Casting Foundry Aluminum Alloy Design

National Laboratory: 
Idaho National Laboratory
Computational Tools Class: 
Materials Processing
Processing/Manufacturing Class: 
Fabrication and synthesis

At a customer's request, Idaho National Laboratory can design novel foundry aluminum alloys that possess excellent castability, molten metal fluidity, resistance to hot solidification cracking, and minimal porosity, as well as yield strength and elongation together with desired general and localized corrosion resistance. INL specializes in developing alloys that require minimal processing, i.e., in the F or T5 tempers ("cast-trim-ship" methodology).

Capability Bounds: 

Limited to foundry aluminum alloys.

Unique Aspects: 

INL focuses on developing patentable alloys that require minimal processing with applications for packaging, automotive panels, and aerospace, among others. Examples include:

  • Novel alloys containing rare earth metals
  • Alloys with small amounts of eutectic
  • High-strength weldable foundry alloys
  • Alloys with transition metals for improved thermal stability
  • Novel alloys with small (<4%) amounts of silicon.

Work can be conducted at INL or at the customer’s casting shop.

Single Point of Contact: 

Name: Dr. Michael V. Glazoff, Distinguished Staff Scientist
Phone: (208) 526-8937

  1. V. S. Zolotorevsky, N. A. Belov, and M. V. Glazoff, Casting Aluminum Alloys, Elsevier, Amsterdam (2007) (Second edition will be published in 2017).
  2. J. C. Lin, C. Yanar, W. Zhang, P. Jacobsen, G. Grasmo, M. Brandt, M. Mbaye, M. Vos, M. V. Glazoff, K. Pettersen, S. Jorgensen, T. Johnsen, An Aluminum Alloy For Producing High Performance Shaped Castings, US Patent  #7,087,125, issued on August 8, 2006.
  3. J.C. Lin, M.V. Glazoff, V.S. Zolotorevsky, S.J. Murtha, and N.A. Belov, An Al-Ni-Mn Casting Alloy for Automotive and Aerospace Structural Components, US Patent  #6,783,730, issued on August 31, 2004.
Supporting Document(s):