Development of a high strength Al-Mg2Si-Mg-Zn based alloy for high pressure die casting

A high strength Al-Mg2Si-Mg-Zn based alloy has been developed for the application in high pressure die casting to provide improved mechanical properties. The effect of various alloying elements on the microstructure and mechanical properties including yield strength, ultimate tensile strength and elongation of the alloy was investigated under the as-cast and heat-treated conditions. The typical composition of the high strength alloy has been optimised to be Al-8.0wt%Mg2Si-6.0wt%Mg-3.5wt%Zn-0.6wt%Mn (Al-11.0wt%Mg-2.9wt%Si-3.5wt%Zn-0.6wt%Mn) with unavoidable trace impurities. The mechanical properties of the alloy were enhanced by a quick solution treatment followed by ageing treatment. The improved tensile properties were at a level of yield strength over 300MPa, the ultimate tensile strength over 420MPa and the elongation over 3% assessed using international standard tensile samples made by high pressure die casting. The microstructure of the die-cast alloy consisted of the primary α-Al phase, Al-Mg2Si eutectics, AlMgZn intermetallics and α-AlFeMnSi intermetallics under the as-cast condition. The AlMgZn intermetallic compound was dissolved into the Al-matrix during solution treatment and subsequently precipitated during ageing treatment for providing the effective improvement of the mechanical properties.The financial support is gratefully acknowledged for the Engineering and Physical Sciences Research Council (EPSRC) (Project number: EP/I038616/1), Technology Strategy Board (TSB) (Project number: 101172) and Jaguar Land Rover (JLR), United Kingdom