Characteristics of New Alloys for HPDC Structural Parts

Rheinfelden Alloys developed new alloys for the future generation of structural components in vehicle construction. This article shows all characteristics of AlMg4Fe2 and AlMg4Zn3Fe2 by discussing mechanical properties, metallurgy investigations, fatigue strength, static and dynamic 3-point bending test and joining techniques such as riveting and welding. Today’s castings are getting thinner and larger with more and more parts integrated. There is the need to offer highest strength and ductility for these crash relevant parts and the riveting process. Structural casting parts should ideally be made without or only with T5 heat treatment to avoid distortion and other problems associated with solution heat treatment. Classic applications are served by the Al-Si family in the range of 7 to 11% Silicon. Varying amounts of Mg (for Mg2Si hardening), low contents of Fe and Mn for die soldering resistance are added as well. If elongations of 10% or higher are required, then a T7 heat treatment is mandatory. In this paper two new alloys are presented offering unique benefits for the production of structure parts in HPDC. AlMg4Fe2 (Castaduct-42) offers a dispersoid hardening mechanism whi...

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