High pressure die castingCasting (HPDCHigh-Pressure Die Casting (HPDC)) aluminiumAluminium for large structural applications, known as giga castingCasting, has recently gained significant interest in the automotiveAutomotive industry as it offers not only substantial cost efficiency, but also sustainable manufacturing. RecyclingRecycling, particularly through increased use of Post Consumer ScrapScrap (PCSPost-Consumer Scrap (PCS)), therefore, plays an important role in this transformation as it not only reduces the carbonCarbon footprint, but also aligns with global sustainabilitySustainability goals. However, using PCSPost-Consumer Scrap (PCS) introduces higher content of impurity elementsImpurity elements such as Fe, Cu, and Zn which may affect the performance of HPDCHigh-Pressure Die Casting (HPDC) components. In this study, the influence of high content of these impurity elementsImpurity elements on the corrosion susceptibility and mechanical propertiesMechanical properties by means of tensile test and VDA bendability of thin-wall AlSi10MgMnAlSi10MgMn HPDCHigh-Pressure Die Casting (HPDC) alloy were investigated. The tests were performed both in T1 and T6 condition. The results indicate that high concentration of Fe, Cu, and Zn gave a more pronounced influence on mechanical propertiesMechanical properties in the T6 condition compared to T1. Similarly, although the extent of the corroded area was comparable between samples subjected to T1 and T6 treatments, the T6 condition generally exhibited deeper pit depths. Among the studied elements, Fe had the least impact on both mechanical and corrosion propertiesCorrosion properties, whereas Cu exhibited the most detrimental effect on corrosion resistance. This detrimental effect of Cu on corrosion resistance, however, appeared to be mitigated when combined with Zn and/or Fe. These findings aim to guide the automotiveAutomotive sector in adopting higher recycled content while maintaining material performance and integrity.

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Influence of Recycled Content on AlSi10MgMn High Pressure Die Casting Alloy for Thin-Wall Structural Automotive Applications

  • Martha Indriyati,
  • Jan Tore Buvik Gundersen,
  • Viktoria Elise Horenburg,
  • Anna Kisko,
  • Alicia Vallejo Olivares,
  • Petter Åsholt

摘要

High pressure die castingCasting (HPDCHigh-Pressure Die Casting (HPDC)) aluminiumAluminium for large structural applications, known as giga castingCasting, has recently gained significant interest in the automotiveAutomotive industry as it offers not only substantial cost efficiency, but also sustainable manufacturing. RecyclingRecycling, particularly through increased use of Post Consumer ScrapScrap (PCSPost-Consumer Scrap (PCS)), therefore, plays an important role in this transformation as it not only reduces the carbonCarbon footprint, but also aligns with global sustainabilitySustainability goals. However, using PCSPost-Consumer Scrap (PCS) introduces higher content of impurity elementsImpurity elements such as Fe, Cu, and Zn which may affect the performance of HPDCHigh-Pressure Die Casting (HPDC) components. In this study, the influence of high content of these impurity elementsImpurity elements on the corrosion susceptibility and mechanical propertiesMechanical properties by means of tensile test and VDA bendability of thin-wall AlSi10MgMnAlSi10MgMn HPDCHigh-Pressure Die Casting (HPDC) alloy were investigated. The tests were performed both in T1 and T6 condition. The results indicate that high concentration of Fe, Cu, and Zn gave a more pronounced influence on mechanical propertiesMechanical properties in the T6 condition compared to T1. Similarly, although the extent of the corroded area was comparable between samples subjected to T1 and T6 treatments, the T6 condition generally exhibited deeper pit depths. Among the studied elements, Fe had the least impact on both mechanical and corrosion propertiesCorrosion properties, whereas Cu exhibited the most detrimental effect on corrosion resistance. This detrimental effect of Cu on corrosion resistance, however, appeared to be mitigated when combined with Zn and/or Fe. These findings aim to guide the automotiveAutomotive sector in adopting higher recycled content while maintaining material performance and integrity.