Die Casting Alloy

Abstract

A die casting alloy on an aluminum-silicon base with a composition having 8.5 to 11.5 wt. % of silicon, 0.1 to 0.5 wt. % of magnesium, 0.3 to 0.8 wt. % of manganese, 0.02 to 0.5 wt. % of iron, 0.005 to 0.5 wt. % of zinc, 0.1 to 0.5 wt. % of copper, 0.02 to 0.3 wt. % of molybdenum, 0.02 to 0.3 wt. % of zirconium, 10 to 200 ppm of gallium and optionally at least one of 30 to 300 ppm of strontium, 5 to 30 ppm of sodium, 1 to 30 ppm of calcium, 5 to 250 ppm of phosphorus, 0.02 to 0.25 wt. % of titanium, and 3 to 50 ppm of boron with the remainder being aluminium and unavoidable impurities. The alloy can be produced with a recycling rate of 50%.

Claims

1. A die-cast alloy, based on aluminum-silicon, comprising: 8.5 to 11.5% by weight silicon 0.1 to 0.5% by weight magnesium 0.3 to 0.8% by weight manganese 0.02-0.5% by weight iron 0.005-0.5% by weight zinc 0.1 to 0.5% by weight copper 0.02 to 0.3% by weight molybdenum 0.02 to 0.3% by weight zirconium 10 to 200 ppm gallium and optionally at least one element selected from the group consisting of 30 to 300 ppm strontium, 5 to 30 ppm sodium, 1 to 30 ppm calcium, 5 to 250 ppm phosphorus, 0.02 to 0.25% by weight titanium, and 3 to 50 ppm boron, with the remainder being aluminium and unavoidable impurities.

2. The die-cast alloy according to claim 1, wherein iron is 0.15-0.5% by weight.

3. The die-cast alloy according to claim 1, wherein molybdenum is 0.05 to 0.20% by weight.

4. The die-cast alloy according to claim 1, wherein zirconium is 0.05 to 0.20% by weight.

5. The die-cast alloy according to claim 1, wherein gallium is 60 to 120 ppm.

6. The die-cast alloy according to claim 1, wherein manganese is 0.3 to 0.5% by weight.

7. The die-cast alloy according to claim 1, wherein zinc is 0.2 to 0.4% by weight.

8. The die-cast alloy according to claim 1, wherein copper is 0.15 to 0.25% by weight.

9. The die-cast alloy according to claim 1, wherein silicon is 8.5 to 10.0% by weight.

10. The die-cast alloy according to claim 1, wherein magnesium is 0.3 to 0.4% by weight.

11. (canceled)

12. A method of making a structural component comprising die-casting the alloy of claim 1 to form the structural component.

13. The die-cast alloy according to claim 1, consisting of: 8.5 to 11.5% by weight silicon 0.1 to 0.5% by weight magnesium 0.3 to 0.8% by weight manganese 0.02-0.5% by weight iron 0.005-0.5% by weight zinc 0.1 to 0.5% by weight copper 0.02 to 0.3% by weight molybdenum 0.02 to 0.3% by weight zirconium 10 to 200 ppm gallium and optionally at least one element selected from the group consisting of 30 to 300 ppm strontium, 5 to 30 ppm sodium, 1 to 30 ppm calcium, 5 to 250 ppm phosphorus, 0.02 to 0.25% by weight titanium, and 3 to 50 ppm boron, with the remainder being aluminium and unavoidable impurities.

Description

COMPARATIVE EXAMPLE

[0051] The compositions of an exemplary alloy from EP 0 687 742 B1 (alloy 1) and two exemplary embodiments (alloys A, B) of the alloy of the invention are compared below. The details are in % by weight. Using these two alloys, the mechanical characteristic values (R.sub.m, R.sub.p0.2 and A.sub.5) were measured on die-cast 3 mm plates. In all tests, the same T6 heat treatment was used with air quenching and with water quenching. In each case the average value of about 30 tension tests is shown.

TABLE-US-00001 Si Fe Cu Mn Mg Zn Alloy 1 10.15 0.110 0.0006 0.658 0.355 0.0013 Alloy A 9.41 0.114 0.197 0.49 0.340 0.296 Alloy B 9.01 0.227 0.198 0.440 0.349 0.351 Ti B Sr Zr Mo Alloy 1 0.050 0.001 0.020 0.002 0.0 Alloy A 0.110 0.0003 0.023 0.117 0.087 Alloy B 0.150 0.0049 0.0175 0.102 0.108 Ga P Alloy 1 0.0050 0.0009 Alloy A 0.0092 0.0020 Alloy B 0.0104 0.0034

[0052] Results Achieved

[0053] T6 Heat Treatment, Quenching in Air

TABLE-US-00002 Rm [N/mm.sup.2] Rp.sub.0.2 [N/mm.sup.2] A.sub.5 [%] Alloy 1 236 167 7.9 Alloy A 288 209 11.0 Alloy B 280 189 9.6

[0054] T6 Heat Treatment, Quenching in Water

TABLE-US-00003 Rm [N/mm.sup.2] Rp.sub.0.2 [N/mm.sup.2] A.sub.5 [%] Alloy 1 326 241 7.9 Alloy A 332 257 10.0 Alloy B 348 264 8.2