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 silicon, zinc, magnesium, copper, manganese, iron, and strontium. After the casting step, the cast aluminum alloy has a yield strength of at least 105 MPa, ultimate tensile strength (UTS) of at least 180 MPa, and an elongation of 8% to 10%.

What is claimed is: 
     
         1 . An aluminum alloy, comprising:
 at least 80 weight percent (wt. %) aluminum; 6.0 to 8.0 wt. % silicon; 1.0 to 2.0 wt. % zinc; less than 0.25 wt. % iron; and 0.2 wt. % to 0.4 wt. % manganese, based on the total weight of the aluminum alloy.   
     
     
         2 . The aluminum alloy according to  claim 1  further including 0.05 to 0.3 wt. % magnesium, less than 0.05 wt. % copper, and 0.03 wt. % to 0.08 wt. % strontium, based on the total weight of the aluminum alloy. 
     
     
         3 . The aluminum alloy according to  claim 2  further including other elements each in an amount of less than 0.05 wt. % and in a total amount of less than 0.15 wt. %, based on the total weight of the aluminum alloy. 
     
     
         4 . A cast component formed of the aluminum alloy of  claim 1 . 
     
     
         5 . The cast component of  claim 4 , wherein the cast aluminum alloy has a yield strength of at least 105 MPa to 110 MPa, ultimate tensile strength (UTS) of at least 180 MPa, and an elongation of 8% to 15%. 
     
     
         6 . An aluminum alloy, comprising:
 at least 80 weight percent (wt. %) aluminum; 6.0 to 8.0 wt. % silicon; 1.0 to 2.0 wt. % zinc; 0.3 to 0.6 wt. % iron; and 0.2 wt. % to 0.5 wt. % manganese, based on the total weight of the aluminum alloy.   
     
     
         7 . The aluminum alloy according to  claim 6 , further including 0.05 to 0.3 wt. % magnesium, 0.10 wt. % to 0.40 wt. % copper, 0.01 wt. % to 0.03 wt. % strontium, and not greater than 0.15 wt. % titanium, based on the total weight of the aluminum alloy. 
     
     
         8 . The aluminum alloy according to  claim 7  further including other elements each in an amount of less than 0.05 wt. % and in a total amount of less than 0.15 wt. %, based on the total weight of the aluminum alloy. 
     
     
         9 . A cast component formed of the aluminum alloy of  claim 6 . 
     
     
         10 . The cast component of  claim 9 , wherein the cast aluminum alloy has a yield strength of at least 110 MPa to 120 MPa, ultimate tensile strength (UTS) of at least 240 MPa, and an elongation of 8% to 10%. 
     
     
         11 . An aluminum alloy, comprising:
 at least 80 weight percent (wt. %) aluminum; 9.5 to 11.5 wt. % silicon; 0.3 to 0.8 wt. % zinc; 0.3 to 0.6 wt. % iron; and 0.2 wt. % to 0.5 wt. % manganese, based on the total weight of the aluminum alloy.   
     
     
         12 . The aluminum alloy according to  claim 11  further including 0.1 to 0.6 wt. % magnesium, 0.20 wt. % to 0.90 wt. % copper, 0.01 wt. % to 0.07 wt. % strontium, and not greater than 0.15 wt. % titanium, based on the total weight of the aluminum alloy. 
     
     
         13 . The aluminum alloy according to  claim 12  further including other elements each in an amount of less than 0.05 wt. % and in a total amount of less than 0.15 wt. %, based on the total weight of the aluminum alloy. 
     
     
         14 . A cast component formed of the aluminum alloy of  claim 11 . 
     
     
         15 . The cast component of  claim 14 , wherein the cast aluminum alloy has a yield strength of at least 125 MPa to 130 MPa, ultimate tensile strength (UTS) of at least 200 MPa, and an elongation of 8% to 10%.