Low cost high ductility cast aluminum alloy

Abstract

An aluminum alloy for casting into a component, such as an automotive vehicle component, is provided. The aluminum alloy includes a reduced amount of silicon (Si), specifically 0.1 weight percent (wt. %) to less than 7.0 wt. %, and preferably 4.0 wt. % or less, to achieve improved ductility and elongation. The aluminum alloy can also include additional alloying elements to achieve desired properties. For example, antimony, calcium, and/or bismuth can be included to counter any detrimental effect of the low silicon content on hot cracking behavior. Zinc can be added to increase strength; and cerium can be added to further increase ductility. The aluminum alloy is typically formed by modifying recycled wrought aluminum, such as a 5000 series or 6000 series aluminum alloy, or by modifying a recycled cast 300 series aluminum alloy.

What is claimed is: 
     
         1 . An aluminum alloy for casting into a component, comprising:
 aluminum in an amount of at least 70 weight percent (wt. %) and silicon in an amount of 0.1 wt. % to less than 7.0 wt. %, based on the total weight of the aluminum alloy.   
     
     
         2 . The aluminum alloy of  claim 1 , wherein the silicon is present in an amount of 2.0 wt. % to 4.0 wt. %, based on the total weight of the aluminum alloy. 
     
     
         3 . The aluminum alloy of  claim 1  further including at least one of magnesium (Mg), manganese (Mn), cerium (Ce), iron (Fe), copper (Cu), zinc (Zn), titanium (Ti), strontium (Sr), calcium (Ca), zirconium (Zr), bismuth (Bi), antimony (Sb), boron (B), molybdenum (Mo), scandium (Sc), and rhenium (Re). 
     
     
         4 . The aluminum alloy of  claim 3  including zinc (Zn); cerium (Ce); and at least one of calcium (Ca), antimony (Sb), and bismuth (Bi). 
     
     
         5 . A cast component, comprising:
 an aluminum alloy including aluminum in an amount of at least 70 wt. % and silicon in an amount of 0.1 wt. % to less than 7.0 wt. %, based on the total weight of the aluminum alloy.   
     
     
         6 . The cast component of  claim 5 , wherein the silicon is present in an amount of 2.0 wt. % to 4.0 wt. %, based on the total weight of the aluminum alloy. 
     
     
         7 . The cast component of  claim 5 , wherein the aluminum alloy further includes at least one of magnesium (Mg), manganese (Mn), cerium (Ce), iron (Fe), copper (Cu), zinc (Zn), titanium (Ti), strontium (Sr), calcium (Ca), zirconium (Zr), bismuth (Bi), antimony (Sb), boron (B), molybdenum (Mo), scandium (Sc), and rhenium (Re). 
     
     
         8 . The cast component of  claim 7  including zinc (Zn); cerium (Ce); and at least one of calcium (Ca), antimony (Sb), and bismuth (Bi). 
     
     
         9 . The cast component of  claim 5 , wherein the component has an elongation ranging from 8% to 10%. 
     
     
         10 . The cast component of  claim 5 , wherein the component is a structural, body-in-white, suspension, or chassis component for an automotive vehicle. 
     
     
         11 . A method of manufacturing an aluminum alloy for casting into a component, comprising the steps of:
 providing an aluminum alloy, wherein the aluminum alloy is selected from a 300 series aluminum alloy, 5000 series aluminum alloy, and 6000 series aluminum alloy;   melting the aluminum alloy; and   adding silicon to the melted aluminum alloy so that the total amount of silicon present ranges from 0.1 wt. % to less than 7.0 wt. %, based on the total weight of the melted aluminum alloy.   
     
     
         12 . The method of  claim 11 , wherein the step of adding silicon includes adding the silicon in an amount so that the total amount of silicon present ranges from 2.0 wt. % to 4.0 wt. %, based on the total weight of the melted aluminum alloy. 
     
     
         13 . The method of  claim 11 , wherein the aluminum alloy includes at least one of magnesium (Mg), manganese (Mn), cerium (Ce), iron (Fe), copper (Cu), zinc (Zn), titanium (Ti), strontium (Sr), calcium (Ca), zirconium (Zr), bismuth (Bi), antimony (Sb), boron (B), molybdenum (Mo), scandium (Sc), and rhenium (Re) after the melting step. 
     
     
         14 . The method of  claim 11 , wherein the aluminum alloy provided includes zinc (Zn); cerium (Ce); and at least one of calcium (Ca), antimony (Sb), and bismuth (Bi) after the melting step. 
     
     
         15 . The method of  claim 11 , wherein the step of providing the aluminum alloy includes recycling a 300 series aluminum alloy, 5000 series aluminum alloy, or 6000 series aluminum alloy. 
     
     
         16 . A method of manufacturing a cast component, comprising the steps of:
 providing an aluminum alloy, wherein the aluminum alloy is selected from a 300 series aluminum alloy, 5000 series aluminum alloy, and 6000 series aluminum alloy;   melting the aluminum alloy;   adding silicon to the melted aluminum alloy so that the total amount of silicon present ranges from 0.1 wt. % to less than 7.0 wt. %, based on the total weight of the melted aluminum alloy; and   casting the melted aluminum alloy.   
     
     
         17 . The method of  claim 16 , wherein the casting step includes high pressure die casting, low pressure casting, or squeeze casting. 
     
     
         18 . The method of  claim 16 , wherein the step of adding the silicon includes adding the silicon to the melted aluminum alloy so that the total amount of silicon present ranges from 2.0 wt. % to 4.0 wt. %, based on the total weight of the melted aluminum alloy. 
     
     
         19 . The method of  claim 16 , wherein the casting step includes forming a component having an elongation ranging from 8% to 10%. 
     
     
         20 . The method of  claim 16 , wherein the casting step includes forming the melted aluminum alloy into a structural, body-in-white, suspension, or chassis component for an automotive vehicle.