Aluminum iron silicon alloys having optimized properties

Abstract

Al—Fe—Si alloys having optimized properties through the use of additives are disclosed. In some aspects, mechanical properties are optimized using mechanical-optimizing additives such as a combination of boron, zirconium, chromium and molybdenum. In some aspects, corrosion-inhibiting properties are optimized using corrosion-inhibiting additives such as chromium, molybdenum, and tungsten. In some aspects, ductility is optimized by the inclusion of twinning additives such as any of zinc, copper, vanadium, and molybdenum.

What is claimed is: 
     
         1 . An alloy comprising:
 aluminum in a first amount;   iron in a second amount;   silicon in a third amount; and   mechanical-optimizing additives consisting of:
 boron in a fourth amount, 
 zirconium in a fifth amount, 
 chromium in a sixth amount, and 
 molybdenum in a seventh amount. 
   
     
     
         2 . The alloy of  claim 1 , wherein the fourth amount is at least twice the fifth amount. 
     
     
         3 . The alloy of  claim 2 , wherein the sixth amount is between about 2 percent by atom and about 6 percent by atom on a basis of all atoms in the first amount through the seventh amount. 
     
     
         4 . The alloy of  claim 3 , wherein the seventh amount is about 0.2 percent by atom on a basis of all atoms in the first amount through the seventh amount. 
     
     
         5 . The alloy of  claim 4 , wherein the first amount is between about 59 percent by atom and about 66 percent by atom on a basis of all atoms in the first amount through the seventh amount. 
     
     
         6 . The alloy of  claim 5 , wherein the second amount is about 24 percent by atom on a basis of all atoms in the first amount through the seventh amount. 
     
     
         7 . The alloy of  claim 6 , wherein the third amount is between about 9.5 percent by atom and about 15 percent by atom on a basis of all atoms in the first amount through the seventh amount. 
     
     
         8 . An alloy comprising:
 aluminum in a first amount;   iron in a second amount;   silicon in a third amount; and   corrosion-inhibiting additives consisting of:
 chromium in a fourth amount, 
 molybdenum in a fifth amount, and 
 tungsten in a sixth amount. 
   
     
     
         9 . The alloy of  claim 8 , wherein the fifth amount is between about 0.2 percent by atom and about 2 percent by atom on a basis of all atoms in the first amount through the sixth amount. 
     
     
         10 . The alloy of  claim 9 , wherein the sixth amount is between about 0.2 percent by atom and about 2 percent by atom on a basis of all atoms in the first amount through the sixth amount. 
     
     
         11 . The alloy of  claim 10 , wherein the fourth amount is between about 2 percent by atom and about 6 percent by atom on a basis of all atoms in the first amount through the sixth amount. 
     
     
         12 . The alloy of  claim 11 , wherein the first amount is between about 59 percent by atom and about 66 percent by atom on a basis of all atoms in the first amount through the sixth amount. 
     
     
         13 . The alloy of  claim 12 , wherein the second amount is about 24 percent by atom on a basis of all atoms in the first amount through the sixth amount. 
     
     
         14 . The alloy of  claim 13 , wherein the third amount is between about 9.5 percent by atom and about 15 percent by atom on a basis of all atoms in the first amount through the sixth amount. 
     
     
         15 . An alloy comprising:
 aluminum in a first amount;   iron in a second amount;   silicon in a third amount; and   a twinning additive in a fourth amount, the twinning additive being configured to produce a twinned structure within the alloy,   wherein the first amount, second amount, third amount, and fourth amount produce an alloy with a stoichiometric formula (Al 1-x M x ) 3 Fe 2 Si where M is the twinning additive.   
     
     
         16 . The alloy of  claim 15 , wherein x is between about 0.01 and about 0.1. 
     
     
         17 . The alloy of  claim 16 , wherein the twinning additive is selected from the group consisting of zinc, copper, vanadium, molybdenum, and combinations thereof. 
     
     
         18 . The alloy of  claim 16 , wherein the twinning additive is zinc. 
     
     
         19 . The alloy of  claim 16 , wherein the twinning additive consists of intermediate-radius atoms. 
     
     
         20 . The alloy of  claim 19 , wherein the twinning additive is a single element having an atomic radius of about 0.1335 nm.