A method of making a die cast part having high wear resistance is provided. The method comprises providing a mold and an insert pin. The mold comprises an interior surface defining a cavity. The mold comprises a bore formed through the interior surface. The insert pin has a magnetic core having a magnetic field and a barrier disposed about the magnetic core. The insert pin is disposed in the bore and extends into the cavity. The method comprises filling the mold with metallic material such that the metallic material is in contact with the insert pin to define a contact layer. The method comprises modifying iron content within the contact layer with the magnetic field to define an outer layer and an inner layer formed between the outer layer and the insert pin. The inner layer has 3-5 wt % Fe and the outer layer has 0.01-0.5 wt % Fe.

The application is directed towards methods for purifying an aluminum feedstock material. A method provides: (a) feeding an aluminum feedstock into a cell (b) directing an electric current into an anode through an electrolyte and into a cathode, wherein the anode comprises an elongate vertical anode, and wherein the cathode comprises an elongate vertical cathode, wherein the anode and cathode are configured to extend into the electrolyte zone, such that within the electrolyte zone the anode and cathode are configured with an anode-cathode overlap and an anode-cathode distance; and producing some purified aluminum product from the aluminum feedstock.

Described herein are levelled and degreased aluminum alloys with a reduced gauge for can body stock production. The aluminum alloys exhibit improved formability. Also described herein are methods for processing the aluminum alloys to produce beverage can bodies. The aluminum alloys and sheets described herein are suitable for manufacturing cups and beverage can bodies at high production rates.

New aluminum casting (foundry) alloys are disclosed. The new aluminum casting alloys generally include from 2.5 to 5.0 wt. % Mg, from 0.70 to 2.5 wt. % Si, wherein the ratio of Mg/Si (in weight percent) is from 1.7 to 3.6, from 0.40 to 1.50 wt. % Mn, from 0.15 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. The new aluminum casting alloys may be high pressure die cast, such as into automotive components. The new aluminum alloys may be supplied in an F or a T5 temper, for instance.

Disclosed is a high-elasticity aluminum alloy which contains carbide to improve elongation. Further, a method of manufacturing the high-elasticity aluminum alloy is provided. The method includes steps of: charging pure aluminum and an Al-5B master alloy in a melting furnace to form a first molten metal; charging an Al-10Ti master alloy in the first molten metal to form a second molten metal; charging silicon (Si) element in the second molten metal to form a third molten metal; adding carbon (C) to the third molten metal to form a fourth molten metal; and tapping the fourth molten metal into a mold to cast the fourth molten metal.

A castable, moldable, or extrudable magnesium-based alloy that includes one or more insoluble additives. The insoluble additives can be used to enhance the mechanical properties of the structure, such as ductility and/or tensile strength. The final structure can be enhanced by heat treatment, as well as deformation processing such as extrusion, forging, or rolling, to further improve the strength of the final structure as compared to the non-enhanced structure. The magnesium-based composite has improved thermal and mechanical properties by the modification of grain boundary properties through the addition of insoluble nanoparticles to the magnesium alloys. The magnesium-based composite can have a thermal conductivity that is greater than 180 W/m-K, and/or ductility exceeding 15-20% elongation to failure.

There is provided an aluminum-ceramic bonded substrate in which an aluminum plate comprising aluminum alloy is directly bonded to one surface of a ceramic substrate and an aluminum base plate comprising aluminum alloy is directly bonded to the other surface of the ceramic substrate, wherein the aluminum alloy is the aluminum alloy containing 0.05% by mass or more and 3.0% by mass or less of at least one element selected from nickel and iron in total amount, containing 0.01% by mass or more and 0.1% by mass or less of at least one element selected from titanium and zirconium in total amount, and containing 0% by mass or more and 0.05% by mass or less of at least one element selected from boron or carbon in total amount, with a balance being aluminum.

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

An aluminum alloy material includes 1.0 wt % to 13.0 wt % of Si, 0.2 wt % to 1.4 wt % of Fe, 0.2 wt % to 0.8 wt % of Ni, and the remainder being Al and inevitable impurities. The aluminum alloy material can be 3D printed or die-casted to form an aluminum alloy object with a high thermal conductivity.

Methods and systems for investment casting with high performance aluminum alloys are described. High performance aluminum alloys can be modified with nanoparticles to be compatible with investment casting processes.