CN110603341A - Al-Mg-Si-Mn-Fe casting alloy - Google Patents

Abstract

New aluminum casting (casting) alloys are disclosed. The new aluminum casting alloys generally comprise from 2.5 wt.% to 5.0 wt.% Mg, from 0.70 wt.% to 2.5 wt.% Si, from 0.40 wt.% to 1.50 wt.% Mn, from 0.15 wt.% to 0.60 wt.% Fe, optionally up to 0.15 wt.% Ti, optionally up to 0.10 wt.% Sr, optionally up to 0.15 wt.% Zr, Sc, Hf, V and Cr, the remainder being aluminum and unavoidable impurities, wherein the Mg/Si ratio (in weight percent) is from 1.7 to 3.6. The new aluminum casting alloys can be high pressure die cast, for example, to form automotive parts. The new aluminum alloys can be supplied, for example, in F or T5 tempers.

Description

Al-Mg-Si-Mn-Fe casting alloy

Background technique

Aluminum alloys can be used in a variety of applications. For example, aluminum casting (foundry) alloys are used in dozens of industries including, for example, the automotive industry and the consumer electronics industry.

Contents of the invention

In general, the present disclosure relates to new aluminum casting (casting) alloys and related products. The new aluminum casting alloys generally comprise (and in some cases consist of or consist essentially of) from 2.5 wt.% to 5.0 wt.% Mg, from 0.70 wt.% to 2.5 wt. % of Si, from 0.40wt.% to 1.5wt.% of Mn, from 0.10wt.% to 0.60wt.% of Fe, optionally up to 0.15wt.% of Ti, optionally up to 0.10wt.% of Sr, and optionally up to 0.15 wt.% of any of Zr, Sc, Hf, V, and Cr, with the remainder being aluminum and unavoidable impurities, wherein the weight ratio of magnesium to silicon (Mg/Si) is From 1.7:1 to 3.6:1. New aluminum casting alloys can achieve improved combinations of properties, such as two or more of improved strength, ductility, castability, die soldering resistance, and quality index, among others combination of species.

i.Composition

As noted above, the new aluminum casting alloys generally contain from 2.5 wt.% to 5.0 wt.% Mg. In one embodiment, the new aluminum casting alloy comprises no greater than 4.75 wt.% Mg. In another embodiment, the new aluminum casting alloy comprises not greater than 4.60 wt.% Mg. In one embodiment, the new aluminum casting alloy comprises at least 2.75 wt.% Mg. In another embodiment, the new aluminum casting alloy comprises at least 3.0 wt. % Mg.

As noted above, the new aluminum casting alloys generally contain from 0.70 wt.% to 2.5 wt.% Si. In one embodiment, the new aluminum casting alloy comprises at least 0.80 wt.% Si. In another embodiment, the new aluminum casting alloy comprises at least 0.90 wt.% Si. In yet another embodiment, the novel aluminum casting alloy comprises at least 0.95 wt.% Si. In another embodiment, the new aluminum casting alloy comprises at least 1.00 wt. % Si. In yet another embodiment, the novel aluminum casting alloy comprises at least 1.05 wt.% Si. In another embodiment, the new aluminum casting alloy comprises at least 1.10 wt.% Si. In yet another embodiment, the new aluminum casting alloy comprises at least 1.15 wt.% Si. In another embodiment, the new aluminum casting alloy comprises at least 1.20 wt.% Si. In one embodiment, the new aluminum casting alloy contains no greater than 2.4 wt.% Si. In another embodiment, the new aluminum casting alloys contain no greater than 2.3 wt.% Si. In yet another embodiment, the new aluminum casting alloys contain no greater than 2.2 wt.% Si. In another embodiment, the new aluminum casting alloys contain no greater than 2.1 wt.% Si. In yet another embodiment, the new aluminum casting alloys contain no greater than 2.0 wt.% Si.

As noted above, the weight ratio of magnesium to silicon in the new aluminum casting alloys is generally from 1.7:1 to 3.6:1 (wt.% Mg/wt.% Si). In one embodiment, the weight ratio of magnesium to silicon in the new aluminum casting alloy is at least 1.8:1. In another embodiment, the weight ratio of magnesium to silicon in the new aluminum casting alloy is at least 1.85:1. In one embodiment, the weight ratio of magnesium to silicon in the new aluminum casting alloy is no greater than 3.6:1. In another embodiment, the weight ratio of magnesium to silicon in the new aluminum casting alloy is no greater than 3.5:1.

In one embodiment, the novel aluminum casting alloys comprise magnesium and silicon in amounts sufficient to facilitate the production of crack-free cast products (eg, crack-free high pressure die cast products). A crack-free product is one that is sufficiently free of cracks such that it can be used for its intended purpose. In one embodiment, the new aluminum casting alloys comprise magnesium and silicon in amounts sufficient to achieve a Hot Cracking Tendency Index (HCTI) of no greater than 0.30, such as any of the low HCTI values disclosed herein.

As noted above, the new aluminum casting alloys generally contain from 0.40 wt.% to 1.5 wt.% Mn. In one embodiment, the new aluminum casting alloy comprises at least 0.45 wt.% Mn. In another embodiment, the new aluminum casting alloy comprises at least 0.50 wt.% Mn. In yet another embodiment, the new aluminum casting alloy comprises at least 0.55 wt.% Mn. In another embodiment, the new aluminum casting alloy comprises at least 0.60 wt.% Mn. In one embodiment, the new aluminum casting alloy contains not greater than 1.45 wt.% Mn. In another embodiment, the new aluminum casting alloys contain not greater than 1.40 wt.% Mn. In yet another embodiment, the new aluminum casting alloy comprises not greater than 1.35 wt.% Mn. In another embodiment, the new aluminum casting alloys contain not greater than 1.30 wt.% Mn. In yet another embodiment, the new aluminum casting alloys comprise not greater than 1.25 wt.% Mn. In another embodiment, the new aluminum casting alloys contain not greater than 1.20 wt.% Mn.

As noted above, the new aluminum casting alloys generally contain from 0.10 wt.% to 0.60 wt.% Fe. In one embodiment, the new aluminum casting alloy comprises at least 0.12 wt.% Fe. In another embodiment, the new aluminum casting alloy comprises at least 0.15 wt.% Fe. In yet another embodiment, the new aluminum casting alloy comprises at least 0.20 wt.% Fe. In another embodiment, the new aluminum casting alloy comprises at least 0.25 wt.% Fe. In yet another embodiment, the new aluminum casting alloy comprises at least 0.30 wt.% Fe. In another embodiment, the new aluminum casting alloy comprises at least 0.35 wt.% Fe. In one embodiment, the new aluminum casting alloy contains no greater than 0.55 wt.% Fe. In another embodiment, the new aluminum casting alloys contain no greater than 0.50 wt.% Fe. In yet another embodiment, the new aluminum casting alloy contains no greater than 0.45 wt.% Fe.

In one embodiment, the new aluminum casting alloys comprise iron and manganese in amounts sufficient to promote the formation of alpha phase particles while limiting the formation of beta phase particles. In one embodiment, at least due to the iron content, the new aluminum casting alloy contains no greater than 0.012 wt. % of β-Al5FeSi compound. In another embodiment, the new aluminum casting alloys contain no greater than 0.010 wt. % of β-Al5FeSi compound. In yet another embodiment, the new aluminum casting alloy comprises not greater than 0.008 wt. % of β-Al5FeSi compound. In another embodiment, the new aluminum casting alloys contain no greater than 0.006 wt. % of β-Al5FeSi compound. In yet another embodiment, the new aluminum casting alloy comprises no greater than 0.004 wt. % of β-Al5FeSi compound. In another embodiment, the new aluminum casting alloys contain no greater than 0.002 wt. % of β-Al5FeSi compound. In yet another embodiment, the new aluminum casting alloys contain no greater than 0.001 wt. % of β-Al5FeSi compound. In another embodiment, the new aluminum casting alloys contain no greater than 0.0005 wt.% β-Al5FeSi compound.

In one embodiment, the new aluminum casting alloy may contain magnesium and silicon in amounts sufficient to meet the requirement: (0.4567*Mg−0.5)<=Si<=(0.4567*Mg+0.2).

In one embodiment, the new aluminum casting alloy may contain magnesium, silicon, manganese and iron in amounts sufficient to meet the following requirements:

(1) wt.%Si≤(0.4567*(wt.%Mg)+0.2*(wt.%Mg)+0.25*(wt.%Fe); and

(2) wt.%Si≥(0.4567*(wt.%Mg)+0.2*(wt.%Mg)+0.25*(wt.%Fe)-0.6).

As noted above, the new aluminum casting alloys may optionally contain up to 0.15 wt.% Ti. In one embodiment, the new aluminum casting alloy comprises at least 0.01 wt.% Ti. In another embodiment, the new aluminum casting alloy comprises at least 0.03 wt. % Ti. In yet another embodiment, the new aluminum casting alloy comprises at least 0.05 wt.% Ti. In another embodiment, the new aluminum casting alloy comprises at least 0.07 wt.% Ti. In one embodiment, the new aluminum casting alloy contains not greater than 0.13 wt.% Ti. In another embodiment, the new aluminum casting alloy contains not greater than 0.115 wt.% Ti. In another embodiment, the new aluminum casting alloys contain no greater than 0.10 wt.% Ti. In one embodiment, the novel aluminum casting alloys comprise titanium in an amount sufficient to promote grain refinement while limiting/avoiding the formation of primary titanium-containing particles. In some embodiments, titanium is included as an impurity in the new aluminum casting alloy.

As noted above, the new aluminum casting alloys may optionally contain up to 0.10 wt.% Sr. In one embodiment, the new aluminum casting alloy comprises strontium in an amount sufficient to promote modification of the Mg2Si eutectic while limiting/avoiding the formation of primary strontium _- containing particles. In one embodiment, the new aluminum casting alloy comprises at least 0.005 wt.% Sr. In one embodiment, the new aluminum casting alloy comprises no greater than 0.08 wt.% Sr. In another embodiment, the new aluminum casting alloys contain no greater than 0.05 wt.% Sr. In some embodiments, strontium is included as an impurity in the new aluminum casting alloy.

As noted above, the new aluminum casting alloys may optionally contain up to 0.15 wt. % of any of Zr, Sc, Hf, V and Cr. In one embodiment, the novel aluminum casting alloys comprise zirconium, scandium, hafnium, vanadium and/or chromium in amounts sufficient to promote solid solution strengthening while limiting/avoiding the formation of primary particles comprising zirconium, scandium, hafnium, vanadium and chromium. In one embodiment, the new aluminum casting alloy comprises at least 0.01 wt. % of any one of Zr, Sc, Hf, V and Cr. In another embodiment, the new aluminum casting alloy comprises at least 0.03 wt. % of any one of Zr, Sc, Hf, V and Cr. In yet another embodiment, the new aluminum casting alloy comprises at least 0.05 wt. % of any of Zr, Sc, Hf, V, and Cr. In one embodiment, the new aluminum casting alloy contains no greater than 0.10 wt. % of any of Zr, Sc, Hf, V and Cr. In some embodiments, zirconium is included as an impurity in the new aluminum casting alloy. In some embodiments, scandium is included as an impurity in the new aluminum casting alloy. In some embodiments, hafnium is included as an impurity in the new aluminum casting alloy. In some embodiments, vanadium is included as an impurity in the new aluminum casting alloy. In some embodiments, chromium is included as an impurity in the new aluminum casting alloy.

The remainder of the new aluminum casting alloy is essentially aluminum and unavoidable impurities. In one embodiment, the new aluminum foundry alloy contains no more than 0.30 wt.% of unavoidable impurities, and wherein the new aluminum foundry alloy contains no more than 0.10 wt.% of any of said unavoidable impurities element. In another embodiment, the new aluminum foundry alloy contains no more than 0.15 wt.% of unavoidable impurities, and wherein the new aluminum foundry alloy contains no more than 0.05 wt.% of any of said unavoidable impurities kind of element. In yet another embodiment, the new aluminum foundry alloy contains no more than 0.10 wt.% of unavoidable impurities, and wherein the new aluminum foundry alloy contains no more than 0.03 wt.% of any of said unavoidable impurities an element.

ii. processing

The new aluminum casting alloys can be cast using any suitable casting method. In one embodiment, the new aluminum casting alloy is direct chill casting as an ingot or billet. In another embodiment, the new aluminum casting alloys are shape cast into shape cast products (eg, complex shape cast products such as complex automotive parts). In one embodiment, the shape cast product is an automotive structural part. In another embodiment, the shape cast product is a door frame. In another embodiment, the shape cast product is a shock tower. In another embodiment, the shape cast product is a tunnel structure for an automobile.

In one embodiment, shape casting includes high pressure die casting. In another embodiment, shape casting comprises permanent mold casting.

The new aluminum casting alloy does not require a solution heat treatment step. Therefore, new aluminum casting alloys can be provided in suitable tempers such as F temper or T5 temper.

iii. Features

As noted above, new aluminum casting alloys may achieve an improved combination of properties, such as a combination of at least two of improved strength, ductility, castability, compression die weldability, and quality index. Mechanical properties can be measured according to ASTM E8 and B557 (eg, when directional solidified). Castability can be measured using the HCTI method described herein. Die weldability can be tested with cast alloys.

In one embodiment, the new aluminum casting alloy realizes an ultimate tensile strength of at least 200 MPa. In another embodiment, the new aluminum casting alloy realizes an ultimate tensile strength of at least 210 MPa. In yet another embodiment, the new aluminum casting alloy realizes an ultimate tensile strength of at least 220 MPa. In another embodiment, the new aluminum casting alloy realizes an ultimate tensile strength of at least 230 MPa.

In one embodiment, the new aluminum casting alloy realizes a tensile yield strength of at least 100 MPa. In another embodiment, the new aluminum casting alloy realizes a tensile yield strength of at least 105 MPa. In yet another embodiment, the new aluminum casting alloy realizes a tensile yield strength of at least 110 MPa. In another embodiment, the new aluminum casting alloy realizes a tensile yield strength of at least 115 MPa. In another embodiment, the new aluminum casting alloy realizes a tensile yield strength of at least 120 MPa. In another embodiment, the new aluminum casting alloy realizes a tensile yield strength of at least 125 MPa. Any of the above tensile yield strength values can be achieved with any of the above ultimate tensile strength values.

In one embodiment, the new aluminum casting alloy achieves an elongation of at least 7%. In another embodiment, the new aluminum casting alloy realizes an elongation of at least 8%. In yet another embodiment, the new aluminum casting alloy achieves an elongation of at least 9%. In another embodiment, the new aluminum casting alloy realizes an elongation of at least 10%. In yet another embodiment, the new aluminum casting alloy achieves an elongation of at least 11%. In another embodiment, the new aluminum casting alloy achieves an elongation of at least 12%. In yet another embodiment, the new aluminum casting alloy achieves an elongation of at least 13%. In another embodiment, the new aluminum casting alloy achieves an elongation of at least 14%. In yet another embodiment, the new aluminum casting alloy achieves an elongation of at least 15%. In another embodiment, the new aluminum casting alloy achieves an elongation of at least 16% or greater. Any of the above values of elongation can be achieved with any of the above values of ultimate tensile strength or tensile yield strength.

In one embodiment, the new aluminum casting alloys achieve an HCTI of no greater than 0.30. In another embodiment, the new aluminum casting alloys achieve an HCTI of no greater than 0.25. In yet another embodiment, the new aluminum casting alloys achieve an HCTI of no greater than 0.20. In another embodiment, the new aluminum casting alloys achieve an HCTI of no greater than 0.15 or lower.

In one embodiment, the new aluminum casting alloy is die weldable, wherein the as-cast aluminum alloy product is removed from the die without damaging the cast product and/or without sticking to the die. Die soldering can occur during high pressure die casting where molten aluminum is soldered to the die surface. In some embodiments, the new aluminum casting alloys described herein can be cast without welding to a die.

These and other combinations of features are disclosed in the following detailed description.

Description of drawings

FIG. 1 is a graph showing silicon content versus hot cracking propensity index for the alloy of Example 1. FIG.

FIG. 2 is a graph showing silicon content versus hot cracking propensity index for the alloy of Example 2. FIG.

FIG. 3 is a graph showing silicon content versus hot cracking propensity index for the alloy of Example 3. FIG.

FIG. 4 is a graph showing manganese content versus hot cracking propensity index for the alloy of Example 4. FIG.

Figure 5a is a graph showing the beta phase content (shown in wt.%) as a function of Mn and Fe content based on ICME modeling; the amounts of 3.6 wt.% Mg and 1.5 wt.% Si were kept constant .

Figure 5b is a graph showing the alpha phase content (shown in wt.%) as a function of Mn and Fe content based on ICME modeling; the amounts of 3.6 wt.% Mg and 1.5 wt.% Si were kept constant .

Figure 6 is a graph showing beta phase content (shown in wt.%) as a function of Fe content based on ICME modeling; 3.6 wt.% Mg, 1.5 wt.% Si and 0.5 wt.% Mn amount remains constant.

Figure 7a is a graph showing ultimate tensile strength (MPa) versus iron content (wt.%) for the Example 6 alloy.

Figure 7b is a graph showing elongation (%) versus iron content (wt.%) for the Example 6 alloy.

Figure 7c is a graph showing tensile yield strength (MPa) versus iron content (wt.%) for the Example 6 alloy.

Figure 7d is a graph showing quality index (Q in MPa) versus iron content (wt.%) for the Example 6 alloy.

Figure 8a is a graph showing HCI (calculated hot cracking index) as a function of Si and Mg content based on ICME modeling; the amounts of 0.70 wt.% Mn and 0.25 wt.% Fe were kept constant.

Figure 8b is a graph showing the non-equilibrium solidification (non-equilibrium solidification) temperature range (°C) as a function of Si and Mg content based on ICME modeling; amount remains constant.

Figure 8c is a graph showing HCI (calculated hot cracking index) as a function of Si and Mn content based on ICME modeling; the amounts of 4.0 wt.% Mg and 0.25 wt.% Fe were kept constant.

Figure 8d is a graph showing HCI (calculated hot cracking index) as a function of Si and Fe content based on ICME modeling; the amounts of 4.0 wt.% Mg and 0.70 wt.% Mn were kept constant.

Detailed ways

Example 1

Six aluminum alloys were cast into pencil probe castings. The composition of the aluminum alloys is given in Table 1 below.

Table 1 - Composition of the alloy of Example 1 (all values are in weight percent)

Each alloy was tested five times and at different connection sizes. Table 2 below provides the hot crack results. In the table below, "C" means cracked during casting, "OK" means casting was successful without cracking, and "NF" means the pencil probe mold was not completely filled. From the results, a Hot Cracking Tendency Index ("HCTI") was calculated for each alloy. Table 2 also lists the calculated HCTI for each alloy.

The hot cracking tendency index (HCTI) of the alloy is defined as

If no cracks are found on any connection rod, the HCTI value will be 0. If a rupture is found in all 7 connecting rods (from 4mm to 16mm), the HCTI value will be 1. Thus, for a particular alloy, a smaller HCTI indicates higher hot cracking resistance.

Hot cracking results of the alloy of table 2-embodiment 1

Figure 1 shows a graph of silicon content versus measured HCTI values. As shown, alloys with from about 1 to about 2 wt. % Si achieve improved hot cracking resistance at similar amounts of Fe, Mn, Mg, and Ti. The Mg/Si ratio of these alloys is from about 2.0 to 3.0. Alloy A4 with 1.56 wt.% Si has a Mg to Si ratio of 2.26.

Example 2

Following Example 1, four additional alloys were cast and their hot tear susceptibility determined. As in Example 1, the silicon content was varied again, but lower nominal amounts of magnesium and manganese were used. The composition of the Example 2 alloy is shown in Table 3 below. The HCTI results for the Example 2 alloy are shown in the figure below. Alloy B2 shows the best hot cracking resistance. The Mg/Si ratio of this alloy is about 2.65.

The composition of table 3-embodiment 2 alloy (all values are by weight percentage)

Figure 2 shows the experimentally measured hot cracking propensity index for Al-2.5Mg-1.1Mn-x%Si alloys. Alloy B2 with 0.96 wt.% Si and 2.54 wt.% Mg showed the best hot cracking resistance. The Mg/Si ratio of this alloy is about 2.65.

Example 3

Following Example 1, four additional alloys were cast and their hot tear susceptibility determined. As in Example 1, the silicon content was varied again, but with a higher nominal amount of magnesium and a lower nominal amount of manganese. The composition of the Example 3 alloy is shown in Table 4 below. The HCTI results for the Example 3 alloy are shown in FIG. 3 . As shown, the HCTI of all alloys is generally good. Alloy C3 with a Mg/Si ratio of 2.22 achieves the lowest HCTI.

The composition of table 4-embodiment 3 alloy (all values are by weight percent)

The results of Examples 1-3 indicate that the Mg/Si (weight ratio) should be from about 1.7 to about 3.6, preferably from about 2.0 to about 3.0 to promote hot crack resistance.

Example 4

Following Example 1, four additional alloys were cast and their hot tear susceptibility determined. This time, the manganese content was varied to target a nominal magnesium amount of 3.6 wt.% and a nominal silicon amount of 1.5 wt.%. The composition of the Example 4 alloy is shown in Table 5 below. The HCTI results for the Example 4 alloy are shown in FIG. 4 . As shown, the HCTI of all alloys is generally good. Alloy D4 with 1.20 wt.% Mn achieved the best HCTI results.

The composition of table 5-embodiment 4 alloy (all values are by weight percentage)

Example 5

Following Example 1, four additional alloys were cast and their hot tear susceptibility determined. This time, the iron content was varied to target a nominal magnesium amount of 3.45 wt.%, a nominal silicon amount of 1.55 wt.%, and a nominal manganese amount of 0.90 wt.%. The composition of the Example 5 alloy is shown in Table 6 below. The HCTI results for the Example 5 alloy are shown in the figure below. As shown, the HCTI of all alloys is generally good. Alloy E4 with 0.29 wt.% Fe achieved the best HCTI results.

The composition of table 6-embodiment 5 alloy (all values are by weight percentage)

These results were unexpected. Iron adversely affects the mechanical properties of Al-Si cast alloys because iron is present as a large primary or pseudo-primary compound that increases hardness but reduces ductility. Modeling (ICME - Integrated Computational Materials Engineering) was performed taking into account these improved HCTI results. These results show that the formation of detrimental acicular β-Al ₅ FeSi can potentially be avoided by controlling the Fe and Mn contents. Figures 5a, 5b and 6 show the correlation between manganese and iron content and the volume fraction of β-Al ₅ FeSi and α-Al ₁₅ FeMn ₃ Si ₂ phase particles (for Al-3.6Mg-1.5Si alloy). The addition of Mn to Al-Mg-Si alloys can promote the formation of α-Al ₁₅ FeMn ₃ Si ₂ phase and limit or prevent the formation of β-Al ₅ FeSi phase. For example, Al-3.6Mg-1.5Si alloys with Mn from 0.4 to 0.6 wt.% reduce the amount of β-Al ₅ FeSi phase with increasing amounts of iron. As shown in Figure 6, by increasing iron from 0.15 wt.% to 0.4 wt.%, the amount of β-Al ₅ FeSi phase is reduced from about 0.018 wt.% to substantially 0 wt.%. Thus, alloys with improved properties (eg, elongation) can be achieved due to the increase in iron in the alloy and the corresponding reduction in the β-Al ₅ FeSi phase.

Example 6

Eight additional alloys were cast by directional solidification. The iron content of all alloys varies. The first group (F) targets a nominal magnesium amount of 3.6 wt.%, a nominal silicon amount of 1.5 wt.%, and a nominal manganese amount of 0.90 wt.%. The second group (G) targets a nominal magnesium amount of 4.0 wt.%, a nominal silicon amount of 1.7 wt.%, and a nominal manganese amount of 0.65 wt.%. The composition of the Example 6 alloy is shown in Table 7 below.

The composition of table 6-embodiment 5 alloy (all values are by weight percentage)

The mechanical properties of directionally solidified alloys were tested according to ASTM E8 and B557, the results of which are provided in Table 7 below. The mechanical properties of the Example 5 alloy were also tested, so those results are also included in Table 7. A quality index (Q) is also provided. (Q=UTS+150*log(elongation)). Various graphs relating these properties and alloy compositions are provided in Figures 7a-7d.

Table 7 - Properties of Alloys E1-E4, F1-F4 and G1-G4

Example 7 - Experimental Modeling

Based on existing experiments, various aluminum alloy compositions were modeled. The results are shown in Figures 8a-8b. These modeling results indicate that for an Al-Mg-Si alloy targeting 0.7 wt.% Mn and 0.25 wt.% Fe, it may be useful to control magnesium and silicon such that (all values in weight percent ): (0.4567*Mg-0.5)<=Si<=(0.4567*Mg+0.2).

Similar modeling was performed for other aluminum alloys, as shown in Figures 8c-8d. These modeling results indicate that as the manganese or iron content increases, the silicon content needs to increase. These results further indicate that it may be useful to control magnesium, silicon, manganese and iron as follows:

(0.4567*Mg+0.2*Mn+0.25*Fe–0.6)<=Si<=(0.4567*Mg+0.2*Mn+0.25*Fe)

While various embodiments of the present disclosure have been described in detail, it is evident that modifications and improvements of those embodiments will occur to those skilled in the art. However, it should be expressly understood that such modifications and improvements are within the spirit and scope of the present disclosure.

Claims (37)

1. An aluminum casting alloy comprising:

from 2.5 to 5.0 wt.% Mg;

from 0.70 to 2.5 wt.% Si;

wherein the weight ratio of magnesium to silicon (wt.% Mg/wt.% Si) is from 1.7:1 to 3.6: 1;

from 0.40 to 1.5 wt.% Mn;

from 0.10 to 0.60 wt.% Fe;

optionally up to 0.15 wt.% Ti;

optionally up to 0.10 wt.% Sr;

optionally up to 0.15 wt.% of any of Zr, Sc, Hf, V and Cr;

the balance being aluminum and unavoidable impurities.

2. The aluminum casting alloy of claim 1, wherein the aluminum casting alloy includes not greater than 4.75 wt.% Mg or not greater than 4.60 wt.% Mg.

3. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes at least 2.75 wt.% Mg or at least 3.0 wt.% Mg.

4. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes at least 0.80 wt.% Si, or at least 0.90 wt.% Si, or at least 0.95 wt.% Si, or at least 1.00 wt.% Si, or at least 1.05 wt.% Si, or at least 1.10 wt.% Si, or at least 1.15 wt.% Si, or at least 1.20 wt.% Si.

5. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes not greater than 2.4 wt.% Si, or not greater than 2.3 wt.% Si, or not greater than 2.2 wt.% Si, or not greater than 2.1 wt.% Si, or not greater than 2.0 wt.% Si.

6. The aluminum casting alloy of any of the preceding claims, wherein the weight ratio of magnesium to silicon is at least 1.8:1, or wherein the weight ratio of magnesium to silicon is at least 1.85: 1.

7. The aluminum casting alloy of any of the preceding claims, wherein the weight ratio of magnesium to silicon is not greater than 3.6:1, or wherein the weight ratio of magnesium to silicon is not greater than 3.5: 1.

8. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes at least 0.45 wt.% Mn, or at least 0.50 wt.% Mn, or at least 0.55 wt.% Mn, or at least 0.60 wt.% Mn.

9. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes not greater than 1.45 wt.% Mn, or not greater than 1.40 wt.% Mn, or not greater than 1.35 wt.% Mn, or not greater than 1.30 wt.% Mn, or not greater than 1.35 wt.% Mn, or not greater than 1.20 wt.% Mn.

10. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes at least 0.12 wt.% Fe, or at least 0.15 wt.% Fe, or at least 0.20 wt.% Fe, or at least 0.25 wt.% Fe, or at least 0.30 wt.% Fe, or at least 0.35 wt.% Fe.

11. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes not greater than 0.55 wt.% Fe, or not greater than 0.50 wt.% Fe, or not greater than 0.45 wt.% Fe.

12. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes at least 0.01 wt.% Ti, or at least 0.03 wt.% Ti, or at least 0.05 wt.% Ti, or at least 0.07 wt.% Ti.

13. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes not greater than 0.13 wt.% Ti, or not greater than 0.115 wt.% Ti, or not greater than 0.10 wt.% Ti.

14. The aluminum casting alloy of any of the preceding claims, wherein the alloy includes not greater than 0.08 wt.% Sr or not greater than 0.05 wt.% Sr.

15. The aluminum casting alloy of any of the preceding claims, wherein the alloy includes at least 0.005 wt.% Sr.

16. The aluminum casting alloy of any of the preceding claims, wherein the alloy includes at least 0.01 wt.% of any of Zr, Sc, Hf, V, and Cr, or at least 0.03 wt.% of any of Zr, Sc, Hf, V, and Cr, or at least 0.05 wt.% of any of Zr, Sc, Hf, V, and Cr.

17. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes not greater than 0.30 wt.% of the unavoidable impurities, and wherein the aluminum casting alloy includes not greater than 0.10 wt.% of any one of the unavoidable impurities.

18. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes not greater than 0.15 wt.% of the unavoidable impurities, and wherein the aluminum casting alloy includes not greater than 0.05 wt.% of any one of the unavoidable impurities.

19. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes not greater than 0.10 wt.% of the unavoidable impurities, and wherein the aluminum casting alloy includes not greater than 0.03 wt.% of any one of the unavoidable impurities.

20. The aluminum casting alloy of any of the preceding claims, wherein (0.4567 x Mg-0.5 x Si (0.4567 x Mg + 0.2)).

21. The aluminum casting alloy of any of claims 1-19, wherein:

(1) wt.% Si ≦ (0.4567 ≦ (wt.% Mg) +0.2 ≦ (wt.% Mg) +0.25 ≦ (wt.% Fe), and

(2) wt. ％ Si ≥ (0.4567 * (wt. ％ Mg) + 0.2 * (wt. ％ Mg) + 0.25 * (wt. ％Fe)-0.6)。

22. the aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy realizes at least one of:

an ultimate tensile strength of at least 200 MPa;

a tensile yield strength of at least 110 MPa; and

an elongation of at least 10%.

23. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy realizes at least two of:

an ultimate tensile strength of at least 200 MPa;

a tensile yield strength of at least 110 MPa; and

an elongation of at least 10%.

24. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy realizes all of:

an ultimate tensile strength of at least 200 MPa;

a tensile yield strength of at least 110 MPa; and

an elongation of at least 10%.

25. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy includes not greater than 0.012 wt.% beta-Al₅A FeSi compound, or not more than 0.010 wt.% of beta-Al₅A FeSi compound, or not more than 0.008 wt.% of beta-Al₅A FeSi compound, or not more than 0.006 wt.% of beta-Al₅A FeSi compound, or not more than 0.004 wt.% of beta-Al₅A FeSi compound, or not more than 0.002 wt.% of beta-Al₅A FeSi compound, or not more than 0.001 wt.% of beta-Al₅A FeSi compound or not more than 0.0005 wt.% beta-Al₅A FeSi compound.

26. The aluminum casting alloy of any of the preceding claims, wherein the aluminum casting alloy realizes a hot cracking propensity index of not greater than 0.30, or not greater than 0.25, or not greater than 0.20, or not greater than 0.15.

27. A high pressure die cast product made from any of the aluminum casting alloys of claims 1-26.

28. The high pressure die cast product of claim 27, wherein the high pressure die cast product is in an F temper or a T5 temper.

29. The high pressure die cast product of claim 27, wherein the high pressure die cast product is in the form of an automotive part.

30. The high pressure die cast product of claim 29 wherein the automotive part is a structural part.

31. The high pressure die cast product of claim 29, wherein the automotive component is a door frame or a shock tower or channel structure.

32. An aluminum casting alloy comprising:

from 3.0 to 4.60 wt.% Mg;

from 1.20 to 2.0 wt.% Si;

wherein the weight ratio of magnesium to silicon (wt.% Mg/wt.% Si) is from 1.85:1 to 3.5: 1;

from 0.60 to 1.20 wt.% Mn;

from 0.20 to 0.60 wt.% Fe;

optionally up to 0.15 wt.% Ti;

optionally up to 0.10 wt.% Sr; and

optionally up to 0.15 wt.% of any of Zr, Sc, Hf, V and Cr;

the balance being aluminum and unavoidable impurities.

33. The aluminum casting alloy of claim 32, wherein the aluminum casting alloy is in the form of a complex-shaped casting.

34. The aluminum casting alloy of claim 33, wherein the complex-shaped casting is an automotive part.

35. The aluminum casting alloy of claim 34, wherein the automotive component is a structural component.

36. The aluminum casting alloy of claim 34, wherein the automobile component is a door frame or a shock tower or channel structure.

37. The aluminum casting alloy of claim 32, comprising from 0.35 wt.% to 0.60 wt.% Fe.