Aluminium Rheinfelden Gmbh

Alusuisse-lonza Services Ltd.

Aluminum Rheinfelden Gmbh

Eads Deutschland Gmbh

Hubert Koch

Blanka Lenczowski

Ulrich Hielscher

Horst Schramm

Jean-Claude Jaquet

Horst Sternau

Peter Krug

Siegfried Botsch

An aluminum alloy suitable for diecasting of components with high elongation in the cast state contains, as well as aluminum and unavoidable impurities, 8.0 to 11.5 w. % silicon, 0.3 to 0.8 w. % manganese, 0.08 to 0.4 w. % magnesium, max 0.4 w. % iron, max 0.1 w. % copper, max 0.1 w. % zinc, max 0.15 w. % titanium and 0.05 to 0.5 w. % molybdenum. Optionally, the alloy also contains 0.05 to 0.3 w. % zirconium, 30 to 300 ppm strontium or 5 to 30 ppm sodium and/or 1 to 30 ppm calcium for permanent refinement and for grain refinement gallium phosphide and/or indium phosphide in a quantity corresponding to 1 to 250 ppm phosphorus and/or titanium and boron added by way of an aluminum master alloy with 1 to 2 w. % Ti and 1 to 2 w. % B.

Aluminum diecasting alloy

In a process to reduce the susceptibility to dross-forming of an aluminium alloy melt with a content of at least 2.5 w. % magnesium, to the melt is added 0.02 to 0.15 w. % vanadium and less than 60 ppm beryllium. By the addition of vanadium, the beryllium addition can be reduced and at the same time the dross-forming resistance of the melt increased.

Treatment of an aluminum alloy melt

An aluminium alloy suitable for diecasting of components with high elongation in the cast state comprises, as well as aluminium and unavoidable impurities, 9.0 to 11.0 w. % silicon, 0.5 to 0.9 w. % manganese, max 0.06 w. % magnesium, 0.15 w. % iron, max 0.03 w. % copper, max 0.10 w. % zinc, max 0.15 w. % titanium, 0.05 to 0.5 w. % molybdenum and 30 to 300 ppm strontium or 5 to 30 ppm sodium and/or 1 to 30 ppm calcium for permanent refinement. Optionally, the alloy also contains 0.05 to 0.3 w. % zirconium and for grain refinement gallium phosphide and/or indium phosphide in a quantity corresponding to 1 to 250 ppm phosphorus and/or titanium and boron added by way of an aluminium master alloy with 1 to 2 w. % Ti and 1 to 2 w. % B.

Casting alloy

Diecasting alloy

Aluminum casting alloy

A brake disc (10) has a cover (12) made of a cast aluminium alloy and a brake ring (14) made of cast steel or cast iron. The cover (12) is cast onto pockets (22) which have a radially inwardly facing pocket opening next to the pocket edge (26), formed on the internal circumference (U.sub.i) of the brake ring, creating a radial distance (b) between the cover (12) and the brake ring (14). The pocket edge (26) is surrounded by the cast cover (12) and the pockets (22) are substantially filled with the cast aluminium alloy. Because of this method of connecting the brake ring (14) to the cover (12), umbrella-like distortion can be largely avoided.

Brake disc

For the grain refinement of aluminum casting alloys, in particular aluminum/silicon casting alloys, gallium phosphide and/or indium phosphide are/is added to the melt, optionally in addition to further grain-refinement and/or modification additions. The addition of gallium phosphide and/or indium phosphide results in a good grain refinement with low shrink-hole tendency and does not have an adverse effect on modification processes.

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Rheinfelden, Germany

Hubert Koch