LOW COST HIGH DUCTILITY CAST ALUMINUM ALLOY

Abstract

An improved aluminum alloy for casting into a component, such as a vehicle component, is provided. The improved aluminum alloy includes at least 80 wt. % aluminum; 6.0 to 8.0 wt. % silicon; 1.0 to 2.0 wt. % zinc; 0.10 to 0.6 wt. % magnesium; 0.1 to 0.60 wt. % copper; 0.20. to 0.60 wt. % manganese; up to 0.25 wt. % iron; 0.015 wt. % to 0.03 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy. This improved aluminum alloy can be formed by combining recycled aluminum or recycled aluminum alloy with at least one additional element. The cast component formed of the improved aluminum alloy has a yield strength of 120 MPa to 130 MPa and an elongation of 8% to 16%, depending on flow length, when the cast component is in the as-cast (F temper) condition.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates generally to an aluminum alloy for casting, a method of forming the aluminum alloy, a vehicle component formed of the cast aluminum alloy, and a method of manufacturing the cast component.

2. Related Art

Casting of aluminum alloys is oftentimes used in the automotive industry to form lightweight components, including complex structural, body-in-white, suspension, and chassis components. There are many types of known casting processes, for example, high pressure die casting, low pressure casting, and squeeze casting. The die is typically formed of a hardened tool steel. Although the casting equipment is expensive, the cost per component formed is relatively low, which makes the process suitable for high volume production.

However, improvements to the casting process and materials used in the casting process are desired. For example, an aluminum alloy capable of forming a component having higher ductility, without loss of fluidity or castability, is desired. The aluminum alloy should also be resistant to damage associated with hot cracking, soldering, shrinkage, and corrosion. In addition, although lightweight components are desired, the components should still provide a high strength and toughness.

SUMMARY

One aspect of the disclosure provides an improved aluminum alloy, comprising: at least 80 weight percent (wt. %) aluminum; 6.0 to 8.0 wt. % silicon; 1.0 to 2.0 wt. % zinc; 0.05 to 0.3 wt. % magnesium; 0.1 to 0.40 wt. % copper; 0.20. to 0.50 wt. % manganese; 0.3 to 0.6 wt. % iron; 0.01 wt. % to 0.03 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.

Another aspect of the disclosure provides a cast component formed of an improved aluminum alloy.

Another aspect of the disclosure provides a method of manufacturing an improved aluminum alloy, comprising the steps of: obtaining recycled aluminum or a recycled aluminum alloy; and combining the recycled aluminum or the recycled aluminum alloy with at least one additional element to form the improved aluminum alloy.

Yet another aspect of the disclosure provides a method of manufacturing a cast component, comprising the steps of: obtaining recycled aluminum or a recycled aluminum alloy; combining the recycled aluminum or the recycled aluminum alloy with at least one additional element to form the improved aluminum alloy.

An improved aluminum alloy, comprising at least 80 weight percent (wt. %) aluminum; 6.0 to 8.0 wt. % silicon; 1.0 to 2.0 wt. % zinc; 0.10 to 0.6 wt. % magnesium; 0.1 to 0.60 wt. % copper; 0.20. to 0.60 wt. % manganese; 0.25 wt. % iron; 0.015 wt. % to 0.03 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.

Yet another aspect of the disclosure provides an improved aluminum alloy, comprising: at least 80 weight percent (wt. %) aluminum; 6.0 to 8.0 wt. % silicon; 1.0 to 2.0 wt. % zinc; at least 0.05 wt. % magnesium; at least 0.1 wt. % copper; at least 0.20. wt. % manganese; iron; 0.01 wt. % to 0.03 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

FIG. 1 illustrates a portion of an example cast ingot which can be used to form an improved aluminum alloy according to an embodiment of the invention;

FIG. 2 illustrates a portion of an example component formed of an improved aluminum alloy according to an embodiment of the invention;

FIGS. 3A and 3B illustrate examples of different scrap streams which can be combined to create an improved aluminum alloy according to example embodiments;

FIG. 3C is an example composition of an improved aluminum alloy according to example embodiments;

FIGS. 3D-3F are examples of cast parts formed of the improved aluminum alloy according to example embodiments;

FIG. 4 illustrates the chemical composition of the aluminum alloy according to an example embodiment of the invention relative to a comparative aluminum alloy;

FIG. 5A shows a cast improved aluminum alloy according to an example embodiment;

FIGS. 5B and 5C illustrate mechanical properties of the cast improved aluminum alloy according to the example embodiment of FIG. 5A relative to a comparative aluminum alloy both cast on a small high pressure die cast machine in two (2) different tempers, specially paint bake at 185° C. (365° F.) for 20 min and as-cast (F Temper);

FIG. 6A shows a cast improved aluminum alloy according to an example embodiment;

FIGS. 6B-6D illustrate mechanical properties of an improved aluminum alloy (Aural 5R) according to an example embodiment relative to a comparative aluminum alloy (Aural 5S) both cast on a large high pressure die cast machine in the as-cast (F Temper);

FIGS. 7A and 7B illustrate mechanical properties of an improved aluminum alloy according to an example embodiment cast on a large high pressure die cast machine at three (3) paint bake exposures, including nominal: 25 min at 171° C. (340° F.), lower: 18 min at 163° C. (325° F.), upper: 60 min at 191° C. (375° F.); and production artificial age (T5) temper 60 min at 215° C. (419° F.) time at temperature.

FIG. 8A-8C illustrate a 3 point bending test comparing an improved aluminum alloy according to an example embodiment relative to a comparative aluminum alloy;

FIG. 8D illustrates the results of the bending test, specifically a bending curve (load v. extension);

FIG. 9A illustrates a VDA 238 bend test comparing an improved aluminum alloy according to an example embodiment relative to a comparative aluminum alloy;

FIG. 9B is a formula used to determine the results of the VDA bend test, considering variation from 2.0 mm thick samples, and FIG. 9C is a table including the results of the bend test;

FIGS. 10A-10C illustrate the results of a rivetability test comparing an improved aluminum alloy according to an example embodiment relative to a comparative aluminum alloy;

FIGS. 11A-11C illustrate the results of two different corrosion tests, including ASTM B117 salt spray for 100 hours and ASTM G110 intergranular corrosion, comparing an improved aluminum alloy according to an example embodiment relative to a comparative aluminum alloy;

FIGS. 12A and 12B illustrate the results of a cyclic corrosion test, SAE J2334, comparing an improved aluminum alloy according to an example embodiment relative to a comparative aluminum alloy;

FIGS. 13A and 13B illustrates the results of a theoretical prediction of increased castability comparing an improved aluminum alloy according to an example embodiment relative to a comparative aluminum alloy;

FIGS. 14A-14I and FIGS. 15A-15I illustrate the results of an x-ray quality test comparing an improved aluminum alloy according to an example embodiment relative to a comparative aluminum alloy; and

FIG. 16 shows intermetallic phase present in the cast improved aluminum alloy according to example embodiments.

DESCRIPTION OF THE ENABLING EMBODIMENT

One aspect of the invention provides an improved aluminum alloy for casting components, such as a lightweight automotive vehicle component, is provided. Examples of such components include structural, body-in-white, suspension, or chassis components. The aluminum alloy provides a component with improved ductility and elongation, and without hot tearing or loss of fluidity or castability. The aluminum alloy is also beneficial for high volume production. The improved aluminum alloy can be created in a reverberatory furnace on-site or cast into an ingot, such as the ingot of FIG. 1, to be shipped to foundry equipped with stack melting capability. Examples of components 10 formed of the improved aluminum alloy according to example embodiments is shown in FIG. 2.

The improved aluminum alloy is aluminum-based, and thus typically includes aluminum in an amount of at least 80 weight percent (wt. %), based on the total weight of the aluminum alloy. The aluminum alloy also includes an amount of silicon (Si), which helps achieve improved castability of the aluminum alloy and thus reduces a scrap rate and reduces costs. The zinc also helps to lower the liquidus temperature and lower thermal conductivity which also helps the castability of the alloy. Besides the large amount of silicon eutectic phase, the elongation of the component formed of the aluminum alloy is typically 5% to 8% in F temper (as-cast). The castability, strength, and toughness of the aluminum alloy can also be adjusted based on the amount of silicon.

Additional alloying elements can also be present in the improved aluminum alloy to further improve elongation and ductility, or to achieve the desired strength and toughness. For example, magnesium (Mg), manganese (Mn), and/or iron (Fe) can be added to further improve ductility, castability, strength, ductility, and/or toughness. In particular, the manganese can be used to prevent die sticking, and the magnesium can be used to form Mg₂Si for strengthening. The aluminum alloy can also include certain amounts of copper (Cu) and zinc (Zn) to increase strength, preferably without negatively impacting corrosion resistance. The zinc is also used as a solid solution strengthener and to improve machinability. The additional alloying elements can provide other metallurgical effects as well, such as improved resistance to hot cracking, soldering, shrinkage, and corrosion. Strontium (Sr) can also be added to modify the silicon eutectic morphology which affects the ductility that occur due to the silicon.

According to a first example embodiment, in addition to at least 80 wt. % aluminum, the aluminum alloy includes 6.0 to 8.0 wt. % silicon; 1.0 to 2.0 wt. % zinc; 0.10 to 0.6 wt. % magnesium; 0.1 to 0.60 wt. % copper; 0.20. to 0.60 wt. % manganese; up to 0.25 wt. % iron; 0.015 wt. % to 0.03 wt. % strontium; and up to 0.15 wt. % titanium. The aluminum alloy can also include other elements, for example impurities, each in an amount of less than 0.05 wt. % and in a total amount of less than 0.15 wt. %, based on the total weight of the aluminum alloy.

According to a second example embodiment, the improved aluminum alloy includes at least 80 weight percent (wt. %) aluminum; 6.0 to 8.0 wt. % silicon; 1.0 to 2.0 wt. % zinc; 0.05 to 0.3 wt. % magnesium; 0.1 to 0.40 wt. % copper; 0.20. to 0.50 wt. % manganese; 0.3 to 0.6 wt. % iron; 0.01 wt. % to 0.03 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy. The first and second example compositions of the improved aluminum alloy are provided in Table 1 below and in FIG. 4.

TABLE 1
									Other	Other
	Si	Zn	Mg	Cu	Mn	Fe	Sr	Ti	Each	Total
Ex. 1 Aural 5R	6.0-8.0	1.0-2.0	0.10-0.60	0.10-0.60	0.2-0.6	0.25	0.015-	0.15	0.05	0.15
						max	0.03	maximum
Ex. 2 Aural 5R	6.0-8.0	1.0-2.0	0.05-0.30	0.10-0.40	0.2-0.5	0.3-0.6	0.01-	0.15	0.05	0.15
							0.03	maximum

The Aural 5R aluminum alloy is preferable obtained from recycled aluminum, such as post-consumer recycled road wheels and pre-consumer wrought stamping offal as shown in FIGS. 3A and 3B. The energy required to produce the aluminum alloy is reduced by about 95% when the aluminum alloy is formed from recycled materials.

Another aspect of the invention provides the cast component 10 formed of the aluminum alloy, and a method of manufacturing the cast component 10 by melting and casting the melted aluminum alloy. The method of forming the cast component typically begins by melting the aluminum alloy. Any casting process used to form components, for example high pressure die casting, low pressure casting, or squeeze casting. In one example embodiment, the casting process is a die casting process, which typically includes forcing the molten aluminum alloy into an heated die or mold cavity under pressure. The die is typically formed from hardened tool steel.

After the casting the Aural 5R aluminum alloy and after either artificial age (T5 temper) or exposing the cast aluminum alloy to a body shop paint bake cycle, the cast aluminum alloy has a yield strength of at least 100 to 120 MPa, ultimate tensile strength (UTS) of at least 180 MPa, and an elongation of 5% to 7%.

An example of the aluminum alloy of the second example embodiment, Aural 5R, has a higher amount of recycled (secondary materials). After casting, the aluminum alloy is either artificially aged (T5 temper) or exposed to a body shop paint bake cycle, and thus the as-cast aluminum alloy (F Temper) typically has a yield strength of at least 120 to 130 MPa, ultimate tensile strength (UTS) of 240 to 260 MPa, and an elongation of 8% to 16%, depending on flow length.

An example of the aluminum alloy of the third example embodiment, Aural 2R, has a higher amount of recycled (secondary materials) and after casting is either artificial aged (T5 temper) or exposed to a body shop paint bake cycle, and thus the cast Aural 5R aluminum alloy in T5 Temper has a yield strength of 150 to 160 MPa, ultimate tensile strength (UTS) of 250 to 270 MPa, and an elongation of 6% to 11%, depending on flow length. The cast Aural 5R after paint bake in the OEM body shop has a condition with a yield strength of at least 125 MPa to 130 MPa, ultimate tensile strength (UTS) of 200 MPa, and an elongation of 8% to 10%.

An example of the aluminum alloy of the third example embodiment, Aural 5R, has a significant amount of recycled (secondary materials) and after casting is either artificial aged (T5 temper) or exposed to a body shop paint bake cycle, and thus the cast Aural 5R after paint bake in the OEM body shop has a condition with a yield strength of 130 MPa to 140 MPa, ultimate tensile strength (UTS) of 250 to 270 MPa, and an elongation of 8% to 15%.

The aluminum alloy according to example embodiments provides for exceptional mechanical properties, corrosion resistance, rivetability, and castability. FIGS. 5B and 5C illustrate the mechanical properties of the aluminum alloy of example 1 (Aural 5R) relative to a comparative aluminum alloy (Aural 5S). The yield strength, ultimate tensile strength, and elongation are tested using ASTM E8/E8M-21 (Standard Test Methods for Tension Testing of Metallic Materials). FIGS. 6B-6D illustrate mechanical properties of a large high pressure die casting from a 4200 IDRA die casting machine comparing the aluminum alloy of example 1 to the comparative aluminum alloy. FIG. 8D is a 3 point bending curve (load v. extension) comparing the aluminum alloy of example 1 (Aural 5R) to the comparative aluminum alloy (Aural 5S). The composition of the comparative aluminum alloy (Aural 5S) includes at least 80 wt. % aluminum, 6.0 to 8.0 wt. % silicon; up to 0.05 wt. % zinc; 0.10 to 0.6 wt. % magnesium; up to 0.05 wt. % copper; 0.40 to 0.60 wt. % manganese; up to 0.25 wt. % iron; 0.01 wt. % to 0.03 wt. % strontium; and up to 0.15 wt. % max titanium, based on the total weight of the aluminum alloy. The test method used to obtain the bending curve is an adaptation based on a German Association of the Automotive Industry or VDA standard VDA 238-100 (Plate bending test for metallic materials). The VDA 238-100 standard is for 2.0 mm thick wrought products (sheet, etc.). Thus, the test is adapted to include castings. A correction factor is applied if the casting thickness is above 2.0 mm. FIG. 9A illustrates a VDA 238-100 test comparing the improved aluminum alloy of example 1 to the comparative aluminum alloy; and FIGS. 9B and 9C include the results.

FIGS. 10A-10C illustrate the results of a rivetability test comparing the aluminum alloy of example 1 (Aural 5R) to the comparative aluminum alloy (Aural 5S). The rivetability test included applying a self-piercing rivet to the aluminum alloy of example 1 (Aural 5R) and the comparative aluminum alloy (Aural 5S). The self-piercing rivet is a single-step technique which includes using a semi-tubular rivet to clinch sheets of the aluminum alloy together. The sheets are clamped between a die and blankholder, and the rivet is driven into the sheets between a punch and a die. The rivet pierces the top sheet and the die shape causes the rivet to flare within the lower sheet to form a mechanical interlock. The die shape causes a button to form on the underside of the lower sheet. Preferably, the rivet tail does not pierce though the button.

The Aural 5R improved aluminum alloy composition exhibits good corrosion resistance when subjected to a salt spray test for 100 hours according to ASTM B117-16 (Standard Practice for Operating Salt Spray (Fog) Apparatus), ASTM G110 (Standard Practice for Evaluating Intergranular Corrosion Resistance of Heat Treatable Aluminum Alloys by Immersion in Sodium Chloride+Hydrogen Peroxide Solution1) and SAE J2334 (Laboratory Cyclic Corrosion). FIGS. 11A-12B includes results of corrosion testing comparing the improved aluminum alloy of example 1 to the comparative aluminum alloy. The corrosion test results show that the Cu and Zn do not impact corrosion resistance. The corrosion tests of FIGS. 11A-11C was conducted according to ASTM B117 and ASTM G110. The corrosion test of FIGS. 12A and 12B was conducted according to SAE J2334. The corrosion test conducted according to SAE J2334 results show that after 20 days (20 cycles), the improved aluminum alloy had the same corrosion resistance as the comparative alloy. There was no weight loss and no coating cracking or peeling

FIGS. 13A and 13B illustrates the results of the theoretical Scheil and thermal conductivity comparing the aluminum alloy of example 1 to a comparative aluminum alloy. The theoretical prediction was increased castability of the Aural 5R alloy compared to the Aural 5S alloy. The Scheil Equation shown in FIG. 13A predicted a lower liquidus temperature of the Aural 5R (secondary) compared to the Aural 5S (primary). The Aural 5R has improved castability due to lower percentage of solid formed during filling. The thermal conductivity modeling of FIG. 13B shows lower values for Aural 5R from 600° C. down to room temperature, compared to the Aural 5S. This helps the improved aluminum alloy to stay molten longer while in contact with the H13 tool steel die and thus have improved castability.

FIGS. 14A-15I illustrate x-ray testing comparing the aluminum alloy of example 1 to the comparative aluminum alloy. The test was conducted according to ASTM E505/Digital ASTM E2973 at 24 locations. The flat areas were at less than level 2. The central boss was at level 3. The metal temperature ranged from 710 to 720° C. The cycle time was 130 seconds and the vacuum level was less than 40 mbr (BDW High Q). The intensification pressure was less than 400 bar.

The cast improved aluminum alloy can include Al—Si—Mn—Fe—Cu—Zn intermetallic and/or Al—Mn—Si—Fe intermetallic. FIG. 16 shows intermetallic phase present in the cast improved aluminum alloy according to example embodiments.

The cast component 10 formed from the casting step can be, for example, a component for use in a vehicle. The molten aluminum is formed to a solid component having the shape of the mold, which can be a complex shape. Many different types of components can be formed by the casting process, for example, a structural, body-in-white, suspension, or chassis component. After the casting process, the method can include an optional heat treating process or other finishing processes. However, it has been found that a heat treatment process may not be necessary when the component is formed from the improved aluminum alloy, which would provide the advantage of reduced process time and costs.

Generally, it takes up to 95 percent less energy to recycle than to produce primary aluminum, which reduces the carbon footprint of the foundries. The aluminum alloys of the present invention which include high amounts of recycled material, known as Aural 5R (R=high amt of recycled material), will utilize both post-consumer recycled shredded road wheels as well as pre-consumer wrought aluminum stamping offal. Development of these green aluminum alloys, using secondary recycled aluminum for BIW and structural components, will allow for both less cost of raw material, and a lower carbon footprint while still meeting stringent automotive industry standards. The cast components formed of the aluminum alloys have good rivetability and castability.

Obviously, many modifications and variations of the present invention are possible in light of the above teachings and may be practiced otherwise than as specifically described while within the scope of the following claims.

Claims

1. An improved aluminum alloy, comprising: at least 80 weight percent (wt. %) aluminum; 6.0 to 8.0 wt. % silicon; 1.0 to 2.0 wt. % zinc; 0.05 to 0.3 wt. % magnesium; 0.1 to 0.40 wt. % copper; 0.20. to 0.50 wt. % manganese; 0.3 to 0.6 wt. % iron; 0.01 wt. % to 0.03 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.

2. The improved aluminum alloy according to claim 1 further including other elements each in an amount of less than 0.05 wt. % and in a total amount of less than 0.15 wt. %, based on the total weight of the improved aluminum alloy.

3. A cast component formed of an improved aluminum alloy according to claim 1.

4. The cast component of claim 3, wherein the cast component is a structural, body-in-white, suspension, or chassis component.

5. The cast component of claim 3, wherein the cast improved aluminum alloy includes Mg2Si.

6. The cast component of claim 3, wherein the cast component has a yield strength of 140 to 150 MPa and an elongation of 5% to 7% when the cast component is in the T5 temper condition.

7. The cast component of claim 3, wherein the cast component has a yield strength of 110 MPa to 120 MPa and an elongation of 8% to 10% when the cast component is in the as-cast (F temper) condition.

8. A method of manufacturing an improved aluminum alloy, comprising the steps of: obtaining recycled aluminum or a recycled aluminum alloy; andcombining the recycled aluminum or the recycled aluminum alloy with at least one additional element to form the improved aluminum alloy, the improved aluminum alloy comprising:at least 80 weight percent (wt. %) aluminum; 6.0 to 8.0 wt. % silicon; 1.0 to 2.0 wt. % zinc; 0.05 to 0.3 wt. % magnesium; 0.1 to 0.40 wt. % copper; 0.20. to 0.50 wt. % manganese; 0.3 to 0.6 wt. % iron; 0.01 wt. % to 0.03 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.

9. The method of claim 8, wherein the improved aluminum alloy further includes other elements each in an amount of less than 0.05 wt. % and in a total amount of less than 0.15 wt. %, based on the total weight of the improved aluminum alloy.

10. A method of manufacturing a cast component, comprising the steps of: obtaining recycled aluminum or a recycled aluminum alloy;combining the recycled aluminum or the recycled aluminum alloy with at least one additional element to form an improved aluminum alloy, the improved aluminum alloy comprising:at least 80 weight percent (wt. %) aluminum; 6.0 to 8.0 wt. % silicon; 1.0 to 2.0 wt. % zinc; 0.05 to 0.3 wt. % magnesium; 0.1 to 0.40 wt. % copper; 0.20. to 0.50 wt. % manganese; 0.3 to 0.6 wt. % iron; 0.01 wt. % to 0.03 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy; andcasting the improved aluminum alloy.

11. The method of claim 10, wherein the improved aluminum alloy further includes other elements each in an amount of less than 0.05 wt. % and in a total amount of less than 0.15 wt. %, based on the total weight of the improved aluminum alloy.

12. The method of claim 10, wherein the casting step includes forming the improved aluminum alloy into the shape of a structural, body-in-white, suspension, or chassis component.

13. An improved aluminum alloy, comprising: at least 80 weight percent (wt. %) aluminum; 6.0 to 8.0 wt. % silicon; 1.0 to 2.0 wt. % zinc; 0.10 to 0.6 wt. % magnesium; 0.1 to 0.60 wt. % copper; 0.20. to 0.60 wt. % manganese; up to 0.25 wt. % iron; 0.015 wt. % to 0.03 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.

14. A cast component formed of the improved aluminum alloy according to claim 13.

15. The cast component according to claim 14, wherein the cast improved aluminum alloy includes Al—Si—Mn—Fe—Cu—Zn intermetallic and/or Al—Mn—Si—Fe intermetallic.

16. The cast component according to claim 14, wherein the cast component has a yield strength of 150 to 160 MPa and an elongation of 6% to 12%, when the cast component is in the T5 temper condition.

17. The cast component according to claim 14, wherein the cast component has a yield strength of 130 to 140 MPa and an elongation of 8% to 15% when the cast component is in a paint bake temper condition.

18. The cast component of claim 14, wherein the cast component has a yield strength of 120 MPa to 130 MPa and an elongation of 8% to 16%, when the cast component is in an as-cast (F temper) condition.

19. A method of manufacturing a cast component, comprising the steps of: obtaining recycled aluminum or a recycled aluminum alloy;combining the recycled aluminum or the recycled aluminum alloy with at least one additional element to form the improved aluminum alloy according to claim 13; andcasting the improved aluminum alloy.

20. A method of manufacturing an improved aluminum alloy, comprising the steps of: obtaining recycled aluminum or a recycled aluminum alloy; andcombining the recycled aluminum or the recycled aluminum alloy with at least one additional element to form the improved aluminum alloy, the improved aluminum alloy comprising:at least 80 weight percent (wt. %) aluminum; 6.0 to 8.0 wt. % silicon; 1.0 to 2.0 wt. % zinc; 0.10 to 0.6 wt. % magnesium; 0.1 to 0.60 wt. % copper; 0.20. to 0.60 wt. % manganese; up to 0.25 wt. % iron; 0.015 wt. % to 0.03 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.

21. An improved aluminum alloy, comprising: at least 80 weight percent (wt. %) aluminum; 6.0 to 8.0 wt. % silicon; 1.0 to 2.0 wt. % zinc; at least 0.05 wt. % magnesium; at least 0.1 wt. % copper; at least 0.20. wt. % manganese; iron; 0.01 wt. % to 0.03 wt. % strontium; and up to 0.15 wt. % titanium, based on the total weight of the improved aluminum alloy.