of forming alloys are also described.

Description

Die-cast aluminum alloy for structural elements

INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

Any and all applications for which a foreign or domestic priority claim is identified, for example, in an application data sheet or application filed with this application, are hereby incorporated by reference in accordance with 37 CFR 1.57 and Rules 4.18 and 20.6, e.g. For example, U.S. Provisional Application No. 62/964,554, filed on January 22, 2020, and U.S. Provisional Application No. 63/093,608, filed on October 19, 2020, are incorporated herein by reference in their entirety.

Field

The present invention relates to aluminum alloys. More specifically, the present invention relates to aluminum alloys with improved strength, ductility and castability for high performance applications including automotive parts.

Commercial cast aluminum alloys for specific applications, such as structural components in electric vehicle chassis, typically require both high strength and ductility. For example, it is desirable to form these parts through a casting process so that they can be cast quickly and reliably through the high pressure die casting process. After casting, a suitable alloy should retain sufficient structural properties for the required use. Poor castability of alloys often results in hot tearing, which can lead to filling problems that reduce the mechanical properties of the part, typically encountered in the casting process. Additionally, many structural elements that are die cast may require heat treatment, quenching, solution treatment, or aging of the element after casting to improve strength or ductility. However, heat treatment may require large capital expenditures and long process times, and may result in costly yield losses. This problem is further compounded by large part sizes that can be complicated to undergo heat treatment processes such as quenching processes.

It may be desirable to produce a cast aluminum alloy that has a high yield strength such that the alloy does not break easily and contains sufficient ductility. It may also be desirable to produce a cast aluminum alloy that does not require heat treatment.

For the purpose of summarizing the present invention and the advantages achieved over the prior art, certain objects and advantages of the present invention are set forth herein. Not all such objects or advantages may be achieved in any particular embodiment. Thus, for example, one of ordinary skill in the art would be skilled in the art that the present invention is implemented or carried out in a manner that achieves or optimizes one advantage or group of advantages taught herein without necessarily achieving another object or advantage that may be taught or suggested herein. will recognize that it can be

All of these embodiments are intended to be within the scope of the invention disclosed herein. These and other embodiments will be readily understood by those skilled in the art from the following detailed description of the preferred embodiments with reference to the accompanying drawings, the invention not being limited to any particular preferred embodiment(s) disclosed.

In one aspect, an alloy composition is described. The alloy composition comprises Al, wherein the alloy has a yield strength of at least about 130 MPa and a bend angle of at least about 20° at 3 mm cross-sectional thickness without further processing in the as-cast state. include

In some embodiments, the alloy comprises a yield strength of at least about 130 MPa in the as-cast state without further processing. In some embodiments, the alloy comprises a bend angle of at least about 24° at a cross-sectional thickness of 3 mm without further processing in the as-cast state. In some embodiments, the alloy comprises a flow length of at least about 1.8 m. In some embodiments, the alloy comprises an α-Al volume fraction of at least about 90%.

In some embodiments, the alloy comprises from about 0.03 weight percent to about 0.25 weight percent Mg ₂ Si phase. In some embodiments, the alloy comprises from about 0.01% to about 0.9% by weight Al ₂ Cu phase. In some embodiments, the alloy comprises from about 0.03 weight percent to about 0.2 weight percent AlCuMgSi phase. In some embodiments, the alloy comprises from about 0.3% to about 3% by weight AlFeSi phase. In some embodiments, the alloy composition further comprises Cu and Mg, wherein the weight ratio of Cu:Mg is from about 4:1 to about 1:1. In some embodiments, the alloy has an oxygen reduction factor (ORF) for A380 kinetics of at most about 1.

In some embodiments, the alloy composition further comprises one or more of the following:

about 6.5 to 7.5 weight percent Si;

about 0.4 to 0.8 weight percent Cu;

about 0.3 to 0.7 weight percent Mn;

about 0.1 to 0.4 weight percent Mg;

up to about 0.4 weight percent Fe;

about 0.05 to 0.15 weight percent V;

about 0.01 to 0.03 weight percent Sr;

up to about 0.15 weight percent Ti;

up to about 0.03 weight percent Cr; and

remaining Al and incidental impurities.

In some embodiments, the alloy composition further comprises one or more of the following:

about 6.5 to 7.5 weight percent Si;

about 0.4 to 0.8 weight percent Cu;

about 0.3 to 0.7 weight percent Mn;

about 0.1 to 0.4 weight percent Mg;

up to about 0.4 weight percent Fe;

about 0.05 to 0.15 weight percent V;

about 0.01 to 0.03 weight percent Sr;

up to about 0.15 weight percent Ti;

up to about 0.03 weight percent Cr; and

remaining Al and incidental impurities.

In some embodiments, the alloy composition further comprises one or more of the following:

about 6 to 11 weight percent Si;

about 0.3 to 0.8 weight percent Cu;

about 0.3 to 0.8 weight percent Mn;

about 0.1 to 0.4 weight percent Mg;

up to about 0.5% by weight Fe;

about 0.05 to 0.15 weight percent V;

about 0.01 to 0.05 weight percent Sr;

up to about 0.15 weight percent Ti;

up to about 0.03 weight percent Cr; and

remaining Al and incidental impurities.

In some embodiments, the incidental impurities are up to about 0.1% by weight.

In another aspect, an automotive article comprising the alloy composition is described. In some embodiments, the automotive article is an automotive chassis.

In one aspect, a method of making an alloy is described. The method includes providing alloy components, wherein at least one of the alloy components comprises Al, melting the alloy components to form a molten alloy, and cooling the molten alloy to cast. forming an alloy that has been formed, wherein the as-cast alloy has a yield strength of at least about 130 MPa, and a bend angle of at least about 20° at a 3 mm cross-sectional thickness.

In some embodiments, no further processing is performed on the cast alloy. In some embodiments, the method further comprises die casting the molten alloy. In some embodiments, the die casting is high-pressure die-casting (HPDC). In some embodiments, the method further comprises further processing the cast alloy to form a treated alloy. In some embodiments, the additional processing step is selected from the group consisting of heat treatment, aging, solution treatment, surface finishing, and combinations thereof.

1 is a chart depicting the bending angle and yield strength of a number of commercial alloys and target alloys of some embodiments.
2 is a bar chart showing predicted and tested yield strengths of alloys of some embodiments.
3A is a plot of bending angle and α-aluminum volume fraction for alloys of some embodiments.
3B is a plot of bending angle and magnesium/nickel content for alloys of some embodiments.
4 is a bar chart depicting predicted and tested normalized flow lengths of alloys of some embodiments.
5 is a plot showing bending angle and yield strength for alloys of some embodiments.
6A is a bar chart showing experimental results of flow length and silicon content for alloys of some embodiments.
6B is a line graph showing calculated results showing the relationship between bending angle and FCC mole fraction as a function of silicon content for alloys of some embodiments.
7 is a predictive model chart showing yield strength at a Cu:Mg ratio of 3:1 at various magnesium and silicon weight percentages for alloys of some embodiments.
8A is a plot showing experimental results of bending angles for alloys of some embodiments comprising various amounts of magnesium and strontium.
8B is a plot showing experimental results of tensile yield strength and bending angle for alloys of some embodiments having various copper and magnesium weight percentages.
9A is an optical microscope cross-sectional image of a comparative alloy.
9B is an optical microscope cross-sectional image of an alloy in accordance with some embodiments.
10A is an optical microscope cross-sectional image of an aluminum and silicon alloy.
10B is an optical microscope cross-sectional image of an aluminum, silicon and strontium alloy.

The present invention may be understood with reference to the following detailed description. It is noted that, for clarity of description, certain elements in the various figures may not be drawn to scale, may be represented schematically or conceptually, or otherwise not correspond exactly to the particular physical configuration of an implementation. do.

Embodiments relate to aluminum alloys useful for making articles such as vehicle chassis or chassis components. In one embodiment, the vehicle is an electric vehicle powered by a battery pack. In one embodiment, the alloy was created to provide sufficient castability, provide relatively high yield strength and ductility, as well as eliminate the need for subsequent heat treatment of the cast alloy. In one embodiment, the alloy comprises a yield strength of at least about 130 MPa and a bend angle of at least about 20° at 3 mm cross-sectional thickness without further processing in the as-cast state. In one embodiment, aluminum alloys include vanadium to provide many of these enhancements. In another embodiment, the aluminum alloy has a specific weight ratio of copper to magnesium to provide these many enhancements of the alloy with the desired characteristics. In one embodiment, the aluminum alloy has a weight ratio of Cu:Mg of from about 4:1 to about 1:1. In one embodiment, the aluminum alloy has a Cu:Mg weight ratio of from about 4:1 to about 2:1. As noted below, aluminum alloys having this composition have been found to have high yield strength and high ductility compared to available aluminum alloys. As noted below, aluminum alloys are described herein as weight percent (wt. %) of the total elements and particles in the alloy, as well as specific properties of the alloy. It will be understood that the remaining composition of any alloy described herein is aluminum and incidental impurities.

aluminum alloy composition

1 is a chart showing the bending angle and yield strength of a number of commercial high pressure die cast (HPDC) alloys. The target alloy mechanical requirements of FIG. 1 indicated that the yield strength was greater than 135 MPa and the bending angle was greater than 24°. However, Figure 1 shows that commercial alloys either require heat treatment to meet the necessary mechanical requirements, or do not meet the necessary requirements.

In contrast, an embodiment of the present invention relates to a cast aluminum alloy having both high yield strength and high ductility without the need for heat treatment after casting. Aluminum alloys have been found to have high yield strength and high ductility compared to existing commercially available aluminum alloys. Aluminum alloys are described herein as weight percent (wt. %) of the total elements and particles in the alloy as well as the specific properties of the alloy. It will be understood that the remaining composition of any alloy described herein is aluminum and incidental impurities.

Impurities may be present in the starting material or may be introduced during one of the processing and/or manufacturing steps to produce the aluminum alloy. Incidental impurities are compounds and/or elements that do not affect or substantially affect the material properties of the composition, such as yield strength, ductility, and eliminating the need for heat treatment. In some embodiments, the total incidental impurities are 1 wt %, 0.5 wt %, 0.2 wt %, 0.1 wt %, 0.05 wt %, or 0.01 wt %, or any value range therebetween, about, at most, or up to about 1 wt%, 0.5 wt%, 0.2 wt%, 0.1 wt%, 0.05 wt%, or 0.01 wt%, or any value range therebetween. In an embodiment, the total incidental impurities are at or about, at most, or at most about 1 wt%, 0.5 wt%, 0.2 wt%, 0.1 wt%, 0.05 wt% or 0.01 wt%, or any value range therebetween 1 wt%, 0.5 wt%, 0.2 wt%, 0.1 wt%, 0.05 wt%, or 0.01 wt%, or any range of values in between. In some embodiments, each incidental elemental impurity is 0.5 wt%, 0.2 wt%, 0.1 wt%, 0.05 wt%, 0.01 wt%, 0.005 wt%, or 0.001 wt%, or any value range in between, or about, at most, or at most about 0.5%, 0.2%, 0.1%, 0.05%, 0.01%, 0.005%, or 0.001% by weight, or any value range therebetween.

In some embodiments, the aluminum alloy composition comprises 6.5 to 7.5 wt%, or about 6.5 to 7.5 wt% Si, 0.4 to 0.8 wt%, or about 0.4 to 0.8 wt% Cu, 0.3 to 0.7 wt%, or Mn in the range of about 0.3 to 0.7 weight percent, Mg in the range of 0.2 to 0.4 weight percent, or Mg in the range of about 0.2 to 0.4 weight percent, up to 0.4 weight percent, or up to about 0.4 weight percent Fe, 0.05 to 0.15 weight percent, or about 0.05 V in the range of 0.15 wt%, 0.01 to 0.03 wt%, or Sr in the range of about 0.01 to 0.03 wt%, up to 0.15 wt%, or up to about 0.15 wt% Ti, up to 0.03 wt%, or up to about 0.03 wt% of Cr, and the remaining composition (based on weight percent) is Al and incidental impurities, with a total maximum incidental impurity of 0.15 or 0.1 weight percent. In some embodiments, each incidental elemental impurity is 0.05 wt%, about 0.05 wt%, up to 0.05 wt%, or up to about 0.05 wt%.

In some embodiments, the aluminum alloy composition comprises 6.5 to 11 wt%, or about 6.5 to 11 wt% Si, 0.3 to 0.8 wt%, or about 0.3 to 0.8 wt% Cu, 0.3 to 0.8 wt%, or Mn in the range of about 0.3 to 0.8 weight percent, Mg in the range of 0.1 to 0.4 weight percent, or about 0.1 to 0.4 weight percent, up to 0.5 weight percent, or up to about 0.5 weight percent Fe, 0.05 to about 0.15 weight percent, or about 0.05 to about 0.15 weight percent V, 0.01 to 0.05 weight percent, or about 0.01 to 0.05 weight percent Sr, up to 0.15 weight percent, or up to about 0.15 weight percent Ti, up to 0.03 weight percent, or up to about 0.03 weight percent % Cr, the remaining composition (based on wt. %) being Al and incidental impurities, with a total maximum incidental impurity of 0.15 or 0.1 wt. %. In some embodiments, each incidental elemental impurity is 0.05 wt%, about 0.05 wt%, up to 0.05 wt%, or up to about 0.05 wt%.

In some embodiments, the aluminum alloy composition comprises 15 wt%, 13 wt%, 12 wt%, 11 wt%, 10 wt%, 9 wt%, 8 wt%, 7 wt%, 6 wt%, of silicon (Si); 5 wt% or 3 wt%, or any range of values therebetween, or about, at most, or at most about 15 wt%, 13 wt%, 12 wt%, 11 wt%, 10 wt%, 9 wt%, 8% by weight, 7% by weight, 6% by weight, 5% by weight or 3% by weight, or any value range therebetween. In some embodiments, the aluminum alloy composition comprises copper (Cu) in 1 wt%, 0.9 wt%, 0.8 wt%, 0.7 wt%, 0.6 wt%, 0.5 wt%, 0.4 wt%, 0.3 wt%, 0.2 wt% or 0.1 wt%, or any range of values therebetween, or about, at most, or at most about 1 wt%, 0.9 wt%, 0.8 wt%, 0.7 wt%, 0.6 wt%, 0.5 wt%, 0.4 wt%, 0.3% by weight, 0.2% by weight or 0.1% by weight, or any value range therebetween. In some embodiments, the aluminum alloy composition contains manganese (Mn) in 0.6 wt%, 0.5 wt%, 0.45 wt%, 0.4 wt%, 0.35 wt%, 0.3 wt%, 0.25 wt%, 0.2 wt%, 0.15 wt%, 0.1 wt% or 0.05 wt%, or any range of values therebetween, or about, at most, or at most about 0.6 wt%, 0.5 wt%, 0.45 wt%, 0.4 wt%, 0.35 wt%, 0.3 wt%, 0.25% by weight, 0.2% by weight, 0.15% by weight, 0.1% by weight or 0.05% by weight, or any value range therebetween. In some embodiments, the aluminum alloy composition contains iron (Fe) in 0.8 wt%, 0.7 wt%, 0.6 wt%, 0.5 wt%, 0.4 wt%, 0.3 wt%, 0.2 wt%, 0.1 wt%, 0.05 wt%, or 0.01 wt%, or any range of values therebetween, or about, at most, or at most about 0.8 wt%, 0.7 wt%, 0.6 wt%, 0.5 wt%, 0.4 wt%, 0.3 wt%, 0.2 wt% , 0.1 wt %, 0.05 wt %, or 0.01 wt %, or any range of values therebetween. In some embodiments, the aluminum alloy composition comprises 4 wt%, 3 wt%, 2.5 wt%, 2 wt%, 1.5 wt%, 1 wt%, 0.5 wt%, 0.4 wt%, 0.3 wt%, vanadium (V); 0.2 wt%, 0.1 wt%, or 0.05 wt%, or any range of values therebetween, or about, at most, or up to about 4 wt%, 3 wt%, 2.5 wt%, 2 wt%, 1.5 wt%, 1 wt %, 0.5 wt %, 0.4 wt %, 0.3 wt %, 0.2 wt %, 0.1 wt % or 0.05 wt %, or any value range therebetween. In some embodiments, the aluminum alloy composition comprises 0.1 wt%, 0.08 wt%, 0.07 wt%, 0.06 wt%, 0.05 wt%, 0.045 wt%, 0.04 wt%, 0.035 wt%, 0.03 wt%, strontium (Sr); 0.025 wt%, 0.02 wt%, 0.015 wt%, 0.01 wt% or 0.005 wt%, or any range of values therebetween, or about, at most, or at most about 0.1 wt%, 0.08 wt%, 0.07 wt%, 0.06 wt%, 0.05 wt%, 0.045 wt%, 0.04 wt%, 0.035 wt%, 0.03 wt%, 0.025 wt%, 0.02 wt%, 0.015 wt%, 0.01 wt% or 0.005 wt%, or any in between Included as an amount in the range of values. In some embodiments, the aluminum alloy composition comprises 0.3 wt%, 0.2 wt%, 0.15 wt%, 0.14 wt%, 0.13 wt%, 0.12 wt%, 0.1 wt%, 0.08 wt%, 0.07 wt%, titanium (Ti); 0.06 wt%, 0.05 wt%, 0.04 wt%, 0.03 wt%, 0.02 wt%, 0.01 wt% or 0.005 wt%, or any range of values therebetween, or about, at most or at most about 0.3 wt%, 0.2 wt%, 0.15 wt%, 0.14 wt%, 0.13 wt%, 0.12 wt%, 0.1 wt%, 0.08 wt%, 0.07 wt%, 0.06 wt%, 0.05 wt%, 0.04 wt%, 0.03 wt%, 0.02 wt% , 0.01% by weight or 0.005% by weight, or any value range therebetween. In some embodiments, the aluminum alloy composition comprises 0.1 wt%, 0.07 wt%, 0.05 wt%, 0.04 wt%, 0.03 wt%, 0.02 wt%, 0.01 wt%, or 0.005 wt% of chromium (Cr), or in between. any range of values, or about, at most, or at most about 0.1 wt%, 0.07 wt%, 0.05 wt%, 0.04 wt%, 0.03 wt%, 0.02 wt%, 0.01 wt%, or 0.005 wt%, or between Inclusive of amounts in any range of values. In some embodiments, the aluminum alloy composition comprises 0.1 wt%, 0.07 wt%, 0.05 wt%, 0.04 wt%, 0.03 wt%, 0.02 wt%, 0.01 wt%, or 0.005 wt% of each minor elemental impurity, or these any range of values in between, or about, at most, or at most about 0.1%, 0.07%, 0.05%, 0.04%, 0.03%, 0.02%, 0.01%, or 0.005% by weight, or these Inclusive of amounts in any range of values in between. In some embodiments, the aluminum alloy composition contains 0.3 wt%, 0.2 wt%, 0.15 wt%, 0.1 wt%, 0.07 wt%, 0.05 wt%, 0.04 wt%, 0.03 wt%, 0.02 wt% of the total maximum incidental impurities %, 0.01 wt%, or 0.005 wt%, or any range of values therebetween, or about, at most, or up to about 0.3 wt%, 0.2 wt%, 0.15 wt%, 0.1 wt%, 0.07 wt%, 0.05 weight percent, 0.04 weight percent, 0.03 weight percent, 0.02 weight percent, 0.01 weight percent, or 0.005 weight percent, or any value range therebetween.

In some embodiments, the aluminum alloy composition has a Cu:Mg weight ratio of 4:1, 3.5:1, 3:1, 2.5:1, 2:1, 1.5:1, or 1:1, or any in-between. range of values, or about 4:1, 3.5:1, 3:1, 2.5:1, 2:1, 1.5:1, or 1:1, or any range of values in between.

In some embodiments, the a-Al volume fraction of the alloy is 85%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, or 99%, or in between. is any range of values, or about, at least, or at least about 85%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98% or 99%, or these Any range of values in between.

In some embodiments, the aluminum alloy composition comprises 2 wt%, 1.5 wt%, 1 wt%, 0.9 wt%, 0.8 wt%, 0.7 wt%, 0.6 wt%, 0.5 wt%, 0.45 wt%, Mg ₂ Si phase, 0.4 wt%, 0.35 wt%, 0.3 wt%, 0.25 wt%, 0.2 wt%, 0.15 wt%, 0.1 wt%, 0.05 wt%, 0.04 wt%, 0.03 wt%, 0.02 wt%, 0.01 wt% or 0.005 wt% %, or any range of values therebetween, or about 2 wt%, about 1.5 wt%, about 1 wt%, about 0.9 wt%, about 0.8 wt%, about 0.7 wt%, about 0.6 wt%, about 0.5 wt% wt%, about 0.45 wt%, about 0.4 wt%, about 0.35 wt%, about 0.3 wt%, about 0.25 wt%, about 0.2 wt%, about 0.15 wt%, about 0.1 wt%, about 0.05 wt%, about 0.04 wt% weight percent, about 0.03 weight percent, about 0.02 weight percent, about 0.01 weight percent, or about 0.005 weight percent, or any range of values therebetween, or less than 2 weight percent, less than 1.5 weight percent, less than 1 weight percent, 0.9 weight percent Less than 0.8 wt%, less than 0.7 wt%, less than 0.6 wt%, less than 0.5 wt%, less than 0.45 wt%, less than 0.4 wt%, less than 0.35 wt%, less than 0.3 wt%, less than 0.25 wt%, 0.2 less than %, less than 0.15%, less than 0.1%, less than 0.05%, less than 0.04%, less than 0.03%, less than 0.02%, less than 0.01%, or less than 0.005% by weight, or in between. Any range of values, or less than about 2 wt%, less than about 1.5 wt%, less than about 1 wt%, less than about 0.9 wt%, less than about 0.8 wt%, less than about 0.7 wt%, less than about 0.6 wt%, about 0.5 wt% less than about 0.45 wt%, less than about 0.4 wt%, less than about 0.35 wt%, about 0 wt% Less than .3 wt%, less than about 0.25 wt%, less than about 0.2 wt%, less than about 0.15 wt%, less than about 0.1 wt%, less than about 0.05 wt%, less than about 0.04 wt%, less than about 0.03 wt%, about less than 0.02% by weight, less than about 0.01% by weight, or less than about 0.005% by weight, or any value range therebetween. In some embodiments, the aluminum alloy composition comprises 2 wt%, 1.7 wt%, 1.5 wt%, 1.4 wt%, 1.3 wt%, 1.2 wt%, 1.1 wt%, 1 wt%, 0.9 wt%, Al ₂ Cu phase, 0.8 wt%, 0.7 wt%, 0.6 wt%, 0.5 wt%, 0.45 wt%, 0.4 wt%, 0.35 wt%, 0.3 wt%, 0.25 wt%, 0.2 wt%, 0.15 wt%, 0.1 wt%, 0.05 wt% %, 0.04 wt%, 0.03 wt%, 0.02 wt%, 0.01 wt%, 0.008 wt%, 0.005 wt% or 0.001 wt%, or any range of values therebetween, or about 2 wt%, about 1.7 wt% , about 1.5 wt%, about 1.4 wt%, about 1.3 wt%, about 1.2 wt%, about 1.1 wt%, about 1 wt%, about 0.9 wt%, about 0.8 wt%, about 0.7 wt%, about 0.6 wt% , about 0.5 wt%, about 0.45 wt%, about 0.4 wt%, about 0.35 wt%, about 0.3 wt%, about 0.25 wt%, about 0.2 wt%, about 0.15 wt%, about 0.1 wt%, about 0.05 wt% , about 0.04 wt%, about 0.03 wt%, about 0.02 wt%, about 0.01 wt%, about 0.008 wt%, about 0.005 wt% or about 0.001 wt%, or any range of values therebetween, or 2 wt% Less than, less than 1.7 wt%, less than 1.5 wt%, less than 1.4 wt%, less than 1.3 wt%, less than 1.2 wt%, less than 1.1 wt%, less than 1 wt%, less than 0.9 wt%, less than 0.8 wt%, 0.7 wt% less than 0.6 wt%, less than 0.5 wt%, less than 0.45 wt%, less than 0.4 wt%, less than 0.35 wt%, less than 0.3 wt%, less than 0.25 wt%, less than 0.2 wt%, less than 0.15 wt%, 0.1 wt% Less than, less than 0.05 wt%, less than 0.04 wt%, less than 0.03 wt%, less than 0.02 wt%, 0.01 Less than % by weight, less than 0.008% by weight, less than 0.005% by weight, or less than 0.001% by weight, or any range of values therebetween, or less than about 2% by weight, less than about 1.7% by weight, less than about 1.5% by weight, about 1.4 Less than about 1.3 wt%, less than about 1.2 wt%, less than about 1.1 wt%, less than about 1 wt%, less than about 0.9 wt%, less than about 0.8 wt%, less than about 0.7 wt%, about 0.6 wt% less than, less than about 0.5%, less than about 0.45%, less than about 0.4%, less than about 0.35%, less than about 0.3%, less than about 0.25%, less than about 0.2%, less than about 0.15%, Less than about 0.1 wt%, less than about 0.05 wt%, less than about 0.04 wt%, less than about 0.03 wt%, less than about 0.02 wt%, less than about 0.01 wt%, less than about 0.008 wt%, less than about 0.005 wt% or about 0.001 wt% % by weight, or any value range therebetween. In some embodiments, the aluminum alloy composition comprises 2 wt%, 1.7 wt%, 1.5 wt%, 1.4 wt%, 1.3 wt%, 1.2 wt%, 1.1 wt%, 1 wt%, 0.9 wt%, 0.8 wt% AlCuMgSi phase %, 0.7 wt%, 0.6 wt%, 0.5 wt%, 0.45 wt%, 0.4 wt%, 0.35 wt%, 0.3 wt%, 0.25 wt%, 0.2 wt% %, 0.15 wt%, 0.1 wt%, 0.05 wt% , 0.04 wt%, 0.03 wt%, 0.02 wt%, 0.01 wt%, 0.008 wt%, 0.005 wt% or 0.001 wt%, or any value range therebetween, or about, at least, or at least about 2 wt% , 1.7 wt%, 1.5 wt%, 1.4 wt%, 1.3 wt%, 1.2 wt%, 1.1 wt%, 1 wt%, 0.9 wt%, 0.8 wt%, 0.7 wt%, 0.6 wt%, 0.5 wt%, 0.45 wt%, 0.4 wt%, 0.35 wt%, 0.3 wt%, 0.25 wt%, 0.2 wt% %, 0.15 wt%, 0.1 wt%, 0.05 wt%, 0.04 wt%, 0.03 wt%, 0.02 wt%, 0.01 wt% %, 0.008% by weight, 0.005% by weight or 0.001% by weight, or any value range therebetween. In some embodiments, the aluminum alloy composition comprises 6 wt%, 5 wt%, 4.5 wt%, 4 wt%, 3.7 wt%, 3.5 wt%, 3.4 wt%, 3.2 wt%, 3.1 wt%, 3 wt% AlFeSi phase %, 2.9 wt%, 2.8 wt%, 2.7 wt%, 2.6 wt%, 2.5 wt%, 2.4 wt%, 2.2 wt%, 2 wt%, 1.8 wt%, 1.5 wt%, 1.2 wt%, 1 wt%, 0.9 wt%, 0.8 wt%, 0.7 wt%, 0.6 wt%, 0.5 wt%, 0.45 wt%, 0.4 wt%, 0.35 wt%, 0.3 wt%, 0.25 wt%, 0.2 wt%, 0.15 wt%, 0.1 wt% % or 0.05 wt%, or any range of values therebetween, or about 6 wt%, about 5 wt%, about 4.5 wt%, about 4 wt%, about 3.7 wt%, about 3.5 wt%, about 3.4 wt% %, about 3.2%, about 3.1%, about 3%, about 2.9%, about 2.8%, about 2.7%, about 2.6%, about 2.5%, about 2.4%, about 2.2% %, about 2 wt%, about 1.8 wt%, about 1.5 wt%, about 1.2 wt%, about 1 wt%, about 0.9 wt%, about 0.8 wt%, about 0.7 wt%, about 0.6 wt%, about 0.5 wt% %, about 0.45 wt%, about 0.4 wt%, about 0.35 wt%, about 0.3 wt%, about 0.25 wt%, about 0.2 wt%, about 0.15 wt%, about 0.1 wt%, or about 0.05 wt%, or in-between or less than 6 wt%, less than 5 wt%, less than 4.5 wt%, less than 4 wt%, less than 3.7 wt%, less than 3.5 wt%, less than 3.4 wt%, less than 3.2 wt%, 3.1 wt% % less than 3 wt%, less than 2.9 wt%, less than 2.8 wt%, less than 2.7 wt%, less than 2.6 wt%, less than 2.5 wt%, less than 2.4 wt%, less than 2.2 wt%, less than 2 wt%, less than 1.8 wt%, less than 1.5 wt%, less than 1.2 wt%, less than 1 wt%, less than 0.9 wt%, less than 0.8 wt%, less than 0.7 wt%, less than 0.6 wt%, less than 0.5 wt%, less than 0.45 wt%; less than 0.4 wt%, less than 0.35 wt%, less than 0.3 wt%, less than 0.25 wt%, less than 0.2 wt%, less than 0.15 wt%, less than 0.1 wt% or less than 0.05 wt%, or any range of values in between; or less than about 6 wt%, less than about 5 wt%, less than about 4.5 wt%, less than about 4 wt%, less than about 3.7 wt%, less than about 3.5 wt%, less than about 3.4 wt%, less than about 3.2 wt%, about Less than 3.1 wt%, less than about 3 wt%, less than about 2.9 wt%, less than about 2.8 wt%, less than about 2.7 wt%, less than about 2.6 wt%, less than about 2.5 wt%, less than about 2.4 wt%, less than about 2.2 wt% %, less than about 2 wt%, less than about 1.8 wt%, less than about 1.5 wt%, less than about 1.2 wt%, less than about 1 wt%, less than about 0.9 wt%, less than about 0.8 wt%, less than about 0.7 wt% , less than about 0.6 wt%, less than about 0.5 wt%, less than about 0.45 wt%, less than about 0.4 wt%, less than about 0.35 wt%, less than about 0.3 wt%, less than about 0.25 wt%, less than about 0.2 wt%, about Less than 0.15 wt%, less than about 0.1 wt%, or less than about 0.05 wt%, or any range of values therebetween, or at least or at least about 6 wt%, 5 wt%, 4.5 wt%, 4 wt%, 3.7 wt% %, 3.5 wt%, 3.4 wt%, 3.2 wt%, 3.1 wt%, 3 wt%, 2.9 wt%, 2.8 wt%, 2.7 wt%, 2.6 wt%, 2.5 wt%, 2.4 wt%, 2.2 wt%, 2 wt%, 1.8 wt%, 1.5 wt%, 1.2 wt%, 1 wt%, 0.9 wt%, 0.8 wt%, 0.7 wt%, 0 .6 wt%, 0.5 wt%, 0.45 wt%, 0.4 wt%, 0.35 wt%, 0.3 wt%, 0.25 wt%, 0.2 wt%, 0.15 wt%, 0.1 wt% or 0.05 wt%, or in between Any range of values is included.

alloy yield strength

Industrial applications where thousands or hundreds of thousands of aluminum alloy parts can be cast may require high yield strength. As shown in Figure 2, the predicted and tested yield strengths of the alloys of embodiments 1B3, 2F5, 3D2, 3C1, 3I1, 365-3, 365-2, 1B4, 3C3a, 3C3b, 3I3a, 3I3b and 3D3 were evaluated became

The aluminum alloys described herein have a yield strength of at least or at least about 120 MPa. In some embodiments, the yield strength is 120 MPa, 125 MPa, 130 MPa, 135 MPa, 140 MPa, 145 MPa, 150 MPa, 155 MPa, 160 MPa, 165 MPa, 170 MPa, 180 MPa or 200 MPa, or these or about, at least, or at least about 120 MPa, 125 MPa, 130 MPa, 135 MPa, 140 MPa, 145 MPa, 150 MPa, 155 MPa, 160 MPa, 165 MPa, 170 MPa, 180 MPa or 200 MPa, or any value range in between. In some embodiments, the yield strength is 120 MPa, 125 MPa, 130 MPa, 135 MPa, 140 MPa, 145 MPa, 150 MPa, 155 MPa, 160 MPa, 165 MPa, 170 MPa, 180 MPa or 200 MPa, or these or about 120 MPa, about 125 MPa, about 130 MPa, about 135 MPa, about 140 MPa, about 145 MPa, about 150 MPa, about 155 MPa, about 160 MPa, about 165 MPa, about 170 MPa, about 180 MPa, or about 200 MPa, or any range of values therebetween.

alloy ductility

The ductility of the metal alloy must also be considered so that the part can be reproducibly manufactured using the casting process. The ductility of an alloy can be measured by the bending angle and/or elongation of the alloy, although the bending angle is preferred.

3A is a plot of bending angle and α-aluminum volume fraction for an alloy, and FIG. 3B is a plot of bending angle and magnesium/nickel content for alloys of some embodiments.

In some embodiments, the bending angle of the alloy is 15°, 20°, 23°, 25°, 30°, 35°, 40°, or 50°, or any value range in between, or about, at least , or at least about 15°, 20°, 23°, 25°, 30°, 35°, 40°, or 50°, or any range of values in between. In some embodiments, the bending angle is 15°, 20°, 23°, 25°, 30°, 35°, 40°, 50° or 60°, or any value range in between, or about 15°, about 20°, about 23°, about 25°, about 30°, about 35°, about 40°, about 50° or about 60°, or any range of values in between. In some embodiments, the bend angle is measured at 3 mm cross-sectional thickness. In some embodiments, the bend angle is measured using the VDA238-100 evaluation standard. In some embodiments,

Die Cast Performance and Flowability

In addition to sufficient yield strength and ductility when casting, the cast aluminum alloy must provide sufficient flowability and resistance to hot tearing and shrinkage cracking during high pressure die casting (HPDC). Unless otherwise specified, flow lengths described herein are flow lengths under HPDC conditions. In a metal casting process, the metal alloy must have sufficient fluidity to flow into the mold and fill all intricacies of the mold. If the mold has narrow and/or long mold channels, a sufficiently high alloy fluidity is required to fill the mold. 4 is a bar chart showing predicted and tested normalized flow lengths of alloys of some embodiments under HPDC conditions.

The formula for predicting the flow length of alloys in sand casting under HPDC conditions is as follows.

Hot tearing and shrinkage cracking are common and fatal defects observed when casting alloys, including aluminum alloys. Without the ability to prevent hot tearing of alloys, reliable and reproducible parts cannot be made. Hot tearing is the formation of irreversible cracks while a cast part is still in a semi-solid casting. Although hot tear is often related to the casting process itself and to the generation of thermal stresses during the contraction of the melt flow during solidification, the basic thermodynamics and microstructure of the alloy play a role.

In some embodiments, the alloy is 1 m, 1.1 m, 1.2 m, 1.3 m, 1.4 m, 1.5 m, 1.6 m, 1.7 m, 1.8 m, 1.9 m, 2 m, 2.2 m, 2.5 m, under HPDC conditions; 3 m or 5 m, or any range of values therebetween, or about, at least, or at least about 1 m, 1.1 m, 1.2 m, 1.3 m, 1.4 m, 1.5 m, 1.6 m, 1.7 m, 1.8 m , 1.9 m, 2 m, 2.2 m, 2.5 m, 3 m or 5 m, or any value range in between. In some embodiments, the alloy does not or substantially does not develop hot tear and/or shrinkage cracking over the entire casting flow length.

Corrosion resistance/oxidation resistance

Structural casting is expected to persist within the harsh environment of automotive applications. In some embodiments, the cast alloy is resistant to corrosion and/or oxidation. In some embodiments, the alloy has an oxygen reduction factor (ORF) for A380 kinetics of 2, 1.5, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2 or 0.1, or any in-between. is a range of values or is about, at most, or at most about 2, 1.5, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2 or 0.1, or any value range in between. The formula to calculate ORF is as follows.

In the above formula,

a _i = current density associated with noble phase i (see Table 3)

Vi = volume fraction of noble phase i

It's _A380 = -965 mV _SCE Oxygen reduction current density of cast A380 (reference alloy) in

processing method

In some embodiments, a melt for an alloy may be prepared by heating the alloy above the melting temperature of the alloy components. As the melt is cast and cooled to room temperature, the alloy can be cooled at various rates. Depending on the processing conditions, the grain size can be larger or smaller, the size and number of deposits can be increased or decreased, and can help to minimize as-cast segregation.

In some embodiments, the alloy is die cast. In some embodiments, the alloy is high pressure die cast (HPDC). In certain embodiments, the aluminum alloy is cast without further processing. In some embodiments, the cast aluminum alloy is not further processed through heat treatment and retains the yield strength and ductility as noted above. In another embodiment, the cast aluminum alloy is further processed. In some embodiments, the additional processing methods include heat treatment, aging, solution treatment, and surface finishing.

In certain embodiments, after forming the aluminum-alloy melt, it can be cast with a die to form a high-performance article or part. In some implementations, the product may be an automotive part, such as a part of a chassis and/or other crash component.

Example

Example 1

A predictive model was performed to calculate the yield strength and ductility (eg, bending angle) of an aluminum alloy cast without additional heat treatment. Many predicted aluminum alloy compositions were produced, including compositions 3C1, 3C3a, 3C3b, 3C4, 3C5, 3C6, 3C7, 3C8, 3C9 and 3C10, and were experimentally tested for casting yield strength and ductility without heat treatment. The results of these experimental tests are shown in Figure 5, a plot showing the bending angle and yield strength of alloy compositions 3C1, 3C3a, 3C3b, 3C4, 3C5, 3C6, 3C7, 3C8, 3C9 and 3C10.

The element weight percent compositions of alloy compositions 3C1, 3C3a, 3C3b, 3C4, 3C5, 3C6, 3C7, 3C8, 3C9 and 3C10 in which the remaining composition is aluminum are shown in Table 1 below. The cast aluminum alloy composition of 3C10 was found to have a yield strength of about 143 MPa and a bending angle of about 25°, and the composition of aluminum alloy 3C10 belongs to alloys 1, 2 and 3 shown in Table 2 below.

Example 2

An increased silicon content is known to decrease the ductility of the alloy, but in traditional die casting conditions for aluminum alloys, the silicon content is relatively high, about 8 to 12 wt % to have sufficient fluidity during casting. This is because the relative increase in the heat of fusion due to the silicon content increases the latent heat contribution so that the heat can be retained in the alloy system during casting so that the alloy can remain in the liquid phase for a sufficient time to obtain a sufficient casting length. However, it is not readily clear whether the same silicon concentration is required for flowability when the alloy is cast under HPDC conditions.

6A is a bar chart showing experimental results of flow length and silicon content for alloys of some embodiments under HPDC conditions through a 3 mm cross-sectional thickness. The casting was made using a high pressure die casting machine weighing approximately 700 tons and a die designed to maintain a uniform flow front for 3 mm thick castings up to 2 m long. Various alloys were tested under identical casting conditions and the casting flow length was quantified.

6A shows that the alloy composition having 7.5 wt % silicon has a flow length of about 1.4 m, the alloy composition having 8.5 wt % silicon has a flow length of about 1.45 m, and the alloy composition having 9.5 wt % silicon has a flow length of about 1.45; It is shown that the flow length is m. As can be seen, there is a sharp drop in the flowability gain of flow length for Si contents above 7.5 wt %. Thus, the silicon range for the alloy composition should be maintained above 6 wt% to achieve advantageous flow length, but at 11 wt% (e.g., to minimize the effect of the eutectic silicon phase on ductility reduction) 8 wt% or 7.5 wt%). As such, it has been found that under HPDC conditions, increased silicon content compared to silicon content in traditional die casting conditions does not necessarily significantly enhance flow length growth. These findings allow the alloy silicon content to be reduced to achieve HPDC cast alloys with relatively longer flow lengths and improved ductility.

6B is a line graph showing calculated results showing the relationship between bending angle and FCC (ie, aluminum matrix) mole fraction as a function of silicon content for alloys of some embodiments. While the FCC of aluminum is the ductile phase present in the alloy composition, the silicon eutectic phase is the relatively more brittle phase. Figure 6b shows this relationship between aluminum and silicon, where the FCC mole fraction and bending angle decrease as the silicon content of the alloy increases.

Example 3

7 is a predictive model chart showing yield strength at a Cu:Mg ratio of 3:1 at various magnesium and silicon weight percentages for alloys of some embodiments. The increase in copper, magnesium and/or silicon is calculated to increase the yield strength of the alloy, in part through the formation of reinforcing deposits (eg, Mg ₂ Si, Al ₂ Cu and AlCuMgSi), but the reduced aluminum content is usually the alloy leads to a decrease in ductility. However, FIG. 7 shows that alloys with a Cu:Mg ratio of about 3:1 (eg, 2:1 to 4:1) and silicon composition ranges of alloys 1, 2, or 3 of Table 2 show the yield strength and ductility of alloys. Demonstrates careful balance. This Cu:Mg ratio selection unexpectedly and advantageously promotes the formation of an AlCuMgSi precipitate, which yields the alloy without substantially interfering with ductility compared to other precipitates (eg, Mg ₂ Si and/or Al ₂ Cu). improve strength;

8A is a plot showing experimental results of bending angles for alloys of some embodiments comprising various amounts of magnesium and strontium. As demonstrated, both the magnesium solute content and Mg ₂ Si contribute to the yield strength, but negatively affect the ductility.

8B is a plot showing experimental results of tensile yield strength and bending angle for alloys of some embodiments having various copper and magnesium weight percentages. As demonstrated, the cast 3 mm coupon results were consistent with the predictions shown in FIG. 7 showing improved yield strength and reduced ductility associated with increased magnesium content.

Example 4

9A and 9B are optical microscopic cross-sectional images of comparative alloys and alloys of the present invention, respectively, in which the indicated phases were found and analyzed using energy-dispersive X-ray spectroscopy (EDS). The comparative alloy of FIG. 9A contains less than 0.05 weight percent vanadium, which is outside the scope of alloys 1, 2 and 3 of Table 2. In FIG. 9A , feature 902 is an AlFeSi(Mn) phase that appears in plate shape, found to contain less than 0.2 wt. % V, and feature 904 is in ductility, found to contain greater than 1.2 wt. % V. AlFeSi(Mn+V) phase with more favorable spherical morphology. Those skilled in the art will recognize that increased sharp morphological features (eg, plate morphology) caused in part by iron impurities increase alloy crack initiation and propagation.

In contrast, the alloy of FIG. 9b exhibits a reduction in plate morphology, and features 906 on AlFeSi(Mn+V), which have a more favorable spherical morphology for ductility, found to generally contain greater than 1.2 wt % V show As such, it was demonstrated that vanadium and manganese can be used to reduce iron impurity solubility and to stabilize the AlFeSi(Mn,V) phase with round morphology. This allows the alloy to maintain high ductility while increasing its tolerance to Fe.

Example 5

10A is an optical microscopy cross-sectional image of aluminum and silicon alloys containing 9.5 wt % silicon and the remainder aluminum and incidental impurities, and FIG. , are optical microscopic cross-sectional images of silicon and strontium alloys. 10A shows a silicon eutectic phase with a sharp morphology known to reduce ductility, whereas the use of a strontium alloy as a modifier in FIG. appear.

While specific embodiments have been described, these examples are presented by way of example only and are not intended to limit the scope of the invention. Indeed, the novel method and system described herein may be embodied in a variety of other forms. Moreover, various omissions, substitutions, and changes may be made in the systems and methods described herein without departing from the spirit of the invention. It is intended that the appended claims and their equivalents cover forms or modifications that fall within the scope and spirit of the present invention.

A feature, material, characteristic, or group described in connection with a particular aspect, embodiment, or example also applies to any other aspect, embodiment, or example described in this section or elsewhere herein, except where incompatible. It should be understood as applicable. All features disclosed in this specification (including any appended claims, abstract and drawings) and/or all steps of any method or process so disclosed constitute a mutually exclusive combination of at least some of such features and/or steps. It can be combined in any combination except for. The scope of protection is not limited to the details of all the aforementioned implementations. The scope of protection extends to any novelty of the features disclosed in this specification (including all appended claims, abstract and drawings), or any novel combination of features, or any novelty of the steps of any method or process so disclosed. , or any novel combination.

Moreover, certain features that are described herein in the context of separate implementations may also be implemented in combination into a single implementation. Conversely, various features that are described in the context of a single implementation may be implemented in multiple implementations individually or in any suitable subcombination. Moreover, although features may be described above as acting in a particular combination, one or more features of a claimed combination may in some cases be eliminated from the combination, and the combination may be claimed as a sub-combination or variant of a sub-combination.

Moreover, although operations may be shown in the drawings or described in the specification in a specific order, such operations need not be performed in the specific order or sequential order presented or all operations are performed to achieve desirable results. Other operations not shown or described may be included in the exemplary methods and processes. For example, one or more additional actions may be performed before, after, concurrently with, or between any described actions. In addition, tasks may be rearranged or rearranged in other implementations. Those skilled in the art will recognize that, in some embodiments, the actual steps taken in the illustrated and/or disclosed processes may differ from the steps presented in the drawings. Depending on the implementation, certain of the above steps may be removed and other steps may be added. Moreover, the features and attributes of certain embodiments disclosed above may be combined in other ways to form additional embodiments, all of which are within the scope of the present invention. Further, the separation of various system components in the foregoing implementations should not be construed as requiring such separation in all implementations, and that the described components and systems may generally be integrated together into a single product or packaged into multiple products. should be understood For example, any of the components for an energy storage system described herein may be provided separately or integrated together (eg, packaged together or attached together) to form an energy storage system.

For the purposes of the present invention, certain aspects, advantages and novel features are described herein. Not all of these advantages may necessarily be achieved with any particular implementation. Thus, for example, one of ordinary skill in the art would know that the invention may be implemented or carried out in a manner that achieves one advantage or group of advantages taught herein without necessarily achieving other advantages that may be taught or suggested herein. will recognize that

Conditional language, such as "can, could, might, or may", unless otherwise specifically stated or understood otherwise within the context in which it is used, generally means that a particular embodiment has a particular feature, element, and/or It is intended to convey that while including steps, other implementations do not.Therefore, such conditional language generally means that features, elements, and/or steps are required for one or more implementations in any way, or that one or more Logic for an implementation to determine, with or without user input or prompting, whether such features, elements and/or steps are included in or performed in any particular implementation. is not intended to imply that it must include

Connection languages such as the phrase "at least one of X, Y, and Z" are generally used to convey that an item, term, etc., can be either X, Y, or Z, unless specifically stated otherwise. understood with context. Accordingly, this connection language is generally not intended to mean that a particular implementation requires the presence of at least one of X, at least one of Y, and at least one of Z.

As used herein, the terms "about," "about," "generally," and "substantially," as used herein, refer to any reference that can perform a desired function or achieve a desired result. Denotes a value, amount, or characteristic that is close to a given value, amount, or characteristic. For example, the terms “approximately”, “about”, “generally”, and “substantially” refer to less than 10%, less than 5%, less than 1% of the stated amount, depending on the desired function or desired result. , less than 0.1%, and less than 0.01%.

The scope of the invention is not intended to be limited by the specific disclosure of preferred embodiments in this section or elsewhere herein, but may be defined by the claims set forth in this section or elsewhere herein or later. have. The language of the claims is to be interpreted broadly based on the language used in the claims, and not limited to the examples set forth herein or during the examination of the application, which examples should be construed as non-exclusive.

The headings provided herein, where present, are for convenience only and do not necessarily affect the scope or meaning of the devices and methods disclosed herein.

Claims (23)

An alloy composition comprising Al, comprising:
wherein the alloy comprises a yield strength of at least about 130 MPa and a bend angle of at least about 20° at 3 mm cross-sectional thickness without further processing in the as-cast state. alloy composition. The composition of claim 1 , wherein the alloy comprises a yield strength of at least about 130 MPa in the as-cast state without further processing. The composition of claim 1 , wherein the alloy comprises a bend angle of at least about 24° at a cross-sectional thickness of 3 mm without further processing in the as-cast state. The composition of claim 1 , wherein the alloy comprises a flow length of at least about 1.8 m. The composition of claim 1 , wherein the alloy comprises an α-Al volume fraction of at least about 90%. The composition of claim 1 , wherein the alloy comprises from about 0.03% to about 0.25% by weight of the Mg ₂ Si phase. The composition of claim 1 , wherein the alloy comprises from about 0.01% to about 0.9% by weight. Al ₂ Cu A composition comprising a phase. The composition of claim 1 , wherein the alloy comprises from about 0.03 weight percent to about 0.2 weight percent AlCuMgSi phase. The composition of claim 1 , wherein the alloy comprises from about 0.3% to about 3% by weight AlFeSi phase. The composition of claim 1 , wherein the composition further comprises Cu and Mg, and the weight ratio of Cu:Mg is from about 4:1 to about 2:1. The composition of claim 1 , wherein the alloy has an oxygen reduction factor (ORF) for A380 kinetics of at most about 1. The composition of claim 1 , further comprising:
about 6 to 11 weight percent Si;
about 0.3 to 0.8 weight percent Cu;
about 0.3 to 0.8 weight percent Mn;
about 0.1 to 0.4 weight percent Mg;
up to about 0.5% by weight Fe;
about 0.05 to 0.15 weight percent V;
about 0.01 to 0.05 weight percent Sr;
up to about 0.15 weight percent Ti;
up to about 0.03 weight percent Cr; and
remaining Al and incidental impurities. The composition of claim 1 , further comprising:
about 6.5 to 7.5 weight percent Si;
about 0.4 to 0.8 weight percent Cu;
about 0.3 to 0.7 weight percent Mn;
about 0.1 to 0.4 weight percent Mg;
up to about 0.4 weight percent Fe;
about 0.05 to 0.15 weight percent V;
about 0.01 to 0.03 weight percent Sr;
up to about 0.15 weight percent Ti;
up to about 0.03 weight percent Cr; and
remaining Al and incidental impurities. The composition of claim 1 , further comprising:
about 6 to 11 weight percent Si;
about 0.3 to 0.8 weight percent Cu;
about 0.3 to 0.8 weight percent Mn;
about 0.15 to 0.4 weight percent Mg;
up to about 0.5% by weight Fe;
about 0.05 to 0.15 weight percent V;
about 0.01 to 0.05 weight percent Sr;
up to about 0.15 weight percent Ti;
up to about 0.03 weight percent Cr; and
remaining Al and incidental impurities. 13. The composition of claim 12, wherein the incidental impurities are up to about 0.1% by weight. An automotive article comprising the composition according to claim 1 . The article of claim 16 , wherein the automotive article is an automotive chassis. A method of making an alloy, the method comprising:
providing alloy components wherein at least one of the alloy components comprises Al;
melting the alloy components to form a molten alloy; and
cooling the molten alloy to form a cast alloy;
wherein the as-cast alloy comprises a yield strength of at least about 130 MPa, and a bend angle of at least about 20° at a 3 mm cross-sectional thickness. The method of claim 18 , wherein no further processing is performed on the cast alloy. 19. The method of claim 18, further comprising die-casting the molten alloy. The method of claim 20 , wherein the die casting is high-pressure die-casting (HPDC). 19. The method of claim 18, further comprising further processing the cast alloy to form a worked alloy. 23. The method of claim 22, wherein the further processing step is selected from the group consisting of heat treatment, aging, solution treatment, surface finishing, and combinations thereof.

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