Development of Al–Ni–Mg–(Cu) aluminum P/M alloys

Automotive companies are seeking to make vehicles lighter in an effort to reduce exhaust emissions and increase gas mileage. Aluminum powder metallurgy (P/M) alloys are materials that can help to achieve this goal. However, one of the major problems affecting the aluminum P/M industry is the lack of commercially available alloys. To remedy this, research is currently underway to develop new aluminum P/M alloys with superior properties. The aim of this particular study was to investigate the effects of copper additions on an emerging series of Al–Ni–Mg P/M alloys. Tests were conducted on alloys with nickel contents of 6, 10, and 15 w/o, and compared to a baseline system with 0 w/o Ni. Optimal sintering procedures were developed for each alloy system. Mechanical testing determined that an alloy with 15% Ni and 5% Cu had the highest tensile strength and offered considerable improvement over conventional P/M alloys such as AC2014 at temperatures up to 200 °C.