AlZn alloy from Rusal promises up to 15% weight reduction in automotive wheels and suspension parts

The Russian aluminium giant Rusal has unveiled a groundbreaking AlZn alloy explicitly designed for the automotive industry. The company has collaborated successfully on multiple research and development initiatives with significant global automotive parts suppliers, creating a proprietary AlZn alloy.

This innovative alloy is formulated based on the Al-Zn-Mg system and enriched with Fe-Ni for enhanced manufacturability during the casting process. It boasts superior strength characteristics compared to the conventional alloys widely employed in the automotive sector. The high-strength cast alloy opens the door for implementing lightweight designs in critical automotive components, such as wheels and suspension parts.

The casting process for the AlZn alloy employs both low-pressure die casting (LPDC) and gravity die casting (GDC). Notably, it does not necessitate costly alloying elements and can utilise end-of-life scrap. The versatility of this alloy is evident in its applicability to both F and T6 tempers, depending on specific requirements. Opting for the T6 temper enhances strength, reducing weight compared to the AlSi7Mg alloy in a similar temper. In its as-cast (F) condition, there is a distinct advantage of avoiding heat treatment, offering a cost-saving benefit. Therefore, applying the AlZn alloy provides flexibility in tempering for casted products, allowing manufacturers to tailor their approach based on priorities such as weight reduction or cost savings.

Victor Mann, the Technical Director of Rusal, said, “Our new AlZn alloy offers significant advantages over alloys currently used in the automotive industry. One of the key advantages of using AlZn alloy is reducing the weight of wheels and vehicle suspension parts by up to 15 per cent by increasing the strength and endurance of the alloy after heat treatment, including solution treatment, quenching, and ageing.”

Roman Andryushin, the Sales and Marketing Director of Rusal, said, “Our clients – the end consumers of the alloy – automotive companies can also reduce the cost of parts without using heat treatment of the metal. AlZn alloy can become an effective tool for the largest international automotive companies and manufacturers of auto components in achieving strategic development goals, both from the point of view of optimizing the cost and strength of parts and from the point of view of the environmental agenda.”

The alloy, developed by RUSAL Light Materials and Technologies Institute, stands out due to its unique combination of a low carbon footprint, reduced reliance on heat treatment, and lightweight properties. This aligns seamlessly with the strategic goals of both TIER1s and OEMs in the automotive industry.