Alcoa's Cast Aluminum Alloys without Heat Treatment
In recent years, the large-scale integrated die-cast technology that emerged with Tesla has become one of the hottest trends in the industry. The promotion and application of the integrated die-cast process require equipment, molds, processes and materials. Heat treatment can easily cause dimensional deformation and surface defects of parts due to the large projected area of integrated die-cast parts. For large-scale integrated parts, it is necessary to bear great cost risks. Therefore, integrated die castings tend to adopt aluminum alloys without heat treatment.
Cast aluminum alloys have always been one of Alcoa's product lines, but Alcoa only provides various cast aluminum alloy ingots to downstream foundries and does not directly participate in the production of aluminum castings.
Before the rise of integrated die-cast technology, Alcoa's 560 cast aluminum alloys without heat treatment were used in the large door parts of the Nissan GT-R in 2008. Nissan's door parts were produced in Soest, Germany, and were the largest vacuum die-cast auto parts at that time, with a projected area of 0.5m2, a wall thickness of only 2mm to 3mm, and a weight of only 5.5kg, achieving the purpose of a weight reduction of 35%.
The 560 alloy developed by Alcoa is a cast aluminum alloy without heat treatment, with Mn and Mg as the main alloying elements, which play the role of solid solution strengthening. The properties of 560 alloy castings are not sensitive to heat treatment and are usually supplied in the F state; the mechanical properties exceed the AlSi10MnMg alloy castings in the T6 state.
On April 22, 2015, at the 119th Metal Casting Conference of the American Foundry Society, Alcoa released 4 new cast aluminum alloy products for the automotive industry, which are SupraCast, EZCast, VersaCast, and EverCast. Among them, the EZCast series alloys are specially developed for high-pressure casting to form thin-walled parts. EZCast derives from high flow, thermal stability and low shrinkage porosity, which makes the alloy very easy to cast. At the same time, it has considerable yield strength and elongation compared to conventional alloys in the field.
In 2019, to meet the needs of the large-scale die casting market, Alcoa upgraded the EZCast series, which was optimized for heat treatment. EZCast-NHT alloys were developed. NHT is the abbreviation of Non-Heat Treatable.
EZCast-NHT alloy is an Al-Mg cast aluminum alloy. Alcoa can provide two products, one is A152, containing about 3% of Mg and the other is A153, containing about 4% of Mg. EZCast-NHT series alloys have excellent casting properties (hot cracking resistance), mechanical properties of F temper being comparable to Al-Si series die casting aluminum alloys of T5/T6, and good riveting properties.
EZCast-NHT series alloys are well suited for high-pressure casting for the manufacture of structural components with complex shapes that require high performance, such as shock towers, beams, battery trays, frame nodes, motor housings, etc.
Cast aluminum alloys have always been one of Alcoa's product lines, but Alcoa only provides various cast aluminum alloy ingots to downstream foundries and does not directly participate in the production of aluminum castings.
Before the rise of integrated die-cast technology, Alcoa's 560 cast aluminum alloys without heat treatment were used in the large door parts of the Nissan GT-R in 2008. Nissan's door parts were produced in Soest, Germany, and were the largest vacuum die-cast auto parts at that time, with a projected area of 0.5m2, a wall thickness of only 2mm to 3mm, and a weight of only 5.5kg, achieving the purpose of a weight reduction of 35%.
The 560 alloy developed by Alcoa is a cast aluminum alloy without heat treatment, with Mn and Mg as the main alloying elements, which play the role of solid solution strengthening. The properties of 560 alloy castings are not sensitive to heat treatment and are usually supplied in the F state; the mechanical properties exceed the AlSi10MnMg alloy castings in the T6 state.
On April 22, 2015, at the 119th Metal Casting Conference of the American Foundry Society, Alcoa released 4 new cast aluminum alloy products for the automotive industry, which are SupraCast, EZCast, VersaCast, and EverCast. Among them, the EZCast series alloys are specially developed for high-pressure casting to form thin-walled parts. EZCast derives from high flow, thermal stability and low shrinkage porosity, which makes the alloy very easy to cast. At the same time, it has considerable yield strength and elongation compared to conventional alloys in the field.
In 2019, to meet the needs of the large-scale die casting market, Alcoa upgraded the EZCast series, which was optimized for heat treatment. EZCast-NHT alloys were developed. NHT is the abbreviation of Non-Heat Treatable.
EZCast-NHT alloy is an Al-Mg cast aluminum alloy. Alcoa can provide two products, one is A152, containing about 3% of Mg and the other is A153, containing about 4% of Mg. EZCast-NHT series alloys have excellent casting properties (hot cracking resistance), mechanical properties of F temper being comparable to Al-Si series die casting aluminum alloys of T5/T6, and good riveting properties.
EZCast-NHT series alloys are well suited for high-pressure casting for the manufacture of structural components with complex shapes that require high performance, such as shock towers, beams, battery trays, frame nodes, motor housings, etc.
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