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The use of high strength 7075 wrought aluminum is widespread in the aerospace industry. The ability to shape cast the high strength 7075 alloy chemistry is desirable to reduce component costs. The high alloy content and corresponding large freezing range of the alloy present challenges related to undesirable segregation during solidification. By combining known foundry practices with high thermal conductivity and high heat capacity chills, high integrity shape castings can be produced with minimal segregation and a refined microstructure.
Chill casting of 7075 step plates and a vehicle component has been conducted through a DOD sponsored and American Foundry Society (AFS) managed program called Achieving Lightweight Casting Solutions (ALSC). It is demonstrated that by controlling the chemistry and cooling rate, wrought alloy mechanical properties can be achieved.