Low cost high ductility cast aluminum alloy

Abstract

An aluminum alloy for casting into a component, such as a vehicle component, is provided. The aluminum alloy includes 2 to 5 wt. % silicon, which is a lower amount of silicon compared to other aluminum alloys used for casting. The aluminum alloy further includes 1.0 to 2.0 wt. % zinc, less than 0.5 wt. % iron, and not greater than 0.6 wt. % manganese, based on the total weight of the aluminum alloy. The aluminum alloy can further include 0.01 to 0.07 wt. % strontium, 0.05 to 0.6 wt. % magnesium, not greater than 0.2 wt. % titanium, and less than 0.02 wt. % copper, based on the total weight of the aluminum alloy. After the casting step, the cast aluminum alloy has a yield strength of at least 110 MPa, ultimate tensile strength (UTS) of 220 to 230 MPa, and an elongation of 10 to 20%.

What is claimed is: 
     
         1 . An aluminum alloy, comprising:
 at least 80 weight percent (wt. %) aluminum, 2 to 5 wt. % silicon, 1.0 to 2.0 wt. % zinc, less than 0.5 wt. % iron, and not greater than 0.6 wt. % manganese, based on the total weight of the aluminum alloy.   
     
     
         2 . The aluminum alloy of  claim 1  including 0.01 to 0.07 wt. % strontium, 0.05 to 0.6 wt. % magnesium, not greater than 0.2 wt. % titanium, and less than 0.02 wt. % copper, based on the total weight of the aluminum alloy. 
     
     
         3 . The aluminum alloy of  claim 1 , wherein the total amount of manganese and iron is 0.6 to 0.8 wt. %, based on the total weight of the aluminum alloy. 
     
     
         4 . The aluminum alloy of  claim 1 , wherein the alloy is cast and has a yield strength of at least 110 MPa, ultimate tensile strength (UTS) of 220 to 230 MPa, and an elongation of 10 to 20%. 
     
     
         5 . The aluminum alloy of  claim 1  including at least 0.16 wt. % iron and at least 0.3 wt. % manganese, based on the total weight of the aluminum alloy. 
     
     
         6 . The aluminum alloy of  claim 2  including at least 0.05 wt. % titanium and at least 0.006 wt. % copper, based on the total weight of the aluminum alloy. 
     
     
         7 . The aluminum alloy of  claim 1 , wherein the aluminum alloy is cast and formed into a component for a vehicle. 
     
     
         8 . A method of manufacturing a component, comprising the steps of:
 casting an aluminum alloy, the aluminum alloy including at least 80 weight percent (wt. %) aluminum, 2 to 5 wt. % silicon, 1.0 to 2.0 wt. % zinc, less than 0.5 wt. % iron, and not greater than 0.6 wt. % manganese, based on the total weight of the aluminum alloy.   
     
     
         9 . The method of  claim 8 , wherein the aluminum alloy includes 0.01 to 0.07 wt. % strontium, 0.05 to 0.6 wt. % magnesium, not greater than 0.2 wt. % titanium, and less than 0.02 wt. % copper, based on the total weight of the aluminum alloy. 
     
     
         10 . The method of  claim 8 , wherein the aluminum alloy has a yield strength of at least 110 MPa, ultimate tensile strength (UTS) of 220 to 230 MPa, and an elongation of 10 to 20% after the casting step. 
     
     
         11 . The method of  claim 8 , wherein the aluminum alloy includes at least 0.16 wt. % iron and at least 0.3 wt. % manganese, based on the total weight of the aluminum alloy. 
     
     
         12 . The method of  claim 9 , wherein the aluminum alloy includes at least 0.05 wt. % titanium and at least 0.006 wt. % copper, based on the total weight of the aluminum alloy. 
     
     
         13 . A method of manufacturing an aluminum alloy, comprising the steps of:
 melting a 300 series aluminum alloy; and   adding silicon to the melted 300 series aluminum alloy to form an improved aluminum alloy and so that the total amount of silicon present in the improved aluminum alloy is 2 to 5 wt. %, based on the total weight of the improved aluminum alloy, and the improved aluminum alloy further includes at least 80 weight percent (wt. %) aluminum, 1.0 to 2.0 wt. % zinc, less than 0.5 wt. % iron, and not greater than 0.6 wt. % manganese, based on the total weight of the improved aluminum alloy.   
     
     
         14 . The method of  claim 13 , wherein the improved aluminum alloy includes 0.01 to 0.07 wt. % strontium, 0.05 to 0.6 wt. % magnesium, not greater than 0.2 wt. % titanium, and less than 0.02 wt. % copper, based on the total weight of the improved aluminum alloy. 
     
     
         15 . The method of  claim 13 , wherein the improved aluminum alloy includes a total amount of manganese and iron of 0.6 to 0.8 wt. %, based on the total weight of the improved aluminum alloy. 
     
     
         16 . The method of  claim 13  including casting the improved aluminum alloy, wherein the improved aluminum alloy has a yield strength of at least 110 MPa, ultimate tensile strength (UTS) of 220 to 230 MPa, and an elongation of 10 to 20% after the casting step. 
     
     
         17 . The method of  claim 16 , wherein the casting step includes forming the aluminum alloy into a component for a vehicle. 
     
     
         18 . The method of  claim 13 , wherein the improved aluminum alloy includes at least 0.16 wt. % iron and at least 0.3 wt. % manganese, at least 0.05 wt. % titanium, and at least 0.006 wt. % copper, based on the total weight of the improved aluminum alloy. 
     
     
         19 . The method of  claim 13 , wherein the 300 series aluminum alloy includes 91.3-93.2 wt. % aluminum, not greater than 0.10 wt. % copper, not greater than 0.12 wt. % iron, 0.30 to 0.45 wt. % magnesium, not greater than 0.05 wt. % manganese, 6.5 to 7.5 wt. % silicon, not greater than 0.20 wt. % titanium, not greater than 0.05 wt. % zinc, other elements each in an amount of not greater than 0.05 wt. %, and other elements in a total amount of not greater than 0.15 wt. %, based on the total weight of the improved aluminum alloy. 
     
     
         20 . The method of  claim 13 , wherein the 300 series aluminum alloy is obtained from recycled road wheels.