Foundry Alloys for High-Pressure Vacuum Die Casting

Abstract

The present disclosure concerns a cast aluminum alloy for making cast aluminum products, especially using high-pressure vacuum die casting operations. The cast aluminum alloy comprises, in weight percent: Ni between about 1.5 and about 6.5; Si between about 0.10 and 1.5; Mg between about 0.10 and about 3; Fe up to about 0.2; Mn up to about 0.65; Ti up to about 0.12; V up to about 0.15; Zr up to about 0.15; Mo up to about 0.15; Cr up to about 0.01; Sr up to about 0.02; and the balance being aluminum and unavoidable impurities.

1 . A foundry alloy comprising, in weight percent:
 Ni between about 1.5 and about 6.5;   Si between about 0.10 and 1.5;   Mg between about 0.10 and about 3;   Fe up to about 0.2;   Mn up to about 0.65;   Ti up to about 0.12;   V up to about 0.15;   Zr up to about 0.15;   Mo up to about 0.15;   Cr up to about 0.01;   Sr up to about 0.02; and   the balance being aluminum and unavoidable impurities.   
     
     
         2 . The foundry alloy of  claim 1  comprising more than about 2.0 Ni. 
     
     
         3 . (canceled) 
     
     
         4 . (canceled) 
     
     
         5 . The foundry alloy of  claim 1  comprising between 0.15 and 0.90 Si. 
     
     
         6 . (canceled) 
     
     
         7 . The foundry alloy of  claim 1  comprising Mg at a weight percentage as determined by formula (I):
   % Mg≤−1.218*ln(% Si)+0.89  (I)
 
 wherein % Mg is the weight percent of Mg; and
 % Si is the weight percent of Si. 
 
 
     
     
         8 . (canceled) 
     
     
         9 . (canceled) 
     
     
         10 . The foundry alloy of  claim 1  comprising up to about 0.10 Fe. 
     
     
         11 . The foundry alloy of  claim 1  comprising between about 0.45 an about 0.65 Mn. 
     
     
         12 . (canceled) 
     
     
         13 . The foundry alloy of  claim 1  comprising between about 0.02 and about 0.12 Ti. 
     
     
         14 . (canceled) 
     
     
         15 . The foundry alloy of  claim 1  comprising between about 0.01 and about 0.15 V. 
     
     
         16 . (canceled) 
     
     
         17 . The foundry alloy of  claim 1  comprising between about 0.01 and about 0.15 Zr. 
     
     
         18 . (canceled) 
     
     
         19 . The foundry alloy of  claim 1  comprising between about 0.01 and about 0.15 Mo. 
     
     
         20 . (canceled) 
     
     
         21 . The foundry alloy of  claim 1  comprising between about 0.005 and about 0.02 Sr. 
     
     
         22 . The foundry alloy of  claim 1 , comprising Mn, Cr, Ti and V at a weight percentage as determined by formula (II):
   % Mn+% Cr+% Ti+% V≤0.025  (II)
   wherein % Mn is the weight percent of Mn;
 % Cr is the weight percent of Cr; 
 % Ti is the weight percent of Ti; and 
 % V is the weight percent of V. 
   
     
     
         23 . The foundry alloy of  claim 1 , comprising an excess of Mg over a weight percent ratio of Mg:Si of more than about 2:1. 
     
     
         24 . A process for improving at least one casting property of a first aluminum alloy for making a first aluminum product when compared to a cast aluminum alloy for making a cast aluminum product, the process comprising combining Ni with the first aluminum alloy to provide the cast aluminum alloy, wherein the first aluminum alloy comprises, in weight percent:
 Si between about 0.10 and 1.5;   Mg between about 0.10 and about 3;   Fe up to about 0.2;   Mn up to about 0.65;   Ti up to about 0.12;   V up to about 0.15;   Zr up to about 0.15;   Mo up to about 0.15;   Cr up to about 0.01;   Sr up to about 0.02; and   the balance being aluminum and unavoidable impurities; wherein the cast aluminum alloy comprises between about 1.5 and about 6.5 Ni.   
     
     
         25 .- 49 . (canceled) 
     
     
         50 . A process for making a cast aluminum product, the process comprising casting the cast aluminum alloy of  claim 1  in a mold. 
     
     
         51 . The process of  claim 50 , further comprising submitting the cast aluminum alloy or the modified dies cast aluminum alloy to high-pressure vacuum die casting. 
     
     
         52 . The process of  claim 50 , further comprising a post-cast heat treatment step. 
     
     
         53 . The process of  claim 52 , wherein the post-cast heat treatment is a T6 temper or a T5 temper. 
     
     
         54 . (canceled) 
     
     
         55 . A cast aluminum product comprising the cast aluminum alloy of  claim 1 . 
     
     
         56 . (canceled) 
     
     
         57 . The cast aluminum product of  claim 55  being electrically conductive or a rotor. 
     
     
         58 . (canceled)