Structural die cast aluminum alloys
Disclosed are aluminum alloys with high iron content and methods of making and using.
1. A method of forming an aluminum alloy, the method comprising:
combining a secondary aluminum alloy with manganese to form the aluminum alloy; and
cooling the aluminum alloy;
wherein the aluminum alloy comprises:
aluminum;
silicon;
from greater than 0.3% by weight to 1% by weight iron, based on the total weight of the aluminum alloy;
from 0.1% by weight to 1.3% by weight manganese, based on the total weight of the aluminum alloy; and
from 0.005% by weight (50 ppm) to 0.018% by weight (180 ppm) strontium, based on the total weight of the aluminum alloy;
wherein the manganese is present in amount effective to suppress the formation of a β-Al 5 FeSi phase during casting of the aluminum alloy,
wherein the iron and manganese are present in an iron to manganese ratio of from 1.6:1 to 2.6:1, and
wherein the cooling comprises cooling the aluminum alloy at a cooling rate ranging from 3° C./s to 350° C./s.
2. The method of claim 1 , wherein the strontium is present in an amount of from 0.005% by weight (50 ppm) to 0.015% by weight (150 ppm), based on the total weight of the aluminum alloy.
3. The method of claim 1 , wherein when the iron and the manganese are present in an iron to manganese ratio of 1:1 or less, the cooling comprises cooling the aluminum alloy at a cooling rate ranging from 0.1° C./s to 4° C./s.
4. The method of claim 3 , wherein the iron to manganese ratio is from 0.6:1 to 1:1.
5. A method of improving mechanical properties of a secondary aluminum alloy, the method comprising:
adding manganese to the secondary aluminum alloy to form the aluminum alloy having improved mechanical properties; and
cooling the aluminum alloy having improved mechanical properties;
wherein the aluminum alloy having improved mechanical properties comprises:
aluminum;
silicon;
from greater than 0.3% by weight to 1% by weight iron, based on the total weight of the aluminum alloy; and
from 0.1% by weight to 1.3% by weight manganese, based on the total weight of the aluminum alloy; and
from 0.005% by weight (50 ppm) to 0.018% by weight (180 ppm) strontium, based on the total weight of the aluminum alloy;
wherein the manganese is present in amount effective to suppress the formation of a β-Al 5 FeSi phase during casting of the aluminum alloy,
wherein the iron and manganese are present in an iron to manganese ratio of from 1.6:1 to 2.6:1, and
wherein the cooling comprises cooling the aluminum alloy at a cooling rate ranging from 3° C./s to 350° C./s.
6. The method of claim 5 , wherein the strontium is present in an amount of from 0.005% by weight (50 ppm) to 0.015% by weight (150 ppm), based on the total weight of the aluminum alloy.
7. The method of claim 5 , wherein when the iron and the manganese are present in an iron to manganese ratio of 1:1 or less, the cooling comprises cooling the aluminum alloy at a cooling rate ranging from 0.1° C./s to 4° C./s.
8. The method of claim 7 , wherein the iron to manganese ratio is from 0.6:1 to 1:1.
9. The method of claim 1 , wherein the strontium is present in an amount of from 0.005% by weight (50 ppm) to 0.010% by weight (100 ppm), based on the total weight of the aluminum alloy.
10. The method of claim 1 , wherein the strontium is present in an amount of from 0.005% by weight (50 ppm) to 0.016% by weight (160 ppm), based on the total weight of the aluminum alloy.
11. The method of claim 5 , wherein the strontium is present in an amount of from 0.005% by weight (50 ppm) to 0.010% by weight (100 ppm), based on the total weight of the aluminum alloy.
12. The method of claim 5 , wherein the strontium is present in an amount of from 0.005% by weight (50 ppm) to 0.016% by weight (160 ppm), based on the total weight of the aluminum alloy.