Aluminium Die-Casting Alloy

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This patent discloses a novel aluminum die casting alloy composition with improved mechanical properties. By optimizing the levels of silicon, chromium, manganese, molybdenum, and/or tungsten—with optional additions of elements like magnesium, zinc, zirconium, titanium, strontium, vanadium, cobalt, copper, nickel, tin, and tantalum—the alloy achieves a unique balance of high strength and high ductility. Such a combination is particularly beneficial for automotive structural components, especially where both durability and crashworthiness are critical. The patent also covers corresponding heat treatment methods to further enhance properties and outlines process compatibility (e.g., vehicle paint curing).

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• Automotive structural components (e.g., chassis, body panels, crash-relevant parts) where high strength and ductility are vital for safety and weight reduction.
• Electric vehicle components requiring improved thermal and electrical conductivity.
• Lightweight parts for transport applications such as rail, aerospace, and commercial vehicles, aiming to minimize material usage and maximize crash performance.
• Applications requiring cost-effective single-step heat treatment integrated with vehicle painting (T5 process), streamlining manufacturing.
• Manufacturing of recyclable components with high performance, accommodating higher levels of recycled content without significant loss in mechanical properties.

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• Simultaneously high strength and superior ductility, overcoming previous trade-offs in conventional aluminum die cast alloys.
• Reduces vehicle part thickness and mass, enabling vehicle lightweighting, improved fuel efficiency, and lower emissions (CO2 reduction).
• Enhanced crash performance and ease of assembly with standard joining techniques (riveting, etc.), improving overall vehicle safety.
• Improved thermal and electrical conductivity, especially relevant for e-mobility applications such as battery housings and electrical enclosures.
• Compatible with various heat treatment routes, including cost-saving, energy-efficient processes such as using the paint-curing process for ageing, reducing manufacturing complexity.
• High resistance to distortion during treatment and use, leading to lower post-processing and alignment costs.
• Better corrosion resistance compared to high-copper alloys, leading to increased component longevity.
• Facilitates the use of recycled aluminum, contributing to sustainability goals.

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The invention relates to an aluminum die casting alloy having the following alloy constituents: 5 to 9.5 wt. %, in particular 6 to 8 wt. %, silicon; 0.0001 to 0.3 wt. %, in particular 0.001 to 0.3 wt. %, in particular 0.05 to 0.25 wt. %, in particular 0.07 to 0.2 wt. %, chromium; 0.0001 to 0.3 wt. %, in particular 0.001 to 0.3 wt. %, in particular 0.05 to 0.25 wt. %, in particular 0.05 to 0.2 wt. %, manganese; 0.0001 to 0.2 wt. %, in particular 0.001 to 0.15 wt. %, in particular 0.01 to 0.15 wt. %, molybdenum and/or tungsten; remainder aluminium and unavoidable impurities.