Aluminum alloys for structural high pressure vacuum die casting applications

Abstract

An improved aluminum alloy for combining with a recycled aluminum alloy to form a blended material is provided. The improved aluminum alloy includes silicon, copper, iron, magnesium, zinc, manganese; nickel, chromium and tin in a total amount up to 0.15 wt. %; the other elements in a total amount up to 0.1 wt. %, up to 0.06 wt. % titanium, and 0.03 to 0.04 wt. % strontium. The recycled aluminum alloy can be obtained from road wheels. The blended material preferable meets the Aural series alloy specifications. The blended material can be cast under high pressure and a vacuum to form a vehicle part designed for use in a chassis or structural body of a vehicle, for example a front subframe, a front shock tower, a rear rail, a front kick-down rail, a front body hinge pillar, a tunnel, a front body hinge pillar, or a rear shock mount.

What is claimed is: 
     
         1 . An improved aluminum alloy, the improved aluminum alloy comprising, in weight percent (wt. %) based on the total weight of the improved aluminum alloy:
 7.4 wt. % to 7.9 wt. % silicon;   up to 0.01 wt. % copper;   0.16 wt. % to 0.2 wt. % iron;   up to 0.1 wt. % magnesium;   up to 0.03 wt. % zinc;   0.92 wt. % to 1.0 wt. % manganese;   nickel, chromium and tin in a total amount up to 0.15 wt. %;   other elements each in an amount up to 0.03 wt. %, the other elements in a total amount up to 0.1 wt. %;   up to 0.06 wt. % titanium; and   0.03 wt. % to 0.04 wt. % strontium.   
     
     
         2 . The improved aluminum alloy of  claim 1 , wherein the improved aluminum alloy consists of, in weight percent (wt. %) based on the total weight of the improved aluminum alloy: 7.4 wt. % to 7.9 wt. % silicon; up to 0.01 wt. % copper; 0.16 wt. % to 0.2 wt. % iron; up to 0.1 wt. % magnesium; up to 0.03 wt. % zinc; 0.92 wt. % to 1.0 wt. % manganese; nickel, chromium and tin in a total amount up to 0.15 wt. %; other elements each in an amount up to 0.03 wt. %, the other elements in a total amount up to 0.1 wt. %; up to 0.06 wt. % titanium; and 0.03 wt. % to 0.04 wt. % strontium. 
     
     
         3 . The improved aluminum alloy of  claim 1 , wherein the improved aluminum alloy has a sludge factor of 1.8, and wherein the sludge factor is equal to (1×Fe wt. %)+(2×Mn wt. %)+(3×Cr wt. %).