Aluminum-based alloy composition and method of making extruded components from aluminum-based alloy compositions

Abstract

The present invention involves an aluminum-based alloy composition for vehicle components. The composition consists essentially of between about 0.15 to 0.6% weight silicon to provide recrystallization, between about 0.2 to 0.7% weight iron, between about 0.4 to 0.6% weight copper, between about 1.1 to 1.4% weight manganese, between about 0.15 to 0.3% weight magnesium, between about 0.15 to 0.4% weight zinc, between about 0.1 to 0.15% weight zirconium, and the balance aluminum.

1 . An aluminum-based alloy composition for vehicle components, consisting essentially of: 
 between about 0.15 to 0.6% by weight of silicon to provide recrystallization;    between about 0.2 to 0.7% by weight iron;    between about 0.4 to 0.6% by weight copper;    between about 1.1 to 1.4% by weight manganese;    between about 0.15 to 0.3% by weight magnesium;    between about 0.15 to 0.4% by weight zinc for reducing grain growth;    between about 0.1 to 0.15% of weight zirconium, and the balance aluminum.    
     
     
         2 . The composition of  claim 1  wherein the balance aluminum includes a ratio of manganese to iron of between about 1 and 3 for high corrosion resistance and formability.  
     
     
         3 . The composition of  claim 1  wherein the zinc is between about 0.25 and 0.4% by weight.  
     
     
         4 . The composition of  claim 1  wherein the silicon is of the form of dymagnesium silicide.  
     
     
         5 . The composition of  claim 1  wherein the Vickers hardness of the intermetallic phases is between about 5,000 and 10,000.  
     
     
         6 . The composition of  claim 1  wherein the grain size of the composition is less than about 60 μm.  
     
     
         7 . An aluminum-based alloy composition for vehicle heat exchanger tubes, consisting essentially of: 
 between about 0.15 to 0.6% weight silicon;    between about 0.2 to 0.7% weight iron;    between about 0.4 to 0.6% weight copper;    between about 1.1 to 1.4% weight manganese;    between about 0.15 to 0.3% weight magnesium;    between about 0.15 to 0.4% weight zinc;    between about 0.1 to 0.15% weight zirconium, and the balance aluminum, the ratio of manganese to iron is between about 1 and 3, for high corrosion resistance and formability.    
     
     
         8 . The composition of  claim 7  wherein the zinc is between about 0.25 and 0.4% weight.  
     
     
         9 . The composition of  claim 7  wherein the zinc content is about 0.25% weight.  
     
     
         10 . The composition of  claim 7  wherein the silicon is of the form of dimagnesium silicide.  
     
     
         11 . The composition of  claim 7  wherein the Vickers hardness number is between about 5,000 and 10,000.  
     
     
         12 . The composition of  claim 7  wherein the grain size of the alloy is less than about 60 μm.  
     
     
         13 . A method of conform extruding an aluminum-based vehicle component, the method comprising: 
 pressing an aluminum-based alloy composition consisting essentially of: 
 between about 0.15 to 0.6% by weight silicon to reduce die wear of the conform extruder;  
 between about 0.2 to 0.7% by weight iron;  
 between about 0.4 to 0.6% by weight copper;  
 between about 1.1 to 1.4% by weight manganese;  
 between about 0.15 to 0.3% by weight magnesium;  
 between about 0.15 to 0.4% by weight zinc;  
 between about 0.1 to 0.15% by weight zirconium to reduce grain growth, and the balance aluminum; to define a formable alloy for providing formability of the alloy; and  
   forming the formable alloy to a predetermined configuration of the aluminum-based vehicle component.    
     
     
         14 . The method of  claim 13  further comprising: 
 providing a conform extrusion machine for extruding the aluminum-based vehicle component; and    introducing feedstock of the aluminum-based alloy to the conform extrusion machine.    
     
     
         15 . The method of  claim 14  wherein the feedstock is a feed rod of between about 9 and 12 mm diameter.  
     
     
         16 . The method of  claim 13  wherein pressing includes: 
 coining the aluminum-based alloy composition to shear the alloy composition; and    shearing the composition to superheat the aluminum-based composition to define the formable alloy for providing formability of the alloy.    
     
     
         17 . The method of  claim 13  wherein the temperature is between about 400° C. and 500° C.  
     
     
         18 . The method of  claim 13  wherein the temperature is about 480° C.  
     
     
         19 . The method of  claim 13  further comprising: 
 providing a conform extrusion machine having an extrusion die through which the formation alloy is pressed.    
     
     
         20 . The method of  claim 13  wherein forming includes: 
 propelling the formable alloy; and    forcing the formable alloy through a die to the predetermined configuration of the aluminum-based vehicle component.