Opportunities for Cost Reduction Using Aluminum Casting Alloy 205

205 Aluminum is a new casting alloy developed by Aeromet in the UK recently.  It is a A201 alloy derivative in which a titanium diboride particulate is added as a nucleating agent in solidification to refine the microstructure from a course dendritic structure to a fine cellular structure.  By changing the solidification structure, you reduce the copper segregation that leads to hot tearing that make 200 series aluminum.  Hot tearing problems has greatly reduced the application of 200 series castings, despite the very high strength of these castings and the complexity of the casting is limited when using 200 series alloys.  205 greatly reduces the hot tearing issues that cause high scrap rates of these alloys at the foundries that make foundries reluctant to pour these alloy.  In the past several years Aeromet went through the MMPDS design allowable process and obtained A and B basis design allowables, which is almost unheard of with aluminum castings.  The minimum tensile strength are almost the same as wrought 7075-T73 with a reduction of ductility as expected.  This opens the door for this alloy to be a candidate for being an option where 2000 and 7000 series wrought alloys.  Traditionally the most common A356/A357 Al-Mg-Si alloys are limited to replacing 6061-T6 alloy and lower strength alloys. This presentation will discuss potential applications for these alloys, current status, and improvements needed with this alloy.