The Need
The transportation industry increasingly relies on aluminum-silicon (Al-Si) casting alloys to reduce vehicle weight and emissions. However, structural applications demand high ductility and strict impurity limits, making them incompatible with most recycled aluminum. Current secondary alloys like A380 cannot meet these mechanical requirements due to elevated levels of Fe, Cu, and Mg. There is a critical need for cost-effective, sustainable aluminum alloys that tolerate higher impurity levels while maintaining structural-grade performance.

The Technology
This innovation introduces a novel aluminum-silicon alloy system designed for high-pressure die casting (HPDC) applications, incorporating small additions of cerium (Ce). Ce promotes the formation of Ce-rich intermetallic phases that act as sinks for impurity elements such as Mg, Cu, and Fe. These phases refine detrimental intermetallic phases and improve ductility, enabling the use of lower-purity scrap without compromising mechanical performance. The alloy is optimized for high pressure die casting conditions and is compatible with existing casting infrastructure.

Commercial Applications
• Structural automotive components
• Lightweight transportation systems
• Consumer electronics housings
• Industrial machinery castings
• Sustainable building materials

Benefits/Advantages
• Enables use of 100% recycled aluminum, reducing raw material costs
• Eliminates or reduces need for costly impurity removal processes
• Improves ductility and mechanical performance in HPDC applications
• Compatible with existing casting processes and infrastructure
• Supports sustainability goals by lowering embodied energy and emissions