Aluminum alloy for structural casting applications, use of the aluminum alloy for die casting structural components, structural component for a motor vehicle and motor vehicle

Abstract

It is an aluminum alloy for structural casting applications with increased ductility, comprising aluminum and unavoidable impurities, as well as 7.5 to 11.5 wt.% silicon, 0.25 to 0.6 wt.% manganese, 0.03 to 0.06 wt.% chromium, 0.001 to 0.048 wt.% molybdenum, 0.04 to 0.095 wt.% magnesium, in particular 0.06 to 0.095 wt.% magnesium, 0.17 to 0.5 wt.% iron, 0.03 to 0.5 wt.% copper, max. 0.35 wt.% zinc and 0.004 to 0.15 wt.% titanium.

Description

[0001] The invention relates to an aluminum alloy for structural casting applications with increased ductility, a use of the aluminum alloy for die casting of structural components, a structural component for a motor vehicle made of the aluminum alloy, and a motor vehicle.

[0002] Solution-annealed alloys are primarily used for highly stressed die-cast components in vehicle structures. This is because solution annealing advantageously alters the microstructure, resulting in high strength and high ductility, which are beneficial for component performance and joining processes.

[0003] On the other hand, using recycled aluminum is a way to reduce costs, decrease energy consumption and thus CO2 emissions (carbon footprint) in the production of a motor vehicle, and improve the sustainability of the aluminum used. With regard to sustainability and climate protection, it is therefore advantageous to use recycled aluminum alloys. Compared to primary aluminum alloys, carbon dioxide savings of approximately 5 to 17 tons of CO2 equivalent per ton of aluminum alloy can be achieved when a recycled alloy is used to manufacture a component instead of primary aluminum alloy.

[0004] When secondary aluminum or recycled scrap is used to manufacture aluminum components, the alloys often contain impurities. Impurities are elements that are not necessary for achieving the desired properties but are instead detrimental. However, they cannot be prevented during the recycling process and are therefore present in the final product. Typical impurities include iron, copper, zinc, and titanium. High proportions of recycled aluminum (secondary aluminum) are associated with an increased concentration of these impurities in the alloys.

[0005] Furthermore, naturally hard alloys of the type AlSi9Mn are advantageously used, which, due to their very low magnesium content, do not harden and therefore do not require subsequent heat treatment or solution annealing. Thus, components made from such alloys are cost-effective to produce due to the lack of heat treatment, and these alloys also enable the production of very large gigacast components. This trend makes it possible to produce vehicle bodies with minimal body surface area and equipment investment.

[0006] For example, publication EP 1 443 122 A1 describes an aluminum alloy suitable for die casting components with high elongation in the as-cast condition, containing 8.5 to 10.5 wt.% silicon, 0.3 to 0.8 wt.% manganese, max. 0.06 wt.% magnesium, max. 0.15 wt.% iron, max. 0.03 wt.% copper, max. 0.10 wt.% zinc, max. 0.15 wt.% titanium, 0.05 to 0.5 wt.% molybdenum and 30 to 300 ppm strontium or 5 to 30 ppm sodium and / or 1 to 30 ppm calcium for permanent finishing. Optionally, the alloy contains 0.05 to 0.3 wt.% zirconium, gallium phosphide and / or indium phosphide in an amount corresponding to 1 to 250 ppm phosphorus for grain refinement, titanium and boron, added via an aluminum master alloy with 1 to 2 wt.% Ti and 1 to 2 wt.% B, for grain refinement, and the remainder being aluminum and unavoidable impurities.

[0007] Furthermore, the publication EP 3 775 309 B1 (WO 2020 / 207 708 A1) describes an aluminum die-casting alloy with the following alloying elements: 7.5 to 11.5 wt.% silicon, 0.25 to 0.6 wt.% manganese, 0.03 to 0.06 wt.% chromium, 0.001 to 0.048 wt.%, in particular 0.001 to 0.043 wt.%, in particular 0.024 to 0.043 wt.% molybdenum, 0.001 to 0.08 wt.% magnesium, optionally 0.001 to 0.15 wt.% iron, optionally 0.004 to 0.15 wt.% titanium, optionally 0.01 to 0.2 wt.% zirconium, optionally 0.008 to 0.02 wt.% strontium, optionally 0.001 to 0.1 wt% vanadium, with the remainder being aluminum and unavoidable impurities.

[0008] Furthermore, the publication EP 3 235 917 A1 describes an aluminum-silicon die-casting alloy with a composition consisting of: 8.5 to 11.5 wt.% silicon; 0.1 to 0.5 wt.% magnesium; 0.3 to 0.8 wt.% manganese; 0.02 to 0.5 wt.% iron; 0.005 to 0.5 wt.% zinc; 0.02 to 0.3 wt.% molybdenum; 0.1 to 0.5 wt.% copper; 0.02 to 0.15 wt.% titanium; 0.02 to 0.3 wt.% zirconium; 5 to 250 ppm phosphorus; 10 to 200 ppm gallium; and the remainder being aluminum and unavoidable impurities. This alloy can be produced with a 50% recycled content.

[0009] Furthermore, the subsequently published document DE 10 2023 114 500 A1 describes a method for producing an aluminum die-casting alloy with secondary aluminum content, an aluminum die-casting alloy with secondary aluminum content, and a structural component for a motor vehicle; the document DE 10 2016 004 216 A1 describes an aluminum alloy, in particular for a casting process, and a method for producing a component from such an aluminum alloy; the document EP 3 775 309 B1 describes an aluminum die-casting alloy; and the document GB 582 732 A describes an aluminum alloy with a low coefficient of thermal expansion.

[0010] It is therefore an object of the invention to provide a naturally hard aluminum casting alloy that does not require subsequent heat treatment after casting, has good mechanical properties and at the same time enables cost reduction and reduces the CO2 footprint.

[0011] According to the invention, this problem is solved by an aluminum alloy for structural casting applications with increased ductility, comprising the features specified in claim 1. Furthermore, the problem is solved by using the aluminum alloy for die casting structural components, by a structural component for a motor vehicle made of the aluminum alloy, and by a motor vehicle incorporating the structural component, as further specified in the independent claims. Advantageous embodiments of the invention are specified in the dependent claims.

[0012] The invention is based on the basic idea of ​​creating an aluminum alloy that allows the use of high proportions of secondary aluminum without compromising its mechanical properties.

[0013] According to a first aspect, the disclosure provides an aluminum alloy for structural casting applications with increased ductility comprising 7.5 to 11.5 wt.% silicon, 0.25 to 0.6 wt.% manganese, 0.03 to 0.06 wt.% chromium, 0.001 to 0.048 wt.% molybdenum, 0.04 to 0.095 wt.% magnesium, in particular 0.06 to 0.095 wt.% magnesium, 0.17 to 0.5 wt.% iron, 0.03 to 0.17 wt.% copper, max. 0.35 wt.% zinc and 0.004 to 0.15 wt.% titanium, with the remainder being aluminum and unavoidable impurities, excluding an aluminum alloy comprising 0.25 wt.% manganese, 0.06 wt.% chromium and 0.05 to 0.095 wt.% magnesium.

[0014] It should be noted that a conflict of objectives exists when using aluminum die-cast components. Silicon-containing alloys are advantageous for aluminum die-cast components due to their casting properties. However, in applications without heat treatment, these alloys are relatively brittle compared to annealed alloys due to the lack of solution annealing. This is because the eutectic silicon is cross-linked, limiting deformability and increasing the susceptibility to cracking inherent in brittle phases.

[0015] Solution-annealed alloys generally yield better mechanical properties, but require costly subsequent heat treatments. These heat treatments severely limit the size of possible components or make them achievable only at great expense and with considerable effort, due to large space requirements, high energy consumption, and long heating and cooling times.

[0016] Naturally hard alloys do not have this limitation and do not require complex downstream processes, which is why manufacturing body components using naturally hard alloys is more cost-effective. However, they are comparatively brittle.

[0017] Naturally hard means that the desired increase in strength is achieved solely through solid solution strengthening and work hardening, without precipitation hardening. Naturally hard alloys are therefore also referred to as non-heat-treatable. In contrast, heat-treatable alloys achieve an increase in strength through precipitation hardening (a specific heat treatment). Some silicon-containing aluminum alloys (AlSi alloys), for example, can be considered naturally hard alloys.

[0018] The increasing component size requires a naturally hard alloy without heat treatment, as this makes it easier to meet tolerance requirements for a car body and avoids high process costs.

[0019] By skillfully selecting the alloying elements, it is possible to produce a naturally hard alloy that is both castable and possesses good mechanical properties and elongation values, although it is an alloy with a high possible recycling rate (secondary aluminum) and a high possible post-consumer rate.

[0020] Here, a silicon content in the range of 7.5 to 11.5 wt.% (weight percent) ensures a good balance between ductility and castability for a wide variety of component sizes. Silicon expands upon solidification and can thus compensate for shrinkage during the solidification of a cast component. Furthermore, silicon releases a very large amount of energy during solidification compared to other elements, so a high silicon content ensures good flowability and thus good castability of the alloy. If a silicon content of less than 7.5 wt.% is chosen, good flowability cannot be achieved, so a silicon content of less than 7.5 wt.% is not preferred. On the other hand, aluminum with a silicon content of more than 11.5 wt.% tends to become brittle, so a silicon content of more than 11.5 wt.% is not preferred.

[0021] The carefully balanced combination of manganese, chromium, and molybdenum content ensures trouble-free demolding and thus defect-free production. Higher proportions of these elements can lead to coarse segregation, which can drastically reduce mechanical properties. Conversely, excessively low levels can result in components sticking to the mold. The specified combination achieves an optimal balance between demolding ease and mechanical properties.

[0022] The upper limit of 0.095 wt.% for magnesium allows for the use of high secondary aluminum content while maintaining the naturally hard character of the alloy disclosed herein. Increasing the magnesium content further to more than 0.095 wt.% can lead to hardening over time (and / or temperature), resulting in an undesirable, unstable strength state. Below 0.04 wt.%, however, the hardening effect of solid solution strengthening is absent, which can result in lower alloy strength. Only in the aforementioned range of 0.04 to 0.095 wt.% magnesium, and particularly 0.06 to 0.095 wt.% magnesium, is the effect of solid solution strengthening highly pronounced, and a thermally stable state can be achieved.

[0023] Furthermore, it is advantageous if, after a painting process that includes heat treatment, the yield strength does not exceed 160 MPa and / or the increase in the yield strength does not exceed 30 MPa (the yield strength does not increase by more than 30 MPa), since such an increase indicates thermal instability. For example, temperatures of 80 to 250 °C may prevail in such a painting process for 10 to 120 minutes, and in particular, temperatures of 150 to 250 °C for 25 to 120 minutes.

[0024] In other words, during a heat treatment that simulates a painting process, or a heat treatment that simulates temperature stress over the service life of a component (for example, this can be simulated by a heat treatment with a temperature exposure of 150 °C for 1000 h), the yield strength should not exceed 160 MPa and / or should not increase by more than 30 MPa, as this would otherwise indicate thermal instability. Furthermore, excessively low yield strength values ​​can lead to problems with fatigue strength.

[0025] The proportions of iron, copper, zinc, and titanium in the alloy disclosed herein enable the alloy to be produced from a mixture of primary and secondary aluminum with a high content of recycled secondary aluminum. Furthermore, according to the invention, these proportions are selected such that, despite the increased levels of iron, copper, zinc, and titanium, no coarser phase agglomerates can form that could negatively affect the mechanical properties. With regard to corrosion resistance, unfavorable properties, which may be mainly due to the presence of copper, can be kept within limits by the specified weight proportions.In order to manufacture components from the resulting aluminum alloy that exhibit high ductility and good corrosion properties or low susceptibility to corrosion, it is advantageous not to choose too high a copper content or an iron content.

[0026] In particular, this can significantly reduce the CO2 footprint in demanding areas such as structural casting, i.e., the production of structural components such as thin-walled body parts. For example, carbon dioxide savings of over 6 kg CO2 equivalent per kilogram of aluminum alloy produced can be achieved. This is very advantageous with regard to reducing the CO2 footprint.

[0027] Furthermore, iron, for example, has virtually no solubility in aluminum alloys and is therefore almost completely precipitated in the form of coarse intermetallic phases. In silicon-containing aluminum alloys, the β-Al₅FeSi phase is particularly problematic because it is acicular or needle-shaped. Such acicular iron-containing phases reduce the ductility of the component obtained from the aluminum alloy. Moreover, these iron-containing intermetallic phases are very brittle and tend to accumulate. With a high iron content in the aluminum alloy, these acicular or needle-shaped iron-containing phases can become very large.

[0028] In particular, such large intermetallic, iron-containing phases strongly induce cracking and thus usually lead to early component failure under mechanical stress. This is primarily due to the low ductility of the component material, which results from the presence of the needle-like or needle-shaped iron-containing phases.

[0029] The incorporation of manganese and / or molybdenum and / or chromium and / or vanadium prevents the formation of the morphologically unfavorable β-Al₅FeSi phase and instead forms an iron-containing α-phase. Such α-phases, which contain manganese and / or molybdenum and / or chromium and / or vanadium in addition to iron and aluminum, ensure a more favorable morphology of the phase containing these additives. In particular, the formation of large, needle-shaped or needle-like iron-containing phases can be prevented. This can lead to an improvement in the mechanical properties of the component manufactured from the resulting aluminum alloy. Specifically, the ductility of the component produced from the resulting aluminum alloy can be significantly improved in this way.

[0030] The invention also includes further developments that result in additional advantages.

[0031] In an advantageous embodiment of the invention, the alloy can also comprise 0.01 to 0.2 wt.% zirconium. This embodiment allows the yield strength of the alloy to be improved without heat treatment. Zirconium forms so-called trialuminides, i.e., Al3Zr phases, which have a grain-refining effect and also increase strength. At very low concentrations, this effect is not noticeable, so a lower limit of 0.01 wt.% is preferred. On the other hand, at concentrations above 0.2%, coarser Al3Zr needles form, which in turn lead to an undesirable decrease in ductility.

[0032] In an advantageous embodiment of the invention, the alloy can also comprise 0.001 to 0.1 wt.% vanadium. This embodiment improves the yield strength of the alloy without heat treatment. Furthermore, the vanadium content allows for the simple use of secondary aluminum. Similar to manganese, vanadium can also prevent or reduce the formation of β-AlFeSi by incorporating it into α-AlFeSi. At lower vanadium contents, the beneficial effect of vanadium is no longer noticeable. If the vanadium content is increased above the specified limit of 0.1 wt.%, the phases can become coarse again, which can result in poor or low ductility.

[0033] In an advantageous embodiment of the invention, the alloy can also comprise 0.002 to 0.030 wt.% strontium. This embodiment allows the yield strength of the alloy to be improved without heat treatment. Strontium can refine silicon phases into a fine network. If the strontium content is too low, this effect is not noticeable. However, if the strontium content is too high, so-called over-refinement can occur, resulting in the silicon phases becoming coarse again and the ductility decreasing. Furthermore, with a strontium content of more than 0.03 wt.%, the hydrogen uptake of the melt can increase, which can reduce the casting quality.

[0034] In an advantageous embodiment of the invention, the aluminum alloy may comprise a secondary aluminum content of 25 wt.% or more and / or a post-consumer secondary aluminum content of 10 wt.% or more. This embodiment offers the advantage that a reduction in the CO2 footprint can be achieved simply by means of this composition.

[0035] In an advantageous embodiment of the invention, the NDS value of the aluminum alloy can be greater than 6, preferably greater than 10, and more preferably greater than 12. Here, the NDS value of the aluminum alloy is the product of the impurity element sum, the elongation at break in percent, and the ratio of the 0.2% proof strength in the as-cast condition F to the 0.2% proof strength in a hardened condition, wherein the impurity element sum is the sum of the element contents of impurities in weight percent, with the iron content being weighted at twice its weight in the impurity element sum.

[0036] In other words, the impurity element sum is calculated by summing the elemental contents of iron, copper, zinc, and titanium, with iron being counted twice due to its significant influence on the ductility of the aluminum alloy. The resulting impurity element sum is then multiplied by the elongation at break in the as-cast condition F in %, and further multiplied by a ratio of the 0.2% proof strength in the as-cast condition F to the 0.2% proof strength after heat treatment at 150 °C for 1000 hours (h) (hardened condition) to obtain the NDS value.

[0037] The NDS value describes a sustainability-ductility-stability factor (NDS) that illustrates the performance of the alloy according to the invention. The NDS value is calculated according to the formula above: NDS=[(2xFe)+Cu+Zn+Ti]*A*[Rp0.2(F) / Rp0.2(T5)] where Fe, Cu, Zn and Ti indicate the elemental contents for iron, copper, zinc and titanium respectively in weight percent (wt%), A indicates the elongation at break in %, R p0,2 (F) the 0.2% proof stress in the as-cast condition F in MPa and R p0,2 (T5) specifies the 0.2% yield strength in the hardened state in MPa.

[0038] The formula above shows that the higher the NDS value, the better the cumulative essential properties for naturally hard recycled car body casting alloys. This is because: - a high impurity element sum enables the use of a large proportion of recycled secondary aluminum, - a high elongation at break of the alloy enables good formability and good punch rivetability of the manufactured components, and High thermal stability means that an alloy retains its advantageous properties even after painting and throughout the component's service life (and does not harden, thereby increasing, for example, the yield strength). This high thermal stability is tested and verified by the heat treatment as described above, and the ratio R p0,2 (F) / R p0,2 (T5) becomes small when the 0.2% yield strength increases significantly after heat treatment (for example at 150 °C for 1000 h).

[0039] Comparing the reference alloys 1, 2 and 3 listed in Tables 1 and 2 with the alloy according to the invention, it can be found that the NDS factor in the alloy according to the invention is increased by more than double that of the best reference alloy (alloy 2).

[0040] This means that a high NDS value of the aluminium alloy is preferred, and it is preferred that the NDS value of the aluminium alloy is greater than 6, more preferably that the NDS value of the aluminium alloy is greater than 10, and even more preferably that the NDS value of the aluminium alloy is greater than 12.

[0041] Furthermore, according to one aspect of the invention, the aluminum alloy described above is used for die casting structural components, particularly in automotive engineering. In other words, the aluminum alloy described above can be used to produce structural components by die casting, which can be used, for example, as body parts in automobile manufacturing.

[0042] Furthermore, according to one aspect of the invention, a structural component for a motor vehicle is provided that is made from the aluminum alloy according to the invention.

[0043] In particular, the structural component can be a gigacasting component. Gigacasting describes a manufacturing process, primarily used in automotive engineering, in which large assemblies, for example made of aluminum, can be produced in a single process step. Gigacasting enables the production of parts of enormous size and complex geometry that were previously impossible to manufacture using conventional casting methods. Gigacasting components can weigh up to 300 kg and can also exceed surface areas of one square meter.

[0044] For example, aluminum or the aluminum alloy according to the invention can be used as a material, which can result in weight and strength advantages in automotive engineering. By using the aluminum alloy according to the invention, the overall weight of the vehicle can be reduced, leading to lower fuel consumption and reduced emissions. Furthermore, gigacasting components can exhibit high stiffness due to their size and shape, which can contribute to stable driving behavior and high handling performance. Gigacasting also makes it possible, for example, to produce complex shapes, thus enabling innovative designs with optimized properties. In addition, gigacasting can reduce the number of components in a motor vehicle, which in turn can simplify the vehicle assembly process and reduce production costs.

[0045] Such a structural component can be used for a wide variety of applications in motor vehicles, as it possesses both the necessary strength and sufficiently high ductility, as well as good demoldability. High strength is advantageous because it allows the vehicle to be manufactured with thin-walled structural components, which in turn can reduce the vehicle's weight. Sufficiently high ductility ensures, for example, that a rivet can be produced without cracks or breaks during self-piercing riveting. Good demoldability is advantageous in manufacturing processes such as die casting of structural components.

[0046] The aluminum alloy according to the invention is particularly well suited for this structural component; however, it can also be used for other components. By foregoing heat treatment of the structural component, geometric distortion can be avoided, thus achieving high geometric accuracy and dimensional accuracy of the structural component.

[0047] In an advantageous embodiment of the invention, the aforementioned structural component, in particular the aforementioned gigacasting component, may have a predetermined thermal stability. In other words, it may be provided that a 0.2% proof strength achieved through heat treatment, for example, heating the structural component to 150 °C for 1000 h, is less than 160 MPa, and that the increase in proof strength is less than 30 MPa.

[0048] Furthermore, it is advantageous if, after exposure to temperatures of 80 °C to 250 °C for 10 min to 120 min, in particular after exposure to temperatures of 150 °C to 250 °C for 25 min to 120 min, the yield strength is less than 160 MPa and an increase in the yield strength is less than 30 MPa, and / or after exposure to temperatures of 150 °C for 1000 hours, the yield strength is less than 160 MPa and an increase in the yield strength is less than 30 MPa.

[0049] If, on the other hand, the yield strength increases above 160 MPa and / or by 30 MPa or more after such temperature exposure, this indicates that precipitation hardening has begun, which suggests thermal instability. Such thermal instability is undesirable, as the elongation at break can decrease, thus reducing the component's load-bearing capacity or, in the case of a motor vehicle, its ability to absorb less deformation energy in an accident. Furthermore, excessively low elongation at break values ​​can lead to fatigue strength problems.

[0050] The aforementioned defined values ​​for heat treatments are based, on the one hand, on the advantage that, after a painting process that includes heat treatment, the yield strength does not exceed 160 MPa and / or the increase in yield strength does not exceed 30 MPa (the yield strength does not increase by more than 30 MPa), since such an increase indicates thermal instability. For example, temperatures of 80 to 250 °C for 10 to 120 minutes may prevail in such a painting process, particularly 150 to 250 °C for 25 to 120 minutes.

[0051] On the other hand, after a heat treatment that simulates temperature stress during the lifetime of a component (for example, this can be simulated by a heat treatment with a temperature exposure of 150 °C for 1000 h), the yield strength should not exceed 160 MPa and / or should not have increased by more than 30 MPa (compared to the as-cast condition), as this also indicates thermal instability.

[0052] Furthermore, according to another aspect of the invention, a motor vehicle is provided with the structural component. In addition to the advantages mentioned above, the use of the structural component eliminates the need for complex heat treatments, thus offering advantages, particularly with regard to costs and manufacturing time. Moreover, the dimensional accuracy of the motor vehicle according to the invention can be improved if distortion caused by heat treatment can be avoided. Furthermore, the use of recycled aluminum can reduce CO2 emissions during the production of the motor vehicle according to the invention, thereby further reducing costs and increasing sustainability.

[0053] The motor vehicle according to the invention is preferably designed as a motor vehicle, in particular as a passenger car or truck, or as a passenger bus or motorcycle.

[0054] The invention also includes combinations of the features of the described embodiments. The invention therefore also includes realizations that each exhibit a combination of the features of several of the described embodiments, provided that the embodiments have not been described as mutually exclusive.

[0055] The following are exemplary embodiments of the invention described. This is illustrated by: Fig. 1 A schematic representation of the dependence of a yield strength on a magnesium content.

[0056] Fig. Figure 1 shows a schematic representation of the dependence of the yield strength 100 of an aluminum alloy on its magnesium content.

[0057] The x-axis (108) shows the Mg content in wt.%, while the y-axis (110) shows the value of the yield strength R. p0,2 is plotted in MPa. The 0.2% proof stress R p0,2This is the (uniaxial) mechanical stress at which the permanent strain (i.e., plastic strain, hence the index) after unloading is 0.2%, based on an initial length of a sample.

[0058] It's out Fig. It is evident that the range 104 chosen in this disclosure represents an optimum for the Mg content, situated between a lower limit 112 of 0.04 wt.% and an upper limit 114 of 0.095 wt.%. Only between the lower limit 112 and the upper limit 114 is it possible to both benefit from the hardening effects of solid solution strengthening and to generate a thermally stable state.

[0059] While the strength of an aluminum alloy with a Mg content of less than 0.04 wt.% is very low (range 102), with high Mg contents (range 106) above the upper limit 114, hardening occurs over time, resulting in thermal instability, which is not desirable.

[0060] The following are listed in Table 1 the compositions of various alloys, the properties of which are listed below in Table 2. Table 1: Compositions of various aluminum alloys composition Reference alloy 1 Reference alloy 2 Reference alloy 3 Alloy according to the invention Si [wt.%] 9,5 9,5 9,5 8,0 Mn [wt.%] 0,61 0,61 0,52 0,35 Cr [wt%] 0,0001 0,0001 0,045 0,045 Mo [wt.%] 0,2 0,2 0,03 0,03 Mg [wt.%] 0,03 0,2 0,03 0,085 Fe [wt.%] 0,12 0,25 0,12 0,35 Cu [wt.%] 0,005 0,20 0,005 0,17 Zn [wt.%] 0,0001 0,18 0,0001 0,15 Ti [wt.%] 0,06 0,06 0,06 0,12 Zr [wt.%] 0,15 0,15 0,15 0,05 V [wt.%] 0,0001 0,0001 0,0001 0,03 Sr [wt.%] 150 ppm 150 ppm 150 ppm 180 ppm Ga [wt.%] 100 ppm Table 2: Properties of different aluminum alloys Characteristic Reference alloy 1 Reference alloy 2 Reference alloy 3 Alloy according to the invention R p0,2 (F) [MPa] 124 136 126 132 A (F) [%] 10,1 7,5 11,6 11,1 R p0,2 (T5) after 1000 h at 150 °C [MPa] 126 172 127 135 A (T5) after 1000 h at 150 °C [%] 9,8 4,8 10,9 10,7 Heat stability ++ - ++ ++ Punch rivetability ++ - ++ ++ Corrosion resistance ++ - ++ + Recycling rate 23 % 72 % 21 % 88 % Post-consumer share 9% 26 % 8 % 36 % NDS factor [%] 3,0 5,6 3,5 12,4

[0061] The first column of Table 1 lists the various chemical elements whose contents in the specified alloys are listed in Table 1 in wt.%.

[0062] Reference alloy 1 was taken from EP 1 443 122 B1, reference alloy 2 was taken from EP 3 235 917 B1, and reference alloy 3 was taken from EP 3 775 309 B1. Furthermore, an alloy according to the invention is listed in the fifth column of Tables 1 and 2.

[0063] The 0.2% proof stress R p0,2 Here, is the (uniaxial) mechanical stress at which the permanent strain relative to an initial length of a specimen (i.e., the subscript p indicates plastic strain) after unloading is 0.2%. Furthermore, with R p0,2 (F) here denotes the 0.2% proof strength in MPa in the as-cast condition F without further heat treatment, and A(F) here denotes the elongation at break in % in the as-cast condition F without further heat treatment. Furthermore, R here denotes p0,2 (T5) denotes the 0.2% proof strength in MPa in a condition after heat treatment at 150 °C for 1000 h, while A (T5) denotes the elongation at break in % after heat treatment at 150 °C for 1000 h.

[0064] In this case, a high value for the 0.2% proof strength in the as-cast condition F of the aluminum alloy is preferred, as this allows for a small wall thickness of a component, which can thus reduce the weight of the component.

[0065] In this context, elongation at break refers to the permanent lengthening of a tensile specimen after fracture in a fracture test, relative to the initial length of the specimen. It characterizes the deformability or ductility of a material. In this case, a high elongation at break of the aluminum alloy is preferred, as this enables good punch riveting.

[0066] The data for heat stability, rivetability, and corrosion resistance refer to test trials with the alloys, whereby the alloys were evaluated with respect to these criteria according to a predefined set of criteria. For example, heat stability was tested by measuring the 0.2% proof strength and the elongation at break on predefined specimens, once without heat treatment and once after heat treatment at 150 °C for a duration of 1000 h. If the increase in R p0,2Thermal stability is not guaranteed above 30 MPa.

[0067] To test the rivetability, self-piercing rivets (rivets with a 5.3 mm diameter) were inserted into a test specimen in a test setup. The specimen consisted of a 2 mm thick 6000 series sheet on the punch side and the joining partner, on the die side, of the die-casting alloy under investigation as a 3 mm thick sheet. After self-piercing, the finished rivet was examined for cracks and defects, and the result was evaluated according to a predefined set of criteria.

[0068] Furthermore, corrosion resistance was assessed in a corrosion cycling test according to a standardized test procedure. This test procedure comprises a cyclically alternating combination of different climatic and / or corrosive stresses. One test cycle consists of: - 4 h salt spray test, NSS test method according to DIN EN ISO 9227, - 4 hours of storage at normal climate, and - 16 h humid heat storage, test climate CH according to DIN EN ISO 6270-2.

[0069] After every 5 cycles, a 2-day rest period follows under normal climatic conditions. A test over 15 cycles therefore takes a total of 3 weeks. This test method allows for the evaluation of corrosion behavior under static stress from salt, humidity, and temperature.

[0070] In this case, high heat stability, good rivetability, and high corrosion resistance are preferred to ensure the wide applicability of the aluminum alloy. High yield strength, high elongation at break, high heat stability, good rivetability, and high corrosion resistance are also referred to as good mechanical properties.

[0071] The recycling rate refers to the proportion of secondary aluminum in the total alloy, expressed as a percentage by weight. The post-consumer content, on the other hand, refers to the proportion of secondary aluminum that has been returned to the recycling loop after use by an end user. A high recycling rate and a high post-consumer content are advantageous for increasing the sustainability of the aluminum alloy used.

[0072] Reference alloys 1 and 3 have low magnesium contents and are therefore naturally hard. They possess good mechanical and physical properties and thermal stability, but due to their low iron, copper, magnesium, and zinc contents, their production from recycled materials is limited. This is reflected in the recycling rate values ​​in Table 2. These values ​​were calculated from or taken directly from the iron and copper contents specified in the publications.

[0073] The use of post-consumer scrap is only possible to a very limited extent due to the low permissible limits for impurity metals in reference alloys 1 and 3.

[0074] Reference alloy 2 achieves very high recycling rates, but compared to reference alloys 1 and 3, it exhibits very limited mechanical and physical properties, as can be seen from the poor ratings regarding heat stability and rivetability in Table 2. Furthermore, the corrosion resistance of this alloy is particularly disadvantageous. In addition, the increased magnesium content of reference alloy 2 means that it lacks the naturally hard character of reference alloy 2 and therefore thermal stability.

[0075] The alloy according to the invention is the only alloy in this comparison that manages to combine all the advantages. Due to the selected range of impurity elements (Fe, Cu, Zn, Ti), the alloy according to the invention can be produced with a high recycling rate. The alloy achieves a recycling rate of 88% and a post-consumer share of 36%, which is even higher than the recycling rates of the aforementioned reference alloys 1, 2, and 3.

[0076] By skillfully adjusting the element contents in the alloy, as well as a suitable ratio of the elements to each other, the alloy according to the invention is also an alloy which is thermally stable on the one hand, has high elongation values ​​on the other hand and also makes it possible to achieve a high recycling content.

[0077] The permitted levels of impurities enable very high recycling rates. Furthermore, the chosen element limits have resulted in a combination of properties that exhibits only minor drawbacks compared to primary aluminum reference alloys, meaning it is essentially equivalent. This creates an alternative alloy that nevertheless offers higher recycling rates and can therefore reduce the CO2 footprint during the production of, for example, a motor vehicle.

[0078] This is expressed by the NDS factor, which in the alloy according to the invention has been increased by more than double that of the best reference alloy (alloy 2).

[0079] To obtain the sustainability ductility stability factor (NDS factor), the concentrations of impurity elements are summed, while the iron content is weighted double due to the significant influence of iron on the ductility of the aluminum alloy. The resulting sum is then multiplied by the elongation at break (in percent) and a coefficient that is the ratio of the 0.2% proof stress R. p0,2 (F) in the as-cast condition F (in MPa) and the 0.2% proof stress R p0,2 (T5) indicates a state after heat treatment at 150 °C for 1000 h.

[0080] Overall, the examples show how an aluminum alloy for structural casting applications with increased ductility, a use of the aluminum alloy for die casting structural components, a structural component for a motor vehicle made from the aluminum alloy, and a motor vehicle with the structural component can be provided. Reference symbol list 100 Yield strength 102 Area without solid solution hardening 104 Area of ​​solid solution hardening 106 Area of ​​thermal instability 108 x-axis 110 y-axis 112 lower limit 114 upper limit

Claims

[1] Aluminium alloy for structural casting applications with increased ductility, comprising - 7.5 to 11.5 wt.% silicon, - 0.25 to 0.6 wt% manganese, - 0.03 to 0.06 wt% chromium, - 0.001 to 0.048 wt% molybdenum, - 0.04 to 0.095 wt% magnesium, in particular 0.06 to 0.095 wt% magnesium, - 0.17 to 0.5 wt% iron, - 0.03 to 0.17 wt% copper, - max. 0.35 wt.% zinc and - 0.004 to 0.15 wt% titanium, - as well as residual aluminum and unavoidable impurities, - except for an aluminium alloy comprising 0.25 wt.% manganese, 0.06 wt.% chromium and 0.05 to 0.095 wt.% magnesium. [2] Aluminium alloy according to claim 1, characterized by 0.01 to 0.2 wt.% zirconium. [3] Aluminium alloy according to claim 1 or 2, characterized by 0.001 to 0.1 wt% vanadium. [4] Aluminium alloy according to any one of the preceding claims, characterized by 0.002 to 0.030 wt% strontium. [5] Aluminium alloy according to any one of the preceding claims, characterized by a secondary aluminium content of 25 wt.% or more, and / or a post-consumer secondary aluminium content of 10 wt.% or more. [6] Aluminium alloy according to any one of the preceding claims, characterized by, that an NDS value of the aluminium alloy is greater than 6, preferably the NDS value of the aluminium alloy is greater than 10 and more preferably the NDS value of the aluminium alloy is greater than 12, wherein the NDS value of the aluminium alloy is the product of an impurity element sum with the elongation at break in percent and the ratio of a 0.2% proof strength in the as-cast condition F and a 0.2% proof strength in a hardened condition, wherein the impurity element sum is a sum of the element contents of impurity elements in weight percent, wherein the iron content is included in the impurity element sum at twice the weight. [7] Use of an aluminium alloy according to any of the preceding claims for die casting of structural components, in particular in automotive engineering. [8] Structural component, in particular gigacasting component, for a motor vehicle made of an aluminium alloy according to any one of claims 1 to 6. [9] Structural component, in particular gigacasting component, according to the preceding claim, characterized by that it has a predetermined thermal stability. [10] Motor vehicle with a structural component according to one of the preceding claims.

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