Abstract: An improved aluminum alloy for casting into a component, such as a vehicle component, is provided. The improved aluminum alloy includes at least 80 wt. % aluminum; 6.0 to 8.0 wt. % silicon; 1.0 to 2.0 wt. % zinc; 0.10 to 0.6 wt. % magnesium; 0.1 to 0.60 wt. % copper; 0.20. to 0.60 wt. % manganese; up to 0.25 wt. % iron; 0.015 wt. % to 0.03 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy. This improved aluminum alloy can be formed by combining recycled aluminum or recycled aluminum alloy with at least one additional element. The cast component formed of the improved aluminum alloy has a yield strength of 120 MPa to 130 MPa and an elongation of 8% to 16%, depending on flow length, when the cast component is in the as-cast (F temper) condition.

Abstract: An improved aluminum alloy for casting into a component, such as a vehicle component, is provided. The aluminum alloy preferably includes at least 80 weight percent (wt. %) aluminum; 9.5 to 11.5 wt. % silicon; 1.5 max wt. % zinc; 0.1 wt. % to 0.6 wt. % magnesium; 0.10 wt. % to 0.60 wt. % copper; 0.2. to 0.6 wt. % manganese; 0.2 wt. % to 0.6 wt. % iron; 0.01 wt. % to 0.07 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the aluminum alloy. This improved aluminum alloy can be formed by combining recycled aluminum or a recycle aluminum alloy with at least one additional element.

Abstract: An aluminum alloy for casting into a component, such as a vehicle component, is provided. The aluminum alloy includes silicon, zinc, magnesium, copper, manganese, iron, and strontium. After the casting step, the cast aluminum alloy has a yield strength of at least 105 MPa, ultimate tensile strength (UTS) of at least 180 MPa, and an elongation of 8% to 10%.

Abstract: An aluminum alloy for die casting parts used in automotive structural applications is provided. According to example embodiments, the alloy includes 0.6 to 2.0 wt. % manganese, 0.5 to 4.0 wt. % magnesium, 0.0 to 1.0 wt. % iron, 0.0 to 3.0 wt. % zinc, 0.0 to 3.0 wt. % silicon, 0.0 to 1.0 wt. % zirconium, 0.0 to 0.5 wt. % titanium and/or boron, 0.0 to 0.05 wt. % strontium, and 85.5 to 98.8 wt. % aluminum, based on the total weight of the aluminum alloy. The alloy maintains good characteristics during the casting process, including fluidity, manageable hot cracking, and anti-soldering. The alloy casting does not require a heat treatment process after the casting step to achieve acceptable mechanical properties. The aluminum alloy casting has a yield strength of at least 90 MPa, an ultimate tensile strength of at least 180 MPa, and an elongation equal to or greater than 10% without heat treatment.

Abstract: A vehicle part formed at least in part of a blended material is provided. The blended material is formed by mixing an improved aluminum alloy and a recycled aluminum alloy. The recycled aluminum alloy can be obtained from road wheels. The blended alloy preferable meets the Aural series alloy specifications. The blended material can be cast under high pressure and a vacuum to form a part designed for use in a chassis or structural body of a vehicle, for example a front subframe, a front shock tower, a rear rail, a front kick-down rail, a front body hinge pillar, a tunnel, a front body hinge pillar, or a rear shock mount.

Abstract: An aluminum alloy for casting into a component, such as a vehicle component, is provided. The aluminum alloy includes 2 to 5 wt. % silicon, which is a lower amount of silicon compared to other aluminum alloys used for casting. The aluminum alloy further includes 1.0 to 2.0 wt. % zinc, less than 0.5 wt. % iron, and not greater than 0.6 wt. % manganese, based on the total weight of the aluminum alloy. The aluminum alloy can further include 0.01 to 0.07 wt. % strontium, 0.05 to 0.6 wt. % magnesium, not greater than 0.2 wt. % titanium, and less than 0.02 wt. % copper, based on the total weight of the aluminum alloy. After the casting step, the cast aluminum alloy has a yield strength of at least 110 MPa, ultimate tensile strength (UTS) of 220 to 230 MPa, and an elongation of 10 to 20%.

Abstract: The invention provides a method of joining dissimilar materials, such as aluminum to steel, by applying low pressure and heat to minimize distortion of the materials and the heat affected zone. The method includes applying current to a weld element, at least partially melting a portion of the first material with the heated weld element, and passing through the at least partially melted portion of the first material with the weld element. The method further includes contacting the second material with the heated weld element, and melting a portion of the weld element and a portion of the second material in contact with one another to form a weld. The weld element is designed with a head to trap the first material between the head and the second material, and a vent for receiving the at least partially melted first material as the weld element passes through.

Abstract: An aluminum alloy for casting into a component, such as an automotive vehicle component, is provided. The aluminum alloy includes a reduced amount of silicon (Si), specifically 0.1 weight percent (wt. %) to less than 7.0 wt. %, and preferably 4.0 wt. % or less, to achieve improved ductility and elongation. The aluminum alloy can also include additional alloying elements to achieve desired properties. For example, antimony, calcium, and/or bismuth can be included to counter any detrimental effect of the low silicon content on hot cracking behavior. Zinc can be added to increase strength; and cerium can be added to further increase ductility. The aluminum alloy is typically formed by modifying recycled wrought aluminum, such as a 5000 series or 6000 series aluminum alloy, or by modifying a recycled cast 300 series aluminum alloy.

Abstract: A die castable magnesium based alloy comprising, by weight, between about 3 and 10% aluminum, between about 0.5 and 2.5% calcium, up to about 1.5% silicon, up to about 0.7% zinc, and the remainder being magnesium. The alloy has been found to exhibit more favorable castability and creep resistance than comparative magnesium based alloys.

Abstract: A die castable magnesium based alloy comprising, by weight, between about 3 and 10% aluminum, between about 0.5 and 2.5% calcium, up to about 1.5% silicon, up to about 0.7% zinc, and the remainder being magnesium. The alloy has been found to exhibit more favorable castability and creep resistance than comparative magnesium based alloys.