Low cost high ductility cast aluminum alloy

Abstract

An improved aluminum alloy for casting into a component, such as a vehicle component, is provided. The aluminum alloy preferably includes at least 80 weight percent (wt. %) aluminum; 9.5 to 11.5 wt. % silicon; 1.5 max wt. % zinc; 0.1 wt. % to 0.6 wt. % magnesium; 0.10 wt. % to 0.60 wt. % copper; 0.2. to 0.6 wt. % manganese; 0.2 wt. % to 0.6 wt. % iron; 0.01 wt. % to 0.07 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the aluminum alloy. This improved aluminum alloy can be formed by combining recycled aluminum or a recycle aluminum alloy with at least one additional element. The cast component formed of the aluminum alloy has a yield strength of 100 to 120 MPa and an elongation of 10% to 20% when the cast component is in the T7 temper condition

What is claimed is: 
     
         1 . An improved aluminum alloy, comprising:
 at least 80 weight percent (wt. %) aluminum; 9.5 to 11.5 wt. % silicon; 0.3 to 0.8 wt. % zinc; 0.1 wt. % to 0.6 wt. % magnesium; 0.20 wt. % to 0.90 wt. % copper; 0.2. to 0.5 wt. % manganese; 0.3 wt. % to 0.6 wt. % iron; 0.01 wt. % to 0.07 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the aluminum alloy.   
     
     
         2 . The improved aluminum alloy according to  claim 1  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 improved aluminum alloy. 
     
     
         3 . A cast component formed of the improved aluminum alloy according to  claim 1 . 
     
     
         4 . The cast component according to  claim 3 , wherein the improved aluminum alloy further includes 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 improved aluminum alloy. 
     
     
         5 . The cast component of  claim 3 , wherein the cast component has a yield strength of at least 140 to 150 MPa and an elongation of 3% to 5% when the cast component is in the T5 temper condition. 
     
     
         6 . The cast component of  claim 3 , wherein the cast component is a structural, body-in-white, suspension, or chassis component. 
     
     
         7 . The cast component of  claim 3 , wherein the cast improved aluminum alloy includes Mg 2 Si. 
     
     
         8 . A method of manufacturing a cast component, comprising the steps of:
 obtaining recycled aluminum or a recycled aluminum alloy;   combining the recycled aluminum or the recycled aluminum alloy with at least one additional element to form the improved aluminum alloy according to  claim 1 ; and   casting the improved aluminum alloy.   
     
     
         9 . The method of  claim 8 , wherein the improved aluminum alloy further includes 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 improved aluminum alloy. 
     
     
         10 . The method of  claim 8 , the cast component has a yield strength of at least 140 to 150 MPa and an elongation of 3% to 5% when the cast component is in the T5 temper condition. 
     
     
         11 . The method of  claim 8 , wherein the casting step includes forming the improved aluminum alloy into the shape of a structural, body-in-white, suspension, or chassis component. 
     
     
         12 . The method of  claim 8 , wherein the cast improved aluminum alloy includes Mg 2 Si. 
     
     
         13 . A method of manufacturing an improved aluminum alloy, comprising the steps of:
 obtaining recycled aluminum or a recycled aluminum alloy; and   combining the recycled aluminum or the recycled aluminum alloy with at least one additional element to form the improved aluminum alloy, the improved aluminum alloy comprising:   at least 80 weight percent (wt. %) aluminum; 9.5 to 11.5 wt. % silicon; 0.3 to 0.8 wt. % zinc; 0.1 wt. % to 0.6 wt. % magnesium; 0.20 wt. % to 0.90 wt. % copper; 0.2. to 0.5 wt. % manganese; 0.3 wt. % to 0.6 wt. % iron; 0.01 wt. % to 0.07 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.   
     
     
         14 . An aluminum alloy, comprising:
 at least 80 weight percent (wt. %) aluminum; 9.5 to 11.5 wt. % silicon; 1.5 max wt. % zinc; 0.1 wt. % to 0.6 wt. % magnesium; 0.10 wt. % to 0.60 wt. % copper; 0.2. to 0.6 wt. % manganese; 0.2 wt. % to 0.6 wt. % iron; 0.01 wt. % to 0.07 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.   
     
     
         15 . A cast component formed of the improved aluminum alloy according to  claim 14 . 
     
     
         16 . The cast component according to  claim 15 , wherein the improved aluminum alloy further includes 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 improved aluminum alloy. 
     
     
         17 . The cast component of  claim 15 , wherein the cast component has a yield strength of at least 100 to 120 MPa and an elongation of 10% to 20% when the cast component is in the T7 temper condition. 
     
     
         18 . A method of manufacturing a cast component, comprising the steps of:
 obtaining recycled aluminum or a recycled aluminum alloy;   combining the recycled aluminum or the recycled aluminum alloy with at least one additional element to form the improved aluminum alloy according to  claim 15 ; and   casting the improved aluminum alloy.   
     
     
         19 . A method of manufacturing an improved aluminum alloy, comprising the steps of:
 obtaining recycled aluminum or a recycled aluminum alloy; and   combining the recycled aluminum or the recycled aluminum alloy with at least one additional element to form the improved aluminum alloy, the improved aluminum alloy comprising:   at least 80 weight percent (wt. %) aluminum; 9.5 to 11.5 wt. % silicon; 1.5 max wt. % zinc; 0.1 wt. % to 0.6 wt. % magnesium; 0.10 wt. % to 0.60 wt. % copper; 0.2. to 0.6 wt. % manganese; 0.2 wt. % to 0.6 wt. % iron; 0.01 wt. % to 0.07 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.   
     
     
         20 . An improved aluminum alloy, comprising:
 at least 80 weight percent (wt. %) aluminum; 9.5 to 11.5 wt. % silicon; zinc; 0.1 wt. % to 0.6 wt. % magnesium; copper; at least 0.2. wt. % manganese; up to 0.6 wt. % iron; 0.01 wt. % to 0.07 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the aluminum alloy.