A New Recycled Al–Si–Mg Alloy for Sustainable Structural Die Casting Applications

Cinkilic, Emre; Moodispaw, Michael; Zhang, Jianyue; Miao, Jiashi; Luo, Alan A.

doi:10.1007/s11661-022-06711-4

A New Recycled Al–Si–Mg Alloy for Sustainable Structural Die Casting Applications

Journal Article · Wed May 18 00:00:00 EDT 2022 · Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science

DOI:https://doi.org/10.1007/s11661-022-06711-4· OSTI ID:2438413

Cinkilic, Emre ^[1]; Moodispaw, Michael ^[2]; Zhang, Jianyue ^[2]; Miao, Jiashi ^[2]; Luo, Alan A. ^[2]

Hakkari University (Turkey); The Ohio State University, Columbus, OH (United States); The Ohio State University
The Ohio State University, Columbus, OH (United States)

The use of secondary aluminum for structural components in the automotive industry is limited by the high Fe contents in recycled alloys which often result in the formation of brittle β-Al₅FeSi phase which reduces the ductility of aluminum castings. In this study, a new secondary Al-Si-Mg alloy with high Fe content (about 0.44 wt.%) was developed for die casting applications. Based on thermodynamic modeling, manganese was added to obtain a designed Fe-to-Mn ratio of 2 which successfully suppressed the formation of β-Al₅FeSi phase, by forming α-Al₁₅(Fe,Mn)₃Si₂ phase with rounded or hexagonal morphology. Additionally, a fine needle-like π-Al₈FeMg₃Si₂ phase was also formed within the eutectic regions. The new recycled alloy showed comparable mechanical properties in as-cast and heat treated (T5 and T6) conditions to three major primary die cast alloys (≤ 0.2 wt.% Fe) with similar composition. Ductility up to 7.4% from tensile elongation was achieved in as-cast recycled alloy due to the modification and refinement of α-Al₁₅(Fe,Mn)₃Si₂ by Mn and Sr additions. Tensile elongation was further improved to 9.1% after T6 treatment as a result of dissolution of π-Al₈FeMg₃Si₂ phase, defragmentation of α-Al₁₅(Fe,Mn)₃Si₂ and the spheroidization of Si phase. This new alloy provides a promising path for increasing usage of recycled aluminum with high Fe content in structural die castings for automotive and other applications.

View Accepted Manuscript (DOE)

Research Organization:: The Ohio State University, Columbus, OH (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Materials & Manufacturing Technologies Office (AMMTO)

Grant/Contract Number:: EE0007897

OSTI ID:: 2438413

Alternate ID(s):: OSTI ID: 1976727

Journal Information:: Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science, Journal Name: Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science Journal Issue: 8 Vol. 53; ISSN 1073-5623

Publisher:: SpringerCopyright Statement

Country of Publication:: United States

Language:: English

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