Al-si-fe casting alloys

Abstract

New aluminum casting (foundry) alloys are disclosed. The new aluminum casting alloys may include from 6.0 to 11.5 wt. % Si, from 0.30 to 0.80 wt. % Fe, optionally from 0.07 to 0.20 wt. % of X, wherein X is selected from the group consisting of Mg, Mo, Zr, and combinations thereof, and optionally 100-500 ppm Sr, the balance being aluminum and unavoidable impurities. The new aluminum casting alloys may be high-pressure die cast into complex shapes. The new aluminum casting alloys may be useful, for instance, in heat sink/antenna applications.

What is claimed is: 
     
         1 . An aluminum casting alloy comprising:
 from 6.0 to 11.5 wt. % Si;   from 0.30 to 0.80 wt. % Fe;   optionally from 0.07 to 0.20 wt. % of X, wherein Xis selected from the group consisting of Mg, Mo, Zr, and combinations thereof; and   optionally 100-500 ppm Sr;   the balance being aluminum and unavoidable impurities.   
     
     
         2 . The aluminum casting alloy of  claim 1 , comprising at least 7.0 wt. % Si, or at least 8.0 wt. % Si, or at least 9.0 wt. % Si, or at least 9.5 wt. % Si. 
     
     
         3 . The aluminum casting alloy of  claim 1 , comprising not greater than 11.0 wt. % Si, or not greater than 10.5 wt. % Si. 
     
     
         4 . The aluminum casting alloy of  claim 1 , comprising at least 0.35 wt. % Fe, or at least 0.40 wt. % Fe, or at least 0.45 wt. % Fe, or at least 0.50 wt. % Fe. 
     
     
         5 . The aluminum casting alloy of  claim 1 , comprising not greater than 0.75 wt. % Fe, or not greater than 0.70 wt. % Fe, or not greater than 0.65 wt. % Fe. 
     
     
         6 . The aluminum casting alloy of  claim 1 , wherein the aluminum casting alloy includes X. 
     
     
         7 . The aluminum casting alloy of  claim 6 , comprising from 0.07 to 0.18 wt. % of X, or from 0.07 to 0.15 wt. % of X, or from 0.07 to 0.12 wt. % of X, or from 0.07 to 0.10 wt. % of X. 
     
     
         8 . The aluminum casting alloy of  claim 1 , wherein the aluminum casting alloy is substantially free of all of Mg, Mo, and Zr, having less than 0.07 wt. % of each of Mg, Mo, and Zr. 
     
     
         9 . The aluminum casting alloy of  claim 8 , comprising not greater than 0.05 wt. % of each of Mg, Mo, and Zr, or not greater than 0.04 wt. % of each of Mg, Mo, and Zr, or not greater than 0.03 wt. % of each of Mg, Mo, and Zr, or not greater than 0.02 wt. % of each of Mg, Mo, and Zr. 
     
     
         10 . The aluminum casting alloy of  claim 1 , wherein the aluminum casting alloy includes Sr. 
     
     
         11 . The aluminum casting alloy of  claim 1 , wherein the aluminum casting alloy includes less than 100 ppm Sr, or not greater than 50 ppm Sr, or not greater than 25 ppm Sr, or not greater than 10 ppm Sr. 
     
     
         12 . The aluminum casting alloy of  claim 1 , wherein the aluminum casting alloys is substantially free of copper, manganese, zinc, titnaium, chromium, nickel, and vanadium. 
     
     
         13 . The aluminum casting alloy of  claim 12 , comprising less than 0.10 wt. % Cu, or not greater than 0.05 wt. % Cu, or not greater than 0.03 wt. % Cu, or not greater than 0.01 wt. % Cu. 
     
     
         14 . The aluminum casting alloy of  claim 12 , comprising not greater than 0.04 wt. % Mn, or not greater than 0.03 wt. % Mn, or not greater than 0.02 wt. % Mn. 
     
     
         15 . The aluminum casting alloy of  claim 12 , comprising less than 0.10 wt. % Zn, or not greater than 0.05 wt. % Zn, or not greater than 0.03 wt. % Zn, or not greater than 0.01 wt. % Zn. 
     
     
         16 . The aluminum casting alloy of  claim 12 , comprising not greater than 0.04 wt. % of each of Ti, Cr, Ni, and V, or not greater than 0.03 wt. % of each of Ti, Cr, Ni, and V, or not greater than 0.02 wt. % of each of Ti, Cr, Ni, and V. 
     
     
         17 . The aluminum casting alloy of  claim 16 , wherein the cummulative amounts of Ti, Cr, Ni, and V do not exceed 0.10 wt. %, or wherein the cummulative amounts of Ti, Cr, Ni, and V do not exceed 0.08 wt. %, or wherein the cummulative amounts of Ti, Cr, Ni, and V do not exceed 0.06 wt. %. 
     
     
         18 . A high-pressure die cast product made from the aluminum casting alloy of  claim 1 . 
     
     
         19 . The high-pressure die cast product of  claim 18 , wherein the product realizes a tensile yield strength of at least 65 MPa and an elongation of at least 2%. 
     
     
         20 . The high-pressure die cast product of  claim 18 , wherein the product realizes a thermal conductivity of at least 160 W/m/° C. at a temperature of 25° C., or at least 170 W/m/° C. at a temperature of 25° C., or at least 175 W/m/° C. at a temperature of 25° C., or at least 180 W/m/° C. at a temperature of 25° C., or at least 185 W/m/° C. at a temperature of 25° C., or at least 190 W/m/° C. at a temperature of 25° C., or at least 195 W/m/° C., or higher, at a temperature of 25° C.