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 improved aluminum alloy includes at least 80 wt. % aluminum; 6.0 to 8.0 wt. % silicon; 1.0 to 2.0 wt. % zinc; 0.10 to 0.6 wt. % magnesium; 0.1 to 0.60 wt. % copper; 0.20. to 0.60 wt. % manganese; up to 0.25 wt. % iron; 0.015 wt. % to 0.03 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy. This improved aluminum alloy can be formed by combining recycled aluminum or recycled aluminum alloy with at least one additional element. The cast component formed of the improved aluminum alloy has a yield strength of 120 MPa to 130 MPa and an elongation of 8% to 16%, depending on flow length, when the cast component is in the as-cast (F temper) condition.

What is claimed is: 
     
         1 . An improved aluminum alloy, comprising:
 at least 80 weight percent (wt. %) aluminum; 6.0 to 8.0 wt. % silicon; 1.0 to 2.0 wt. % zinc; 0.05 to 0.3 wt. % magnesium; 0.1 to 0.40 wt. % copper; 0.20. to 0.50 wt. % manganese; 0.3 to 0.6 wt. % iron; 0.01 wt. % to 0.03 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved 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 an improved aluminum alloy according to  claim 1 . 
     
     
         4 . The cast component of  claim 3 , wherein the cast component is a structural, body-in-white, suspension, or chassis component. 
     
     
         5 . The cast component of  claim 3 , wherein the cast improved aluminum alloy includes Mg 2 Si. 
     
     
         6 . The cast component of  claim 3 , wherein the cast component has a yield strength of 140 to 150 MPa and an elongation of 5% to 7% when the cast component is in the T5 temper condition. 
     
     
         7 . The cast component of  claim 3 , wherein the cast component has a yield strength of 110 MPa to 120 MPa and an elongation of 8% to 10% when the cast component is in the as-cast (F temper) condition. 
     
     
         8 . 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; 6.0 to 8.0 wt. % silicon; 1.0 to 2.0 wt. % zinc; 0.05 to 0.3 wt. % magnesium; 0.1 to 0.40 wt. % copper; 0.20. to 0.50 wt. % manganese; 0.3 to 0.6 wt. % iron; 0.01 wt. % to 0.03 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of 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 . 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 an improved aluminum alloy, the improved aluminum alloy comprising:   at least 80 weight percent (wt. %) aluminum; 6.0 to 8.0 wt. % silicon; 1.0 to 2.0 wt. % zinc; 0.05 to 0.3 wt. % magnesium; 0.1 to 0.40 wt. % copper; 0.20. to 0.50 wt. % manganese; 0.3 to 0.6 wt. % iron; 0.01 wt. % to 0.03 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy; and   casting the improved aluminum alloy.   
     
     
         11 . The method of  claim 10 , 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. 
     
     
         12 . The method of  claim 10 , wherein the casting step includes forming the improved aluminum alloy into the shape of a structural, body-in-white, suspension, or chassis component. 
     
     
         13 . An improved aluminum alloy, comprising:
 at least 80 weight percent (wt. %) aluminum; 6.0 to 8.0 wt. % silicon; 1.0 to 2.0 wt. % zinc; 0.10 to 0.6 wt. % magnesium; 0.1 to 0.60 wt. % copper; 0.20. to 0.60 wt. % manganese; up to 0.25 wt. % iron; 0.015 wt. % to 0.03 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.   
     
     
         14 . A cast component formed of the improved aluminum alloy according to  claim 13 . 
     
     
         15 . The cast component according to  claim 14 , wherein the cast improved aluminum alloy includes Al—Si—Mn—Fe—Cu—Zn intermetallic and/or Al—Mn—Si—Fe intermetallic. 
     
     
         16 . The cast component according to  claim 14 , wherein the cast component has a yield strength of 150 to 160 MPa and an elongation of 6% to 12%, when the cast component is in the T5 temper condition. 
     
     
         17 . The cast component according to  claim 14 , wherein the cast component has a yield strength of 130 to 140 MPa and an elongation of 8% to 15% when the cast component is in a paint bake temper condition. 
     
     
         18 . The cast component of  claim 14 , wherein the cast component has a yield strength of 120 MPa to 130 MPa and an elongation of 8% to 16%, when the cast component is in an as-cast (F temper) condition. 
     
     
         19 . 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 13 ; and   casting the improved aluminum alloy.   
     
     
         20 . 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; 6.0 to 8.0 wt. % silicon; 1.0 to 2.0 wt. % zinc; 0.10 to 0.6 wt. % magnesium; 0.1 to 0.60 wt. % copper; 0.20. to 0.60 wt. % manganese; up to 0.25 wt. % iron; 0.015 wt. % to 0.03 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.   
     
     
         21 . An improved aluminum alloy, comprising:
 at least 80 weight percent (wt. %) aluminum; 6.0 to 8.0 wt. % silicon; 1.0 to 2.0 wt. % zinc; at least 0.05 wt. % magnesium; at least 0.1 wt. % copper; at least 0.20. wt. % manganese; iron; 0.01 wt. % to 0.03 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.