CAST ALLOYS FOR HIGH-PRESSURE VACUUM CASTING

Abstract

This description refers to a cast aluminum alloy for manufacturing cast aluminum products, especially using high-pressure vacuum die-casting operations. The aluminum alloy comprises, in weight percent: Ni from about 1.5 to about 6.5; Si from about 0.10 to 1.5; Mg from about 0.10 to about 3; Fe up to about 0.2; Mn up to about 0.65; Ti up to about 0.12; V up to about 0.15; Zr up to about 0.15; Mo up to about 0.15; Cr up to about 0.01; Sr up to about 0.02; the remainder being aluminum and unavoidable impurities.

Description

CASTING ALLOYS FOR HIGH-PRESSURE VACUUM CASTING Cross-reference with related applications This is an application claiming priority of U.S. application number 62 / 796,735 filed on January 25, 2019, and is incorporated herein in its entirety. Technical field of the invention This application refers to casting alloys that exhibit acceptable strength properties once cast. Background of the invention Alloying commercially pure aluminum alloys can create a solid solution or individual phases that greatly improve tensile strength due to solid solution strengthening and precipitation strengthening. However, electrical conductivity can decrease due to the increased scattering of free electrons among the solute and precipitate atoms. For electrical applications, finding a favorable combination of high electrical conductivity with improved mechanical properties is a challenge in alloy design and development. In addition, for applications requiring high-pressure vacuum die casting, it is important that the alloy achieves adequate fluidity to be melted into a mold and exhibits limited hot tearing and die welding. It would be desirable to obtain an aluminum alloy with improved casting properties, for example, improved fluidity and increased hot tear resistance. Alternatively or in combination, it would be desirable to obtain a conductive aluminum alloy that has improved electrical conductivity without substantially diminishing its mechanical properties. Brief description of the invention This disclosure provides for the use of Ni in a low-Si aluminum casting alloy to increase its fluidity during casting, limit hot tearing during high-pressure vacuum casting operations and / or to increase weld strength during high-pressure vacuum casting operations. According to a first aspect, the present disclosure provides a cast alloy comprising, in weight percentage: Not between around 1.5 and around 6.5; If between approximately 0.10 and 1.5; Mg between around 0.10 and around 3; Fe up to around 0.2; Mn up to around 0.65; Ti up to around 0.12; QL / onn / Lznz / E / Yii V up to around 0.15; Zr up to around 0.15; Mo up to around 0.15; Cr up to around 0.01; Sr up to around 0.02; and the remainder being aluminum and unavoidable impurities. In one embodiment, the cast alloy comprises more than about 2.0 Ni. In another embodiment, the cast alloy comprises between about 2.5 and about 6.5 Ni. In yet another embodiment, the cast alloy comprises between about 1.8 and about 3.0 Ni. In another embodiment, the cast alloy comprises between 0.15 and 0.90 Si. In another embodiment, the cast alloy comprises between 0.3 and 0.75 Si. In yet another embodiment, the cast alloy comprises Mg in a weight percent determined by formula (I): % Mg < -1.218 * In (% Si) + 0.89 (I) where % Mg is the weight percentage of Mg; and % Si is the weight percentage of Si. In one embodiment, the cast alloy comprises from about 0.15 to about 1.8 Mg. In another embodiment, the cast alloy comprises from about 0.30 to about 1.0 Mg. In yet another embodiment, the cast alloy comprises up to about 0.10 Fe. In another embodiment, the cast alloy comprises from about 0.45 to about 0.65 Mn. In another embodiment, the cast alloy comprises up to about 0.01 Mn. In another embodiment, the cast alloy comprises from about 0.02 to about 0.12 Ti. In yet another embodiment, the cast alloy comprises up to about 0.01 Ti. In another embodiment, the cast alloy comprises between approximately 0.01 and approximately 0.15 V. In another embodiment, the cast alloy comprises up to approximately 0.01 V. In another embodiment, the cast alloy comprises between approximately 0.01 and approximately 0.15 Zr.In another embodiment, the cast alloy comprises up to about 0.01 Zr. In another embodiment, the cast alloy comprises between about 0.01 and about 0.15 Mo. In another embodiment, the cast alloy comprises up to about 0.01 Mo. In another embodiment, the cast alloy comprises between about 0.005 and about 0.02 Sr. In a further embodiment, the cast alloy comprises an excess of Mg over a weight percent ratio of Mg:Si of more than about 2:1. In a further embodiment, especially when the aluminum alloy is intended for use in electrical applications, the cast alloy comprises Mn, Cr, Ti, and V in a weight percent determined by formula (II):. %Mn + %Cr + %T¡ + %V < 0.025 (II) where %Mn is the weight percentage of Mn; %Cr is the percentage by weight of Cr; %Ti is the weight percentage of Ti; and %V is the weight percentage of V. αί / οηη / ίζηζ / Ε / γι According to a second aspect, this disclosure provides a process for improving at least one casting property of a first aluminum alloy for manufacturing a first aluminum product compared to a cast aluminum alloy for manufacturing a cast aluminum product. The process comprises combining Ni with the first aluminum alloy to provide the cast aluminum alloy. The first aluminum alloy comprises, in weight percent: αί / οηη / ίζηζ / Ε / γι Si between approximately 0.10 and 1.5; Mg between approximately 0.10 and approximately 3; Fe up to approximately 0.2; Mn up to approximately 0.65; Ti up to approximately 0.12; V up to approximately 0.15; Zr up to approximately 0.15; Mo up to approximately 0.15; Cr up to approximately 0.01; Sr up to approximately 0.02; and the remainder being aluminum and unavoidable impurities. In the process of this disclosure, the The modified aluminum alloy comprises between about 1.5 and about 6.5 Ni. In one embodiment, at least one casting property is an increase in fluidity during casting, a reduction in hot tearing, and / or an increase in weldability during high-pressure vacuum casting. In one embodiment, the modified aluminum alloy comprises at least about 2.0 Ni. In another embodiment, the modified aluminum alloy comprises between about 2.5 and about 6.5 Ni. In another embodiment, the modified aluminum alloy has an excess of Mg over a weight percent Mg:Si ratio of more than about 2:1. In yet another embodiment, the modified aluminum alloy comprises between about 1.8 and about 3.0 Ni. In another embodiment, the first aluminum alloy comprises between 0.15 and 0.90 Si. In another embodiment, the first aluminum alloy comprises between 0.3 and 0.75 Si.In yet another form, the first aluminum alloy comprises Mg in a percentage by weight determined by formula (I):. %Mg < -1.218*ln(%Si) + 0.89 (I) where % Mg is the weight percentage of Mg; and % Si is the weight percentage of Si. In one further embodiment, the first aluminum alloy comprises from about 0.15 to about 1.8 Mg. In another further embodiment, the first aluminum alloy comprises from about 0.30 to about 1.0 Mg. In yet another embodiment, the aluminum alloy comprises up to about 0.10 Fe. In another further embodiment, the first aluminum alloy comprises from about 0.45 to about 0.65 Mn. In yet another embodiment, the aluminum alloy comprises up to about 0.01 Mn. In yet another embodiment, the first aluminum alloy comprises from about 0.02 to about 0.12 Ti. In yet another embodiment, the aluminum alloy comprises up to about 0.01 Ti. In one embodiment, the first aluminum alloy comprises from about 0.01 to about 0.15 V. In another embodiment, the first aluminum alloy comprises up to about 0.01 V. In another further embodiment, the first aluminum alloy comprises from about 0.0.01 and about 0.15 Zr. In yet another embodiment, the first aluminum alloy comprises up to about 0.01 Zr. In a further embodiment, the first aluminum alloy comprises between about 0.01 and about 0.15 Mo. In yet another embodiment, the first aluminum alloy comprises up to about 0.01 Mo. In one embodiment, the first aluminum alloy comprises between about 0.005 and about 0.02 Sr. In yet another embodiment, especially when the modified aluminum alloy is intended for use in electrical applications, the first aluminum alloy comprises Mn, Cr, Ti, and V in a weight percentage determined by formula (II):. %Mn + %Cr + %T¡ + %V < 0.025 (II) where %Mn is the weight percentage of Mn; %Cr is the percentage by weight of Cr; %T¡ is the weight percentage of Ti; and %V is the weight percentage of V. According to a third aspect, the present disclosure provides a modified cast aluminum alloy manufactured from the process described herein. According to a fourth aspect, this disclosure provides a process for manufacturing a cast aluminum product, the process comprising casting the described cast aluminum alloy or the described modified cast aluminum alloy in a mold. In one embodiment, the process comprises subjecting the cast aluminum alloy or the modified die-cast aluminum alloy to high-pressure vacuum die-casting. In another embodiment, the process of the claim further comprises a post-casting heat treatment step, such as, for example, T6 quenching or T5 quenching. According to a fifth aspect, this disclosure provides a cast aluminum product comprising either the cast aluminum alloy described herein or the modified cast aluminum alloy described herein. In one embodiment, the cast aluminum product can be manufactured by the process described herein. In one embodiment, the cast aluminum product is electrically conductive. In another embodiment, the cast aluminum product is a rotor. Brief description of the drawings Having thus described in general terms the nature of the invention, reference will now be made to the accompanying drawings, which illustrate a preferred embodiment thereof, and in which: Figure 1 illustrates the Scheil solidification curves for AI-6% Ni (♦), AI-1.8% Fe (A), AI-1.8% Fe-1% Ni (·), and AI-5% Ni-1.8% Fe () alloys. The results are shown as temperature as a function of the mole fraction of the solid. QL / Qnn / Lznz / E / Yi Figure 2 provides the mechanical properties of the various alloys in the casting quench. The results are shown for ultimate tensile strength (UTS in MPa, first column for each alloy tested, left axis), yield strength (YS in MPa, second column for each alloy tested, left axis), quality index (Ql in MPa, gray column for each alloy tested), or elongation (% elongation, empty column for each alloy tested) for the different alloys in the casting quench. Figure 3 shows the effect of magnesium and silicon content on the mechanical properties of the cast iron. The results are shown for yield strength (♦, in MPa, left axis) and elongation (El, in percent, right axis) as a function of the magnesium and silicon content (weight percent) used. Figure 4 shows the mechanical properties of the different alloys in T5 temper (aged for 1 h at 210°C). The results are shown for ultimate tensile strength (UTS in MPa, first column for each alloy tested, left axis), yield strength (YS in MPa, second column for each alloy tested, left axis), quality index (Ql in MPa, gray column for each alloy tested), or elongation (% elongation, empty column for each alloy tested) for the different alloys in T5 temper. Figure 5 shows a microscopic view of the alloy Al₂S₀.15Mg₀.15 as cast temper. Scale bar = 20 pm. Figure 6 shows a microscopic view of the AlNi2Si0.3Mg0.6 alloy as a molten temper. Scale bar = 20 pm. Arrows point to undissolved MgSi from solidification. Figure 7 shows the mechanical properties of the different alloys in T6 quench (solution heat treated for 1h at 460 °C or 500 °C, rapid air quenched at 5 °C / s, natural aging at room temperature for 12 h, aged for 2.5 h at 185 °C). The results are shown for ultimate tensile strength (UTS in MPa, first column for each alloy tested, left axis), yield strength (YS in MPa, second column for each alloy tested, left axis), quality index (Ql in MPa, gray column for each alloy tested) or elongation (% elongation, empty column for each alloy tested) for the different alloys in T6 quench. Figure 8 shows the effect of magnesium and silicon content on the T6 mechanical properties. The results are shown for the yield strength (YS, ♦, in MPa, left axis) and elongation (El, , in percent, right axis) as a function of the content (weight percent) of magnesium and silicon used. Figure 9 shows a microscopic view of the alloy Al₂Si₀.15Mg₀.15 in T6 temper. Scale bar = 20 pm. Figure 10 shows a microscopic view of the alloy AIN2Si0.15Mg0.3 in T6 temper. Scale bar = 20 pm. Figure 11 shows a microscopic view of the AINi2S10.3Mg0.3 alloy in T6 temper. Scale bar = 20 pm. QL / Qnn / Lznz / E / Yi Figure 12 shows a microscopic view of the alloy Al₂Si₀.3Mg₀.6 in T6 temper. Scale bar = 20 pm. Figure 13 shows a microscopic view of the alloy Al₂S₀0.3Mg0.6Mn in T6 temper. Scale bar = 20 pm. Figure 14 shows a microscopic view of the alloy Al₂Si₀.5Mg₀.5 in T6 temper. Scale bar = 30 pm. Figure 15 shows a microscopic view of the alloy Al₂Si₀.9Mg₀.8 in T6 temper. Scale bar = 30 pm. Figure 16 shows the electrical conductivity (% IACS) of the tested alloy types as a function of the Mg + Si content (weight percent) of the alloy in T6 temper. Figure 17 shows the electrical conductivity (% IACS) of the tested alloy types as a function of the yield strength (in MPa) of the alloy in T6 temper. Figure 18 shows the mechanical properties of the different alloys in T6 quench (solution heat treated for 1h or 2h at 500°C, rapid air quenched at 5°C / s, natural aging at room temperature for 12h, aged for 2.5h at 185°C). The results are shown for ultimate tensile strength (UTS in MPa, first column for each alloy tested, left axis), yield strength (YS in MPa, second column for each alloy tested, left axis), quality index (Ql in MPa, gray column for each alloy tested) or elongation (% elongation, empty column for each alloy tested) for the different alloys in T6 quench. Figure 19 shows the mechanical properties of the different alloys in T6 quench (solution heat treated for 1h or 2h at 500 °C, rapid air quenched at 5 °C / s, natural aging at room temperature for 12 h, aged for 2.5 h at 185 °C). The results are shown for ultimate tensile strength (UTS in MPa for 1 h solid line with ♦, UTS in MPa for 2h line with x), yield strength (YS in MPa for 1h solid line with , US in MPa for 2h line with *), elongation (% elongation for 1 h solid line with ▲, % elongation for 2 h line with ·). Figure 20 shows the electrical conductivity (% IACS) of various T6 quenched alloys (solution heat-treated for 1 h at 500 sC, rapid air quenched at 5 °C / s, natural aging at room temperature for 12 h, aged for 2.5 h at 185 °C) as a function of the yield strength (in MPa) of the alloy. The yield strength results for the same alloy with a 1 h treatment (shown with ♦) and a 2 h treatment (shown with ) are linked by a line for comparison. Figure 21 provides the mechanical properties of the various alloys in temper F. The results are shown for ultimate tensile strength (UTS in MPa, first column for each alloy tested, left axis), yield strength (YS in MPa, second column for each alloy tested, left axis), quality index (Ql in MPa, gray column for each alloy tested), or elongation (% elongation, empty column for each alloy tested) for the different QL / Qnn / Lznz / E / Yi alloys in temper F. Figure 22 shows the mechanical properties of the various alloys in T5 temper (aged for 1 h at 210°C). The results are shown for ultimate tensile strength (UTS in MPa, first column for each alloy tested, left axis), yield strength (YS in MPa, second column for each alloy tested, left axis), quality index (Ql in MPa, gray column for each alloy tested), or elongation (% elongation, empty column for each alloy tested) for the different alloys in T5 temper. Figure 23 shows the mechanical properties of the different alloys in T6 quench (solution heat treated for 1h or 500SC, rapid air quenched at 5 °C / s, natural aging at room temperature for 12 h, aged for 2.5 h at 185 °C). The results are shown for ultimate tensile strength (UTS in MPa, first column for each alloy tested, left axis), yield strength (YS in MPa, second column for each alloy tested, left axis), quality index (Ql in MPa, gray column for each alloy tested) or elongation (% elongation, empty column for each alloy tested) for the different alloys in T6 quench. Figure 24 shows a microscopic view of AINÍ3Si0.3Mg0.6 in temper F. Scale bar = 20 pm. Figure 25 shows a microscopic view of AINi3S10.3Mg0.6 in T6 temper. Scale bar = 20 pm. Figure 26 shows the electrical conductivity (% IACS) as a function of the Ni content (% by weight) in the T6 temper. Figure 27 shows a hot rip mold in high pressure vacuum die casting (HPVDC). Figure 28 shows a sensitivity map of the hot tear index (HTI) with the wt% of Mg as a function of the wt% of Si. The range of HTI values ​​is specified within the areas. Detailed description of the invention This disclosure relates to the use of Ni in Al-Si-Mg alloys (such as 6xxx series alloys) to provide a casting alloy. In some embodiments, the casting alloy of this disclosure can be used in high-pressure vacuum die casting to provide cast aluminum products. The presence of Ni in the casting alloy of this disclosure does not substantially affect the strengthening mechanism of MgzSi precipitation (since Ni is inert with respect to Mg and Si and is not expected to affect the formation of MgzSi precipitates), advantageously allows the alloy to be cast, limits hot tearing, and improves weldability when the casting alloy is subjected to high-pressure vacuum die casting.In some embodiments, the cast alloy of the present disclosure also exhibits increased electrical conductivity as well as substantially similar mechanical properties (especially strength and ductility) compared to control alloys (such as alloys). QL / Qnn / Lznz / E / Yi A365.1). In the context of this disclosure, nickel (Ni) may be added to aluminum alloys intended for use in casting applications. For example, Ni may be added to wrought alloys of the 3xxx, 5xxx, or 6xxx series to create a casting alloy. In some specific embodiments, Ni may be added to wrought alloys of the 6xxx series to create a casting alloy. Ni may also be added to aluminum alloys intended for use in high-pressure vacuum die casting applications to limit hot tearing and / or pressure welding. For example, Ni may be added to alloys of the 2xxx, 3xxx, 4xxx, 5xxx, or 6xxx series to limit hot tearing and / or pressure welding during high-pressure vacuum die casting applications.In another embodiment, nickel (Ni) can be added to 6xxx series alloys to limit hot tearing and / or die welding during high-pressure vacuum casting applications. For the purposes of this disclosure, the Ni must be provided at a minimum weight percentage (e.g., 1.5, 1.8, 2.0, 2.5, or greater than 2.5) that will permit casting and, in some embodiments, specifically prevent die welding in high-pressure vacuum casting operations. Ni may be added, in a weight percentage of between about 1.5 and about 6.5 to the cast alloy of the present disclosure. In one embodiment, Ni is present in the cast alloy of the present disclosure in a weight percent of at least about (for example, a minimum of) 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, .0, 6.1, 6.2, 6.3 or 6.4. In yet another embodiment, Ni is present in the cast alloy of the present disclosure in a weight percent of not more than about (for example, a maximum of) 6.5, 6.4, 6.3, 6.2, 6.1, 6.0, 5.9, 5.8, 5.7, 5.6, 5.5, 5.4, 5.3, 5.2, 5.1, 5.0, 4.9, 4.8, 4.7, 4.6, 4.5, 4.4, 4.3, 4.2, 0.1, 4.0, 3.9, 3.8, 3.7, 3.6, 3.5, 3.4, 3.3, 3.2, 3.1, 3.0, 2.9, 2.8, 2.7, 2.6, 2.5, 2.4, 2.3, 2.2, 2.1,2.0, 1.9,1.8, .7 or 1.6.In yet another additional embodiment, Ni is present in the cast alloy of the present disclosure in a weight percentage of between about 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8. 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3 or 6.4 and around 6.5, 6.4, 6.3, 6.2, 6.1, 6.0, 5.9, 5.8, 5.7, 5.6, 5.5, 5.4, 5.3, 5.2, 5.1, 5.0, 4.9, 4.8, 4.7, 4.6, 4.5, 4.4, 4.3, 4.2, 4.1, 4.0, 3.9, 3.8 3.7, 3.6, 3.5, 3.4, 3.3, 3.2, 3.1,3.0, 2.9, 2.8, 2.7, 2.6, 2.5, 2.4, 2.3, 2.2, 2.1,2.0, 1.9, 1.8, 1.7 or1.6. In an additional embodiment, Ni is present in the casting alloy at a weight percent greater than approximately 2.0. As shown in the following examples, the inclusion of Ni at a weight percent greater than 2.0 limits hot tearing and increases die-weld resistance. In such an embodiment, Ni may be present in the casting alloy at a weight percent greater than approximately 2.0 and equal to or less than approximately 6.5. In additional forms, Ni may be present in the casting alloy in a weight percentage greater than around 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3 or 6.4. In still others In QL / Qnn / Lznz / E / Yii modalities, Ni may be present in the casting alloy in a weight percentage equal to or less than approximately 6.5, 6.4, 6.3, 6.2, 6.1, 6.0, 5.9, 5.8, 5.7, 5.6, 5.5, 5.4, 5.3, 5.2, 5.1, 5.0, 4.9, 4.8, 4.7, 4.6, 4.5, 4.4, 4.3, 4.2, 4.1, 4.0, 3.9, 3.8, 3.7, 3.6, 3.5, 3.4, 3.3, 3.2, 3.1, 3.0, 2.9, 2.8, 2.7, 2.6, 2.5, 2.4, 2.3, 2.2 or 2.1. In yet another additional modality, Ni may be present in the cast alloy in a weight percentage greater than around 2.0 2.1,2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1,3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7 5.8, 5.9, 6.0, 6.1, 6.2, 6.3 or 6.4 and equal to or less than approximately 6.5, 6.4, 6.3, 6.2, 6.1, 6.0, 5.9, 5.8, 5.7, 5.6, 5.5, 5.4, 5.3, 5.2, 5.1, 5.0, 4.9, 4.8, 4.7, 4.6, 4.5, 4.4, 4.3, 4.2, 4.1, 4.0, 3.9, 3.8, 3.7, 3.6, 3.5, 3.4, 3.3 3.2, 3.1,3.0, 2.9, 2.8, 2.7, 2.6, 2.5, 2.4, 2.3, 2.2 or 2.1. In another embodiment, Ni is present in the casting alloy at a weight percent between approximately 1.8 and 3.0. In one embodiment, Ni is present in the casting alloy of this disclosure at a weight percent of at least approximately (for example, a minimum of) 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, or 2.9. In yet another embodiment, Ni is present in the casting alloy of this disclosure at a weight percent of no more than approximately (for example, a maximum of) 3.0, 2.9, 2.8, 2.7, 2.6, 2.5, 2.4, 2.3, 2.2, 2.1, 2.0, or 1.9. In another additional embodiment, Ni is present in the cast alloy of the present disclosure in a weight percentage of around 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8 or 2.9 and around 3.0, 2.9, 2.8, 2.7, 2.6, 2.5, 2.4, 2.3, 2.2, 2.1, 2.0 or 1.9. In yet another form, Ni can be added, in a weight percentage of between about 2.5 and about 6.5 to the cast alloy of the present disclosure. In one embodiment, Ni is present in the cast alloy of the present disclosure in a weight percent of at least about (for example, a minimum of) 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3 or 6.4. In yet another embodiment, Ni is present in the cast alloy of the present disclosure in a weight percent of not more than about (for example, a maximum of) 6.5, 6.4, 6.3, 6.2, 6.1, 6.0, 5.9, 5.8, 5.7, 5.6, 5.5, 5.4, 5.3, 5.2, 5.1, 5.0, 4.9, 4.8, 4.7, 4.6, 4.5, 4.4, 4.3, 4.2, 4.1, 4.0, 3.9, 3.8, 3.7, 3.6, 3.5, 3.4, 3.3, 3.2, 3.1, 3.0, 2.9, 2.8, 2.7 or 2.6. In yet another additional embodiment, Ni is present in the cast alloy of the present disclosure in a weight percentage of between approximately 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4 and around 6.5, 6.4, 6.3, 6.2, 6.1, 6.0, 5.9, 5.8, 5.7, 5.6, 5.5, 5.4, 5.3, 5.2, 5.1, 5.0, 4.9, 4.8, 4.7, 4.6, 4.5, 4.4, 4.3, 4.2, 4.1, 4.0 3.9, 3.8, 3.7, 3.6, 3.5, 3.4, 3.3, 3.2, 3.1,3.0, 2.9, 2.8, 2.7 or 2.6. In an additional embodiment, Ni is present in the cast alloy in a weight percentage greater than about 2.5. In such embodiment, Ni may be present in the cast alloy in a weight percentage greater than about 2.5 and equal to or less than about 6.5. In additional forms, Ni may be present in the cast alloy in a weight percentage exceeding approximately 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, or 6.4. In QL / Qnn / Lznz / E / Yi and other forms, Ni may be present in the casting alloy in a weight percentage equal to or less than around 6.5, 6.4, 6.3, 6.2, 6.1, 6.0, 5.9, 5.8, 5.7, 5.6, 5.5, 5.4, 5.3, 5.2, 5.1, 5.0, 4.9, 4.8, 4.7, 4.6, 4.5, 4.4, 4.3, 4.2, 4.1, 4.0, 3.9, 3.8, 3.7, 3.6, 3.5, 3.4, 3.3, 3.2, 3.1, 3.0, 2.9, 2.8, 2.7 or 2.6. In yet another additional modality, Ni may be present in the cast alloy in a weight percentage greater than around 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3 or 6.4 and equal to or less than approximately 6.5, 6.4, 6.3, 6.2, 6.1, 6.0, 5.9, 5.8, 5.7, 5.6, 5.5, 5.4, 5.3, 5.2, 5.1, 5.0, 4.9, 4.8, 4.7, 4.6, 4.5, 4.4, 4.3, 4.2, 4.1,4.0, 3.9, 3.8, 3.7, 3.6, 3.5, 3.4, 3.3, 3.2, 3.1,3.0, 2.9, 2.8, 2.7 or 2.6. The cast alloy of this disclosure also includes Si and Mg. In the cast alloy of this disclosure, Si and Mg form precipitates (Mg₂Si particles, for example) that are expected to provide some of the mechanical properties (especially strength and ductility) of the cast aluminum products comprising the cast aluminum alloy of this disclosure. As is known in the art, the solubilities of Si and Mg in the aluminum matrix are codependent. In some embodiments, the Mg / Si atomic ratio is between 1 and 2. In some embodiments, the weight percent of Mg is related to the weight percent of Si in the aluminum alloy of this disclosure as follows: %Mg < -1.218*ln(%S¡) + 0.89 (I) In some embodiments, when the molten aluminum product is in temper T6, the Mg and Si content is related as indicated in Formula (I). In some embodiments, when the molten aluminum product is in temper F, the Mg / Si atomic ratio is closer to 1. In additional forms, Mg is present in excess at a Mg:S ratio (weight percent) of 2:1. In some forms, the Mg:S ratio is higher than approximately 2:1. This can be beneficial, in some forms, for reducing the hot tear index of the aluminum alloy. Silicon (Si) is present in the casting alloy of this disclosure in a weight percent between about 0.10 and about 1.5. It is important that the casting alloys of this disclosure include at least about 0.10 Si to form precipitates with Mg and no more than about 1.5 Si to provide acceptable electrical properties (such as electrical conductivity) and avoid the formation of silicon eutectics. In one embodiment, Si is present in the casting alloy of this disclosure in a weight percent of at least about (for example, a minimum of) 0.10, 0.20, 0.30, 0.40, 0.50, 0.60, 0.70, 0.80, 0.90, 1.00, 1.10, 1.20, 1.30 or 1.40. In another embodiment, Si is present in the casting alloy of this disclosure in a weight percent of no more than about (for example, a maximum of) 1.50, 1.40, 1.30, 1.20, 1.10, 0.90, 0.80, 0.70, 0.60, 0.50, 0.40, 0.30 or 0.20. In another embodiment, Si is present in the cast alloy of the present disclosure in a weight percentage of around 0.10, 0.20, 0.30, 0.40, 0.50, 0.60, 0.70, 0.80, 0.90, 1.00, 1.10, 1.20, 1.30 or 1.40 and around 1.50, 1.40, 1.30, 1.20, 1.10, 0.90, 0.80, 0.70, 0.60, 0.50, 0.40, 0.30 or 0.20. qi / onn / i 7n7 / E / Yl· In one embodiment, Si is present in the casting alloy of this disclosure in a weight percent between about 0.15 and about 0.90. In one embodiment, Si is present in the casting alloy of this disclosure in a weight percent of at least about (for example, a minimum of) 0.15, 0.20, 0.30, 0.40, 0.50, 0.60, 0.70, or 0.80. In another embodiment, Si is present in the casting alloy of this disclosure in a weight percent of no more than about (for example, a maximum of) 0.90, 0.80, 0.70, 0.60, 0.50, 0.40, 0.30, or 0.20. In another embodiment, Si is present in the cast alloy of the present disclosure in a weight percentage of around 0.15, 0.20, 0.30, 0.40, 0.50, 0.60, 0.70 or 0.80 and around 0.90, 0.80, 0.70, 0.60, 0.50, 0.40, 0.30 or 0.20. In one additional embodiment, Si is present in the casting alloy of this disclosure in a weight percent between about 0.30 and about 0.75. In one embodiment, Si is present in the casting alloy of this disclosure in a weight percent of at least about (for example, a minimum of) 0.30, 0.40, 0.50, 0.60, or 0.70. In another embodiment, Si is present in the casting alloy of this disclosure in a weight percent of no more than about (for example, a maximum of) 0.75, 0.70, 0.60, 0.50, or 0.40. In another embodiment, Si is present in the cast alloy of the present disclosure in a weight percentage of around 0.30, 0.40, 0.50, 0.60 or 0.70 and around 0.75, 0.70, 0.60, 0.50 or 0.40. Mg is present in the cast alloy of this disclosure in a weight percent between about 0.10 and about 3.0. It is important that the cast alloys of this disclosure include at least about 0.10 Mg to form precipitates with Si and no more than about 3.0 Mg to provide acceptable electrical properties (such as electrical conductivity). In one embodiment, Mg is present in the cast alloy of the present disclosure in a weight percent of at least about (for example, a minimum of) 0.10, 0.20, 0.30, 0.40, 0.50, 0.60, 0.70, 0.80, 0.90, 1.00, 1.10, 1.20, 1.30, 1.40, 1.50, 1.60, 1.70, 1.80, 1.90, 2.00, 2.10, 2.20, 2.30, 2.40, 2.50, 2.60, 2.70, 2.80 or 2.90. In one embodiment, Mg is present in the cast alloy of the present disclosure in a weight percent of not more than about (for example, a maximum of) 3.00, 2.90, 2.80, 2.70, 2.60, 2.50, 2.40, 2.30, 2.20, 2.10, 2.00, 1.90, 1.80, 1.70, 1.60, 1.50, 1.40, 1.30, 1.20, 1.10, 0.90, 0.80, 0.70, 0.60, 0.50, 0.40, 0.30 or 0.20. In another embodiment, Mg is present in the cast alloy of the present disclosure in a weight percentage of between about 0.10, 0.20, 0.30, 0.40, 0.50, 0.60, 0.70, 0.80, 0.90, 1.00, 1.10, 1.20, 1.30, 1.40, 1.50, 1.60, 1.70, 1.80, 1.90, 2.00, 2.10, 2.20, 2.30, 2.40, 2.50, 2.60, 2.70, 2.80 or 2.90 and about 3.00, 2.90, 2.80, 2.70, 2.60, 2.50, 2.40, 2.30, 2.20, 2.10, 2.00, 1.90, 1.80, 1.70, 1.60, 1.50, 1.40, 1.30, 1.20, 1.10, 0.90, 0.80, 0.70, 0.60, 0.50, 0.40, 0.30 or 0.20. In one embodiment, Mg is present in the cast alloy of this disclosure in a weight percent between about 0.15 and about 1.8. In another embodiment, Mg is present in the cast alloy of this disclosure in a weight percent of at least about (for example, a minimum of) 0.15, 0.20, 0.30, 0.40, 0.50, 0.60, 0.70, 0.80, 0.90, 1.00, 1.10, 1.20, 1.30, 1.40, 1.50, 1.60, or 1.70. In yet another embodiment, Mg is present in the cast alloy of this disclosure. QL / Qnn / Lznz / E / Yii disclosure in a weight percent of not more than about (for example, a maximum of) 1.80, 1.70, 1.60, 1.50, 1.40, 1.30, 1.20, 1.10, 1.00, 0.90, 0.80, 0.70, 0.60, 0.50, 0.40, 0.30 or 0.20. In another embodiment, Mg is present in the cast alloy of the present disclosure in a weight percentage of between about 0.15, 0.20, 0.30, 0.40, 0.50, 0.60, 0.70, 0.80, 0.90, 1.00, 1.10, 1.20, 1.30, 1.40, 1.50, 1.60 or 1.70 and about 1.80, 1.70, 1.60, 1.50, 1.40, 1.30, 1.20, 1.10, 1.00, 0.90, 0.80, 0.70, 0.60, 0.50, 0.40, 0.30 or 0.20. In one embodiment, Mg is present in the cast alloy of this disclosure at a weight percent between about 0.3 and about 1.0. In another embodiment, Mg is present in the cast alloy of this disclosure at a weight percent of at least about (for example, a minimum of) 0.30, 0.40, 0.50, 0.60, 0.70, 0.80, or 0.90. In yet another embodiment, Mg is present in the cast alloy of this disclosure at a weight percent of no more than about (for example, a maximum of) 1.00, 0.90, 0.80, 0.70, 0.60, 0.50, or 0.40. In another embodiment, Mg is present in the cast alloy of the present disclosure in a weight percentage of around 0.30, 0.40, 0.50, 0.60, 0.70, 0.80 or 0.90 and around 1.00, 0.90, 0.80, 0.70, 0.60, 0.50 or 0.40. In the alloys of this disclosure, iron (Fe) is not included as an alloying element in the cast alloy of this disclosure and, if detected, is present only as an impurity or trace element. The presence of Fe would be detrimental to the alloys of this disclosure because it is expected to favor the brittle phases of AlFeSi. However, since Fe is a known impurity in aluminum smelting operations, a weight percent of up to 0.20 Fe is expected in some primary aluminum. In some embodiments, Fe is present in the cast alloy of this disclosure at a weight percent of 0.2, 0.19, 0.18, 0.17, 0.16, 0.15, 0.14, 0.13, 0.12, 0.11, or 0.10 or less. In some additional embodiments, Fe is present in the cast alloy at a weight percent of 0.10 or less. In some additional embodiments, the casting alloy of this disclosure may include Mn. Mn can be used, for example, to limit die welding during high-pressure casting operations. However, because the presence of Mn can be detrimental to the electrical conductivity of aluminum products comprising the cast aluminum alloy, when present, Mn is present in the casting alloy of this disclosure at a weight percent of no more than 0.65. In some embodiments, Mn is present in the casting alloy of this disclosure at a weight percent between about 0.45 and 0.65. In some embodiments, Mn is present in the casting alloy of this disclosure at a weight percent equal to or less than about 0.01.In some additional embodiments, the cast alloy of this disclosure may exclude Mn as an alloying element. In some additional embodiments, the cast aluminum alloy of this disclosure may include Ti. Ti can be used, for example, as a grain refiner. However, because the presence of Ti can be detrimental to the electrical conductivity of aluminum products comprising the cast aluminum alloy, when present, Ti is present in the alloy of QL / Qnn / Lznz / B / Yi smelting of this disclosure in a weight percent of not more than 0.12. In some embodiments, Ti is present in the smelting alloy of this disclosure in a weight percent between about 0.02 and 0.12. In some additional embodiments, Ti is present in the smelting alloy of this disclosure in a weight percent equal to or less than about 0.01. In some additional embodiments, the smelting alloy of this disclosure may exclude Ti as an alloying element. In some additional embodiments, the cast alloy of this disclosure may include V. V may be used, for example, to enhance the mechanical properties of a cast aluminum product comprising the cast aluminum alloy of this disclosure. However, because the presence of V can be detrimental to the electrical conductivity of aluminum products comprising the cast aluminum alloy, when present, V is present in the cast alloy of this disclosure at a weight percent of not more than 0.15. In some embodiments, V is present in the cast alloy of this disclosure at a weight percent between about 0.02 and 0.15. In some embodiments, V is present in the cast alloy of this disclosure at a weight percent equal to or less than about 0.01.In some additional embodiments, the cast alloy of this disclosure may exclude V as an alloying element. In some additional embodiments, the cast alloy of this disclosure may include Zr. Zr may be used, for example, to enhance the mechanical properties of a cast aluminum product comprising the cast aluminum alloy of this disclosure. Zr may be present in the cast alloy of this disclosure at a weight percent of not more than 0.15. In some embodiments, Zr is present in the cast alloy of this disclosure at a weight percent between about 0.01 and 0.15. In some additional embodiments, Zr is present in the cast alloy of this disclosure at a weight percent equal to or less than about 0.01. In some additional embodiments, the cast alloy of this disclosure may exclude Zr as an alloying element. In some additional embodiments, the cast alloy of this disclosure may include Mo. Mo may be used, for example, to enhance the mechanical properties of a cast aluminum product comprising the cast aluminum alloy of this disclosure. Mo may be present in the cast alloy of this disclosure at a weight percent of not more than 0.15. In some embodiments, Mo is present in the cast alloy of this disclosure at a weight percent between about 0.01 and 0.15. In some additional embodiments, Mo is present in the cast alloy of this disclosure at a weight percent equal to or less than about 0.01. In some additional embodiments, the cast alloy of this disclosure may exclude Mo as an alloying element. In some additional embodiments, the cast alloy of this disclosure may include Sr. Sr may be used, for example, to modify the structure of the cast aluminum alloy of this disclosure. Sr may be present in the cast alloy of this QL / Qnn / Lznz / E / Yii disclosure in a weight percent of not more than 0.02. In alternative embodiments, Sr may be a voluntary addition to the aluminum alloy. For example, Sr is present in the casting alloy of this disclosure in a weight percent between about 0.005 and 0.02. In the alloys of this disclosure, chromium (Cr) is not included as an alloying element in the cast alloy of this disclosure and, if detected, is present only as an impurity or trace element. The presence of Cr would be detrimental to the alloys of this disclosure because it impairs the electrical conductivity of the cast alloy. In some embodiments, Cr is present in the cast alloy of this disclosure at a weight percent equal to or less than (for example, up to) about 0.01. In the alloys of this disclosure, copper (Cu) is not included as an alloying element and, if detected, is present only as an impurity or trace element. The presence of Cu would be detrimental to the casting alloys of this disclosure because it is not inert with respect to the nickel (Ni) and magnesium (MgSi) particles in the casting alloy. The casting alloy of this disclosure excludes Cu as an alloying element. In some forms of the casting alloys of this disclosure, it is preferable to limit the Mn, Cr, Ti, and V content to preserve electrical conductivity. As such, the Mn, Cr, Ti, and V content may follow formula (II): %Mn + %Cr + %T¡ + %V < 0.025 (II) where %Mn is the weight percentage of Mn; %Cr is the percentage by weight of Cr; %T¡ is the weight percentage of Ti; and % V is the weight percentage of V. In embodiments where the casting alloy is intended for use in electrical applications or is required to have a specific electrical conductivity, the casting alloy may include boron (B) as an optional alloying element. B can be used, for example, to precipitate the titanium (Ti) and vanadium (V) content of the alloy. In some embodiments, the presence of B can improve the electrical conductivity by 1% IACS. A grain refiner, such as titanium, titanium boride, or titanium carbide, may be optionally included in the aluminum alloys of this disclosure to solidify the aluminum alloys with a fully equiaxed, fine-grained structure. In one embodiment, the grain refiner is in the form of Ti, TiB, or TiC. When TiB is used as a grain refiner, this may result in a boron content of up to 0.05 wt%. When TiC is used as a grain refiner, this may result in a carbon content of up to 0.01 wt%. The remainder of the aluminum alloy in this disclosure is aluminum (Al) and unavoidable impurities. In one embodiment, each impurity is present, by weight percent, at a maximum of about 0.03 and the total of unavoidable impurities is present, by weight percent, at less than about 0.10. The cast aluminum alloy described herein can be subjected to various QL / Qnn / Lznz / E / Yii Casting operations include, but are not limited to, high-pressure vacuum die casting (HPVDC) to produce a molten aluminum product. The presence of Ni in the molten aluminum alloy of this disclosure may increase the fluidity of the alloy (compared to a corresponding alloy lacking Ni), which, in turn, may enable casting operations (such as, for example, high-pressure die casting). In some embodiments, the presence of Ni in the molten aluminum alloy of this disclosure may reduce hot tearing and / or increase weld strength during high-pressure die casting operations (compared to a corresponding alloy lacking Ni). The cast aluminum alloys of this disclosure may be subjected to HPVDC operations to produce cast aluminum products. In one embodiment of this disclosure, cast aluminum products manufactured from the aluminum alloys of this disclosure by HPVDC exhibit ultimate tensile strength, yield strength, quality index, and / or percent elongation substantially similar to those of a corresponding aluminum product manufactured by HPVDC but with a control aluminum alloy (for example, an A365.1 alloy), as well as increased electrical conductivity compared to the control alloy. This disclosure also provides a process for manufacturing an aluminum product comprising the cast aluminum alloy described herein. The process comprises working the aluminum alloy or modified aluminum alloy described herein, or the cast ingot described herein, into the aluminum product. The working step may include casting the aluminum alloy directly into a cast product or intermediate ingots intended for remelting. As such, in the context of this disclosure, the term "aluminum product" may refer to a final cast product (such as a rotor, for example) or to an intermediate ingot that can be remelted into a differently shaped aluminum product. In embodiments where the aluminum product is a cast product, the process may also exclude any post-casting treatment (e.g., it may be provided as cast or tempered).Alternatively, the process may include post-casting heat treatment, such as T5, T6, or T7 (e.g., solution heat treatment and artificial aging stages). In cases where the aluminum product is a casting, this casting may be an automotive part, such as a chassis or rotor. In some forms, when the cast aluminum product is not subjected to post-casting heat treatment and is in an F temper, the cast aluminum product may have a quality index of at least approximately 185 MPa. Also in this form, the cast aluminum product may have a quality index of at least approximately 185, 190, 195, or 200 MPa. Also in this form, the cast aluminum product may have a yield strength of at least approximately 75, 80, 85, 90, 95, or 100 MPa. Also in this form, the cast aluminum product may have a UTS (Ultra-Surface Strength) of at least approximately 200, 205, 210, 215, or 220 MPa. Also in this form, the cast aluminum product may have an elongation of at least approximately 6.5, 7, 7.5, or 8%. In some additional forms, when the molten aluminum product is subjected to a QL / Qnn / Lznz / E / Yi temper T5 has a quality index of at least approximately 195, 200, 205, 210, 215, 220, 225, 230, 235, 240, 245, 250 or 255 MPa. In a form where the T5 temper includes artificial aging at 210 °C for 1 h, it has a quality index of at least approximately 195, 200, 205, 210, 215, 220, 225, 230, 235, 240, 245, 250 or 255 MPa. In this configuration, the cast aluminum product may have a UTS of at least approximately 220, 225, 230, 235, 240, or 245 MPa. Also in this configuration, the cast aluminum product may have a yield strength of at least approximately 130, 135, 140, 145, 150, or 155. Also in this configuration, the cast aluminum product may have an elongation of at least approximately 5, 5.5, or 6%. In some additional forms, when the cast aluminum product is subjected to a T6 temper, it has a quality index of at least around 155, 160, 165, 170, 175, 180, 185, 190, 195, 200, 205, 210, 215, 220, 225, 230, 235, 240, 245, 250, 255, 260, 265, 270, 275, 280, 285, 290, 295, 300, 305, 310 or 315 MPa. In additional embodiments, the T6 tempered cast aluminum product has a yield strength of at least approximately 190, 195, 200, 205, 210, 215, 220, 225, 230, 235, 240, or 245 MPa. In other embodiments, the T6 tempered cast aluminum product has a UTS (Ultra-Stepping Tensile Strength) of at least approximately 250, 255, 260, 265, 270, 275, or 280 MPa. In other embodiments, the T6 tempered aluminum product has an elongation of at least approximately 5.5, 6, 6.5, or 7%.In the modality where the T6 tempering includes a solution heat treatment at 460 °C for 1 h, air quenching at a rate of 5 °C / s followed by 12 hours of natural aging at room temperature and artificial aging at 185 °C for 2.5 h, the cast aluminum product may have a quality index of at least 155, 160, 165, 170, 175, 180, 185, 190, 195, 200, 205, 210, 215, 220, 225, 230, 235, 240, 245, 250, 255, 260, 265, 270, 275, 280, 285, 290, 295 or 300 MPa. In the modality where the T6 tempering includes a solution heat treatment at 500 °C for 1 h, air cooling at a rate of 5 °C / s followed by 12 hours of natural aging at room temperature and artificial aging at 185 °C for 2.5 h, the cast aluminum product may have a quality index of at least 215, 220, 225, 230, 235, 240, 245, 250, 255, 260, 265, 270, 275, 280, 285, 290, 295 or 300 MPa. In some additional forms, the electrical conductivity of an aluminum product in T6 temper is at least 40%, 41%, 42%, 43%, 44% or 45% of IACS. The present invention will be more easily understood by reference to the following examples, which are given to illustrate the invention rather than limit its scope. Examples EXAMPLE I: REDUCTION OF HOT TEAR Three alloys were selected based on their potential to exhibit a eutectic reaction (calculated using Thermocalc): Al-Fe, Al-Ni, and Al-Fe-Ni. As can be seen in their phase diagrams (Thermocalc software, TCAL5 database), all three systems exhibit a eutectic reaction, which is understood to increase fluidity and limit hot tearing. Schell solidification curves, also determined using Thermocalc, were plotted in the eutectic chemistry for the three systems and are presented in Figure 1. Due to their eutectic reactions, all three systems lower the solidus temperature of the aluminum. The low solidus temperature and eutectic solidification are expected to provide good fluidity. Regarding hot tearing, all three alloy systems exhibit relatively small solidification ranges (5 to 50 °C) and flat solidification curves between 87 and 94% solids. As such, low sensitivity to hot tearing is predicted. Finally, the pressure weldability trends were considered favorable for high-pressure die casting in light of the temary diagram (Mondolfo LF, Aluminium Alloys Structure & Properties, 1976, p. 532) and observations made during casting tests. From these experiments, it is understood that above 2% nickel, a ternary iron intermetallic compound will form on the die surface, thus reducing die weldability. EXAMPLE II - CHARACTERIZATION OF ALLOYS COMPRISING NI The Al-Ni-Mg-Si alloys (see chemistry in Table 1) were cast on a 250-ton Buhler machine. Before casting, each variant was degassed using argon for 20 minutes. Fluxing was performed once daily (once every two alloys) using Promag SI at a rate of 0.5 g of salt per kg of aluminum. Table 1. Alloy chemistry. The presence of traces of Ti, B and V in these alloys was also determined. QL / Qnn / Lznz / E / Yi; Lilili Alloy Mg Ni Iltlllí Mn A Ti IBIIIIII: mlllll AINi2Si0.15Mg0.15 0.16 0.13 2.0 0.09 0.01 0.052 0.0002 0.010 AINÍ2Si0.15Mg0.3 0.16 0.27 2.0 0.09 0.01 0.055 0.0001 0.010 AIN2Si0.3Mg0.3 0.32 0.27 1.9 0.09 0.01 0.054 0.0003 0.010 AIN2S¡0.3Mg0.6 0.32 0.58 1.9 0.09 0.01 0.060 0.0001 0.010 AINi2SiO.3MgO.6Mn 0.29 0.59 1.8 0.09 0.69 0.055 0.0003 0.011 AINi2SiO.3MgO.6MnB 0.29 0.56 1.8 0.09 0.68 0.006 0.0083 0.001 AINi2Si0.5Mg0.5 0.45 0.48 2.1 0.09 <0.01 0.049 0.0004 0.010 AINÍ2Si0.9Mg0.8 0.75 0.71 2.1 0.10 <0.01 0.048 0.0001 0.010 AINI2SI1.1 Mg1 1.05 1.01 2.1 0.10 <0.01 0.044 0.0000 0.010 AINI2S¡1.5Mg1.5 1.62 1.56 2.0 0.11 <0.01 0.043 0.0000 0.010 The newly cast plates underwent one week of natural aging at room temperature before mechanical testing or heat treatment. Two distinct heat treatments were performed: artificial aging at 210 °C for 1 h (T5 temper) and solution heat treatment at 500 °C for 1 h, air quenching at a rate of 5 °C / s followed by 12 hours of natural aging at room temperature and artificial aging at 185 °C for 2.5 h (T5 temper). T6). Full-size ASTM E8 flat tension bars were cut from the plates after heat treatment. As shown in Figure 2, in the freshly cast state, A365.1 provides the best combination of strength and ductility. For the other alloys, incremental amounts of magnesium and silicon gradually increased strength while decreasing ductility. Figure 3 illustrates the impact of silicon and magnesium on the alloy's strength and ductility. The mechanical properties in the T5 temper show the same trend as in the freshly cast temper. The incremental amount of magnesium and silicon gradually increases strength while reducing ductility (Figure 4). The reduction in ductility is explained by the presence of Mg₂Si constituents that form during solidification. Figures 5 and 6 show the progression of Mg₂Si in the freshly cast structure of the alloy Al₂Si₀.15Mg₀.15 to Al₂Si₀.3Mg₀.6 (the Mg₂Si appears dark black). As shown in Figure 7, A365.1 still provides the best mechanical properties in the T6 temper. However, the AlNi2Si0.3Mg0.6 alloy provides mechanical properties almost equivalent to those of A365.1. The incremental amount of magnesium and silicon gradually increases strength while reducing ductility. Figure 8 shows the impact of silicon and magnesium on strength and ductility in the T6 temper. Heat treatment of the solution at 500 °C for 1 hour allowed the dissolution of most of the Mg2Si constituents. At a magnesium level above 0.5%, some Mg2Si is still visible in the microstructure as seen in Figures 9 to 15. Considering only mechanical properties, A365.1 remains the highest-performing alloy. However, 6xxx series alloys can provide similar mechanical properties to A365.1 with a more dilute chemistry, resulting in higher electrical conductivity. Measured electrical conductivities are presented in Table 2. Two variants of A365.1 were used for comparison: A365.1A (0.31% Mg) and A365.1B (0.79% Mg). The impact of magnesium and silicon content on electrical conductivity is shown in Figures 16 and 17. Table 2. Electrical conductivity of the tested alloys. Ρί / οπη / ίζηζ / Ε / γι Alloy Temper Electrical Conductivity (% IACS) A365.1A T6 39.8 A365.1B 39.5 AINi2Si0.15Mg0.15 51.7 AINi2Si0.15Mg0.3 49.7 AINi2Si0.3Mg0.3 49.7 AINi2Si0.3Mg0.6 47.8 AINi2SiO.3MgO.6Mn 30.5 AINi2SiO.3MgO.6MnB 31.3 AINi2Si0.5Mg0.5 46.3 Alloy Temper Electrical Conductivity (% IACS) AINi2Si0.9Mg0.8 46.2 αί / οηη / ίζηζ / Ε / γι The magnesium content of A365.1 used for mechanical property measurement falls between that of A365.1A and A365.1B. Therefore, the electrical conductivity of A365.1 would be between 39.5 and 39.8% IACS. Due to the high silicon content of A365.1 alloys and the need for manganese to prevent die welding, the electrical conductivity of A365.1 alloys is much lower than that of the tested alloys. Therefore, the alloy Al₂S₀.3Mg₀.6, which provides similar mechanical properties to A365.1 but much higher electrical conductivity, would be suitable for high-strength, high-electrical-conductivity applications. Electrical conductivity follows an inverse relationship with magnesium and silicon content, as well as with the yield strength. Electrical conductivity decreases in aluminum with increasing alloying elements. Therefore, the most dilute variant provides the highest electrical conductivity but the lowest resistance. The addition of manganese drastically reduces the electrical conductivity of the alloy. Therefore, its use is not recommended for die welding, both due to its mechanical properties and its electrical conductivity. Boron can be used to precipitate the titanium and vanadium content of the alloy. In some formulations, boron treatment can improve electrical conductivity by 1% IACS. EXAMPLE III - EFFECTS OF HEAT TREATMENT OF THE SOLUTION The remaining plates were used as melts from Example II in a 250-t Buhler machine to further study the impact of solution heat treatment on the mechanical and electrical properties of the 6xxx series alloys in Table 3. Table 3. Alloy chemistry. Mg Alloy AINi2S¡0.15Mg0.3 0.16 0.27 2.0 0.009 0.01 0.055 1x1 o-4 0.010 408 AIN¡2Si0.3Mg0.3 0.32 0.27 2.0 0.009 0.01 0.054 3x104 0.010 431 AINi2S¡0.3Mg0.6 0.32 0.58 1.9 0.009 0.01 0.060 1x10-4 0.010 480 AIN¡2S¡0.5Mg0.5 0.45 0.48 2.1 0.009 <0.01 0.049 4x10'4 0.010 480 AIN¡2S¡0.9Mg0.8 0.75 0.71 2.1 0.010 <0.01 0.048 1x10'4 0.010 527 As shown in Figures 18 and 19, a solution heat treatment at 500 °C for 1 h, cooled in air at a rate of 5 °C / s, followed by 12 h of natural aging at room temperature and artificial aging at 185 °C for 2.5 h (T6 tempering), was insufficient to completely dissolve all the Mg₂S₂ formed during solidification. Therefore, a solution heat treatment at 500 °C for 2 h was performed while maintaining the same cooling and aging cycle (Figures 18 and 19). A longer solution heat treatment had a positive impact on all the tested alloys. The yield strength was improved from 15 to 25 MPa without affecting the elongation. Furthermore, the impact of solution heat treatment time on electrical conductivity is shown in Figure 20. A longer solution heat treatment had no statistically significant impact on the electrical conductivity of all the tested alloys except the Al₂S₀.9Mg₀.8 alloy. Therefore, a longer solution heat treatment would be favored to increase strength without affecting electrical conductivity. EXAMPLE IV - EFFECT OF NICKEL CONTENT Based on the Al-Ni phase diagram and die-casting tests (Example I), it was determined that good die-weld resistance can be achieved above 2% nickel. The 6xxx series alloys presented in Table 3 contain sufficient nickel to prevent die-weld, but low enough to reduce cost. However, the nickel content can be increased if greater fluidity or die-weld resistance is required. Alloys with higher nickel content were cast to confirm that nickel does not interfere with Mg₂Si precipitation. The alloy chemistries are presented in Table 4. οί / οηη / ίζηζ / Ε / γι Table 4. Alloy chemistries. Alloy lllilll llillii Ni ililllii wiiiiii illlilll AINi2S¡0.3Mg0.6 0.32 0.58 1.9 0.09 0.01 0.060 1x1 o-4 0.010 AIN¡2.5S¡0.3Mg0.6 0.30 0.64 2.4 0.09 <0.01 0.048 5x10-4 0.011 AIN¡3S¡0.3Mg0.6 0.34 0.68 2.9 0.09 <0.01 0.050 5x104 0.011 AIN¡3.5S¡0.3Mg0.6 0.33 0.76 3.5 0.09 <0.01 0.057 4x104 0.011 The mechanical properties of the alloys in Table 4 are presented in Figures 21 to 23. In temper F (Figure 21), strength increased while elongation decreased from the AlNi2Si0.3Mg0.6 alloy to the AlNi3.5Si0.3Mg0.6 alloy. The change in mechanical properties may be associated with the increase in nickel content, but also with the increase in magnesium content. The yield strength increased from 10 to 15 MPa for every 0.5% increase in Ni between the 2% and 3% nickel alloys. Mechanical properties stabilized between the 3% and 3.5% nickel alloys. A similar pattern was observed in the T5 temper (Figure 22). The strength increase was between 15 and 20 MPa for each 0.5% increase in Ni between the 2% and 3% nickel alloys, and the mechanical properties stabilized between the 3% and 3.5% nickel alloys. In the T6 temper (Figure 23), the strength increased by 40 MPa from the AlNi2Si0.3Mg0.6 alloy to the AlNi3Si0.3Mg0.6 alloy. However, the elongation was stable. Therefore, a higher nickel content had no impact on the ductility of the alloy in the T6 temper. The reduced ductility observed in tempers F and T5, and the stable ductility in temper T6, could be explained by the eutectic morphology of the nickel. Without intending to impose any theory, it is believed that during solution heat treatment, the sharp Al-Ni particles from temper F become spheroidized. This could improve ductility, as seen in Figures 24 and 25. Therefore, the nickel can be adapted to the die welding and the fluidity required for the application. The impact of nickel content on electrical conductivity, in the T6 temper (500 °C-1h, 185 °C-2.5h), is shown in Figure 26. From 2 to 3% nickel, the electrical conductivity does not change statistically. EXAMPLE V - HOT WEAR TEST The 6xx series alloys are not currently used in the foundry industry due to their high hot tearing potential. To optimize 6xx + Ni alloys, hot tearing tests were performed on a Buhler high-pressure die casting press. A specific mold, as shown in Figure 27, was designed to quantify hot tearing during mold hot tearing in high-pressure vacuum casting (HPVDC). The mold contains four thin sections surrounded by risers. The bar lengths are 50, 100, 150, and 200 mm. Each bar was inspected for cracks after casting according to four criteria: - position of the crack (near the lower elevator, near the lower elevator, in the elevator), - length of the crack (full, partial or fine crack), - severity of the crack (through thickness or not), and - presence or absence of cracks along the bar. Each crack was quantified using the parameters in Table 5. αί / οηη / ίζηζ / Ε / γι Table 5. Parameters for quantifying cracks Parameter Name Meaning B Near Lower Riser 1 H Near Upper Riser 1 M In Riser 1 DA Through Thickness 2 ND Not Through Thickness 1 C Complete 2 P Partial 1 TP Fine -1 FT Crack in Bar 0 Each bar is assigned a score calculated as follows. If a crack appears, it is given the score from Table 5. If there are no visible cracks for the specific parameter, it is given a score of 0. Then, the following calculations are performed using the following formulas. Cb= B(D + ND + C + P + TP) + H(D + ND + C + P + TP) + M “n” castings were produced. Therefore, an average value was calculated for each bar: QL / Qnn / Lznz / B / Yi Finally, an overall hot tear index was calculated for the alloy: V r - = \ «»c '•«««y / Where “b” is the rating assigned to the bars. The 50 mm bar has the highest “b” rating because a crack in the small section reveals a more critical level of sensitivity to hot tearing. The b ratings are summarized in Table 6 below. Table 6. b rating for each bar Bar length (mm) Rating b 200 1 150 2 100 3 50 4 The ternary alloys in Table 7 were characterized. The results are presented in Figure 28. Table 7. Chemistry of alloys characterized in the present example. Alloys ||ígl|:|||g|j|lggg||^ 2.0 0.15 0.15 0.30 0.60 1.20 0.30 0.15 0.30 0.60 1.20 0.60 0.15 0.30 0.60 1.20 1.20 0.15 0.30 0.60 1.20 A lower hot tear index (HTI) is beneficial, while alloys with a high HTI are prone to cracking during solidification. The HTI of the tested alloys ranged from 10 to 45. For magnesium content below 0.6%, the HTI increased with increasing silicon content, reaching a maximum between 0.3% and 0.6% Si. Higher silicon content (around 1.2%) reduced the HTI. For magnesium content above 0.6%, silicon content had less impact on the HTI. From Example III, the maximum strength was obtained for the alloys AlNi2Si0.3Mg0.6 and AlNi2Si0.5Mg0.5, where the silicon and magnesium content is around 1%. The optimum strength and electrical conductivity ratio were obtained with a Mg:Si ratio between 2:1 and 1:1. This ratio is related to the precipitation of MgSi and Mg2Si. However, these alloys exhibited a high hot tear index. From Figure 28, a higher magnesium content was more beneficial for improving the HTI than a higher silicon content. For example, for the alloy AlNi2Si0.3Mg0.6, the HTI was 30–35. Increasing the Mg content to 1.2% reduced the HTI drastically to 10–15. An increase in silicon content to 1.2% would have reduced the HTI to only 25–30. Therefore, a high magnesium content is preferred for castability. However, magnesium will affect the alloy's electrical conductivity. Excess magnesium would reduce electrical conductivity by 5% (IACS, "Properties, Physical Metallurgy, and Phase Diagrams, Vol. 1, Aluminium," Van Horn, KR, ed., American Society for Metals, 1967, p. 174). Chemical optimization is necessary to obtain good castings while maintaining good electrical conductivity. These optimizations are performed based on the casting's morphology. Although the invention has been described in relation to specific embodiments thereof, it shall be understood that the scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.

Claims

A cast alloy comprising, in weight percent: between about 1.5 and about 6.5; Si between about 0.10 and 1.5; Mg between about 0.10 and about 3; Fe up to about 0.2; Mn up to about 0.65; Ti up to about 0.12; V up to about 0.15; Zr up to about 0.15; Mo up to about 0.15; Cr up to about 0.01; Sr up to about 0.02; the remainder being aluminum and unavoidable impurities.

2. The casting alloy according to claim 1 comprising more than about 2.0 Ni.

3. The casting alloy according to claim 1 or 2 comprising between about 2.5 and about 6.5 Ni.

4. The casting alloy according to claim 1 comprising between about 1.8 and about 3.0 Ni.

5. Casting alloy according to any of claims 1 to 4, comprising between 0.15 and 0.90 Si.

6. The casting alloy according to any of claims 1 to 5 comprising from about 0.3 to about 0.75 Si.

7. The cast alloy according to any of claims 1 to 6 comprising Mg in a weight percent determined by formula (I): %Mg < -1.218*ln(%Si) + 0.89 (I) where % Mg is the weight percent of Mg; and % Si is the weight percent of Si.

8. The cast alloy according to any of claims 1 to 7 comprising from about 0.15 to about 1.8 Mg.

9. The cast alloy according to any of claims 1 to 8 comprising from about 0.30 to about 1.0 Mg.

10. The cast alloy according to any of claims 1 to 9 comprising up to about 0.10 Fe.

11. The casting alloy according to any of claims 1 to 10 comprising from about 0.45 to about 0.65 Mn.

12. The cast alloy according to any of claims 1 to 10 comprising up to about 0.01 Mn.

13. The casting alloy according to any of claims 1 to 12 comprising from about 0.02 to about 0.12 Ti.

14. The casting alloy according to any one of 1 to 12 comprises up to about 0.01 Ti. QL / Qnn / Lznz / E / Yi 15. The casting alloy according to any of claims 1 to 14 comprising between about 0.01 and about 0.15 V.

16. The cast alloy according to any of claims 1 to 14 comprising up to about 0.01 V.

17. The casting alloy according to any of claims 1 to 16 comprising from about 0.01 to about 0.15 Zr.

18. The casting alloy according to any of claim 1 comprises up to about 0.01 Zr.

19. The casting alloy according to any of claim 1 comprises between about 0.01 and about 0.15 Mo.

20. The cast alloy according to any of claim 1 comprises up to about 0.01 Mo.

21. The casting alloy according to any of claim 1 comprises between about 0.005 and about 0.02 Sr.

22. The cast alloy according to any of claims 1 to 16, 18, 20, and 21 comprising Mn, Cr, Ti, and V in a weight percent determined by formula (II): %Mn + %Cr + %Ti + %V < 0.025 (II) where %Mn is the weight percent of Mn; %Cr is the weight percent of Cr; %Ti is the weight percent of Ti; and %V is the weight percent of V.

23. The cast alloy according to any of claims 1 to 22, comprising an excess of Mg over a weight percent ratio of Mg:Si of more than about 2:

1.

24. A process for improving at least one casting property of a first aluminum alloy for manufacturing a first aluminum product compared to a cast aluminum alloy for manufacturing a cast aluminum product, the process comprising combining Ni with the first aluminum alloy to provide the cast aluminum alloy, wherein the first aluminum alloy comprises, in weight percent: Si from about 0.10 to 1.5; Mg from about 0.10 to about 3; Fe up to about 0.2; Mi, Ti, Zr, Mo, Cr, Sr up to about 0.65; up to about 0.12; up to about 0.15; up to about 0.15; up to about 0.15; up to about 0.01; up to about 0.02; and the remainder aluminum and unavoidable impurities; wherein the modified aluminum alloy comprises from about 1.5 to about 6.5 Ni.

25. The process according to claim 24, wherein at least one casting property is an increase in fluidity during casting.

26. The process according to claim 24 or 25, wherein the casting property is a reduction in hot tearing or an increase in vacuum die casting strength.

27. The process according to any of the modified aluminum claims 24 comprises at least about 2.0 Ni.

28. The process according to any of claims 24 of modified aluminum comprises between about 2.5 and about 6.5 Ni.

29. The process according to any of claims 24 of modified aluminum comprises between about 1.8 and about 3.0 Ni.

30. The process according to any aluminum alloy comprises between 0.15 and 0.90 Si.

31. The process according to any aluminum alloy comprises between 0.3 and 0.75 Si.

32. The process according to any of the claims 24 of 26 is welding during the aluminum alloy 27, where the alloy 26, where the alloy 29, where 30, where 31, where the aluminum alloy comprises Mg in a weight percent determined by the formula (I): % Mg < -1.218 * In (% Si) + 0.89 (I) where % Mg is the weight percent of Mg; and % Si is the weight percent of Si.

33. The process according to any of claims 24 aluminum alloy comprises between about 0.15 and about 1.8 Mg.

34. The process according to any of claims 24 aluminum alloy comprises between about 0.30 and about 1.0 Mg.

35. The process according to any of claims 24 aluminum alloy comprises up to about 0.10 Fe.

36. The process according to any of claims 24 aluminum alloy comprises between about 0.45 and about 0.65 Mn.

37. The process according to any of claims 24 the first the first the first 32, wherein the first 33, wherein the first 34, wherein the first 35, wherein the first 36, wherein the first QL / Qnn / Lznz / E / Yi aluminum alloy comprises up to about 0.01 Mn.

38. The process according to any of claims 24 to 37, wherein the first aluminum alloy comprises from about 0.02 to about 0.12 Ti.

39. The process according to any of claims 24 to 37, wherein the first aluminum alloy comprises up to about 0.01 Ti.

40. The process according to any of claims 24 to 39, wherein the first aluminum alloy comprises between about 0.01 and about 0.15 V.

41. The process according to any of claims 24 to 39, wherein the first aluminum alloy comprises up to about 0.01 V.

42. The process according to any of claims 24 to 41, wherein the first aluminum alloy comprises between about 0.01 and about 0.15 Zr.

43. The process according to any of claims 24 to 41, wherein the first aluminum alloy comprises up to about 0.01 Zr.

44. The process according to any of claims 24 to 43, wherein the first aluminum alloy comprises from about 0.01 to about 0.15 Mo.

45. The process according to any of claims 24 to 43, wherein the first aluminum alloy comprises up to about 0.01 Mo.

46. ​​The process according to any of claims 24 to 45, wherein the first aluminum alloy comprises between about 0.005 and about 0.02 Sr.

47. The process according to any of claims 24 to 46, wherein the first aluminum alloy comprises Mn, Cr, Ti and V in a weight percent determined by formula (II): %Mn + %Cr + %Ti + %V < 0.025 (II) where %Mn is the weight percent of Mn; %Cr is the weight percent of Cr; %Ti is the weight percent of Ti; and %V is the weight percent of V.

48. The process according to any of claims 24 to 47, wherein the modified aluminum alloy comprises an excess of Mg over a weight percent ratio of Mg:S of more than about 2:

1.

49. A modified cast aluminum alloy manufactured from the process according to any of claims 24 to 48.

50. A process for manufacturing an aluminum casting product, comprising the process of melting the aluminum casting alloy according to any of claims 1 to 23 or the modified aluminum casting alloy according to claim 49 in a mold.

51. The process according to claim 50, further comprising subjecting the molten aluminum alloy or the molten aluminum alloy with modified dies to high-pressure vacuum die casting.

52. The process according to claim 50 or 51, further comprising a post-casting heat treatment stage QL / Qnn / Lznz / E / Yii.

53. The process according to claim 52, wherein the post-casting heat treatment is a T6 quench.

54. The process according to claim 52, wherein the post-casting heat treatment is a T5 quench.

55. An aluminum casting product comprising the aluminum casting alloy according to any of claims 1 to 22 or the modified aluminum casting alloy according to claim 49.

56. A cast aluminum product manufactured by the process according to any of claims 24 to 54.

57. The cast aluminum product according to claim 55 or 56 is electrically conductive.

58. The cast aluminum product according to any of claims 55 to 57 is a rotor.