US 2025/0059629 A1Published application

Powder Metallurgy Counterpart to Wrought Aluminum Alloy 6063

AssigneeGKN Sinter Metals, LLC

InventorsIan W. Donaldson, Donald Paul Bishop, Richard L. Hexemer, JR., Conner Spence

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Abstract

A powder metal composition for a powder metal material to be compacted, sintered, and heat treated is comparable to wrought 6063 aluminum alloy. The powder metal composition consists essentially of an aluminum powder metal with no pre-alloyed alloying additions, an aluminum-silicon powder metal, an elemental magnesium powder metal, optionally an elemental tin powder metal, and optionally a ceramic addition (which is not included when calculating the weight percentages of the alloying elements). A weight percent of silicon is in a range of 0.2 to 0.6 wt % of the powder metal composition, of magnesium is in a range of 0.5 to 0.9 wt %, and of tin is in a range of 0.0 to 1.0 wt %. This powder metal is compactable to form a green compact which is further sinterable and heat treatable to provide a powder metal composition comparable to a wrought 6063 aluminum alloy and which offers exceptional thermal conductivity.

Claims18

Dependent claims

A powder metal composition providing a powder metal material to be compacted, sintered, and heat treated to be comparable to wrought 6063 aluminum alloy, the powder metal composition consisting essentially of:

an aluminum powder metal with no pre-alloyed alloying additions apart from any inevitable non-effective trace amounts;
an aluminum-silicon powder metal;
an elemental magnesium powder metal;
optionally an elemental tin powder metal;
optionally a ceramic powder addition to provide a metal matrix composite upon sintering, which ceramic powder addition is not taken into account when calculating alloying percentages of the powder metal composition;
and
a lubricant wherein the weight percentages of the alloying elements are exclusive of the weight of the lubricant as the lubricant is configured to be burned off during sintering of the powder metal composition;
wherein a weight percent of silicon in the powder metal composition is in a range of 0.2 to 0.6 wt % of the powder metal composition, a weight percent of magnesium in the powder metal composition is in a range of 0.5 to 0.9 wt % of the powder metal composition, and a weight percent of tin in the powder metal composition is in a range of 0.0 to 1.0 wt % of the powder metal composition.

5 more elements

Dependencies are inferred from the claim text.