Invention Reference Number
This technology is a newly developed cast aluminum-silicon alloy designed to achieve strong mechanical performance directly in the as-cast condition, eliminating the need for post-casting heat treatment. The alloy addresses manufacturing challenges such as hot tearing, shrinkage porosity, and limited ductility while supporting flexible casting processes. By tolerating higher levels of common alloying impurities, the material offers improved manufacturing robustness and material utilization. The technology is well suited for structural casting applications where dimensional stability, strength, and production efficiency are critical.
Description
Oak Ridge National Laboratory, in collaboration with General Motors and Ohio State University, has developed a cast aluminum-silicon alloy engineered to deliver enhanced as-cast mechanical properties without reliance on thermal or heat-treatment processes. The alloy is compatible with multiple industrial casting methods, including sand casting, semi-permanent mold casting, and high-pressure die casting, enabling broad adoption across manufacturing environments.
The material is designed to exhibit favorable solidification behavior, including a reduced solidification range and low susceptibility to hot cracking. Its microstructural design limits the formation of phases that typically degrade ductility, while promoting strengthening mechanisms active in the as-cast state. The alloy also accommodates elevated levels of commonly present alloying elements that are often restricted in conventional casting alloys, improving tolerance to feedstock variability.
Collectively, these attributes allow manufacturers to achieve a balance of strength, elongation, and castability without additional processing steps, supporting efficient production of complex structural components.
Benefits
- Eliminates the need for post-casting heat treatment
- Improved castability with reduced cracking and porosity
- Strong mechanical performance in the as-cast condition
- Greater tolerance to common alloying impurities
Applications and Industries
- Automotive structural components
- Large-scale metal casting operations
- Transportation and mobility manufacturing
- Industrial component production
Contact
To learn more about this technology, email partnerships@ornl.gov or call 865-574-1051.
