Aluminum alloy composition for simplified semi-solid casting process and method of semi-solid casting

Abstract

An aluminum alloy having about 0.03 wt % to about 0.50 wt % Niobium (Nb); about 0.03 wt % to about 0.50% Vanadium (V); about 0.03 wt % to about 0.50% Titanium (Ti), greater than 0 wt % to about 0.50 wt % Boron (B); and the balance is Aluminum (Al) and impurities. The alloy includes a weight percent ratio of (Nb+V)/Ti from about 1 to about 5, preferably from about 2 to about 3. The alloy may include a weight percent ratio (Nb+V+Ti)/B from about 1 to about 15, preferably from about 5 to about 10. The aluminum alloy may be form by incorporating 1 part master alloy, grain refiner, having about 1.5 wt % to about 4.0 wt % Niobium (Nb); from about 0.5 wt % to about 2.0% Titanium (Ti), and from about 0.2 wt % to about 0.8 wt % Boron (B) to about 27 to 80 part conventional aluminum alloy, by weight.

What is claimed is: 
     
         1 . An aluminum alloy comprising:
 about 0.03 wt % to about 0.50 wt % Niobium (Nb);   about 0.03 wt % to about 0.50% Vanadium (V);   about 0.03 wt % to about 0.50% Titanium (Ti), and   a remainder comprising Aluminum (Al) and impurities.   
     
     
         2 . The aluminum alloy of  claim 1 , further comprising a weight percent ratio of (Nb+V)/Ti from about 1 to about 5. 
     
     
         3 . The aluminum alloy of  claim 2 , wherein the weight percent ratio of (Nb+V)/Ti is from about 2 to about 3. 
     
     
         4 . The aluminum alloy of  claim 1  further comprising greater than 0 wt % to about 0.50 wt % Boron (B). 
     
     
         5 . The aluminum alloy of  claim 4 , further comprising a weight percent ratio (Nb+V+Ti)/B from about 1 to about 15. 
     
     
         6 . The aluminum alloy of  claim 5 , wherein the weight percent ratio (Nb+V+Ti)/B is from about 5 to about 10. 
     
     
         7 . The aluminum alloy of  claim 4  further comprising about 4.00 wt % to about 10.00 wt % Silicon (Si). 
     
     
         8 . The aluminum alloy of  claim 7  further comprising about 0.01 wt % to about 3.00 wt % Copper (Cu). 
     
     
         9 . The aluminum alloy of  claim 8  further comprising about 0.10 wt % to about 1.00 wt % Magnesium (Mg). 
     
     
         10 . The aluminum alloy of  claim 4 , further comprising about 0.01 wt % to about 0.03 wt % Strontium (Sr). 
     
     
         11 . A method of semi-solid casting, comprising:
 heating an aluminum alloy until the aluminum alloy transform into a liquid aluminum alloy;   cooling the liquid aluminum alloy until the liquid aluminum alloy transform into a semi-solid aluminum alloy;   pouring the semi-solid aluminum alloy into a casting die; and   cooling the semi-solid aluminum alloy until the semi-solid aluminum alloy transform into a solid aluminum alloy within the casting die;   wherein the aluminum alloy comprises:   about 0.03 wt % to about 0.50 wt % Niobium (Nb);   about 0.03 wt % to about 0.50% Vanadium (V);   about 0.03 wt % to about 0.50% Titanium (Ti), and a remainder comprising Aluminum (Al) and impurities.   
     
     
         12 . The method of  claim 11 , wherein the aluminum alloy further comprises a weight percent ratio of (Nb+V)/Ti from about 1 to about 5. 
     
     
         13 . The method of  claim 12 , wherein the weight percent ratio of (Nb+V)/Ti is from about 2 to about 3. 
     
     
         14 . The method of  claim 11 , wherein the aluminum alloy further comprises greater than 0 wt % to about 0.50 wt % Boron (B). 
     
     
         15 . The method of  claim 14 , wherein the aluminum alloy further comprises a weight percent ratio of (Nb+V+Ti)/B from about 1 to about 15. 
     
     
         16 . The method of  claim 15 , wherein the weight percent ratio of (Nb+V+Ti)/B is from about 5 to about 10. 
     
     
         17 . The method of  claim 16 , wherein the aluminum alloy further comprises:
 about 4.00 wt % to about 10.00 wt % Silicon (Si);   about 0.01 wt % to about 3.00 wt % Copper (Cu);   about 1.00 wt % Magnesium (Mg);   about 0.03 wt % Strontium (Sr);   greater than 0.0 wt % but less than or equal to about 0.50 wt % Manganese (Mn), and   greater than 0.0 wt % but less than or equal to about 0.50 wt % Chromium (Cr).   
     
     
         18 . The method of  claim 17 , wherein heating the aluminum alloy until the aluminum alloy transform into a liquid aluminum alloy includes heating the solid aluminum alloy to a liquidus range between about 30° C. to about 80° C. 
     
     
         19 . The method of  claim 18 , wherein cooling the liquid aluminum alloy until the liquid aluminum alloy transform into a semi-solid aluminum alloy includes cooling the liquid aluminum alloy at a rate greater than 5° C. per second. 
     
     
         20 . A grain refiner for aluminum alloys, comprising:
 about 1.5 wt % to 4.0 wt % Niobium (Nb);   about 0.5 wt % to 2.0 wt % Titanium (Ti),   about 0.2 wt % to about 0.8 wt % Boron (B); and   a remainder comprising Aluminum (Al) and impurities.