Semi‐Solid Processing of Tailored Aluminium‐Lithium Alloys for Automotive Applications

Abstract This paper describes the development and evaluation of thixoformable Al‐Li‐Mg‐based alloys performed at the collaborative research center SFB 289, RWTH Aachen. Scandium and zirconium were added to AlLi2.1Mg5.5 (A1420) with the aid of DoE (Design of Experiments), and precursor billets were manufactured by pressure induction melting (PIM). To evaluate the thixoformability of the synthesized alloys semi‐solid processed connecting rods were manufactured by the rheo container process (RCP). Subsequent heat treatment raised the mechanical properties to maximum values of tensile strength, 430 MPa, yield strength of 250 MPa, and an elongation to fracture of 13 %. The RCP process was designed for the special requirements of highly reactive alloys. The paper presents the remarkable property and process benefits of the semi‐solid processing of Al‐Li alloys.