Abstract: A method for making an aluminum alloy includes steps of (1) weighing out starting materials to achieve a mass of material having a composition that includes aluminum, about 1.8 to about 5.6 percent by weight copper, about 0.6 to about 2.6 percent by weight lithium, and at least one of lanthanum up to about 1.5 percent by weight, strontium up to about 1.5 percent by weight, cerium up to about 1.5 percent by weight, and praseodymium up to about 1.5 percent by weight; (2) loading said starting materials into a crucible; (3) inserting said crucible into a chamber; (4) evacuating said chamber to a predetermined vacuum level; (5) melting said starting materials to form a molten mass; and (6) casting said molten mass into a mold.

Abstract: An alloy composition comprising Al is described, wherein the alloy comprises a yield strength of at least about 130 MPa and a bend angle of at least about 20° at a 3 mm section thickness when as-cast and without further processing. Processes for forming the alloy are also described.

Abstract: In various embodiments, aluminum alloys having yield strengths greater than 120 MPa, and typically in the range from 140 MPa to 175 MPa, are described. Further, such alloys can have electrical conductivity of greater than 45% IACS, typically in the range from 45-55% IACS. In one embodiment, the aluminum alloy comprises Si from 1 to 4.5 wt %, Mg from 0.3 to 0.5 wt %, TiB2 from 0.02 to 0.07 wt %, Fe less than 0.1 wt %, Zn less than 0.01 wt %, Cu less than 0.01 wt %, Mn less than 0.01 wt %, the remaining wt % being Al and incidental impurities. Such alloys can be used to cast a variety of automotive parts, including rotors, stators, busbars, inverters, and other parts.

Abstract: In various embodiments, aluminum alloys having yield strengths greater than 120 MPa, and typically in the range from 140 MPa to 175 MPa, are described. Further, such alloys can have electrical conductivity of greater than 45% IACS, typically in the range from 45-55% IACS. In one embodiment, the aluminum alloy comprises Si from 1 to 4.5 wt %, Mg from 0.3 to 0.5 wt %, TiB2 from 0.02 to 0.07 wt %, Fe less than 0.1 wt %, Zn less than 0.01 wt %, Cu less than 0.01 wt %, Mn less than 0.01 wt %, the remaining wt % being Al and incidental impurities. Such alloys can be used to cast a variety of automotive parts, including rotors, stators, busbars, inverters, and other parts.

Abstract: A high performance die castable aluminum alloy is described, wherein the aluminum alloy is characterized as having a high yield strength and high conductivity, and also a high flowability and low susceptibility to hot tearing when die cast.

Abstract: A method for making an aluminum alloy includes steps of (1) weighing out starting materials to achieve a mass of material having a composition that includes aluminum, about 1.8 to about 5.6 percent by weight copper, about 0.6 to about 2.6 percent by weight lithium, and at least one of lanthanum up to about 1.5 percent by weight, strontium up to about 1.5 percent by weight, cerium up to about 1.5 percent by weight, and praseodymium up to about 1.5 percent by weight; (2) loading said starting materials into a crucible; (3) inserting said crucible into a chamber; (4) evacuating said chamber to a predetermined vacuum level; (5) melting said starting materials to form a molten mass; and (6) casting said molten mass into a mold.

Abstract: In various embodiments, aluminum alloys having yield strengths greater than 120 MPa, and typically in the range from 140 MPa to 175 MPa, are described. Further, such alloys can have electrical conductivity of greater than 45% IACS, typically in the range from 45-55% IACS. In one embodiment, the aluminum alloy comprises Si from 1 to 4.5 wt %, Mg from 0.3 to 0.5 wt %, TiB2 from 0.02 to 0.07 wt %, Fe less than 0.1 wt %, Zn less than 0.01 wt %, Cu less than 0.01 wt %, Mn less than 0.01 wt %, the remaining wt % being Al and incidental impurities. Such alloys can be used to cast a variety of automotive parts, including rotors, stators, busbars, inverters, and other parts.

Abstract: An aluminum alloy including aluminum, about 1.8 to about 5.6 percent by weight copper, about 0.6 to about 2.6 percent by weight lithium, and at least one of lanthanum up to about 1.5 percent by weight, strontium up to about 1.5 percent by weight, cerium up to about 1.5 percent by weight and praseodymium up to about 1.5 percent by weight.