Abstract
In this work, the development of AlZnMg(Cu) alloys was performed by thermodynamic simulations and experimental tests. With calculations, the solidification processes and phase compositions could be predicted. As secondary casting alloys, the selected compositions of AlZn4Mg3Cu(Fe) and AlZn5Mg4Cu have higher contents of alloying elements, such as iron and silicon, and were successfully processed with a cold-chamber die casting machine. In addition, an energy- and time-saving optimization of the material properties was performed by a modified heat treatment (T6*) with a total time of only 12 h. The alloys were evaluated based on the characterization of their mechanical properties and the analysis of their microstructures. In particular, the elimination of cost-intensive alloying elements and the application of a modified heat treatment method clearly show the potential of AlZnMg(Cu) die-cast alloys for future industrial use.
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