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Development of High-Ductility and Low-Hot-Tearing-Susceptibility Non-heat Treatment Al–Mg–Mn-Based Die Casting Alloy for Automotive Structural Parts

International Journal of Metalcasting (2023)Cite this article

Abstract

Non-heat-treated Al–Mg-based die casting alloys have been developed for the structural parts of automobiles. In previous studies, alloy compositions with at least 1.0%Si have been proposed to reduce the hot tearing susceptibility (HTS). On the other hand, the increase in the Si content reduces the ductility. For some automotive body structures, Al–Mg alloy die castings with Si content exceeding 1.0% should not have the required ductility. This study aims to develop an Al–Mg alloy with both high ductility and low HTS by investigating the following three characteristics of an Al–4.5Mg–1.0Mn alloy with 0.2%Si added: (1) additional elements to reduce the HTS, (2) the associated mechanical properties (requirements for the automotive company: 0.2% proof stress ≥ 140 MPa and fracture elongation ≥ 15%), and (3) the mechanism of decreasing the HTS. It was revealed that the co-addition of 0.025%Sr, 0.08%Ti, and 0.016%B reduced the HTS when the hydrogen content of the melt was 0.5–1.0 mL/100 g Al. Furthermore, the 0.2% proof stress and fracture elongation of a lower link arm produced via HPDC with the above composition were found to achieve the requirements. It was also indicated that the mechanism of decrease in the HTS by the Sr addition should result from the decrease in the thermal tensile load due to the formation of hydrogen porosity at a lower solid fraction than that without Sr. It is suggested that when 0.025%Sr, 0.08%Ti, and 0.016%B are added to the Al–4.5Mg–1.0Mn–0.2Si alloy, non-heat-treated automotive structural parts with both high ductility and low HTS will be obtained by high-pressure die casting.

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Acknowledgements

This manuscript is based upon a translated version of a paper published in Japanese in “Journal of Japan Foundry Engineering Society, 94 (2022)” under an agreement between IJMC, AFS, and the Japanese Foundry Society. The authors are grateful to the Die Casting Aluminum Alloys Committee established by the Japan Die Casting Association and Japan Aluminum Alloy Refiners Association for collaboration on this study. We would like to also thank Dr. T. Goda of Nissan Motor Co., Ltd., for conducting the experiment and Dr. K. Moizumi of Isuzu Motors, Ltd., for development of the test device.

Funding

This study was supported by Special Young Scientist Research Fellowship from the Japan Foundry Engineering Society.

Author information

Author notes

  1. Hiroshi Kambe

    Present address: Japan Foundry Engineering Society, Minato, Tokyo, Japan

  2. Kiyotaka Kato

    Present address: ENEOS Co., Chiyoda, Tokyo, Japan

Authors and Affiliations

  1. Department of Modern Mechanical Engineering, School of Creative Science and Engineering, Waseda University, Shinjuku, Tokyo, Japan

    Yoshihiro Nagata, Kiyotaka Kato, Takuma Shishido & Ao Tsuchiya

  2. Nikkei MC Aluminium Co., Ltd, Minato, Tokyo, Japan

    Sanji Kitaoka

  3. Daiki Aluminium Industry Co., Ltd., Osaka, Osaka, Japan

    Naoto Oshiro

  4. Department of Manufacturing Technologists, Faculty of Technologists, Institute of Technologists, Gyoda, Saitama, Japan

    Naomi Nishi & Toshimitsu Okane

  5. Mino Industry Co., Ltd., Nakatsugawa, Gifu, Japan

    Naoki Nonaka, Takayuki Koike & Toshimitsu Oike

  6. Nissan Motor Co., Ltd., Yokohama, Kanagawa, Japan

    Kenji Hayashi

  7. Department of Mechanical Engineering, Faculty of Engineering, Universiti Malaya, Kuala Lumpur, Malaysia

    Khairi Faiz Muhammad

  8. Kagami Memorial Research Institute for Materials Science and Technology, Waseda University, Shinjuku, Tokyo, Japan

    Makoto Yoshida

  9. Nissan Motor Co., Ltd., Yokohama, Kanagawa, Japan

    Hiroshi Kambe

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  1. Yoshihiro Nagata
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Nagata, Y., Kato, K., Shishido, T. et al. Development of High-Ductility and Low-Hot-Tearing-Susceptibility Non-heat Treatment Al–Mg–Mn-Based Die Casting Alloy for Automotive Structural Parts. Inter Metalcast (2023). https://doi.org/10.1007/s40962-023-01047-0

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