Aluminum alloys for die casting and related methods for producing die-cast aluminum alloy parts

Abstract

Disclosed herein are aluminum alloys comprising recycled aluminum alloys for die casting large automotive parts. The aluminum alloy described herein can tolerate the addition of Zn and other alloying elements in the casting composition, thereby increasing the types and amounts of recycled aluminum alloy materials that can be used to produce the cast aluminum alloy product without deteriorating the performance of the product or its casting ability. The aluminum alloy can incorporate high amounts of unconventional recycled aluminum alloy materials (e.g., twitch scrap and heat exchanger scrap) to produce die-cast products.

Description

Attorney Docket No.108050-1471224 ALUMINUM ALLOYS FOR DIE CASTING AND RELATED METHODS FOR PRODUCING DIE-CAST ALUMINUM ALLOY PARTS CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No.63 / 627,417, filed January 31, 2024, which is hereby incorporated by reference in its entirety for all intents and purposes. FIELD

[0002] The present disclosure relates to aluminum alloys for die casting. More specifically, the present disclosure relates to aluminum alloys produced from a high amount of recycled aluminum alloy scrap for high pressure die casting that exhibits good strength, ductility, and castability for high-performance applications, for example, automobile parts. BACKGROUND

[0003] There is an increasing demand in the automotive industry for large aluminum alloy castings for structural components. For example, die-casting large aluminum alloy parts, commonly referred to as “gigacasting” or “megacasting”, is being investigated to produce structural parts to reduce cost, reduce complexity of assembly, and improve efficiency for vehicles. These parts may be cast quickly through a high pressure die casting process. The rising adoption of die-cast aluminum alloy parts for structural applications is primarily driven by the need to reduce vehicle weight, enhance vehicle range (fuel efficiency), and accommodate the growing demand for battery electric vehicles. Megacasting can theoretically slash per-unit manufacturing costs by eliminating various joints and associated joining technologies by casting one single part and by reducing complexity of assembling multiple parts.

[0004] However, there are many roadblocks in implementing megacasting technology. Commercial cast aluminum alloys for structural components generally require both high strength and good ductility. After casting, suitable alloys should maintain their structural properties sufficiently for the necessary application. However, poor castability of the alloy often results in observed hot tearing, and can cause die filling issues which typicallyAttorney Docket No.108050-1471224 decreases the mechanical properties of the part that results from the casting process. Additionally, die-cast aluminum alloys are typically not produced from recycled aluminum alloy materials that include high amounts of iron, manganese, and silicon content. Since these alloying elements are difficult to remove, their presence is predominantly limited to prevent or lower the contamination of scrap streams thereby limiting the amount of recycled aluminum alloy materials used to produce cast aluminum alloy products.

[0005] Therefore, current techniques of using recycled aluminum alloy materials to produce certain cast aluminum alloy products, especially those that must have material properties within certain specification limits, are either expensive in terms of time, space, and energy (e.g., removing impurities from liquid metal or extensive post-casting processing and treatments) or require the use of significant amounts of new materials (e.g., by diluting liquid metal with sufficient amounts of primary aluminum or alloying elements). SUMMARY

[0006] The term embodiment and like terms are intended to refer broadly to all of the subject matter of this disclosure and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the claims below. Embodiments of the present disclosure covered herein are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the disclosure and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this disclosure, any or all drawings, and each claim.

[0007] Described herein is a method of producing a cast product. The method includes providing an aluminum alloy melt including 6.00 wt. % to 10.00 wt. % Si, up to 0.50 wt. % Fe, up to 1.10 wt. % Cu, up to 1.00 wt. % Mn, up to 0.50 wt. % Mg, up to 0.90 wt. % Zn, up to 0.10 wt. % V, up to 0.20 wt. % Ti, up to 0.20 wt. % Cr, up to 0.25 wt. % Sr, up to 0.15 wt. % impurities, and the remainder Al, and casting the aluminum alloy melt in a mold to produce a cast product. In some embodiments, providing the aluminum alloy melt may include melting recycled aluminum alloy materials to produce the aluminum alloy melt. In some embodiments, the recycled aluminum alloy materials may include one or more of end-Attorney Docket No.108050-1471224 of life aluminum articles, mixed automotive scrap, twitch, Zorba scrap, used beverage can (UBC), extrusion scrap, used aluminum wheels, and heat exchanger scrap. In some embodiments, the twitch may include at least 0.25 wt. % Zn (e.g., from 0.25 wt. % to 1.20 wt. %). In some embodiments, the method may include adding an alloying element to the aluminum alloy melt, the alloying element may include one or more of Mg, Si, Cu, Mn or Sr.

[0008] In some embodiments, the aluminum alloy melt may include Zn in an amount of at least 0.10 wt. %. In some embodiments, the aluminum alloy melt may include Zn in an amount of at least 0.20 wt. %. In some embodiments, the cast product is an automotive part. In some embodiments, the cast product may exhibit a yield strength of at least 100 MPa. In some embodiments, the recycled aluminum alloy materials may include used automotive scrap may include a mixture of 5xxx and 6xxx series aluminum alloys. In some embodiments, the aluminum alloy melt may include at least 60 % recycled aluminum alloy materials. In some embodiments, the aluminum alloy melt may include at least 80 % recycled aluminum alloy materials. In some embodiments, a high pressure die cast product is produced from the aforementioned method.

[0009] In some embodiments, the present disclosure provides a high pressure die cast product comprising an aluminum alloy comprising 6.00 wt. % to 10.00 wt. % Si, up to 0.50 wt. % Fe, up to 1.10 wt. % Cu, up to 1.00 wt. % Mn, up to 0.50 wt. % Mg, up to 0.90 wt. % Zn, up to 0.10 wt. % V, up to 0.20 wt. % Ti, up to 0.20 wt. % Cr, up to 0.25 wt. % Sr, up to 0.15 wt. % impurities, and the remainder Al, wherein the high pressure die cast product is cast from an aluminum alloy melt comprising at least 50 % of recycled aluminum alloy materials. In some embodiments, the aluminum alloy comprises 6.50 wt. % to 7.50 wt. % Si, up to 0.40 wt. % Fe, up to 1.10 wt. % Cu, up to 0.90 wt. % Mn, up to 0.50 wt. % Mg, up to 0.80 wt. % Zn, up to 0.10 wt. % V, up to 0.20 wt. % Ti, up to 0.20 wt. % Cr, up to 0.25 wt. % Sr, up to 0.15 wt. % impurities, and the remainder Al. In some embodiments, the aluminum alloy comprises 6.50 wt. % to 7.50 wt. % Si, 0.10 wt. % to 0.40 wt. % Fe, 0.10 wt. % to 0.60 wt. % Cu, 0.40 wt. % to 0.60 wt. % Mn, 0.25 wt. % to 0.40 wt. % Mg, up to 0.80 wt. % Zn, up to 0.10 wt. % V, up to 0.15 wt. % Ti, up to 0.10 wt. % Cr, up to 0.25 wt. % Sr, up to 0.15 wt. % impurities, and the remainder Al. In some embodiments, the aluminum alloy melt is produced from at least 80% of the recycled aluminum alloy materials. In some embodiments, the recycled aluminum alloy materials may include one or more of end-of life aluminum articles, mixed automotive scrap, twitch, Zorba scrap, UBC, extrusion scrap, used aluminum wheels, and heat exchanger scrap. The high pressure die cast product may have a yield strength of at least 100 MPa. The high pressure die cast product may have an ultimate tensileAttorney Docket No.108050-1471224 strength of at least 210 MPa. The high pressure die cast product may comprise a total elongation of at least 2 %. BRIEF DESCRIPTION OF DRAWINGS

[0010] The specification makes reference to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components.

[0011] FIG.1 is a flowchart depicting a process for die casting an aluminum alloy from recycled aluminum alloy materials according to certain aspects of the present disclosure.

[0012] FIG.2A shows a histogram of the yield strength (MPa) (left bar) and ultimate tensile strength (MPa) (right bar) of the example alloys in the F temper.

[0013] FIG.2B shows a histogram of the yield strength (MPa) (left bar) and ultimate tensile strength (MPa) (right bar) of the example alloys after paint bake at 185° C for 20 minutes.

[0014] FIG.3A shows a histogram of the elongation (%) of the example alloys in the F temper.

[0015] FIG.3B shows a histogram of the elongation (%) values of the example alloys after paint bake at 185° C for 20 minutes.

[0016] FIG.4A shows a histogram of the VDA Bend Angle (°) values of the example alloys in the F temper.

[0017] FIG.4B shows a histogram of the VDA Bend Angle (°) values of the example alloys after paint bake at 185° C for 20 minutes.

[0018] FIG.5 shows a histogram of the maximum corrosion pit depth (µm) (left) and the average corrosion pit depth (µm) (right) of the example alloys subjected to the intergranular corrosion (IGC) test set forth in ISO 11846B (2024) for 24 hours.

[0019] FIG.6 shows the number of density of particles in the microstructure of the example alloys.

[0020] FIG.7 shows X-ray Tomography (XRT) images of the microstructure of the example alloys.

[0021] FIG.8 shows a graph of the fatigue performance of the example alloys in the paint bake temper.Attorney Docket No.108050-1471224 DETAILED DESCRIPTION

[0022] The present disclosure relates to aluminum alloys for die casting (e.g., high- pressure die casting) and methods of producing die-cast aluminum alloy parts (e.g., using rheocasting). In some embodiments, the die-cast aluminum alloy parts are produced from recycled aluminum alloy materials or scrap (e.g., end of life (EOL) aluminum alloy scrap). The recycled aluminum alloy scrap can be used to prepare cast aluminum alloy products having mechanical properties (e.g., strength and crash resistance) suitable for use in a variety of applications, such as for die casting automotive parts (e.g., front or rear underbody, shock towers). The aluminum alloys described herein can be used to produce die-cast automobile parts having complex geometries with good strength and ductility properties using high- pressure die casting. For example, the aluminum alloys can be used to die-cast structural automotive parts such as shock towers, underbody parts (e.g., rear end, front end, center floor), battery housing, C / D pillar stiffening castings, and door inners.

[0023] Conventional aluminum alloys for high-pressure die casting are generally not recycle friendly (e.g., cannot utilize recycled aluminum scrap to produce the aluminum alloy). For example, A356 aluminum alloy is commonly employed for producing high pressure die cast products because the alloy has good casting and machining performance suitable for use as structural castings that require high strength. A356 aluminum alloy is often used to manufacture intricate and complex aluminum castings, which provides lightweight, pressure tightness, and good mechanical properties; however, A356 aluminum alloy is a high- purity aluminum alloy which limits the amount of recycled aluminum materials used to produce the aluminum alloy. Therefore, very limited amounts of recycled aluminum alloy materials can be used to produce the aluminum alloy since it cannot tolerate alloying elements (e.g., Fe, Cu, and Zn) beyond a certain threshold without sacrificing mechanical properties and other attributes. For example, recycled aluminum alloy materials that include high amounts of Fe, Si, Cu and Zn cannot be used to produce A356 aluminum alloy.

[0024] The aluminum alloys described herein can be used to produce high pressure die- cast aluminum alloy products with good mechanical properties despite being produced from a high content of recycled aluminum alloy materials. Specifically, the aluminum alloys described herein have a carefully controlled composition based on specific ratios of recycled aluminum alloy materials that enable the use of high amounts of recycled aluminum alloy materials. In some embodiments, the aluminum alloy for producing die-cast aluminum alloy parts may comprise 6.00 wt. % to 8.00 wt. % Si, up to 0.50 wt. % Fe, up to 1.10 wt. % Cu, up to 1.00 wt. % Mn, up to 0.50 wt. % Mg, up to 0.90 wt. % Zn, up to 0.10 wt. % V, up to 0.20Attorney Docket No.108050-1471224 wt. % Ti, up to 0.20 wt. % Cr, up to 0.25 wt. % Sr, up to 0.15 wt. % impurities, and the remainder Al. Beneficially, the aluminum alloy described herein can tolerate the addition of Fe, Mn, Cu, Zn and other alloying elements in the casting composition, thereby increasing the types and amounts of recycled aluminum alloy materials that can be used to produce the cast aluminum alloy product without deteriorating the performance of the product or its casting ability. Therefore, the aluminum alloy can incorporate high amounts of unconventional recycled aluminum alloy materials (e.g., twitch scrap and heat exchanger scrap), making the cast product a more economical and sustainable solution to conventional casting alloys.

[0025] In some embodiments, a method of producing a cast product may include melting a mixture of recycled aluminum scrap to produce an aluminum alloy melt. In some embodiments, certain alloying elements can be added to the aluminum alloy melt prepared from the recycled aluminum scrap to produce a modified aluminum alloy melt. The aluminum alloy can be cast in a mold using, for example, high-pressure die casting. For example, the use of the aluminum alloy melt in a die can result in a cast alloy product with minimal risk of hot cracking during the casting process. In some cases, combining the casting with a subsequent heat treatment can produce a cast aluminum product having desirable mechanical properties. The concepts disclosed herein can allow inexpensive and recycled aluminum alloy materials to be efficiently repurposed for new applications, such as automotive parts. For example, a cast aluminum alloy product as disclosed herein can meet and / or exceed the specification requirements set by an original equipment manufacturer (OEM) for automotive underbody, shock towers, pillars, and other structural parts. The aluminum alloys described herein are particularly suitable for die casting structural automobile parts. For example, the aluminum alloys described herein can be used in megacasting processes to produce large automobile parts that are high-pressure die cast as a singular piece, decreasing production costs.

[0026] Definitions and Descriptions:

[0027] The terms “invention,” “the invention,” “this invention,” and “the present invention” used herein are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.

[0028] As used herein, the meaning of “a,” “an,” or “the” includes singular and plural references unless the context clearly dictates otherwise.Attorney Docket No.108050-1471224

[0029] In this description, reference is made to alloys identified by aluminum industry designations, such as “series” or “5xxx.” For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, see “International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys” or “Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot,” both published by The Aluminum Association.

[0030] Reference is made in this application to alloy temper or condition. For an understanding of the alloy temper descriptions most commonly used, see “American National Standards (ANSI) H35 on Alloy and Temper Designation Systems.” An F condition or temper refers to an aluminum alloy as fabricated. An O condition or temper refers to an aluminum alloy after annealing. An Hxx condition or temper, also referred to herein as an H temper, refers to a non-heat treatable aluminum alloy after cold rolling with or without thermal treatment (e.g., annealing). Suitable H tempers include HX1, HX2, HX3 HX4, HX5, HX6, HX7, HX8, or HX9 tempers. A T1 condition or temper refers to an aluminum alloy cooled from hot working and naturally aged (e.g., at room temperature). A T2 condition or temper refers to an aluminum alloy cooled from hot working, cold worked and naturally aged. A T3 condition or temper refers to an aluminum alloy solution heat treated, cold worked, and naturally aged. A T4 condition or temper refers to an aluminum alloy solution heat treated and naturally aged. A T5 condition or temper refers to an aluminum alloy cooled from hot working and artificially aged (at elevated temperatures). A T6 condition or temper refers to an aluminum alloy solution heat treated and artificially aged. A T7 condition or temper refers to an aluminum alloy solution heat treated and artificially overaged. A T8x condition or temper refers to an aluminum alloy solution heat treated, cold worked, and artificially aged. A T9 condition or temper refers to an aluminum alloy solution heat treated, artificially aged, and cold worked. A W condition or temper refers to an aluminum alloy after solution heat treatment.

[0031] As used herein, "twitch" refers to any fragmented aluminum scrap. Twitch may be produced by a float process whereby the scrap is immersed in water. The aluminum scrap floats to the top and heavier metal scrap pieces sink. For example, in some processes, sand may be mixed in to change the density of the water in which the scrap is immersed.

[0032] As used herein, the meaning of “room temperature” can include a temperature of from about 15 °C to about 30 °C, for example about 15 °C, about 16 °C, about 17 °C, aboutAttorney Docket No.108050-1471224 18 °C, about 19 °C, about 20 °C, about 21 °C, about 22 °C, about 23 °C, about 24 °C, about 25 °C, about 26 °C, about 27 °C, about 28 °C, about 29 °C, or about 30 °C.

[0033] As used herein, the term metal product can refer to any suitable shape or size of cast product, as appropriate.

[0034] All ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, e.g.1 to 6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10.

[0035] The following aluminum alloys are described in terms of their elemental composition in weight percentage (wt. %) based on the total weight of the alloy. In certain examples of each alloy, the remainder is aluminum, with a maximum wt. % of 0.15 % for the sum of the impurities.

[0036] As used herein, the terms recycled scrap (e.g., recycled stock) can refer to a collection of recycled metal. Recycled scrap can include materials recycled from any suitable source, such as from a metal production facility (e.g., metal casting facility), from a metalworking facility (e.g., production facility that uses metal product to create consumable products), or from post-consumer sources (e.g., regional recycling facilities) including end- of-life scrap (e.g., from automobiles or other transportation vehicles). Certain aspects of the present disclosure can be well-suited for recycled scrap from sources other than a metal production facility, since such recycled scrap likely contains a mixture of alloys or is mixed with other impurities or elements (e.g., such as paints or coatings). Recycled scrap can refer to recycled aluminum, such as recycled sheet aluminum products (e.g., aluminum pots and pans), recycled cast aluminum products (e.g., aluminum grills and wheel rims), UBC scrap (e.g., used beverage cans), aluminum wire, extrusion scrap, used aluminum wheels, and heat exchanger scrap, and other aluminum materials.

[0037] Aluminum Alloys

[0038] Described herein are aluminum alloys prepared from recycled aluminum alloy materials. For example, the techniques disclosed herein can allow suitable die cast products to be produced from an aluminum alloy melt containing at or more than about 50%, about 60%, about 70%, about 80%, about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about 98%, or about 99% recycled aluminum alloy materials. In other words, the die cast products described herein can include at or less thanAttorney Docket No.108050-1471224 about 20%, about 15%, about 10%, about 9%, about 8%, about 7%, about 6%, about 5%, about 4%, about 3%, about 2%, or about 1% primary aluminum. Certain aspects of the present disclosure relate to cast aluminum alloy products made using an aluminum alloy melt that is mostly recycled scrap.

[0039] The aluminum alloys described herein are produced with a high content of recycled scrap. In some embodiments, recycled scrap from a metal casting facility (e.g., internal scrap or run-around scrap) or metalworking facility (e.g., segregated automotive scrap) may account for a majority of the recycled scrap content. For example, recycled scrap from a metal casting facility or metalworking facility may account for up to 95 % of the recycled scrap content. The recycled scrap recovered from a metal casting facility or a metalworking facility (e.g., segregated automotive scrap) are high performance aluminum alloys that have consistent compositions and mechanical properties.

[0040] The recycled scrap may include mixed alloy scrap (e.g., automotive scrap containing one or more of 5xxx, 6xxx, and / or 7xxx series aluminum alloys). In some aspects, the recycled scrap comprises one or more of end-of life aluminum articles, mixed automotive scrap, twitch, Zorba scrap, UBC, extrusion scrap, used aluminum wheels, and heat exchanger scrap (e.g., Hex scrap). In some aspects, the recycled scrap comprises the end-of-life aluminum articles and wherein the end-of life aluminum articles are derived from aluminum-intensive vehicles. In some aspects, the recycled scrap comprises 100 % of scrap derived from the end-of-life aluminum articles. In some aspects, the recycled scrap comprises the heat exchanger scrap and wherein the heat exchanger scrap comprises braze alloy scrap. In some aspects, the recycle scrap comprises the mixed automotive scrap and the mixed automotive scrap comprises recycled scrap from wrought alloys and cast alloys. In some aspects, the aluminum alloy comprises up to 25 % primary aluminum alloy.

[0041] The recycled scrap may include a mixtures of alloys. These mixtures of alloys, when melted, result in an alloy composition that can be difficult to die cast and can result in undesirable mechanical characteristics in a resulting product. Further, recycled scrap can contain other impurities and alloying elements, which end up in the liquid metal when the recycled scrap is melted. High concentrations of impurities and alloying elements in the liquid metal can result in casting problems, including hot cracking, element control issues (particularly for iron, manganese, and silicon), centerline segregation, porosity, and other issues. The concentrations of these impurities and alloying elements can be lowered byAttorney Docket No.108050-1471224 processing the liquid metal (e.g., thermally, chemically, magnetically, and / or electrically) to remove impurities or alloying elements, and / or by adding new alloying elements to the melt.

[0042] Optionally, the recycled scrap can be modified with one or more additional elements to prepare the recycled content alloys. In some examples, it can be desirable to add strontium (Sr) or Cerium (Ce) to the aluminum alloy melt. Sr or Ce can be added to the aluminum alloy melt as a modifying agent that promotes rounded intermetallics in the as-cast microstructure of the aluminum alloy which are desirable over the plate-like intermetallics. The plate-like intermetallics degrades mechanical performance, for example, the toughness of the aluminum alloy.

[0043] The aluminum alloys described herein may be used in a die-casting operation, and is particularly suitable for use in thixocasting and rheocasting operations.

[0044] In some examples, the aluminum alloys described herein can have the following elemental composition as provided in Table 1. Table 1

[0045] In some examples, the aluminum alloys described herein can have the following elemental composition as provided in Table 2.Attorney Docket No.108050-1471224 Table 2

[0046] In some examples, the aluminum alloys described herein can have the following elemental composition as provided in Table 3. Table 3Attorney Docket No.108050-1471224

[0047] In some examples, the aluminum alloys described herein can have the following elemental composition as provided in Table 4. Table 4

[0048] In some examples, the aluminum alloys described herein can have the following elemental composition as provided in Table 5. Table 5Attorney Docket No.108050-1471224

[0049] In some examples, the aluminum alloys described herein can have the following elemental composition as provided in Table 6. Table 6

[0050] In some examples, the aluminum alloys described herein can have the following elemental composition as provided in Table 7. Table 7Attorney Docket No.108050-1471224

[0051] In some examples, the aluminum alloys described herein can have the following elemental composition as provided in Table 8. Table 8

[0052] In some examples, the aluminum alloys described herein can have the following elemental composition as provided in Table 9. Table 9Attorney Docket No.108050-1471224

[0053] In some examples, the aluminum alloys described herein can have the following elemental composition as provided in Table 10. Table 10

[0054] In some examples, the aluminum alloys described herein can have the following elemental composition as provided in Table 11.Attorney Docket No.108050-1471224 Table 11

[0055] In some examples, the aluminum alloys described herein can have the following elemental composition as provided in Table 12. Table 12Attorney Docket No.108050-1471224

[0056] In some examples, the alloys described herein include Si in an amount from about 6.00 % to about 10.00 % (e.g., from about 6.00 % to about 9.00 %, from about 6.00 % to about 8.00 %, from about 6.25 % to about 7.75 %, from about 6.50 % to about 7.50 %, from about 6.50 % to about 7.00 %, from about 6.50 % to about 6.75 %, from about 7.00 % to about 7.50 %, or from about 7.25 % to about 7.50 %) based on the total weight of the alloy. For example, the alloy can include 6.00 %, 6.01 %, 6.02 %, 6.03 %, 6.04 %, 6.05 %, 6.06 %, 6.07 %, 6.08 %, 6.09 %, 6.10 %, 6.11 %, 6.12 %, 6.13 %, 6.14 %, 6.15 %, 6.16 %, 6.17 %, 6.18 %, 6.19 %, 6.20 %, 6.21 %, 6.22 %, 6.23 %, 6.24 %, 6.25 %, 6.26 %, 6.27 %, 6.28 %, 6.29 %, 6.30 %, 6.31 %, 6.32 %, 033 %, 6.34 %, 6.35 %, 6.36 %, 6.37 %, 6.38 %, 6.39 %, 6.40 %, 6.41 %, 6.42 %, 6.43 %, 6.44 %, 6.45 %, 6.46 %, 6.47 %, 6.48 %, 6.49 %, 6.50 %, 6.51 %, 6.52 %, 6.53 %, 6.54 %, 6.55 %, 6.56 %, 6.57 %, 6.58 %, 6.59 %, 6.60 %, 6.61 %, 6.62 %, 6.63 %, 6.64 %, 6.65 %, 6.66 %, 6.67 %, 6.68 %, 6.69 %, 6.70 %, 6.71 %, 6.72 %, 6.73 %, 6.74 %, 6.75 %, 6.76 %, 6.77 %, 6.78 %, 6.79 %, 6.80 %, 6.81 %, 6.82 %, 6.83 %, 6.84 %, 6.85 %, 6.86 %, 6.87 %, 6.88 %, 6.89 %, 6.90 %, 6.91 %, 6.92 %, 6.93 %, 6.94 %, 6.95 %, 6.96 %, 6.97 %, 6.98 %, 6.99 %, 7.00 %, 7.01 %, 7.02 %, 7.03 %, 7.04 %, 7.05 %, 7.06 %, 7.07 %, 7.08 %, 7.09 %, 7.10 %, 7.11 %, 7.12 %, 7.13 %, 7.14 %, 7.15 %, 7.16 %, 7.17 %, 7.18 %, 7.19 %, 7.20 %, 7.21 %, 7.22 %, 7.23 %, 7.24 %, 7.25 %, 7.26 %, 7.27 %, 7.28 %, 7.29 %, 7.30 %, 7.31 %, 7.32 %, 033 %, 7.34 %, 7.35 %, 7.36 %, 7.37 %, 7.38 %, 7.39 %, 7.40 %, 7.41 %, 7.42 %, 7.43 %, 7.44 %, 7.45 %, 7.46 %, 7.47 %, 7.48 %, 7.49 %, 7.50 %, 7.51 %, 7.52 %, 7.53 %, 7.54 %, 7.55 %, 7.56 %, 7.57 %, 7.58 %, 7.59 %, 7.60 %, 7.61 %, 7.62 %, 7.63 %, 7.64 %, 7.65 %, 7.66 %, 7.67 %, 7.68 %, 7.69 %, 7.70 %, 7.71 %, 7.72 %, 7.73 %, 7.74 %, 7.75 %, 7.76 %, 7.77 %, 7.78 %, 7.79 %, 7.80 %, 7.81 %, 7.82 %, 7.83 %, 7.84 %, 7.85 %, 7.86 %, 7.87 %, 7.88 %, 7.89 %, 7.90 %, 7.91 %, 7.92 %, 7.93 %, 7.94 %, 7.95 %, 7.96 %, 7.97 %, 7.98 %, 7.99 %, 8.00 %, 8.01 %, 8.02 %, 8.03 %, 8.04 %, 8.05 %, 8.06 %, 8.07 %, 8.08 %, 8.09 %, 8.10 %, 8.11 %, 8.12 %, 8.13 %, 8.14 %, 8.15 %, 8.16 %, 8.17 %, 8.18 %, 8.19 %, 8.20 %, 8.21 %, 8.22 %, 8.23 %, 8.24 %, 8.25 %, 8.26 %, 8.27 %, 8.28 %, 8.29 %, 8.30 %, 8.31 %, 8.32 %, 033 %, 8.34 %, 8.35 %, 8.36 %, 8.37 %, 8.38 %, 8.39 %, 8.40 %, 8.41 %, 8.42 %, 8.43 %, 8.44 %, 8.45 %, 8.46 %, 8.47 %, 8.48 %, 8.49 %, 8.50 %, 8.51 %, 8.52 %, 8.53 %, 8.54 %, 8.55 %, 8.56 %, 8.57 %, 8.58 %, 8.59 %, 8.60 %, 8.61 %, 8.62 %, 8.63 %, 8.64 %, 8.65 %, 8.66 %, 8.67 %, 8.68 %, 8.69 %, 8.70 %, 8.71 %, 8.72 %, 8.73 %, 8.74 %, 8.75 %, 8.76 %, 8.77 %, 8.78 %, 8.79 %, 8.80 %, 8.81 %, 8.82 %, 8.83 %, 8.84 %, 8.85 %, 8.86 %, 8.87 %, 8.88 %, 8.89 %, 8.90 %, 8.91 %, 8.92 %, 8.93 %, 8.94 %, 8.95 %, 8.96 %, 8.97 %, 8.98 %, 8.99 %, 9.00 %, 9.01 %, 9.02 %, 9.03 %, 9.04 %, 9.05 %, 9.06 %, 9.07 %, 9.08 %, 9.09 %, 9.10 %, 9.11 %, 9.12 %, 9.13 %, 9.14 %,Attorney Docket No.108050-1471224 9.15 %, 9.16 %, 9.17 %, 9.18 %, 9.19 %, 9.20 %, 9.21 %, 9.22 %, 9.23 %, 9.24 %, 9.25 %, 9.26 %, 9.27 %, 9.28 %, 9.29 %, 9.30 %, 9.31 %, 9.32 %, 033 %, 9.34 %, 9.35 %, 9.36 %, 9.37 %, 9.38 %, 9.39 %, 9.40 %, 9.41 %, 9.42 %, 9.43 %, 9.44 %, 9.45 %, 9.46 %, 9.47 %, 9.48 %, 9.49 %, 9.50 %, 9.51 %, 9.52 %, 9.53 %, 9.54 %, 9.55 %, 9.56 %, 9.57 %, 9.58 %, 9.59 %, 9.60 %, 9.61 %, 9.62 %, 9.63 %, 9.64 %, 9.65 %, 9.66 %, 9.67 %, 9.68 %, 9.69 %, 9.70 %, 9.71 %, 9.72 %, 9.73 %, 9.74 %, 9.75 %, 9.76 %, 9.77 %, 9.78 %, 9.79 %, 9.80 %, 9.81 %, 9.82 %, 9.83 %, 9.84 %, 9.85 %, 9.86 %, 9.87 %, 9.88 %, 9.89 %, 9.90 %, 9.91 %, 9.92 %, 9.93 %, 9.94 %, 9.95 %, 9.96 %, 9.97 %, 9.98 %, 9.99 %, or 10.00 % Si. All are expressed in wt. %. The aluminum alloys described herein include from about 6.00 % to about 10.00 % Si (e.g., from about 6.00 % to about 8.00 %) to improve the fluidity of the molten aluminum alloy for die casting applications. The molten aluminum alloy needs to conform to the mold for efficient die casting into a high pressure die cast product.

[0057] In some examples, the alloys described herein include iron (Fe) in an amount up to 0.50 % (e.g., up to 0.40 %, from about 0.01 % to about 0.50 %, from about 0.05 % to about 0.40 %, from about 0.10 % to about 0.40 %, from about 0.20 % to about 0.40 %, or from about 0.30 % to about 0.50 %) based on the total weight of the alloy. For example, the alloy can include 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 033 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, 0.40 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, or 0.50 % Fe. All are expressed in wt. %.

[0058] In some examples, the alloys described herein include Cu in an amount up to 1.10 wt. % (e.g., up to 1.00 wt. %, up to 0.90 wt. %, up to 0.80 wt. %, up to 0.70 wt. %, up to 0.60 wt. %, 0.10 % to about 0.60 %, about 0.40 % to about 1.00 %, about 0.50 % to about 1.00 %, about 0.50 % to about 0.65 %, from about 0.55 % to about 0.65 %, from about 0.60 % to about 0.65 %, or from about 0.80 % to about 1.00 %) based on the total weight of the alloy. For example, the alloy can include 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 033 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, 0.40 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.69 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %, 0.78 %, 0.79 %, 0.80 %, 0.81 %, 0.82 %, 0.83 %, 0.84 %,Attorney Docket No.108050-1471224 0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89 %, 0.90 %, 0.91 %, 0.92 %, 0.93 %, 0.94 %, 0.95 %, 0.96 %, 0.97 %, 0.98 %, 0.99 %, 1.00 %, 1.01 %, 1.02 %, 1.03 %, 1.04 %, 1.05 %, 1.06 %, 1.07 %, 1.08 %, 1.09 %, or 1.10 % Cu. All are expressed in wt. %.

[0059] In some examples, the alloys described herein include manganese (Mn) in an amount up to 1.00 % (e.g., up to 0.90 %, up to 0.80 %, up to 0.70 %, from about 0.50 % to about 0.70 %, from about 0.30 % to about 1.00 %, from about 0.40 % to about 0.60 %, from about 0.50 % to about 0.60 %, from about 0.60 % to about 0.70 %, or from about 0.55 % to about 0.65 %) based on the total weight of the alloy. For example, the alloy can include 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 033 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, 0.40 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.69 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %, 0.78 %, 0.79 %, 0.80 %, 0.81 %, 0.82 %, 0.83 %, 0.84 %, 0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89 %, 0.90 %, 0.91 %, 0.92 %, 0.93 %, 0.94 %, 0.95 %, 0.96 %, 0.97 %, 0.98 %, 0.99 %, or 1.00 % Mn. All are expressed in wt. %.

[0060] In some examples, the alloys described herein include Mg in an amount up to 0.50 % (e.g., up to 0.40 %, from about 0.25 % to about 0.50 %, from about 0.30 % to about 0.50 %, from about 0.40 % to about 0.50 %, from about 0.25 % to about 0.40 %, or from about 0.35 % to about 0.45 %) based on the total weight of the alloy. For example, the alloy can include 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 033 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, 0.40 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, or 0.50 % Mg. All are expressed in wt. %.

[0061] In some examples, the alloys described herein include zinc (Zn) in an amount up to 0.90 % (e.g., up to 0.80 %, up to 0.70 %, from about 0.40 % to about 0.80 %, from about 0.40 % to about 0.60 %, from about 0.50 % to about 0.70 %, from about 0.50 % to about 0.60 %, from about 0.01 % to about 0.30 %, from about 0.02 % to about 0.30 %, from about 0.05 % to about 0.30 %, from about 0.10 % to about 0.30 %, or from about 0.10 % to about 0.25 %) based on the total weight of the alloy. For example, the alloy can include 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %,Attorney Docket No.108050-1471224 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, 0.30 %, 0.31 %, 0.32 %, 033 %, 0.34 %, 0.35 %, 0.36 %, 0.37 %, 0.38 %, 0.39 %, 0.40 %, 0.41 %, 0.42 %, 0.43 %, 0.44 %, 0.45 %, 0.46 %, 0.47 %, 0.48 %, 0.49 %, 0.50 %, 0.51 %, 0.52 %, 0.53 %, 0.54 %, 0.55 %, 0.56 %, 0.57 %, 0.58 %, 0.59 %, 0.60 %, 0.61 %, 0.62 %, 0.63 %, 0.64 %, 0.65 %, 0.66 %, 0.67 %, 0.68 %, 0.69 %, 0.70 %, 0.71 %, 0.72 %, 0.73 %, 0.74 %, 0.75 %, 0.76 %, 0.77 %, 0.78 %, 0.79 %, 0.80 %, 0.81 %, 0.82 %, 0.83 %, 0.84 %, 0.85 %, 0.86 %, 0.87 %, 0.88 %, 0.89 %, or 0.90 % Zn. All are expressed in wt. %.

[0062] In some examples, the alloys described herein include vanadium (V) in an amount up to about 0.10 % (e.g., up to about 0.05 % or up to about 0.03 %) based on the total weight of the alloy. For example, the alloy can include 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, or 0.10 % V. In some cases, V is not present in the alloy (i.e., 0 %). All are expressed in wt. %.

[0063] In some examples, the alloys described herein include Sr in an amount up to 0.25 % (e.g., from about 0.01 % to about 0.25 %, from about 0.05 % to about 0.25 %, from about 0.05 % to about 0.20 %, or from about 0.10 % to about 0.25 %) based on the total weight of the alloy. For example, the alloy can include 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, 0.20 %, 0.21 %, 0.22 %, 0.23 %, 0.24 %, 0.25 %, 0.26 %, 0.27 %, 0.28 %, 0.29 %, or 0.30 % Sr. All are expressed in wt. %.

[0064] In some examples, the alloys described herein include titanium (Ti) in an amount up to 0.20 % (e.g., from about 0.01 % to about 0.20 %, from about 0.05 % to about 0.20 %, up to 0.15 %, or up to 0.10 %) based on the total weight of the alloy. For example, the alloy can include 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, or 0.20 % Ti. All are expressed in wt. %.

[0065] In some examples, the alloys described herein include chromium (Cr) in an amount up to 0.20 % (e.g., from about 0.01 % to about 0.20 %, from about 0.05 % to about 0.20 %, up to 0.15 %, or up to 0.10 %) based on the total weight of the alloy. For example, the alloy can include 0.01 %, 0.02 %, 0.03 %, 0.04 %, 0.05 %, 0.06 %, 0.07 %, 0.08 %, 0.09 %, 0.10 %, 0.11 %, 0.12 %, 0.13 %, 0.14 %, 0.15 %, 0.16 %, 0.17 %, 0.18 %, 0.19 %, or 0.20 % Cr. All are expressed in wt. %.

[0066] Optionally, the alloy compositions described herein can further include other minor elements, sometimes referred to as impurities, in amounts of 0.05 % or below, 0.04 %Attorney Docket No.108050-1471224 or below, 0.03 % or below, 0.02 % or below, or 0.01 % or below for each impurity. These impurities may include, but are not limited to, Sn, Ga, Ca, Bi, Na, Pb, Li, W, Mo, Ni, or combinations thereof. Accordingly, Sn, Ga, Ca, Bi, Na, Pb, Li, W, Mo, or Ni, may be present in alloys in amounts of 0.05 % or below, 0.04 % or below, 0.03 % or below, 0.02 % or below or 0.01 % or below. In some cases, the sum of all impurities does not exceed 0.15 % (e.g., 0.10 %). All expressed in wt. %. The remaining percentage of the alloy is aluminum.

[0067] In some embodiments, the present disclosure provides an aluminum alloy comprising 6.50 wt. % to 7.50 wt. % Si, up to 0.50 wt. % Fe, 0.50 wt. % to 1.00 wt. % Cu, 0.50 wt. % to 0.90 wt. % Mn, 0.25 wt. % to 0.50 wt. % Mg, up to 0.30 wt. % Zn, up to 0.10 wt. % V, up to 0.20 wt. % Ti, up to 0.20 wt. % Cr, up to 0.25 wt. % Sr, up to 0.15 wt. % impurities, and the remainder Al.

[0068] Properties

[0069] In some cases, the aluminum alloy products described herein can have a yield strength of at least about 100 MPa. For example, the metal products described herein can have a yield strength of from about 100 MPa to about 300 MPa (e.g., from about 130 MPa to about 160 MPa). In some cases, the yield strength can be about 100 MPa, 110 MPa, 120 MPa, 130 MPa, 140 MPa, 150 MPa, 160 MPa, 170 MPa, 180 MPa, 190 MPa, 200 MPa, 210 MPa, 220 MPa, 230 MPa, 240 MPa, 250 MPa, 260 MPa, 270 MPa, 280 MPa, 290 MPa, or 300 MPa.

[0070] In some cases, the aluminum alloy products described herein can have an ultimate tensile strength of at least about 210 MPa. For example, the metal products described herein can have an ultimate tensile strength of from about 210 MPa to about 350 MPa (e.g., from about 250 MPa to about 325 MPa). In some cases, the ultimate tensile strength can be about 210 MPa, 220 MPa, 230 MPa, 240 MPa, 250 MPa, 260 MPa, 270 MPa, 280 MPa, 290 MPa, 300 MPa, 310 MPa, 320 MPa, 330 MPa, 340 MPa, or 350 MPa.

[0071] In some cases, the aluminum alloy products described herein can have a total elongation of at least 2 % and up to 25 %. For example, the metal products described herein can have a total elongation up to 20 % (e.g., from 2 % to 20 %, from 5 % to 15 %, from 10 % to 20 %, or from 15 % to 20 %). In some cases, the total elongation can be 2 %, 4 %, 5 %, 6 %, 7 %, 8 %, 9 %, 10 %, 11 %, 12 %, 13 %, 14 %, 15 %, 16 %, 17 %, 18 %, 19 %, 20 %, 21 %, 22 %, 23 %, 24 %, or 25 %.

[0072] In some cases, the aluminum alloy products described herein can exhibit a VDA Bend Angle of at least 19° when in the F temper as determined by the VDA 238-100 testAttorney Docket No.108050-1471224 (e.g., at least 19°, at least 20°, at least 21°, at least 22°, or at least 23°). In some embodiments, the aluminum alloy products described herein can exhibit a VDA Bend Angle of 19°, 20°, 21°, 22°, 23°, 24°, 25°, 26°, 27°, 28°, 29°, or 30°.

[0073] In some cases, the aluminum alloy products described herein can exhibit a maximum pit depth of 300 microns when subjected to the intergranular corrosion (IGC) test set forth in ISO 11846B (2024) in the F temper (e.g., 290 microns, 280 microns, 270 microns, 260 microns, 250 microns, 240 microns, 230 microns, 220 microns, 210 microns, 200 microns, 190 microns, 190 microns, 180 microns, 170 microns, 160 microns, or 150 microns. Die-Casting

[0074] The aluminum alloys described herein can be used to produce high-pressure die cast aluminum alloy products. In some embodiments, the aluminum alloys described herein can be provided to a casting die to produce large structural parts for automobiles with complex geometries. In some embodiments, further processing is not performed on the as- cast alloy.

[0075] The aluminum alloys can be used to produce various die cast products. The method for producing die cast products may include providing one or more types of recycled scrap. The recycled scrap may comprise recycled scrap from a metal casting facility (e.g., internal scrap or run-around scrap) or metalworking facility (e.g., segregated automotive scrap). In some aspects, the recycled scrap comprises one or more of end-of life aluminum articles, mixed automotive scrap, twitch, Zorba scrap, UBC, extrusion scrap, used aluminum wheels, and heat exchanger scrap. The method includes melting the recycled scrap to produce the aluminum alloy melt. In some embodiments, one or more alloying elements can be added to the aluminum alloy melt. The method includes casting the aluminum alloy melt in a mold. For example, the method includes die-casting the molten aluminum alloy. In some embodiments, die-casting is high-pressure die-casting. In some embodiments, the process further comprises further processing the as-cast alloy to form a processed alloy. In some embodiments, the further processing step is selected from the group consisting of heat treating, aging, solution treating, surface finishing and combinations thereof.

[0076] Prior to casting, aluminum alloy melt from recycled scrap can optionally be degassed to reduce the amount of gas (e.g., hydrogen) dissolved in the aluminum alloy melt. In some cases, the degassing can include bubbling a gas, such as an inert gas (e.g., argon orAttorney Docket No.108050-1471224 nitrogen), through the aluminum alloy melt to induce dissolving of the gas bubbles into the gas, and thus out of the aluminum alloy melt. Any suitable degassing technique can be used.

[0077] After the optional degassing step, the alloy described herein can be cast using any suitable casting method known to those of ordinary skill in the art. A direct chill casting system can include a mold cavity and a retractable bottom block. As liquid metal solidifies in the mold cavity, the bottom block can be retracted away from the mold cavity to support the solidifying ingot (e.g., embryonic ingot) as the ingot continuous to grow in length due to solidifying metal at the surfaces of the ingot and as the ingot continuous to solidify throughout. The continuous casting system can include a pair of moving opposed casting surfaces (e.g., moving opposed belts, rolls or blocks), a casting cavity between the pair of moving opposed casting surfaces, and a molten metal injector. The molten metal injector can have an end opening from which molten metal can exit the molten metal injector and be injected into the casting cavity. Certain aspects of the present disclosure can involve continuous casting using a twin belt continuous casting device or a twin roll continuous casting device.

[0078] These illustrative examples are given to introduce the reader to the general subject matter discussed here and are not intended to limit the scope of the disclosed concepts. The following sections describe various additional features and examples with reference to the drawings in which like numerals indicate like elements, and directional descriptions are used to describe the illustrative embodiments but, like the illustrative embodiments, should not be used to limit the present disclosure. The elements included in the illustrations herein may not be drawn to scale.

[0079] FIG.1 is a flowchart depicting a process 100 for casting an aluminum alloy product from recycled aluminum alloy materials according to certain aspects of the present disclosure. At block 102, recycled aluminum alloy materials are melted. The recycled aluminum alloy materials can be melted in any suitable vessel, such as a rotary furnace, a crucible furnace, or any other suitable heating device. The aluminum alloy melt resulting from the recycled aluminum alloy materials can include alloying elements that would render the aluminum alloy melt a non-standard alloy, such as an alloy that is not normally used for automotive parts. For example, the aluminum alloy melt can have the composition provided in Tables 1-6.

[0080] At block 104, additional alloying elements can optionally be added to the aluminum alloy melt to achieve a modified aluminum alloy melt with desired concentrations of alloying elements. Adding alloying elements can include melting raw elements or mixturesAttorney Docket No.108050-1471224 of aluminum and the alloying elements into the aluminum alloy melt from block 102. After adding the alloying elements, the modified aluminum alloy melt can have a desired composition of alloying elements and aluminum. For example, Sr or Zn can be added to the aluminum alloy melt.

[0081] At block 106, the modified aluminum alloy melt from block 104 can be cast in a die to result in an die-cast product 116. The modified aluminum alloy melt cast at block 106 can include little or no primary aluminum. In some cases, the modified aluminum alloy melt can include at or less than approximately 20%, 15%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, or 1% primary aluminum.

[0082] Heat treatment can improve metallurgical and / or mechanical properties of the metal product. For example, solution heat treatment and artificial ageing can result in improvements to the strength, toughness, corrosion resistance of the metal product.

[0083] In some embodiments, the method for producing a die-cast product may include a process including rheocasting. Rheocasting is a semi-solid die casting process in which the aluminum alloy melt is in a semi-solid state. This state is called slurry. For example, rheocasting involves preparation of slurry directly from the aluminum alloy melt, followed by a forming process such as high pressure die casting.

[0084] In some embodiments, the method for producing a high pressure die cast product using rheocasting may include melting recycled aluminum alloy materials to produce an aluminum alloy melt. Optionally, additional alloying elements may be added to the aluminum alloy melt. The method may include processing the aluminum alloy melt to produce a slurry. In some embodiments, the slurry is in a semi-solid state. The method includes injecting the slurry into a die cavity to produce a cast product (e.g., using high-pressure die casting). Recycled Content Alloys

[0085] The aluminum alloys for high pressure die casting described herein can be produced from a substantial portion of recycled scrap. In some embodiments, the aluminum alloys described herein can be produced from a combination of different recycled scrap materials. Recycled aluminum alloy scrap (e.g., recycled scrap) can be obtained from various sources at all stages of the aluminum life cycle. In some cases, recycled scrap can refer to a collection of recycled metal. Recycled scrap can include materials recycled from any suitable source, such as from a metal production facility (e.g., a metal casting facility), from a metalworking facility (e.g., a production facility that uses metal products to create consumable products), or from post-consumer sources (e.g., regional recycling facilities). ForAttorney Docket No.108050-1471224 example, internal scrap may be produced during production of an aluminum alloy in a metal casting facility (e.g., scrap from producing an aluminum ingot, billet, sheet, plate, etc.), customer scrap may be produced during stamping, milling, and other processes in a metalworking facility (e.g., scrap from creating can bodies, can ends, automobile parts, etc.), and post-consumer scrap may be produced from aluminum products used by consumers and collected at regional recycling facilities (e.g., used beverage cans, used automobile parts, etc.). Each of these types of recycled scrap can be a substitute for primary aluminum.

[0086] The aluminum alloys described herein can be produced from high amounts of recycled scrap and still exhibit desirable mechanical properties. The impact of the impurities and / or alloying elements on the mechanical properties of the aluminum alloy is reduced by providing a specific aluminum alloy composition to compensate for the impurities. This enables a higher amount of less expensive, higher impurity aluminum scrap for producing aluminum alloys that can still exhibit desirable properties.

[0087] In some aspects, the aluminum alloy can be produced from up to 100 % recycled scrap

[0088] (e.g., from 70 % to 100 %, from 75 % to 100 %, from 80 % to 100 %, or from 90 % to 100 %), based on the total weight of the aluminum alloy. All are expressed in wt. %.

[0089] In some embodiments, prime aluminum alloy can be used in combination with the recycled scrap to produce the aluminum alloys described herein. For example, up to 20 % prime aluminum (e.g., up to 18 %, up to 15 %, up to 12 %, up to 10 %, up to 8 %, up to 6 %, up to 4 %, up to 2 %, or up to 1 %) can be used to produce the aluminum alloys described herein. All are expressed in wt. %. In some embodiments, no prime aluminum alloy is used with the recycled scrap.

[0090] In some embodiments, a combination of different recycled scrap materials can be melted to produce an aluminum alloy melt having the composition described herein. For example, the mixture of EOL Twitch, Tainted Tabor, heat exchanger scrap, and used 3xxx series aluminum alloys can be melted to produce the aluminum alloy melt. The combination of the mixed recycled scrap materials may include greater than 40 wt. % heat exchanger scrap (e.g., greater than 50 wt. %, greater than 60 wt. %, greater than 70 wt. %, greater than 75 wt. %, or greater than 80 wt. %).

[0091] In some embodiments, the EOL Twitch comprises greater than 4 wt. % Si and greater than 1 wt. % Cu. In some embodiments, the heat exchanger scrap comprises greater than 2 wt. % Si and greater than 0.5 wt. % Cu.Attorney Docket No.108050-1471224

[0092] In some embodiments, end of life scrap (e.g., end of life aluminum alloy articles) comprises a mixture of different aluminum alloys. For example, end of life scrap may include one or more of 1xxx series aluminum alloys, 2xxx series aluminum alloys, 3xxx series aluminum alloys, 4xxx series aluminum alloys, 5xxx series aluminum alloys, 6xxx series aluminum alloys, or 7xxx series aluminum alloys. Illustrations of Suitable Products and Methods

[0093] As used below, any reference to a series of illustrations is to be understood as a reference to each of those illustrations disjunctively (e.g., “Illustrations 1-4” is to be understood as “Illustrations 1, 2, 3, or 4”).

[0094] Illustration 1 is a method of producing a high pressure die cast product, the method comprising: providing an aluminum alloy melt comprising 6.00 wt. % to 10.00 wt. % Si, up to 0.50 wt. % Fe, up to 1.10 wt. % Cu, up to 1.00 wt. % Mn, up to 0.50 wt. % Mg, up to 0.90 wt. % Zn, up to 0.10 wt. % V, up to 0.20 wt. % Ti, up to 0.20 wt. % Cr, up to 0.25 wt. % Sr, up to 0.15 wt. % impurities, and the remainder Al; and casting the aluminum alloy melt in a mold to produce a cast product.

[0095] Illustration 2: The illustration of any preceding or subsequent illustration, wherein providing the aluminum alloy melt comprises melting recycled aluminum alloy materials to produce the aluminum alloy melt.

[0096] Illustration 3: The illustration of any preceding or subsequent illustration, wherein the recycled aluminum alloy materials comprises one or more of end-of life aluminum articles, mixed automotive scrap, twitch, Zorba scrap, UBC, extrusion scrap, used aluminum wheels, and heat exchanger scrap.

[0097] Illustration 4: The illustration of any preceding or subsequent illustration, wherein the twitch comprises at least 0.25 wt. % Zn.

[0098] Illustration 5: The illustration of any preceding or subsequent illustration, further comprising adding an alloying element to the aluminum alloy melt, the alloying element comprising one or more of Mg, Si, or Cu.

[0099] Illustration 6: The illustration of any preceding or subsequent illustration, wherein the aluminum alloy melt comprises Zn in an amount of at least 0.10 wt. %.

[0100] Illustration 7: The illustration of any preceding or subsequent illustration, wherein the aluminum alloy melt comprises Zn in an amount of at least 0.20 wt. %.

[0101] Illustration 8: The illustration of any preceding or subsequent illustration, wherein the cast product is an automotive part.Attorney Docket No.108050-1471224

[0102] Illustration 9: The illustration of any preceding or subsequent illustration, wherein the cast product comprises a yield strength of at least 100 MPa.

[0103] Illustration 10: The illustration of any preceding or subsequent illustration, wherein the recycled aluminum alloy materials comprises used automotive scrap comprising a mixture of 5xxx and 6xxx series aluminum alloys.

[0104] Illustration 11: The illustration of any preceding or subsequent illustration, wherein the aluminum alloy melt comprises at least 60 % the recycled aluminum alloy materials.

[0105] Illustration 12: The illustration of any preceding or subsequent illustration, wherein the aluminum alloy melt comprises at least 80 % the recycled aluminum alloy materials.

[0106] Illustration 13: A high pressure die cast product produced according to any preceding or subsequent illustration.

[0107] Illustration 14: A high pressure die cast product comprising an aluminum alloy comprising 6.00 wt. % to 10.00 wt. % Si, up to 0.50 wt. % Fe, up to 1.10 wt. % Cu, up to 1.00 wt. % Mn, up to 0.50 wt. % Mg, up to 0.90 wt. % Zn, up to 0.10 wt. % V, up to 0.20 wt. % Ti, up to 0.20 wt. % Cr, up to 0.25 wt. % Sr, up to 0.15 wt. % impurities, and the remainder Al, wherein the high pressure die cast product is cast from an aluminum alloy melt comprising at least 50 % of recycled aluminum alloy materials.

[0108] Illustration 15: The illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises 6.50 wt. % to 7.50 wt. % Si, up to 0.40 wt. % Fe, up to 1.10 wt. % Cu, up to 0.90 wt. % Mn, up to 0.50 wt. % Mg, up to 0.80 wt. % Zn, up to 0.10 wt. % V, up to 0.20 wt. % Ti, up to 0.20 wt. % Cr, up to 0.25 wt. % Sr, up to 0.15 wt. % impurities, and the remainder Al.

[0109] Illustration 16: The illustration of any preceding or subsequent illustration, wherein the aluminum alloy comprises 6.50 wt. % to 7.50 wt. % Si, 0.10 wt. % to 0.40 wt. % Fe, 0.10 wt. % to 0.60 wt. % Cu, 0.40 wt. % to 0.60 wt. % Mn, 0.25 wt. % to 0.40 wt. % Mg, up to 0.80 wt. % Zn, up to 0.10 wt. % V, up to 0.15 wt. % Ti, up to 0.10 wt. % Cr, up to 0.25 wt. % Sr, up to 0.15 wt. % impurities, and the remainder Al.

[0110] Illustration 17: The illustration of any preceding or subsequent illustration, wherein the aluminum alloy melt is produced from at least 80% of the recycled aluminum alloy materials.

[0111] Illustration 18: The illustration of any preceding or subsequent illustration, wherein the recycled aluminum alloy materials comprises one or more of end-ofAttorney Docket No.108050-1471224 life aluminum articles, mixed automotive scrap, twitch, Zorba scrap, UBC, extrusion scrap, used aluminum wheels, and heat exchanger scrap.

[0112] Illustration 19: The illustration of any preceding or subsequent illustration, wherein the high pressure die cast product comprises a yield strength of at least 100 MPa.

[0113] Illustration 20: The illustration of any preceding or subsequent illustration, wherein the high pressure die cast product comprises an ultimate tensile strength of at least 210 MPa.

[0114] Illustration 21: The illustration of any preceding or subsequent illustration, wherein the high pressure die cast product comprises a total elongation of at least 2 %. Examples

[0115] Example alloys were tested to determine performance of high-pressure die products produced from the aluminum alloys described herein. The example alloys were produced using a lab-scale high-pressure die casting system to produce sheets of different widths. The cast products were produced by melting the aluminum alloys, providing the molten alloy to a mold, and high-pressure die casting to produce the cast products. The average melt temperature of the samples was about 710° C and the average die temperature ranged from 160° C to 180° C. The compositions of the example cast products are provided in Table 13 all expressed in wt. % unless otherwise specified. TABLE 13

[0116] As provided in Table 13, Examples 1 and 2 included 0.40 wt. % Zn or greater, Example Alloys 3-6 included a Cu content ranging from 0.40 wt. % to 1.00 wt. % and a Zn content of 0.10 wt. %, and Example Alloys 7-10 included about from 0.35 wt. % to 0.45 wt.Attorney Docket No.108050-1471224 % Fe, 0.30 to 0.90 wt. % Mn, and greater than 0.20 wt. % Zn. Comparative Alloy 1 is a baseline high-purity A356 die-cast alloy, Comparative Alloy 2 is the C611 EZCastTMalloy (from Alcoa), Comparative Alloy 3 is a high-pressure cast alloy used currently in the automotive market, and Comparative Alloy 4 is high-pressure die cast part from a commercially available electric vehicle.

[0117] The example alloys were tested to determine the properties of the high-pressure die cast products produced from the aluminum alloys described herein. A 2.5 mm thick cast sheet for each sample was tested to determine the yield strength, ultimate tensile strength (UTS), and total elongation. A 3.0 mm thick cast sheet for each sample was tested to determine the VDA Bend angle properties. The properties for each example alloy are provided in Table 14 (F temper) and Table 15 (after paint bake). F temper refers to as-cast condition without applying any heat treatment or strain. Paint baking simulation was conducted by heating samples to 185ºC and holding for 20 minutes followed by cooling in ambient air. This is to reflect the typical E-coat baking conditions being used in automobile manufacturing.Attorney Docket No.108050-1471224

[0118] FIG.2A shows a histogram of the yield strength (MPa) (left bar) and ultimate tensile strength (MPa) (right bar) values of the example alloys in the F temper. The minimum strength specification for the high-pressure die cast products in a F temper for structural automotive parts is a yield strength of greater than or equal to 130 MPa (lower black line) and a UTS of greater than or equal to 210 MPa (higher black line). FIG.2B shows a histogram of the yield strength (MPa) (left bar) and ultimate tensile strength (MPa) (right bar) values of the example alloys after paint bake at 185° C for 20 minutes. The minimum strength specification for the high-pressure die cast products in an after paint bake temper for structural automotive parts is a yield strength of greater than or equal to 140 MPa (lower black line) and a UTS of greater than or equal to 240 MPa (higher black line).

[0119] As demonstrated in Table 14 and shown in FIGs.2A and 2B, each of Example Alloys 1-10 had a yield strength of at least 130 MPa and a UTS of at least 210 MPa in the F temper. In fact, each of Example Alloys 1-10 had a UTS that was at least 50 MPa greater thanAttorney Docket No.108050-1471224 the minimum specification value. Additionally, each of Example Alloys 1-10 had a yield strength of at least 140 MPa and a UTS of at least 210 MPa in the after paint bake temper. The data demonstrates that each of Example Alloys 1-10 had strength values that were similar to or better than the comparative examples, which is the current high-pressure die cast alloys used in the market.

[0120] FIG.3A shows a histogram of the elongation (%) values of the example alloys in the F temper and FIG.3B shows a histogram of the elongation (%) values of the example alloys after paint bake at 185° C for 20 minutes. The black line denotes the minimum elongation target specification of 8 % for structural automotive parts. As shown in FIG.3A and Table 15, each of the example alloys exhibited an elongation greater than the target specification of 8 % other than Example Alloys 2, 7, and 10. The elongation values of each of the examples were slightly lower after paint bake. In FIG.3B, Example Alloys 1, 2 and 4-6 each had an elongation greater than 8 % after paint bake. Notably, Example Alloy 1 had a Zn content of about 0.40 wt. % and still achieved the target specification for strength and elongation in the F temper and the after paint bake temper. Each of Example Alloys 3-6 had a combination of high strength and elongation in the F temper and after paint bake temper. Additionally, all of the example alloys had a higher elongation in the after paint bake temper than Comparative Example 4.

[0121] The VDA Bend Angle test was performed on the example alloys to provide further data on the bending properties of the alloy. The VDA bend angle is determined by the VDA 238-100 test, which is a bending test for metallic materials. The test is used to determine how a material deforms, how likely it is to fail during forming processes, and how likely it is to fail during crash loading. For example, the VDA bend angle demonstrates how the alloy bends and cracks, whereas elongation testing stops at the first formation of a crack. Thus, the VDA bend angle can provide further information regarding how the alloy performs at high loads.

[0122] FIG.4A shows a histogram of the VDA Bend Angle (°) values of the example alloys in the F temper. FIG.4B shows a histogram of the VDA Bend Angle (°) values of the example alloys in the after paint bake temper. The black line denotes the minimum VDA bend angle target specification of 24° for structural automotive parts. A higher bend angle represents the alloys ability to bend without completely fracturing. Example Alloy 1 exhibited a VDA Bend Angle of 24° in the F temper and 18° in the after paint bake temper. Surprisingly, each of Example Alloys 3-6 each exhibited a VDA bend angle that was about or greater than 24° in the F temper and after paint bake temper. Notably, three of the currentAttorney Docket No.108050-1471224 market alloys (Comparative Examples 1, 3 and 4) did not achieve the target specification for VDA bend angle in the after paint bake temper.

[0123] FIG.5 shows the maximum and average pit depths after the example alloys (in the F temper) were subjected to the intergranular corrosion (IGC) test set forth in ISO 11846B (2024) for 24 hours. Each of the example alloys had better corrosion performance than Comparative Examples 1 and 3. Example Alloys 3-6 had the best corrosion performance as the maximum pit depth was less than 250 microns and the average pit depth was less than 100 microns.

[0124] The microstructure of the example alloys were investigated to determine the effect of the particles on the properties of the alloys. Feature Detection Classification (FDC) was performed for particle analysis and SEM / EDS was performed for optical imaging of the example alloys. Table 16 provides the average particle size of the alpha, beta, and Mg2Si particles in the microstructure of the example alloys.Attorney Docket No.108050-1471224

[0125] The example alloys generally had large particle sizes when taking into account both the alpha phase particles and beta phase particles. Example Alloy 3 had alpha particles with an average particle size of 5.19 µm2, which was significantly larger than the particle size of Comparative Examples 2 and 3. FIG.6 shows the number of density of particles in the microstructure of the aluminum alloys. Example Alloys 3-6 exhibited a much greater number density of particles than Comparative Examples 2 and 3.

[0126] FIG.7 shows X-Ray-Tomography (XRT) images of the void volume fraction of the example alloys (dots represent voids and void size). To determine fatigue performance, the size of the largest void and the void volume fraction are important factors. From left to right, the figure shows the XRT images of Comparative Example 2, Example Alloy 2, Example Alloy 3, Example Alloy 6, Example Alloy 7, Example Alloy 10, Comparative Example 3, and Comparative Example 4. Comparative Example 4 has a void volume fraction of 0.5 %, which is substantially higher than the void volume fraction of the example alloys. As demonstrated in FIG.7, Example Alloy 2, Example Alloy 3, Example Alloy 6, Example Alloy 7, Example Alloy 10 each had much smaller and less voids than the comparative alloys.

[0127] Tests were conducted to determine the fatigue performance of the example alloys. Each of the example alloys were provided in the paint bake temper (paint bake applied at 185° C for 20 minutes). In general, fatigue testing can evaluate the ability of a material to withstand cyclical fatigue when directly stressed for a relatively large number of cycles. Fatigue testing at constant force was performed according to ASTM E466. As an example, an aluminum alloy can pass a fatigue test without failure after a stress amplitude of 103 MPa, a frequency of 30 Hz, an R ratio of 0.1, and a maximum cycle count of 5,000,000. The stress used for fatigue was 90% of yield strength (~145MPa) and 95% of yield strength (~155MPa). The Table 17 shows the fatigue results of the example alloys.Attorney Docket No.108050-1471224

[0128] FIG.8 shows a graph of the fatigue performance of the example alloys in the paint bake temper. The overall fatigue performance of the tested example alloys were comparable or better than Comparative Example 4 (the high-pressure die cast part from a commercially available electric vehicle). For example, Example Alloys 1 and 5 each demonstrated better fatigue performance at 90% yield strength (~145MPa) and 95% yield strength (~155MPa) than Comparative Example 4.

[0129] All patents, publications, and abstracts cited above are incorporated herein by reference in their entireties. Various embodiments of the invention have been described in fulfillment of the various objectives of the invention. It should be recognized that these embodiments are merely illustrative of the principles of the present invention. Numerous modifications and adaptions thereof will be readily apparent to those skilled in the art without departing from the spirit and scope of the present invention as defined in the following claims.

Claims

Attorney Docket No.108050-1471224 WHAT IS CLAIMED IS:

1. A method of producing a high pressure die cast product, the method comprising: providing an aluminum alloy melt comprising 6.00 wt. % to 10.00 wt. % Si, up to 0.50 wt. % Fe, up to 1.10 wt. % Cu, up to 1.00 wt. % Mn, up to 0.50 wt. % Mg, up to 0.90 wt. % Zn, up to 0.10 wt. % V, up to 0.20 wt. % Ti, up to 0.20 wt. % Cr, up to 0.25 wt. % Sr, up to 0.15 wt. % impurities, and the remainder Al; and casting the aluminum alloy melt in a mold to produce a die cast product.

2. The method of claim 1, wherein providing the aluminum alloy melt comprises melting recycled aluminum alloy materials to produce the aluminum alloy melt.

3. The method of claim 2, wherein the recycled aluminum alloy materials comprises one or more of end-of life aluminum articles, mixed automotive scrap, twitch, Zorba scrap, UBC, extrusion scrap, used aluminum wheels, and heat exchanger scrap.

4. The method of claim 3, wherein the twitch comprises at least 0.25 wt. % Zn.

5. The method of claim 1, further comprising adding an alloying element to the aluminum alloy melt, the alloying element comprising one or more of Mg, Si, or Cu.

6. The method of claim 1, wherein the aluminum alloy melt comprises Zn in an amount of at least 0.10 wt. %.

7. The method of claim 1, wherein the aluminum alloy melt comprises Zn in an amount of at least 0.20 wt. %.

8. The method of claim 1, wherein the cast product is an automotive part.

9. The method of claim 1, wherein the cast product comprises a yield strength of at least 100 MPa.

10. The method of claim 2, wherein the recycled aluminum alloy materials comprises used automotive scrap comprising a mixture of 5xxx and 6xxx series aluminum alloys.Attorney Docket No.108050-1471224 11. The method of claim 2, wherein the aluminum alloy melt comprises at least 60 % the recycled aluminum alloy materials.

12. The method of claim 11, wherein the aluminum alloy melt comprises at least 80 % the recycled aluminum alloy materials.

13. A high pressure die cast product produced according to the method of claim 1.

14. A high pressure die cast product comprising an aluminum alloy comprising 6.00 wt. % to 10.00 wt. % Si, up to 0.50 wt. % Fe, up to 1.10 wt. % Cu, up to 1.00 wt. % Mn, up to 0.50 wt. % Mg, up to 0.90 wt. % Zn, up to 0.10 wt. % V, up to 0.20 wt. % Ti, up to 0.20 wt. % Cr, up to 0.25 wt. % Sr, up to 0.15 wt. % impurities, and the remainder Al, wherein the high pressure die cast product is cast from an aluminum alloy melt comprising at least 50 % of recycled aluminum alloy materials.

15. The high pressure die cast product of claim 14, wherein the aluminum alloy comprises 6.50 wt. % to 7.50 wt. % Si, up to 0.40 wt. % Fe, up to 1.10 wt. % Cu, up to 0.90 wt. % Mn, up to 0.50 wt. % Mg, up to 0.80 wt. % Zn, up to 0.10 wt. % V, up to 0.20 wt. % Ti, up to 0.20 wt. % Cr, up to 0.25 wt. % Sr, up to 0.15 wt. % impurities, and the remainder Al.

16. The high pressure die cast product of claim 14, wherein the aluminum alloy comprises 6.50 wt. % to 7.50 wt. % Si, 0.10 wt. % to 0.40 wt. % Fe, 0.10 wt. % to 0.60 wt. % Cu, 0.40 wt. % to 0.60 wt. % Mn, 0.25 wt. % to 0.40 wt. % Mg, up to 0.80 wt. % Zn, up to 0.10 wt. % V, up to 0.15 wt. % Ti, up to 0.10 wt. % Cr, up to 0.25 wt. % Sr, up to 0.15 wt. % impurities, and the remainder Al.

17. The high pressure die cast product of claim 14, wherein the aluminum alloy melt is produced from at least 80% of the recycled aluminum alloy materials.

18. The high pressure die cast product of claim 14, wherein the recycled aluminum alloy materials comprises one or more of end of life aluminum articles, mixed automotive scrap, twitch, Zorba scrap, UBC, extrusion scrap, used aluminum wheels, and heat exchanger scrap.Attorney Docket No.108050-1471224 19. The high pressure die cast product of claim 14, wherein the high pressure die cast product comprises a yield strength of at least 100 MPa.

20. The high pressure die cast product of claim 14, wherein the high pressure die cast product comprises an ultimate tensile strength of at least 210 MPa.

21. The high pressure die cast product of claim 14, wherein the high pressure die cast product comprises a total elongation of at least 2 %.

22. The high pressure die cast product of claim 18, wherein the end of life aluminum articles comprises one or more of 1xxx series aluminum alloys, 2xxx series aluminum alloys, 3xxx series aluminum alloys, 4xxx series aluminum alloys, 5xxx series aluminum alloys, 6xxx series aluminum alloys, or 7xxx series aluminum alloys.

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