Sustainable Al-based AlFeMgSi Alloy with High Ductility

An alloy consisting essentially of:

• 0.4-1.4
• wt. %
• Fe
• 2.2-3.5
• wt. %
• Mg
• 0.2-1.5
• wt. %
• Si
• ≤0.2
• wt. %
• Cr
• ≤0.6
• wt. %
• Mn
• ≤0.3
• wt. %
• Cu
• ≤0.3
• wt. %
• Zn
• ≤0.2
• wt. %
• Ti
• ≤0.05
• wt. %
• Be
• ≤0.05
• wt. %
• Sr
• ≤0.04
• wt. %
• B
• balance Al, wherein Fe + Mg + Si ≤ 5.5 wt. %.

An alloy consisting of:

• 0.4-1.4
• wt. %
• Fe
• 2.2-3.5
• wt. %
• Mg
• 0.2-1.5
• wt. %
• Si
• ≤0.2
• wt. %
• Cr
• ≤0.6
• wt. %
• Mn
• ≤0.3
• wt. %
• Cu
• ≤0.3
• wt. %
• Zn
• ≤0.2
• wt. %
• Ti
• ≤0.05
• wt. %
• Be
• ≤0.05
• wt. %
• Sr
• ≤0.04
• wt. %
• B
• balance Al, wherein Fe + Mg + Si ≤ 5.5 wt. %.

A method of making an alloy comprising the steps of:

• combining 0.4-1.4 wt. % Fe;
• 2.2-3.5 wt. % Mg;
• 0.2-1.5 wt. % Si;
• ≤0.2 wt. % Cr;
• ≤0.6 wt. % Mn;
• ≤0.3 wt. % Cu;
• ≤0.3 wt. % Zn;
• ≤0.2 wt. % Ti;
• ≤0.05 wt. % Be;
• ≤0.05 wt. % Sr;
• ≤0.04 wt. % B;
• balance Al, wherein Fe+Mg+Si≤5.5 wt. % to form a precursor combination;
• melting the precursor combination to form a precursor liquid;
• solidifying the precursor liquid with a cooling rate between 100 and 104° C./s, which results in co-precipitating Al13M4 and FCC aluminum to form Al13M4 precipitates having a lamellar structure with an average inter-lamellar spacing less than 2 μm followed by co-precipitating Al13Fe4, FCC Al, and Mg2Si.