High corrosion resistance aluminum alloy

Abstract

An aluminum-based die casting alloy exhibiting improved corrosion resistance and good die-castability contains from about 4.5 to about 12 percent silicon by weight, at least 87 percent aluminum by weight, and a maximum of 0.2 percent copper by weight. The alloys preferably contain iron in an amount sufficient to improve hot tear resistance and to decrease the tendency for die sticking or soldering during die casting.

1 . An aluminum-based alloy comprising: 
 at least about 87 percent aluminum by weight;    from about 4.5 percent to about 12 percent silicon by weight;    a maximum of about 0.08 percent copper by weight; and    from about 0.8 percent to about 2.0 percent iron by weight.    
     
     
         2 . The alloy of  claim 1 , wherein the iron is present in an amount of from about 0.8 to about 1.3 percent by weight.  
     
     
         3 . The alloy of  claim 1 , wherein the iron is present in an amount of from about 0.8 percent to about 1.0 percent by weight.  
     
     
         4 . The alloy of  claim 1 , having a maximum of 0.05 percent copper by weight.  
     
     
         5 . The alloy of  claim 1 , containing silicon in an amount of from about 8 percent to about 12 percent by weight.  
     
     
         6 . The alloy of  claim 1 , containing silicon in an amount of from about 9.5 percent to about 12 percent by weight.  
     
     
         7 . The alloy of  claim 1 , wherein the aluminum is present in the alloy in an amount of at least 88 percent by weight.  
     
     
         8 . The alloy of  claim 1 , wherein the aluminum is present in the alloy in an amount of at least 89 percent by weight.  
     
     
         9 . An article of manufacture made from an aluminum alloy comprising: 
 at least about 87 percent aluminum by weight;    from about 4.5 percent to about 12 percent silicon by weight;    a maximum of about 0.08 percent copper by weight; and    from about 0.8 percent to about 2.0 percent iron by weight.    
     
     
         10 . The article of  claim 9 , wherein the iron is present in an amount of from about 0.8 percent to about 1.3 percent by weight.  
     
     
         11 . The article of  claim 9 , wherein the iron is present in an amount of from about 0.8 percent to about 1.0 percent by weight.  
     
     
         12 . The article of  claim 9 , having a maximum of 0.05 percent copper by weight.  
     
     
         13 . The article of  claim 9 , containing silicon in an amount of from about 8 percent to about 12 percent by weight.  
     
     
         14 . The article of  claim 9 , containing silicon in an amount of from about 9.5 percent to about 12 percent by weight.  
     
     
         15 . The article of  claim 9 , wherein the aluminum is present in the alloy in an amount of at least 88 percent by weight.  
     
     
         16 . The article of  claim 9 , wherein the aluminum is present in the alloy in an amount of at least 89 percent by weight.  
     
     
         17 . A process for making an aluminum alloy component, comprising: 
 shaping an aluminum alloy into the desired component, the alloy containing at least about 87 percent aluminum by weight, from about 4.5 to about 12 percent silicon by weight, a maximum of about 0.08 percent copper by weight, and from about 0.8 percent to about 2.0 percent iron by weight.    
     
     
         18 . The process of  claim 17 , wherein the shaping is achieved by a die casting operation.  
     
     
         19 . The process of  claim 17 , wherein the shaping is achieved by a semi-solid molding operation.  
     
     
         20 . The process of  claim 17 , wherein the shaping is achieved by a semi-solid forging operation.