US20240133001A1 - Low cost high ductility cast aluminum alloy - Google Patents
Low cost high ductility cast aluminum alloy Download PDFInfo
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- US20240133001A1 US20240133001A1 US18/402,499 US202418402499A US2024133001A1 US 20240133001 A1 US20240133001 A1 US 20240133001A1 US 202418402499 A US202418402499 A US 202418402499A US 2024133001 A1 US2024133001 A1 US 2024133001A1
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- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 127
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 33
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 32
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 32
- 238000005266 casting Methods 0.000 claims abstract description 22
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 19
- 239000010703 silicon Substances 0.000 claims abstract description 19
- 239000010949 copper Substances 0.000 claims abstract description 17
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 16
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims abstract description 16
- 229910052802 copper Inorganic materials 0.000 claims abstract description 16
- 229910052742 iron Inorganic materials 0.000 claims abstract description 16
- 239000011777 magnesium Substances 0.000 claims abstract description 16
- 239000011701 zinc Substances 0.000 claims abstract description 16
- 229910052725 zinc Inorganic materials 0.000 claims abstract description 16
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims abstract description 15
- 229910052749 magnesium Inorganic materials 0.000 claims abstract description 15
- 239000011572 manganese Substances 0.000 claims abstract description 15
- 229910052712 strontium Inorganic materials 0.000 claims abstract description 14
- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 claims abstract description 14
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 claims abstract description 13
- 229910052748 manganese Inorganic materials 0.000 claims abstract description 13
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims abstract description 12
- 239000010936 titanium Substances 0.000 claims abstract description 12
- 229910052719 titanium Inorganic materials 0.000 claims abstract description 12
- 238000000034 method Methods 0.000 claims description 16
- 238000004519 manufacturing process Methods 0.000 claims description 10
- 239000000725 suspension Substances 0.000 claims description 5
- 229910019752 Mg2Si Inorganic materials 0.000 claims description 3
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 13
- 230000007797 corrosion Effects 0.000 description 8
- 238000005260 corrosion Methods 0.000 description 8
- 230000000052 comparative effect Effects 0.000 description 7
- 239000000203 mixture Substances 0.000 description 7
- 238000012360 testing method Methods 0.000 description 6
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- 230000008901 benefit Effects 0.000 description 3
- 238000004512 die casting Methods 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- 229910001315 Tool steel Inorganic materials 0.000 description 2
- 238000005275 alloying Methods 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 230000005496 eutectics Effects 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 238000005476 soldering Methods 0.000 description 2
- 238000009716 squeeze casting Methods 0.000 description 2
- 229910009369 Zn Mg Inorganic materials 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 125000004122 cyclic group Chemical group 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000007730 finishing process Methods 0.000 description 1
- 230000003116 impacting effect Effects 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000006104 solid solution Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 238000007655 standard test method Methods 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- JBQYATWDVHIOAR-UHFFFAOYSA-N tellanylidenegermanium Chemical compound [Te]=[Ge] JBQYATWDVHIOAR-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/02—Alloys based on aluminium with silicon as the next major constituent
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
- B22D21/002—Castings of light metals
- B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/002—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working by rapid cooling or quenching; cooling agents used therefor
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
- C22F1/043—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with silicon as the next major constituent
Definitions
- the invention relates generally to an aluminum alloy for casting, a method of forming the aluminum alloy, a vehicle component formed of the cast aluminum alloy, and a method of manufacturing the cast component.
- Casting of aluminum alloys is oftentimes used in the automotive industry to form lightweight components, including complex structural, body-in-white, suspension, and chassis components.
- casting processes for example, high pressure die casting, low pressure casting, and squeeze casting.
- the die is typically formed of a hardened tool steel.
- the casting equipment is expensive, the cost per component formed is relatively low, which makes the process suitable for high volume production.
- an aluminum alloy capable of forming a component having higher ductility, without loss of fluidity or castability is desired.
- the aluminum alloy should also be resistant to damage associated with hot cracking, soldering, shrinkage, and corrosion.
- the components should still provide a high strength and toughness.
- One aspect of the invention provides an improved aluminum alloy, comprising: at least 80 weight percent (wt. %) aluminum; 9.5 to 11.5 wt. % silicon; 1.5 max wt. % zinc, for example 0.3 to 0.8 wt. % zinc; 0.1 wt. % to 0.6 wt. % magnesium; 0.10 wt. % to 0.60 wt. % copper, or 0.20 wt. % to 0.90 wt. % copper; 0.2. to 0.6 wt. % manganese, for example 0.2. to 0.5 wt. % manganese; 0.2 wt. % to 0.6 wt. % iron, for example 0.3 wt. % to 0.6 wt. % iron; 0.01 wt. % to 0.07 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.
- Another aspect of the disclosure provides a cast component formed of the improved aluminum alloy.
- Yet another aspect of the disclosure provides a method of manufacturing an improved aluminum alloy.
- the method comprises the steps of: obtaining recycled aluminum or a recycled aluminum alloy; and combining the recycled aluminum or the recycled aluminum alloy with at least one additional element to form the improved aluminum alloy, the improved aluminum alloy comprising: at least 80 weight percent (wt. %) aluminum; 9.5 to 11.5 wt. % silicon; 1.5 max wt. % zinc, for example 0.3 to 0.8 wt. % zinc; 0.1 wt. % to 0.6 wt. % magnesium; 0.10 wt. % to 0.60 wt. % copper, or 0.20 wt. % to 0.90 wt. % copper; 0.2. to 0.6 wt.
- manganese for example 0.2. to 0.5 wt. % manganese; 0.2 wt. % to 0.6 wt. % iron, for example 0.3 wt. % to 0.6 wt. % iron; 0.01 wt. % to 0.07 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.
- Another aspect of the disclosure provides a method of manufacturing a cast component.
- the method comprises the steps of: obtaining recycled aluminum or a recycled aluminum alloy; and combining the recycled aluminum or the recycled aluminum alloy with at least one additional element to form an improved aluminum alloy, the improved aluminum alloy comprising: at least 80 weight percent (wt. %) aluminum; 9.5 to 11.5 wt. % silicon; 1.5 max wt. % zinc, for example 0.3 to 0.8 wt. % zinc; 0.1 wt. % to 0.6 wt. % magnesium; 0.10 wt. % to 0.60 wt. % copper, or 0.20 wt. % to 0.90 wt. % copper; 0.2. to 0.6 wt.
- the method further comprises casting the improved aluminum alloy.
- Another aspect of the disclosure provides an improved aluminum alloy comprising at least 80 weight percent (wt. %) aluminum; 9.5 to 11.5 wt. % silicon; zinc; 0.1 wt. % to 0.6 wt. % magnesium; copper; at least 0.2. wt. % manganese; up to 0.6 wt. % iron; 0.01 wt. % to 0.07 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.
- FIG. 1 illustrates a raw material, specifically a portion of a cast ingot, formed of an aluminum alloy according to an embodiment of the invention
- FIG. 2 illustrates a portion of a component formed of an aluminum alloy according to an embodiment of the invention
- FIG. 3 A discloses examples of different scrap streams, including post-consumer recycled road wheels and pre-consumer wrought stamping offal which can be combined in certain ratios to form an aluminum alloy and cast parts formed of the aluminum alloy according to example embodiments;
- FIGS. 3 B- 3 D illustrate cast parts formed of the aluminum alloy according to example embodiments
- FIG. 4 illustrates a chemical composition of an aluminum alloy according to an example embodiment of the invention (Aural 2R) relative to a comparative aluminum alloy (Aural 2);
- FIG. 5 A is a chart and FIG. 5 B is a table illustrating mechanical properties of the aluminum alloy compositions of FIG. 4 ;
- FIGS. 6 A and 6 B are pictures and FIG. 6 C is a table illustrating results of a rivetability test comparting the aluminum alloy compositions according to FIG. 4 ;
- FIGS. 7 and 8 are results of a corrosion testing on the improved aluminum alloy according to an example embodiment and a comparative aluminum alloy.
- One aspect of the invention provides an improved aluminum alloy for casting components, such as a lightweight automotive vehicle component, is provided.
- components include structural, body-in-white, suspension, or chassis components.
- the aluminum alloy provides a component with improved ductility and elongation, and without hot tearing or loss of fluidity or castability.
- the aluminum alloy is also less expensive than other aluminum alloys used for casting, which is especially beneficial for high volume production.
- An example of a component 10 formed of the aluminum alloy according to example embodiments is shown in FIGS. 2 and 3 B- 3 D .
- the improved aluminum alloy is aluminum-based, and thus typically includes aluminum in an amount of at least 80 weight percent (wt. %), based on the total weight of the aluminum alloy.
- the aluminum alloy also includes an amount of silicon (Si), which helps achieve improved castability of the aluminum alloy and thus reduces a scrap rate and reduces costs.
- Si silicon
- the elongation of the component formed of the aluminum alloy is typically 10% to 20%.
- the castability, strength, and toughness of the aluminum alloy can also be adjusted based on the amount of silicon.
- Additional alloying elements can also be present in the improved aluminum alloy to further improve elongation and ductility, or to achieve the desired strength and toughness.
- magnesium (Mg), manganese (Mn), and/or iron (Fe) can be added to further improve ductility, castability, strength, ductility, and/or toughness.
- the manganese can be used to prevent die sticking, and the magnesium can be used to form Mg 2 Si for strengthening.
- the aluminum alloy can also include certain amounts of copper (Cu) and zinc (Zn) to increase strength, preferably without negatively impacting corrosion resistance.
- the zinc is also used as a solid solution strengthener and to improve machinability.
- the additional alloying elements can provide other metallurgical effects as well, such as improved resistance to hot cracking, soldering, shrinkage, and corrosion.
- Strontium (Sr) can also be added to modify the silicon eutectic morphology which affects the ductility that occur due to the silicon that occur due to the silicon.
- the aluminum alloy in addition to at least 80 wt. % aluminum, includes 9.5 to 11.5 wt. % silicon; 0.1 wt. % to 0.6 wt. % magnesium; 0.10 wt. % to 0.60 wt. % copper; 0.2. to 0.6 wt. % manganese; 0.2 wt. % to 0.6 wt. % iron; 0.01 wt. % to 0.07 wt. % strontium, up to 1.5 wt. % zinc; and up to 0.15 wt. % titanium, based on the total weight of the aluminum alloy.
- the aluminum alloy can also include other elements, for example impurities, each in an amount up to 0.05 wt. % and in a total amount up to 0.15 wt. %, based on the total weight of the aluminum alloy.
- the aluminum alloy in addition to at least 80 wt. % aluminum, includes 9.5 to 11.5 wt. % silicon, 0.3 wt. % to 0.8 wt. % zinc, 0.1 to 0.6 wt. % magnesium, 0.20 wt. % to 0.90 wt. % copper, 0.2 wt. % to 0.5 wt. % manganese, 0.3 wt. % to 0.6 wt. % iron, 0.01 wt. % to 0.03 wt. % strontium, and 0.15 wt. % maximum titanium, based on the total weight of the aluminum alloy.
- the aluminum alloy can also include other elements, for example impurities, each in an amount of less than 0.05 wt. % and in a total amount of less than 0.15 wt. %, based on the total weight of the aluminum alloy.
- compositions of the aluminum alloys according to the first and second example embodiments is provided in Table 1 below.
- the aluminum alloy according to the example embodiments is often referred to as Aural 2R because it is preferably obtained, in part, from recycled aluminum, such as recycled road wheels.
- the energy required to produce the aluminum alloy is reduced by about 95% when the aluminum alloy is formed from recycled materials.
- Another aspect of the invention provides the cast component 10 formed of the aluminum alloy, and a method of manufacturing the cast component 10 by melting and casting the melted aluminum alloy.
- the method of forming the cast component typically begins by melting the aluminum alloy.
- Any casting process used to form components for example high pressure die casting, low pressure casting, or squeeze casting.
- the casting process is a die casting process, which typically includes forcing the molten aluminum alloy into an unheated die or mold cavity under pressure.
- the die is typically formed from hardened tool steel.
- the aluminum alloy according to example embodiments such as the Aural 2R alloys, has a high amount of recycled (secondary materials), and after casting experiences a heat treatment, solution (T4), forced air quench and then artificial age (T7 temper).
- T4 heat treatment, solution
- T7 temper artificial age
- the cast aluminum alloy has a yield strength of at least 100 to 120 MPa, ultimate tensile strength (UTS) of 200 to 210 MPa, and an elongation of 10% to 20%.
- FIG. 4 discloses the composition of the aluminum alloy according to an example embodiment (Aural 2R) relative to a comparative aluminum alloy (Aural 2).
- the aluminum alloy according to example embodiments provides for exceptional mechanical properties, corrosion resistance, rivetability, and castability.
- FIGS. 5 A and 5 B illustrate the mechanical properties of the aluminum alloy according to an example embodiment (Aural 2R) relative to a comparative aluminum alloy (Aural 2). The yield strength, ultimate tensile strength, and elongation are tested using ASTM E8/E8M-21 (Standard Test Methods for Tension Testing of Metallic Materials).
- the composition of the comparative aluminum alloy (Aural 2) includes at least 80 wt. % aluminum, 9.5 to 11.5 wt. % silicon, 0.1 to 0.6 wt.
- magnesium 0.4 wt. % to 0.6 wt. % manganese, 0.25 wt. % max iron, and 0.01 wt. % to 0.25 wt. % strontium, based on the total weight of the aluminum alloy.
- FIGS. 6 A- 6 C illustrate the results of a rivetability test comparing the aluminum alloy of the example embodiment (Aural 2R) to the comparative aluminum alloy (Aural 2).
- the rivetability test included applying a self-piercing rivet to the example aluminum alloy (Aural 2R) and the comparative aluminum alloy (Aural 2).
- the self-piercing rivet is a single-step technique which includes using a semi-tubular rivet to clinch sheets of the aluminum alloy together. The sheets are clamped between a die and blankholder, and the rivet is driven into the sheets between a punch and a die.
- the rivet pierces the top sheet and the die shape causes the rivet to flare within the lower sheet to form a mechanical interlock.
- the die shape causes a button to form on the underside of the lower sheet.
- the rivet tail does not pierce though the button.
- Aural 2R composition exhibited good corrosion resistance when subjected to a salt spray test for 100 hours according to Intergranular Corrosion (IGC) ASTM G110 and Cyclic Corrosion SAE J2334.
- IRC Intergranular Corrosion
- the cast component 10 formed from the casting step can be, for example, a component for use in a vehicle.
- the molten aluminum is formed to a solid component having the shape of the mold, which can be a complex shape.
- Many different types of components can be formed by the casting process, for example, a structural, body-in-white, suspension, or chassis component.
- the method can include an optional heat treating process or other finishing processes. However, it has been found that a heat treatment process may not be necessary when the component is formed from the improved aluminum alloy, which would provide the advantage of reduced process time and costs.
- the cast components formed of the aluminum alloys have good rivetability and castability.
Abstract
An improved aluminum alloy for casting into a component, such as a vehicle component, is provided. The aluminum alloy preferably includes at least 80 weight percent (wt. %) aluminum; 9.5 to 11.5 wt. % silicon; 1.5 max wt. % zinc; 0.1 wt. % to 0.6 wt. % magnesium; 0.10 wt. % to 0.60 wt. % copper; 0.2. to 0.6 wt. % manganese; 0.2 wt. % to 0.6 wt. % iron; 0.01 wt. % to 0.07 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the aluminum alloy. This improved aluminum alloy can be formed by combining recycled aluminum or a recycle aluminum alloy with at least one additional element. The cast component formed of the aluminum alloy has a yield strength of 100 to 120 MPa and an elongation of 10% to 20% when the cast component is in the T7 temper condition
Description
- This U.S. Continuation-In-Part (CIP) Patent Application claims the benefit of U.S. Utility patent application Ser. No. 17/366,175, filed on Jul. 2, 2021, the entire disclosures of the applications being considered part of the disclosure of this application and hereby incorporated by reference.
- The invention relates generally to an aluminum alloy for casting, a method of forming the aluminum alloy, a vehicle component formed of the cast aluminum alloy, and a method of manufacturing the cast component.
- Casting of aluminum alloys is oftentimes used in the automotive industry to form lightweight components, including complex structural, body-in-white, suspension, and chassis components. There are many types of known casting processes, for example, high pressure die casting, low pressure casting, and squeeze casting. The die is typically formed of a hardened tool steel. Although the casting equipment is expensive, the cost per component formed is relatively low, which makes the process suitable for high volume production.
- However, improvements to the casting process and materials used in the casting process are desired. For example, an aluminum alloy capable of forming a component having higher ductility, without loss of fluidity or castability, is desired. The aluminum alloy should also be resistant to damage associated with hot cracking, soldering, shrinkage, and corrosion. In addition, although lightweight components are desired, the components should still provide a high strength and toughness.
- One aspect of the invention provides an improved aluminum alloy, comprising: at least 80 weight percent (wt. %) aluminum; 9.5 to 11.5 wt. % silicon; 1.5 max wt. % zinc, for example 0.3 to 0.8 wt. % zinc; 0.1 wt. % to 0.6 wt. % magnesium; 0.10 wt. % to 0.60 wt. % copper, or 0.20 wt. % to 0.90 wt. % copper; 0.2. to 0.6 wt. % manganese, for example 0.2. to 0.5 wt. % manganese; 0.2 wt. % to 0.6 wt. % iron, for example 0.3 wt. % to 0.6 wt. % iron; 0.01 wt. % to 0.07 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.
- Another aspect of the disclosure provides a cast component formed of the improved aluminum alloy.
- Yet another aspect of the disclosure provides a method of manufacturing an improved aluminum alloy. The method comprises the steps of: obtaining recycled aluminum or a recycled aluminum alloy; and combining the recycled aluminum or the recycled aluminum alloy with at least one additional element to form the improved aluminum alloy, the improved aluminum alloy comprising: at least 80 weight percent (wt. %) aluminum; 9.5 to 11.5 wt. % silicon; 1.5 max wt. % zinc, for example 0.3 to 0.8 wt. % zinc; 0.1 wt. % to 0.6 wt. % magnesium; 0.10 wt. % to 0.60 wt. % copper, or 0.20 wt. % to 0.90 wt. % copper; 0.2. to 0.6 wt. % manganese, for example 0.2. to 0.5 wt. % manganese; 0.2 wt. % to 0.6 wt. % iron, for example 0.3 wt. % to 0.6 wt. % iron; 0.01 wt. % to 0.07 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.
- Another aspect of the disclosure provides a method of manufacturing a cast component. The method comprises the steps of: obtaining recycled aluminum or a recycled aluminum alloy; and combining the recycled aluminum or the recycled aluminum alloy with at least one additional element to form an improved aluminum alloy, the improved aluminum alloy comprising: at least 80 weight percent (wt. %) aluminum; 9.5 to 11.5 wt. % silicon; 1.5 max wt. % zinc, for example 0.3 to 0.8 wt. % zinc; 0.1 wt. % to 0.6 wt. % magnesium; 0.10 wt. % to 0.60 wt. % copper, or 0.20 wt. % to 0.90 wt. % copper; 0.2. to 0.6 wt. % manganese, for example 0.2. to 0.5 wt. % manganese; 0.2 wt. % to 0.6 wt. % iron, for example 0.3 wt. % to 0.6 wt. % iron; 0.01 wt. % to 0.07 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the aluminum alloy. The method further comprises casting the improved aluminum alloy.
- Another aspect of the disclosure provides an improved aluminum alloy comprising at least 80 weight percent (wt. %) aluminum; 9.5 to 11.5 wt. % silicon; zinc; 0.1 wt. % to 0.6 wt. % magnesium; copper; at least 0.2. wt. % manganese; up to 0.6 wt. % iron; 0.01 wt. % to 0.07 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.
- Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
-
FIG. 1 illustrates a raw material, specifically a portion of a cast ingot, formed of an aluminum alloy according to an embodiment of the invention; -
FIG. 2 illustrates a portion of a component formed of an aluminum alloy according to an embodiment of the invention; -
FIG. 3A discloses examples of different scrap streams, including post-consumer recycled road wheels and pre-consumer wrought stamping offal which can be combined in certain ratios to form an aluminum alloy and cast parts formed of the aluminum alloy according to example embodiments; -
FIGS. 3B-3D illustrate cast parts formed of the aluminum alloy according to example embodiments; -
FIG. 4 illustrates a chemical composition of an aluminum alloy according to an example embodiment of the invention (Aural 2R) relative to a comparative aluminum alloy (Aural 2); -
FIG. 5A is a chart andFIG. 5B is a table illustrating mechanical properties of the aluminum alloy compositions ofFIG. 4 ; -
FIGS. 6A and 6B are pictures andFIG. 6C is a table illustrating results of a rivetability test comparting the aluminum alloy compositions according toFIG. 4 ; -
FIGS. 7 and 8 are results of a corrosion testing on the improved aluminum alloy according to an example embodiment and a comparative aluminum alloy. - One aspect of the invention provides an improved aluminum alloy for casting components, such as a lightweight automotive vehicle component, is provided. Examples of such components include structural, body-in-white, suspension, or chassis components. The aluminum alloy provides a component with improved ductility and elongation, and without hot tearing or loss of fluidity or castability. The aluminum alloy is also less expensive than other aluminum alloys used for casting, which is especially beneficial for high volume production. An example of a
component 10 formed of the aluminum alloy according to example embodiments is shown inFIGS. 2 and 3B-3D . - The improved aluminum alloy is aluminum-based, and thus typically includes aluminum in an amount of at least 80 weight percent (wt. %), based on the total weight of the aluminum alloy. The aluminum alloy also includes an amount of silicon (Si), which helps achieve improved castability of the aluminum alloy and thus reduces a scrap rate and reduces costs. Besides the large amount of silicon eutectic phase, after the T7 heat treatment, the elongation of the component formed of the aluminum alloy is typically 10% to 20%. The castability, strength, and toughness of the aluminum alloy can also be adjusted based on the amount of silicon.
- Additional alloying elements can also be present in the improved aluminum alloy to further improve elongation and ductility, or to achieve the desired strength and toughness. For example, magnesium (Mg), manganese (Mn), and/or iron (Fe) can be added to further improve ductility, castability, strength, ductility, and/or toughness. In particular, the manganese can be used to prevent die sticking, and the magnesium can be used to form Mg2Si for strengthening. The aluminum alloy can also include certain amounts of copper (Cu) and zinc (Zn) to increase strength, preferably without negatively impacting corrosion resistance. The zinc is also used as a solid solution strengthener and to improve machinability. The additional alloying elements can provide other metallurgical effects as well, such as improved resistance to hot cracking, soldering, shrinkage, and corrosion. Strontium (Sr) can also be added to modify the silicon eutectic morphology which affects the ductility that occur due to the silicon that occur due to the silicon.
- According to a first example embodiment, in addition to at least 80 wt. % aluminum, the aluminum alloy includes 9.5 to 11.5 wt. % silicon; 0.1 wt. % to 0.6 wt. % magnesium; 0.10 wt. % to 0.60 wt. % copper; 0.2. to 0.6 wt. % manganese; 0.2 wt. % to 0.6 wt. % iron; 0.01 wt. % to 0.07 wt. % strontium, up to 1.5 wt. % zinc; and up to 0.15 wt. % titanium, based on the total weight of the aluminum alloy. The aluminum alloy can also include other elements, for example impurities, each in an amount up to 0.05 wt. % and in a total amount up to 0.15 wt. %, based on the total weight of the aluminum alloy.
- According to another example embodiment, in addition to at least 80 wt. % aluminum, the aluminum alloy includes 9.5 to 11.5 wt. % silicon, 0.3 wt. % to 0.8 wt. % zinc, 0.1 to 0.6 wt. % magnesium, 0.20 wt. % to 0.90 wt. % copper, 0.2 wt. % to 0.5 wt. % manganese, 0.3 wt. % to 0.6 wt. % iron, 0.01 wt. % to 0.03 wt. % strontium, and 0.15 wt. % maximum titanium, based on the total weight of the aluminum alloy. The aluminum alloy can also include other elements, for example impurities, each in an amount of less than 0.05 wt. % and in a total amount of less than 0.15 wt. %, based on the total weight of the aluminum alloy.
- The compositions of the aluminum alloys according to the first and second example embodiments is provided in Table 1 below.
-
TABLE 1 Other Other Si Zn Mg Cu Mn Fe Sr Ti Each Total Ex. 1 Aural 5M 6.0-8.0 1.0-2.0 0.05-0.30 <0.05 0.20-0.40 0.25 0.03-0.08 0.05 0.15 Ex. 2 Aural 5R 6.0-8.0 1.0-2.0 0.05-0.30 0.10-0.40 0.2-0.5 0.3-0.6 0.01-0.03 0.15 0.05 0.15 maximum Ex. 3 Aural 2R 9.5-11.5 0.3-0.8 0.1-0.6 0.20-0.90 0.2-0.5 0.3-0.6 0.01-0.07 0.15 0.05 0.15 maximum - The aluminum alloy according to the example embodiments is often referred to as Aural 2R because it is preferably obtained, in part, from recycled aluminum, such as recycled road wheels. The energy required to produce the aluminum alloy is reduced by about 95% when the aluminum alloy is formed from recycled materials.
- Another aspect of the invention provides the
cast component 10 formed of the aluminum alloy, and a method of manufacturing thecast component 10 by melting and casting the melted aluminum alloy. The method of forming the cast component typically begins by melting the aluminum alloy. Any casting process used to form components, for example high pressure die casting, low pressure casting, or squeeze casting. In one example embodiment, the casting process is a die casting process, which typically includes forcing the molten aluminum alloy into an unheated die or mold cavity under pressure. The die is typically formed from hardened tool steel. - The aluminum alloy according to example embodiments, such as the Aural 2R alloys, has a high amount of recycled (secondary materials), and after casting experiences a heat treatment, solution (T4), forced air quench and then artificial age (T7 temper). Thus, the cast aluminum alloy has a yield strength of at least 100 to 120 MPa, ultimate tensile strength (UTS) of 200 to 210 MPa, and an elongation of 10% to 20%.
-
FIG. 4 discloses the composition of the aluminum alloy according to an example embodiment (Aural 2R) relative to a comparative aluminum alloy (Aural 2). The aluminum alloy according to example embodiments provides for exceptional mechanical properties, corrosion resistance, rivetability, and castability.FIGS. 5A and 5B illustrate the mechanical properties of the aluminum alloy according to an example embodiment (Aural 2R) relative to a comparative aluminum alloy (Aural 2). The yield strength, ultimate tensile strength, and elongation are tested using ASTM E8/E8M-21 (Standard Test Methods for Tension Testing of Metallic Materials). The composition of the comparative aluminum alloy (Aural 2) includes at least 80 wt. % aluminum, 9.5 to 11.5 wt. % silicon, 0.1 to 0.6 wt. % magnesium, 0.4 wt. % to 0.6 wt. % manganese, 0.25 wt. % max iron, and 0.01 wt. % to 0.25 wt. % strontium, based on the total weight of the aluminum alloy. -
FIGS. 6A-6C illustrate the results of a rivetability test comparing the aluminum alloy of the example embodiment (Aural 2R) to the comparative aluminum alloy (Aural 2). The rivetability test included applying a self-piercing rivet to the example aluminum alloy (Aural 2R) and the comparative aluminum alloy (Aural 2). The self-piercing rivet is a single-step technique which includes using a semi-tubular rivet to clinch sheets of the aluminum alloy together. The sheets are clamped between a die and blankholder, and the rivet is driven into the sheets between a punch and a die. The rivet pierces the top sheet and the die shape causes the rivet to flare within the lower sheet to form a mechanical interlock. The die shape causes a button to form on the underside of the lower sheet. Preferably, the rivet tail does not pierce though the button. - Aural 2R composition exhibited good corrosion resistance when subjected to a salt spray test for 100 hours according to Intergranular Corrosion (IGC) ASTM G110 and Cyclic Corrosion SAE J2334.
- The
cast component 10 formed from the casting step can be, for example, a component for use in a vehicle. The molten aluminum is formed to a solid component having the shape of the mold, which can be a complex shape. Many different types of components can be formed by the casting process, for example, a structural, body-in-white, suspension, or chassis component. After the casting process, the method can include an optional heat treating process or other finishing processes. However, it has been found that a heat treatment process may not be necessary when the component is formed from the improved aluminum alloy, which would provide the advantage of reduced process time and costs. - Generally, it takes up to 95 percent less energy to recycle than to produce primary aluminum, which reduces the carbon footprint of the foundries. The aluminum alloys of the present invention which include high amounts of recycled material, known as Aural 2R (R=high amt of recycled material), will utilize both post-consumer recycled shredded road wheels as well as pre-consumer wrought stamping offal. Development of these green aluminum alloys, using secondary recycled aluminum for BIW and structural components, will allow for both less cost of raw material, and a lower carbon footprint while still meeting stringent automotive industry standards. The cast components formed of the aluminum alloys have good rivetability and castability.
- Obviously, many modifications and variations of the present invention are possible in light of the above teachings and may be practiced otherwise than as specifically described while within the scope of the following claims.
Claims (20)
1. An improved aluminum alloy, comprising:
at least 80 weight percent (wt. %) aluminum; 9.5 to 11.5 wt. % silicon; 0.3 to 0.8 wt. % zinc; 0.1 wt. % to 0.6 wt. % magnesium; 0.20 wt. % to 0.90 wt. % copper; 0.2. to 0.5 wt. % manganese; 0.3 wt. % to 0.6 wt. % iron; 0.01 wt. % to 0.07 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the aluminum alloy.
2. The improved aluminum alloy according to claim 1 further including other elements each in an amount of less than 0.05 wt. % and in a total amount of less than 0.15 wt. %, based on the total weight of the improved aluminum alloy.
3. A cast component formed of the improved aluminum alloy according to claim 1 .
4. The cast component according to claim 3 , wherein the improved aluminum alloy further includes other elements each in an amount of less than 0.05 wt. % and in a total amount of less than 0.15 wt. %, based on the total weight of the improved aluminum alloy.
5. The cast component of claim 3 , wherein the cast component has a yield strength of at least 140 to 150 MPa and an elongation of 3% to 5% when the cast component is in the T5 temper condition.
6. The cast component of claim 3 , wherein the cast component is a structural, body-in-white, suspension, or chassis component.
7. The cast component of claim 3 , wherein the cast improved aluminum alloy includes Mg2Si.
8. A method of manufacturing a cast component, comprising the steps of:
obtaining recycled aluminum or a recycled aluminum alloy;
combining the recycled aluminum or the recycled aluminum alloy with at least one additional element to form the improved aluminum alloy according to claim 1 ; and
casting the improved aluminum alloy.
9. The method of claim 8 , wherein the improved aluminum alloy further includes other elements each in an amount of less than 0.05 wt. % and in a total amount of less than 0.15 wt. %, based on the total weight of the improved aluminum alloy.
10. The method of claim 8 , the cast component has a yield strength of at least 140 to 150 MPa and an elongation of 3% to 5% when the cast component is in the T5 temper condition.
11. The method of claim 8 , wherein the casting step includes forming the improved aluminum alloy into the shape of a structural, body-in-white, suspension, or chassis component.
12. The method of claim 8 , wherein the cast improved aluminum alloy includes Mg2Si.
13. A method of manufacturing an improved aluminum alloy, comprising the steps of:
obtaining recycled aluminum or a recycled aluminum alloy; and
combining the recycled aluminum or the recycled aluminum alloy with at least one additional element to form the improved aluminum alloy, the improved aluminum alloy comprising:
at least 80 weight percent (wt. %) aluminum; 9.5 to 11.5 wt. % silicon; 0.3 to 0.8 wt. % zinc; 0.1 wt. % to 0.6 wt. % magnesium; 0.20 wt. % to 0.90 wt. % copper; 0.2. to 0.5 wt. % manganese; 0.3 wt. % to 0.6 wt. % iron; 0.01 wt. % to 0.07 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.
14. An aluminum alloy, comprising:
at least 80 weight percent (wt. %) aluminum; 9.5 to 11.5 wt. % silicon; 1.5 max wt. % zinc; 0.1 wt. % to 0.6 wt. % magnesium; 0.10 wt. % to 0.60 wt. % copper; 0.2. to 0.6 wt. % manganese; 0.2 wt. % to 0.6 wt. % iron; 0.01 wt. % to 0.07 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.
15. A cast component formed of the improved aluminum alloy according to claim 14 .
16. The cast component according to claim 15 , wherein the improved aluminum alloy further includes other elements each in an amount of less than 0.05 wt. % and in a total amount of less than 0.15 wt. %, based on the total weight of the improved aluminum alloy.
17. The cast component of claim 15 , wherein the cast component has a yield strength of at least 100 to 120 MPa and an elongation of 10% to 20% when the cast component is in the T7 temper condition.
18. A method of manufacturing a cast component, comprising the steps of:
obtaining recycled aluminum or a recycled aluminum alloy;
combining the recycled aluminum or the recycled aluminum alloy with at least one additional element to form the improved aluminum alloy according to claim 15 ; and
casting the improved aluminum alloy.
19. A method of manufacturing an improved aluminum alloy, comprising the steps of:
obtaining recycled aluminum or a recycled aluminum alloy; and
combining the recycled aluminum or the recycled aluminum alloy with at least one additional element to form the improved aluminum alloy, the improved aluminum alloy comprising:
at least 80 weight percent (wt. %) aluminum; 9.5 to 11.5 wt. % silicon; 1.5 max wt. % zinc; 0.1 wt. % to 0.6 wt. % magnesium; 0.10 wt. % to 0.60 wt. % copper; 0.2. to 0.6 wt. % manganese; 0.2 wt. % to 0.6 wt. % iron; 0.01 wt. % to 0.07 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.
20. An improved aluminum alloy, comprising:
at least 80 weight percent (wt. %) aluminum; 9.5 to 11.5 wt. % silicon; zinc; 0.1 wt. % to 0.6 wt. % magnesium; copper; at least 0.2. wt. % manganese; up to 0.6 wt. % iron; 0.01 wt. % to 0.07 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the aluminum alloy.
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US17/366,175 Continuation-In-Part US20230002863A1 (en) | 2021-07-02 | 2021-07-02 | Low cost high ductility cast aluminum alloy |
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