Aluminium Alloys with Unique Property Combinations by Spray Casting

Abstract

In the present paper examples are considered of 2xxx, 7xxx, and 8xxx alloys in which spray casting has been used to achieve high solute contents. In the spray casting process there is minimal segregation with little need for subsequent homogenisation, and the high stress levels that lead to cracking in direct chill casting are absent. Alloys with a combination of properties that cannot be obtained by conventional casting may thus be produced. Spray casting has led to elements such as zirconium, vanadium, and titanium being incorporated into the 2xxx series of alloys of the ES2x family giving room temperature strength comparable with 2014 and elevated temperature strength similar to 2618. High zinc levels in SS7x alloys allow an unusual combination of high strength and toughness. The high lithium and zinc content alloy UL30 may be suitable for near net shape forgings as the high precipitate density leads to a reduced necessity for cold work compared with a conventional Al–Li alloy such as 8090. PM/0648