Tesla, Inc.

Zapi S.p.a.

Ethan Filip

Gerald W Brown

Sivanesh Palanivel

Charlie Kuehmann

Paul D Edwards

Jason Robert Stucki

Paul K Edwards

A high performance die castable aluminum alloy is described, wherein the aluminum alloy is characterized as having a high yield strength and high conductivity compared to conventional aluminum alloys, and also a high flowability and low susceptibility to hot tearing when die cast. The aluminum alloy may contain 4-6 wt. % nickel, a yield strength of at least about 90 MPa, and an electrical conductivity of at least about 48% IACS.

Aluminum alloys for die casting

In various embodiments, aluminum alloys having yield strengths greater than 120 MPa, and typically in the range from 140 MPa to 175 MPa, are described. Further, such alloys can have electrical conductivity of greater than 45% IACS, typically in the range from 45-55% IACS. In one embodiment, the aluminum alloy comprises Si from 1 to 4.5 wt %, Mg from 0.3 to 0.5 wt %, TiBfrom 0.02 to 0.07 wt %, Fe less than 0.1 wt %, Zn less than 0.01 wt %, Cu less than 0.01 wt %, Mn less than 0.01 wt %, the remaining wt % being Al and incidental impurities. Such alloys can be used to cast a variety of automotive parts, including rotors, stators, busbars, inverters, and other parts.

Casting aluminum alloys for high-performance applications

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Los Altos, CA, United States of America

Ethan Filip