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This study investigates the naturally hard aluminumAluminum die-castingCasting alloy trimal-38 of the type AlSi8ZnMn, developed for structural components in the automotiveAutomotive sector. The objective is to validate the potential of a secondary based version containing elevated levels of the critical elements ironIron (0.35 wt%) and copperCopper (0.15 wt%). Building on insights from previous laboratory-scale gravity castingCasting experiments, the process was upscaled to high pressure die castingDie casting to assess the transferability of the findings. Mechanical propertiesMechanical properties were characterized through tensile testing and complementary plate bending testsBending test to provide detailed insights into deformation behavior. Thermodynamic calculationsThermodynamic calculations support the interpretation of microstructural evolution, which was further examined through qualitative microstructural analyses. Potential concentration ranges for ironIron and copperCopper are discussed with regard to their influence on microstructureMicrostructure and mechanical propertiesMechanical properties, and their suitability for a secondary-based production is being evaluated.

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Alloy Design for Circularity: Mechanical and Microstructural Evaluation of Secondary AlSi8ZnMn HPDC Alloy with Elevated Fe and Cu Content

  • 会议论文

  • 发表日期：

    2026年

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  • A. Siemund,
  • P. Decker,
  • T. Beyer,
  • A. Kleine

摘要

This study investigates the naturally hard aluminumAluminum die-castingCasting alloy trimal-38 of the type AlSi8ZnMn, developed for structural components in the automotiveAutomotive sector. The objective is to validate the potential of a secondary based version containing elevated levels of the critical elements ironIron (0.35 wt%) and copperCopper (0.15 wt%). Building on insights from previous laboratory-scale gravity castingCasting experiments, the process was upscaled to high pressure die castingDie casting to assess the transferability of the findings. Mechanical propertiesMechanical properties were characterized through tensile testing and complementary plate bending testsBending test to provide detailed insights into deformation behavior. Thermodynamic calculationsThermodynamic calculations support the interpretation of microstructural evolution, which was further examined through qualitative microstructural analyses. Potential concentration ranges for ironIron and copperCopper are discussed with regard to their influence on microstructureMicrostructure and mechanical propertiesMechanical properties, and their suitability for a secondary-based production is being evaluated.