A206 alloy is significantly stronger than the best alloys used today for automotive castings, and has mechanical properties approaching some grades of ductile iron. It also has excellent high temperature tensile and low cycle fatigue strength. Consequently, this material could be used in a number of applications to reduce vehicle weight. Cost savings may also result, because less material would be required to provide the strength needed for the application. In spite of its excellent properties, A206 alloy is seldom used because of its propensity for hot cracking. An improved method to grain refine this alloy has been developed, which reduces its tendency for hot cracking. Also, a new ultrasonic inspection technique to test for hot cracks has been developed. Consequently, it appears to be time to reconsider the commercial feasibility of 206 alloy, and a number of other Al-Cu alloys. Two control arms were produced to establish the viability of this material for suspension components. The results from the first stage of production trials are presented in this paper. This work is being carried out as part of the USCAR project "Design and Product Optimization for Cast Light Metals".
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