| Abstract Scope |
The dilute eutectic casting aluminium (DECA) alloys was developed over the past decade to provide a more effective alternate solution in the structural shaped casting of Al automotive products than the present-day eutectic casting aluminium (ECA) alloys for automotive structural applications such as the Al-Si-Mg and Al-Si-Cu families. Two families of DECA in (Al,Zn,Mg)-Fe and (Al,Zn,Mg)-Co shall be explored here with high pressure die casting and permanent mould casting, respectively; the Fe and Co form the dilute eutectic regimes, respectively with Al, while the Zn and Mg are solid solution strengtheners. Thermodynamic simulations, casting quality, mechanical properties, microstructure, and heat treatment shall be presented alongside a baseline comparison from the ECA alloy system. The outcome is our potential for significant (>50%) lightweighting of our structural components with cost savings, through significant improvements in strength, toughness and performance of the DECA in both the as-cast and heat-treated tempers. |