Aluminum alloy compositions and methods for die-casting thereof

A method of forming a structural compressor component for a compressor comprising:

• a. die-casting an aluminum alloy comprising a synergistic amount of manganese and silicon comprising greater than or equal to about 1 weight % to less than or equal to about 1.2 weight % of manganese in the aluminum alloy and from greater than or equal to about 9 weight % to less than or equal to about 10 weight % silicon in the aluminum alloy;
• b. solidifying the aluminum alloy to form the structural compressor component, wherein the solidified aluminum alloy has an elongation of greater than or equal to 7% and a tensile strength of greater than or equal to 38,000 psi;
• c. heating the solid structural compressor component by exposure to a heat source having a rate of heating of greater than or equal to about 50° F. per hour to less than or equal to about 200° F. per hour to reach a holding temperature;
• and
• d. annealing the aluminum alloy for greater than or equal to five hours to less than or equal to 24 hours at the holding temperature of greater than or equal to about 500° F. to less than or equal to about 800° F., so that the solid structural compressor component has a hardness of greater than or equal to about 75 to less than or equal to about 90 HRH (Rockwell Hardness H Scale).

A method of forming a structural scroll compressor component for a scroll compressor comprising:

• casting a molten aluminum alloy material to form a solid scroll compressor structural component, wherein the aluminum alloy material comprises:
• silicon at greater than or equal to about 8 weight % to less than or equal to about 10 weight % of the aluminum alloy material;
• manganese at greater than 1 weight % to less than or equal to about 1.9 weight % of the aluminum alloy material;
• iron at greater than or equal to about 0.1 weight % to less than or equal to about 0.5 weight % of the aluminum alloy material;
• magnesium at greater than or equal to about 0.2 weight % to less than or equal to about 0.7 weight % of the aluminum alloy material;
• boron at greater than or equal to about 0.002 weight % to less than or equal to about 0.15 weight % of the aluminum alloy material;
• strontium at greater than or equal to about 0.006 weight % to less than or equal to about 0.017 weight % of the aluminum alloy material;
• less than or equal to about 0.25 weight % copper of the aluminum alloy material;
• less than or equal to about 0.35 weight % zinc of the aluminum alloy material;
• less than or equal to about 0.25 weight % titanium of the aluminum alloy material;
• and
• a balance of the aluminum alloy material being aluminum;
• annealing the solid scroll compressor structural component by exposure to a heat source having a holding temperature of greater than or equal to about 500° F. to less than or equal to about 800° F. for greater than or equal to five hours to less than or equal to 24 hours, wherein after the annealing, the solid scroll compressor structural component has a hardness of greater than or equal to about 75 to less than or equal to about 90 HRH (Rockwell Hardness H Scale) and a percentage of elongation of greater than or equal to 7%;
• and
• machining the solid scroll compressor structural component for incorporation into the scroll compressor.