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MAXXALLOY® - ULTRA©:

The winner of the Salzburg Innovation Award of 2005 with astonishing new material properties.

The die casting process is generally considered the most economical way to manufacture large series of cast parts. Technological progress in recent years has now also achieved levels of quality that were previously possible only with significantly more expensive forged articles. Ranging from mechanical properties to options in further processing of the articles, such as suitability for welding, this new potential has caught the attention of many users and presents casters with new challenges that can often only be mastered through cooperation with alloy manufacturers who are also actively engaged in development work.

Just what are the requirements for a modern casting material? In addition to continuous improvement of the material properties, such as the mechanical values or the suitability of the material for welding mentioned above, it must also be possible to manufacture complex casting geometries. Cost-conscious manufacturers also expect that heat treatment should not be necessary or should only be required to a limited extent in the interests of keeping the entire process economical.

The newly developed die casting alloy MAXXALLOY® - ULTRA© from Aluminium Lend GmbH – a 100% subsidiary of Salzburger Aluminum AG, which is specialised in continuous development of aluminium die casting alloys – satisfies these requirements extensively.

MAXXALLOY® - ULTRA© offers designers an aluminium material with extraordinary mechanical properties. For instance, it is possible to produce parts with a 0.2% yield strength of 200 to 220 N/mm² immediately after casting; this can even be increased up to 250 N/mm² through ageing at 200 to 250°C, though this is associated with a corresponding decrease in the ductile yield. Because these values can be achieved in thicknesses as low as 2 mm and heat treatment is generally unnecessary, there are significant economic advantages as well. Reduction of the part weight through the use of thinner walls and a shorter process chain thanks to the elimination of heat treatment reduce manufacturing costs while also improving quality.

Si

Fe

Cu

Mn

Mg

Zn

Ti

Other

2.2 – 3.0

0.2

0.02

0.6 – 0.8

5.6 – 6.2

0.07

0.05 – 0.15

0.02 each

Table 1: Chemical composition of MAXXALLOY® - ULTRA©

(values in percent by mass)

Wall Thickness

[mm]

0.2% Yield Strength

Rp 0.2 [N/mm²]

Tensile Strength

Rm [N/mm²]

Ductile Yield

A 5 [%]

Brinell Hardness

HB 5/250

2 – 4

220

350

14-16

95 – 110

4 – 6

200

330

9-12

90 -100

Table 2: Mechanical properties of MAXXALLOY® - ULTRA©

Cost consciousness is also an important topic during the production of the material. The melting technology developed specially for the production of MAXXALLOY® - ULTRA© has a low environmental impact, and thanks to the economical and qualitative advantages of the horizontal continuous casting (HCC) process, Aluminium Lend can produce the material economically to ensure competitive pricing.

This was certainly part of the reason for which MAXXALLOY® - ULTRA© was chosen on November 9th, 2005 by a jury of experts as the winner of the "2005 Innovation Award of the Salzburg Economy – Industry Field". According to the jurors, both the low environmental impact of the manufacturing process as well as the overall economic advantages – from input material to cast part – were decisive for the selection.

Another product from SAG Aluminium Lend GmbH + Co KG is the ductile die casting alloy MAXXALLOY® - 59©. We offer this material specially for thin-walled die cast parts with high demands on ductility and suitability for welding. MAXXALLOY® - 59© is particularly well suited for structural parts with wall thicknesses from 4 to 6 mm in automotive engineering.

Si

Fe

Cu

Mn

Mg

Zn

Ti

Other

1.8 – 2.6

0.15

0.02

0.5 – .8

5.0 – 6.0

0.07

0.05-0.15

0.02 each

Table 3: Chemical composition of MAXXALLOY® - 59©

(values in percent by mass)

Despite the low iron content, MAXXALLOY® - 59© has a low sticking tendency, and the presence of manganese allows easy demoulding of thin-walled parts.

Wall Thickness mm

0.2% Yield Strength
Rp 0.2 [N/mm²]

Tensile Strength
Rm [N/mm²]

Ductile Yield
A 5 [%]

Brinell Hardness
HB 5/250

2 – 4

150 – 195

270 - 310

10 – 18

85 – 100

4 – 6

130 - 175

250 – 280

9 – 16

75 – 95

6 - 12

100 - 145

210 - 250

7 – 10

70 - 85

Table 4: Mechanical properties of MAXXALLOY® - 59©

The mechanical properties of MAXXALLOY® - 59© depend on the wall thickness of the cast part. This material behaviour must be taken into consideration in the structural design of cast parts.


For more information, please contact:

Öffnet einen externen Link in einem neuen Fensterwww.sag.at
SAG Aluminium Lend GmbH + Co KG
A 5651 Lend. Österreich
+43 6416 6500 – 0
+43 6416 6500 – 360
Öffnet ein Fenster zum Versenden einer E-Mailaluminium.lend(at)sag.at

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