Methods and Systems for High Pressure Die Casting

Abstract

Methods and systems for high pressure die casting with metal alloys of low silicon content are described. Metal alloys can be modified with nanoparticles to achieve high fluidity and hot cracking resistance to be compatible with high pressure die casting. The die cast metal parts have high strength, high ductility, and high thermal and electrical conductivity. The die cast metal parts can be anodized with different colors.

What is claimed is: 
     
         1 . A metal alloy for high pressure die casting, comprising:
 a metal alloy selected from the group consisting of an aluminum alloy, a magnesium alloy, a copper alloy, and a zinc alloy; and   at least one type of nanoparticle dispersed in the metal alloy;   wherein the metal alloy comprises less than 4.0 wt. % silicon; and   wherein the metal alloy is compatible with a high pressure die casting process.   
     
     
         2 . The metal alloy of  claim 1 , wherein the metal alloy is selected from the group consisting of A201, AA2024, A206, AA2618, AA5083, AA6013, AA6061, AA6063, AA6069, AA7034, AA7050, AA7075, and AA7068. 
     
     
         3 . The metal alloy of  claim 1 , wherein the at least one type of nanoparticle is selected from the group consisting of a metal oxide, a non-metal oxide, a metal carbide, a non-metal carbide, a metal silicide, a metal boride, a metal nitride, and any combinations thereof. 
     
     
         4 . The metal alloy of  claim 1 , wherein the at least one type of nanoparticle has a structure of a core-shell particle. 
     
     
         5 . The metal alloy of  claim 1 , wherein the nanoparticle comprises less than 30 vol. % of the metal alloy. 
     
     
         6 . The metal alloy of  claim 1 , wherein the nanoparticle comprises 0.1 vol. % to 2 vol. % of the metal alloy. 
     
     
         7 . The metal alloy of  claim 1 , wherein the metal alloy comprises AA6061 and the nanoparticle comprises TiC, and the TiC nanoparticle comprises 1.0 vol. % of the metal alloy. 
     
     
         8 . The metal alloy of  claim 1 , wherein the high pressure die casting process uses a pressure between 30 MPa and 100 MPa. 
     
     
         9 . The metal alloy of  claim 1 , wherein the high pressure die casting process uses a pressure greater than 100 MPa. 
     
     
         10 . The metal alloy of  claim 1 , wherein the high pressure die casting process comprises a cooling step with a cooling rate between 100° C./s and 300° C./s. 
     
     
         11 . A method for high pressure die casting comprising:
 providing a metal alloy modified with at least one type of nanoparticle, wherein the metal alloy comprises a silicon weight concentration of less than 4.0%;   melting the metal alloy and filling a die with the molten metal alloy under a pressure, wherein the pressure is compatible with the high pressure die casting process; and   cooling the die to solidify the molten metal alloy.   
     
     
         12 . The method of  claim 11 , further comprising anodizing the die cast metal alloy with at least one color. 
     
     
         13 . The method of  claim 11 , wherein the metal alloy is selected from the group consisting of an aluminum alloy, a magnesium alloy, a copper alloy, and a zinc alloy. 
     
     
         14 . The method of  claim 11 , wherein the metal alloy is selected from the group consisting of A201, AA2024, A206, AA2618, AA5083, AA6013, AA6061, AA6063, AA6069, AA7034, AA7050, AA7075, and AA7068. 
     
     
         15 . The method of  claim 11 , wherein the at least one type of nanoparticle is selected from the group consisting of a metal oxide, a non-metal oxide, a metal carbide, a non-metal carbide, a metal silicide, a metal boride, a metal nitride, and any combinations thereof. 
     
     
         16 . The method of  claim 11 , wherein the at least one type of nanoparticle has a structure of a core-shell particle. 
     
     
         17 . The method of  claim 11 , wherein the at least one type of nanoparticle comprises less than 30 vol. % of the metal alloy. 
     
     
         18 . The method of  claim 11 , wherein the nanoparticle comprises 0.1 vol. % to 2 vol. % of the metal alloy. 
     
     
         19 . The method of  claim 11 , wherein the metal alloy comprises AA6061 and the nanoparticle comprises TiC, and the TiC nanoparticle comprises 1.0 vol. % of the metal alloy. 
     
     
         20 . The method of  claim 11 , wherein the die cast metal alloy as formed has a elongation equal to or less than 30% and an ultimate tensile strength greater than 500 MPa. 
     
     
         21 . The method of  claim 11 , wherein the die cast metal alloy has a thickness of at least 0.2 mm. 
     
     
         22 . The method of  claim 11 , wherein the pressure is between 30 MPa and 100 MPa. 
     
     
         23 . The method of  claim 11 , wherein the pressure is greater than 100 MPa. 
     
     
         24 . The method of  claim 11 , wherein the die is cooled with a cooling rate between 100° C./s and 300° C./s. 
     
     
         25 . The method of  claim 11 , further comprising a post process of the die cast metal alloy. 
     
     
         26 . The method of  claim 25 , wherein the post process is selected from the group consisting of: a T5 treatment, a natural aging treatment, and a T6 treatment. 
     
     
         27 . A high pressure die cast metal part comprising:
 a metal alloy; and   at least one type of nanoparticle dispersed in the metal alloy;   wherein the metal alloy comprises less than 4.0 wt. % silicon;   wherein the metal part is produced via a high pressure die casting process; and   wherein the die cast metal part has a thickness of at least 0.2 mm.   
     
     
         28 . The die cast metal part of  claim 27 , wherein the metal alloy is selected from the group consisting of an aluminum alloy, a magnesium alloy, a copper alloy, and a zinc alloy. 
     
     
         29 . The die cast metal part of  claim 27 , wherein the metal alloy is selected from the group consisting of A201, AA2024, A206, AA2618, AA5083, AA6013, AA6061, AA6063, AA6069, AA7034, AA7050, AA7075, and AA7068. 
     
     
         30 . The die cast metal part of  claim 27 , wherein the at least one type of nanoparticle is selected from the group consisting of a metal oxide, a non-metal oxide, a metal carbide, a non-metal carbide, a metal silicide, a metal boride, a metal nitride, and any combinations thereof. 
     
     
         31 . The die cast metal part of  claim 27 , wherein the at least one type of nanoparticle has a structure of a core-shell particle. 
     
     
         32 . The die cast metal part of  claim 27 , wherein the nanoparticle comprises less than 30 vol. % of the metal alloy. 
     
     
         33 . The die cast metal part of  claim 27 , wherein the nanoparticle comprises 0.1 vol. % to 2 vol. % of the metal alloy. 
     
     
         34 . The die cast metal part of  claim 27 , wherein the metal alloy comprises AA6061 and the nanoparticle comprises TiC, and the TiC nanoparticle comprises 1.0 vol. % of the metal alloy. 
     
     
         35 . The die cast metal part of  claim 27 , wherein the high pressure die casting process uses a pressure between 30 MPa and 100 MPa. 
     
     
         36 . The die cast metal part of  claim 27 , wherein the high pressure die casting process uses a pressure greater than 100 MPa. 
     
     
         37 . The die cast metal part of  claim 27 , wherein the high pressure die casting process comprises a cooling step with a cooling rate between 100° C./s and 300° C./s. 
     
     
         38 . The die cast metal part of  claim 27 , wherein the metal part is anodized with at least one color. 
     
     
         39 . A method for improving castibility of a metal alloy, comprising:
 incorporating at least one type of nanoparticle into a metal alloy;   wherein the metal alloy comprises less than 4.0 wt. % silicon;   wherein the nanoparticle comprises less than 30 vol. % of the metal alloy; and   wherein the metal alloy is compatible with a high pressure die casting process.   
     
     
         40 . The method of  claim 39 , wherein the metal alloy selected from the group consisting of an aluminum alloy, a magnesium alloy, a copper alloy, and a zinc alloy. 
     
     
         41 . The method of  claim 39 , wherein the metal alloy is selected from the group consisting of A201, AA2024, A206, AA2618, AA5083, AA6013, AA6061, AA6063, AA6069, AA7034, AA7050, AA7075, and AA7068. 
     
     
         42 . The method of  claim 39 , wherein the at least one type of nanoparticle is selected from the group consisting of a metal oxide, a non-metal oxide, a metal carbide, a non-metal carbide, a metal silicide, a metal boride, a metal nitride, and any combinations thereof. 
     
     
         43 . The method of  claim 39 , wherein the at least one type of nanoparticle has a structure of a core-shell particle. 
     
     
         44 . The method of  claim 39 , wherein the nanoparticle comprises 0.1 vol. % to 2 vol. % of the metal alloy. 
     
     
         45 . The method of  claim 39 , wherein the metal alloy comprises AA6061 and the nanoparticle comprises TiC, and the TiC nanoparticle comprises 1.0 vol. % of the metal alloy. 
     
     
         46 . The method of  claim 39 , wherein the high pressure die casting process uses a pressure between 30 MPa and 100 MPa. 
     
     
         47 . The method of  claim 39 , wherein the high pressure die casting process uses a pressure greater than 100 MPa. 
     
     
         48 . The method of  claim 39 , wherein the high pressure die casting process comprises a cooling step with a cooling rate between 100° C./s and 300° C./s.