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Aluminum alloys, aluminum alloy products and methods for making the same

  • US 8,950,465 B2
  • Filed: 12/03/2012
  • Issued: 02/10/2015
  • Est. Priority Date: 01/16/2009
  • Status: Active Grant
First Claim
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1. A method comprising:

  • (a) selecting a product application for a shape cast aluminum alloy product;

    (b) selecting a finishing style for the shape cast aluminum alloy product;

    wherein the finishing style includes a visually apparent defect free surface;

    (c) selecting, based on at least one of steps (a) and (b);

    (i) a predetermined microstructure of the shape cast aluminum alloy product;

    wherein the predetermined microstructure comprises a layered microstructure, wherein the layered microstructure comprises an outer layer having alpha aluminum phase and eutectic microstructure; and

    (ii) an alloy for use in producing the shape cast aluminum alloy product, wherein the alloy is one of;

    (A) an Al—

    Ni casting alloy comprising from about 0.5 wt. % to about 8.0 wt. % Ni; and

    (B) an Al—

    Ni—

    Mn casting alloy comprising from about 0.5 wt. % to about 8.0 wt. % Ni and from about 0.5 wt. % to about 3.5 wt. % Mn;

    (d) producing the shape cast aluminum alloy product in response to the selection step (c), wherein the producing comprises;

    (i) die casting the shape cast aluminum alloy product from either the Al—

    Ni or the Al—

    Ni—

    Mn alloy;

    wherein the shape cast aluminum alloy product realizes the layered microstructure, wherein the outer layer has a thickness of not greater than about 400 microns;

    (ii) removing at least a portion of the outer layer from the shape cast aluminum alloy product; and

    (iii) anodizing the shape cast aluminum alloy product, wherein the anodizing comprises forming a uniform oxide layer from a portion of the shape cast aluminum alloy product;

    wherein after the anodizing step (iii), the shape cast aluminum alloy product realizes both (A) a CIELAB L-value of at least about 55 and (B) an ISO brightness of at least about 20.

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