Invention Reference Number
This invention introduces a new family of Al-Mg alloys that exhibit excellent ductility, even with high levels of impurities typically found in recycled aluminum. Unlike existing Al-Mg alloys, which can only tolerate one type of impurity, these new alloys can accommodate both iron (Fe) and silicon (Si) impurities without compromising ductility, making them ideal for use in automotive applications.
Description
Aluminum production is energy intensive. By the 2030s, hundreds of thousands of tons of automotive aluminum body scrap will enter U.S. recycling streams. Today, most of the automotive aluminum scrap is downcycled or exported. The increasing availability of recycled aluminum offers an opportunity to strengthen the existing supply chain.
However, impurities such as Fe and Si in recycled aluminum often compromise the ductility of aluminum alloys. This invention presents a novel family of Al-Mg alloys that can tolerate higher levels of Fe (up to 1.5 wt%) and Si (up to 1.5 wt%) while maintaining or enhancing ductility. By suppressing the formation of brittle Fe-intermetallic phases, these alloys are ideal for use in automotive and other industrial applications, reducing the need for additional alloying elements like manganese (Mn) or chromium (Cr).
ORNL researchers have developed RidgeAlloy, a new high pressure die cast aluminum alloy that transforms automotive body post-consumer mixed sheet scrap into high-strength, crashworthy parts. For U.S. manufacturing, the impact is significant: reduced reliance on imports, up to 95% lower energy use, and a secure domestic supply of critical materials.
Benefits
- High ductility: The alloys maintain excellent ductility (7-13%elongation)
- Accommodates high impurity levels: The alloys can tolerate up to 1.5 wt% Fe and 1.5 wt% Si, which is higher than what is typically manageable in current alloys.
- No need for additional alloying elements: Unlike other alloys, this new family does not require extra elements like Mn or Cr to maintain ductility.
- Superior microstructure: The alloys feature a unique microstructure that suppresses the formation of large, brittle Fe-intermetallic phases, enhancing overall strength and flexibility.
Applications and Industries
- Structural high pressure die castings
- Automotive, terrestrial and marine transportation: engine components, structural parts, electric vehicle components
- Aerospace and automotive lightweighting initiatives
- Structural aluminum parts where material source has supply chain uncertainty
Contact:
To learn more about this technology, email partnerships@ornl.gov or call 865-574-1051.
