Squeeze cast rear suspension components using ADC12-T4 aluminum alloy

Abstract

An aluminum alloy product is provided that includes an ADC12-T4 aluminum alloy. The ADC12-T4 aluminum alloy is cast into the product utilizing a high pressure, slow velocity casting technique. Further, an alloy is provided that in some embodiments produces cast parts with high strength, wear resistance, hardness and/or ductility, with little or no soldering.

1 . A rear suspension component for an automobile, the rear suspension component comprising: 
 an ADC12 aluminum alloy, wherein the ADC12 aluminum alloy is squeeze cast to generate the rear suspension component, the ADC12 aluminum alloy consists essentially of the following constituents by percentage of weight:    9.6 to 12.0 percent silicon;    0.0 to 1.3 percent iron;    1.5 to 3.5 percent copper;    0.0 to 0.5 percent manganese;    0.0 to 0.3 percent magnesium;    0.0 to 1.0 percent zinc;    0.0 to 0.5 percent nickel;    0.0 to 0.3 percent tin;    0.0 to 0.15 percent one or more other elements; and 
 aluminum as the remainder; and  
   wherein the cast rear suspension component is T4 tempered.    
   
   
       2 . The rear suspension component according to  claim 1 , wherein the ADC12 aluminum alloy consists essentially of the following constituents by percentage of weight: 
 0.6 to 10.2 percent silicon;    0.75 to 1.0 percent iron;    0.5 to 3.5 percent copper;    0.1 to 0.5 percent manganese;    0.1 to 0.3 percent magnesium;    0.1 to 1.0 percent zinc;    0.1 to 0.5 percent nickel;    0.1 to 0.3 percent tin;    0.05 to 0.15 percent one or more other elements; and 
 aluminum as the remainder.  
   
   
   
       3 . The rear suspension component according to  claim 1 , wherein the ADC12 aluminum alloy consists essentially of the following constituents by percentage of weight: 
 9.6 to 10.2 percent silicon;    0.75 to 1.0 percent iron;    1.5 to 2.5 percent copper;    0 percent manganese;    0.2 to 0.3 percent magnesium;    0 percent zinc;    0 percent nickel;    0 percent tin;    0 percent one or more other elements; and 
 aluminum as the remainder.  
   
   
   
       4 . The rear suspension component according to  claim 1 , wherein the rear suspension component is a knuckle.  
   
   
       5 . The rear suspension component according to  claim 1 , wherein the rear suspension component is an upper control arm.  
   
   
       6 . The rear suspension component according to  claim 1 , wherein the rear suspension component is a lower control arm.  
   
   
       7 . An apparatus for casting a rear suspension component for an automobile, the apparatus comprising: 
 means for heating an ADC12 aluminum alloy to liquefy the ADC12 aluminum alloy;    means for injecting the ADC12 aluminum alloy into a die corresponding to the rear suspension component;    means for solidifying the ADC12 aluminum alloy to generate the rear suspension component; and    means for tempering the rear suspension component, wherein the ADC12 aluminum alloy consists essentially of the following constituents by percentage of weight:    9.6 to 12.0 percent silicon;    0.0 to 1.3 percent iron;    1.5 to 3.5 percent copper;    0.0 to 0.5 percent manganese;    0.0 to 0.3 percent magnesium;    0.0 to 1.0 percent zinc;    0.0 to 0.5 percent nickel;    0.0 to 0.3 percent tin;    0.0 to 0.15 percent one or more other elements; and 
 aluminum as the remainder; and  
   means for tempering the cast rear suspension component.    
   
   
       8 . The apparatus according to  claim 7 , wherein the ADC12 aluminum alloy consists essentially of the following constituents by percentage of weight: 
 9.6 to 10.2 percent silicon;    0.75 to 1.0 percent iron;    1.5 to 3.5 percent copper;    0.1 to 0.5 percent manganese;    0.1 to 0.3 percent magnesium;    0.1 to 1.0 percent zinc;    0.1 to 0.5 percent nickel;    0.1 to 0.3 percent tin;    0.05 to 0.15 percent one or more other elements; and 
 aluminum as the remainder.  
   
   
   
       9 . The apparatus according to  claim 7 , wherein the ADC12 aluminum alloy consists essentially of the following constituents by percentage of weight: 
 9.6 to 10.2 percent silicon;    0.75 to 1.0 percent iron;    1.5 to 2.5 percent copper;    0 percent manganese;    0.2 to 0.3 percent magnesium;    0 percent zinc;    0 percent nickel;    0 percent tin;    0 percent one or more other elements; and 
 aluminum as the remainder.  
   
   
   
       10 . The apparatus according to  claim 7 , wherein the means for tempering is a means for T4 tempering.  
   
   
       11 . The apparatus according to  claim 7 , wherein the rear suspension component is a knuckle.  
   
   
       12 . The apparatus according to  claim 7 , wherein the rear suspension component is an upper control arm.  
   
   
       13 . The apparatus according to  claim 7 , wherein the rear suspension component is a lower control arm.  
   
   
       14 . A method of casting a rear suspension component for an automobile, the method comprising: 
 heating an ADC12 aluminum alloy to liquefy the ADC12 aluminum alloy;    injecting the ADC12 aluminum alloy into a die corresponding to the rear suspension component;    solidifying the ADC12 aluminum alloy to generate the rear suspension component; and    tempering the rear suspension component, wherein the ADC12 aluminum alloy consists essentially of the following constituents by percentage of weight:    9.6 to 12.0 percent silicon;    0.0 to 1.3 percent iron;    1.5 to 3.5 percent copper;    0.0 to 0.5 percent manganese;    0.0 to 0.3 percent magnesium;    0.0 to 1.0 percent zinc;    0.0 to 0.5 percent nickel;    0.0 to 0.3 percent tin;    0.0 to 0.15 percent one or more other elements; and 
 aluminum as the remainder.  
   
   
   
       15 . The method according to  claim 14 , wherein the ADC12 aluminum alloy consists essentially of the following constituents by percentage of weight: 
 9.6 to 10.2 percent silicon;    0.75 to 1.0 percent iron;    1.5 to 3.5 percent copper;    0.1 to 0.5 percent manganese;    0.1 to 0.3 percent magnesium;    0.1 to 1.0 percent zinc;    0.1 to 0.5 percent nickel;    0.1 to 0.3 percent tin;    0.05 to 0.15 percent one or more other elements; and 
 aluminum as the remainder.  
   
   
   
       16 . The method according to  claim 14 , wherein the ADC12 aluminum alloy consists essentially of the following constituents by percentage of weight: 
 9.6 to 10.2 percent silicon;    0.75 to 1.0 percent iron;    1.5 to 2.5 percent copper;    0 percent manganese;    0.2 to 0.3 percent magnesium;    0 percent zinc;    0 percent nickel;    0 percent tin;    0 percent one or more other elements; and 
 aluminum as the remainder.  
   
   
   
       17 . The method according to  claim 14 , wherein the tempering is a T4 temper.  
   
   
       18 . The method according to  claim 14 , wherein the rear suspension component is a knuckle.  
   
   
       19 . The method according to  claim 14 , wherein the rear suspension component is an upper control arm.  
   
   
       20 . The method according to  claim 14 , wherein the rear suspension component is a lower control arm.