Patent Publication Number: US-6706242-B2

Title: Heat resistant Al die cast material

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to a heat resistant Al die cast material and, more particularly, to a heat resistant Al die cast material suited as a part of an internal combustion system, such as a piston. 
     BACKGROUND OF THE INVENTION 
     Conventional heat resistant Al materials consist of elements like Si, Cu, Mg, Ni and Ti added to Al at concentration levels appropriate for abrasion resistance, seizure resistance, and thermal resistance. An important application for heat resistant Al materials is pistons, which are a part of internal combustion systems. “Al alloy cast metal” is standardized in JIS H 5202 (1992). Table 1 in this standard lists the types of alloys and their codes, Table 2 lists chemical compositions, and Table 3 lists mechanical properties of cast metal test samples. Table 1 through Table 3 below summarize the JIS Table 1 through Table 3. 
     
       
         
           
               
               
             
               
                   
                 TABLE 1 
               
             
            
               
                   
                   
               
               
                   
                 Comments 
               
            
           
           
               
               
               
               
               
            
               
                   
                   
                 Types of 
                 Alloy 
                   
               
               
                 Codes 
                 Types of Alloy 
                 Mold 
                 Characteristics 
                 Applications 
               
               
                   
               
               
                 AC8A 
                 Al-Si-Cu-Ni-Mg 
                 metal mold 
                 temperature 
                 automotive 
               
               
                   
                   
                   
                 and abrasion 
                 diesel engine 
               
               
                   
                   
                   
                 resistant 
                 piston 
               
               
                   
                   
                   
                 small coeffi- 
                 naval piston 
               
               
                   
                   
                   
                 cient of 
                 pulley 
               
               
                   
                   
                   
                 expansion 
                 bearings 
               
               
                   
                   
                   
                 high tensile 
               
               
                   
                   
                   
                 strength 
               
               
                 AC8B 
                 Al-Si-Cu-Ni-Mg 
                 metal mold 
                 same as above 
                 automotive 
               
               
                   
                   
                   
                   
                 piston 
               
               
                   
                   
                   
                   
                 pulley 
               
               
                   
                   
                   
                   
                 bearings 
               
               
                 AC8C 
                 Al-Si-Cu-Ni-Mg 
                 metal mold 
                 same as above 
                 automotive 
               
               
                   
                   
                   
                   
                 piston 
               
               
                   
                   
                   
                   
                 pulley 
               
               
                   
                   
                   
                   
                 bearings 
               
               
                   
               
            
           
         
       
     
     As shown in the right-hand column in Table 1, under the “Applications” header, the AC8A, AC8B and AC8C Al alloy die cast metals are used for pistons in automobiles. 
     “Metal molds” listed under the “Type of Mold” in the third column of Table 1 represent regular metal casting. 
     
       
         
           
               
             
               
                 TABLE 2 
               
             
            
               
                   
               
               
                 Unit: % 
               
            
           
           
               
               
            
               
                   
                 Chemical Compositions 
               
            
           
           
               
               
               
               
               
               
               
               
               
               
               
               
               
            
               
                 Codes 
                 Cu 
                 Si 
                 Mg 
                 Zn 
                 Fe 
                 Mn 
                 Ni 
                 Ti 
                 Pb 
                 Sn 
                 Cr 
                 Al 
               
               
                   
               
               
                 AC8A 
                 0.8-1.3 
                 11.0-13.0 
                  0.7-1.3 
                 ≦0.15 
                 ≦0.8 
                 ≦0.15 
                  0.8-1.5 
                 ≦0.20 
                 ≦0.05 
                 ≦0.05 
                 ≦0.10 
                 Balance 
               
               
                 AC8B 
                 2.0-4.0 
                  8.5-10.5 
                 0.50-1.5 
                 ≦0.50 
                 ≦1.0 
                 ≦0.50 
                 0.10-1.0 
                 ≦0.20 
                 ≦0.10 
                 ≦0.10 
                 ≦0.10 
                 Balance 
               
               
                 AC8C 
                 2.0-4.0 
                  8.5-10.5 
                 0.50-1.5 
                 ≦0.50 
                 ≦1.0 
                 ≦0.50 
                 ≦0.50 
                 ≦0.20 
                 ≦0.10 
                 ≦0.10 
                 ≦0.10 
                 Balance 
               
               
                   
               
            
           
         
       
     
     Table 2 shows the chemical compositions of the AC8A, AC8B and AC8C Al alloy die cast materials. AC8A is an Al—Si—Cu—Ni—Mg alloy containing 0.8% to 1.3% Cu, 11.0% to 13.0% Si, 0.7% to 1.3% Mg, and 0.8% to 1.5% Ni. AC8B is an Al—Si—Cu—Ni—Mg alloy containing 2.0% to 4.0% Cu, 8.5% to 10.5% Si, 0.5% to 1.5% Mg, and 0.1% to 1.0% Ni. AC8C is an Al—Si—Cu—Ni—Mg alloy containing 2.0% to 4.0% Cu, 8.5% to 10.5% Si, 0.5% to 1.5% Mg and 0.5% to 1.5% Ni. 
     As shown in Table 2, Zn content is less than or equal to 0.15% in AC8A and less than or equal to 0.50% in AC8B and AB8C. “Less than or equal to” means that Zn content can be 0%. In other words, Zn content should not exceed the prescribed amount (0.15% or 0.5%). 
     
       
         
           
               
               
               
             
               
                   
                 TABLE 3 
               
             
            
               
                   
                   
               
               
                   
                   
                 Reference 
               
               
                   
                 Brinell 
                 Heat Treatment 
               
            
           
           
               
               
               
               
               
               
            
               
                   
                 Tensile Test 
                 Hard- 
                 Annealing 
                 Solution Treatment 
                 Solution Treatment 
               
            
           
           
               
               
               
               
               
               
               
               
               
               
               
            
               
                   
                   
                 Tensile 
                   
                 ness 
                 Tem- 
                   
                 Tem- 
                   
                 Tem- 
                   
               
               
                   
                   
                 Strength 
                 Length- 
                 HB (10/ 
                 perature 
                   
                 perature 
                   
                 perature 
                   
               
               
                 Types 
                 Codes 
                 N/mm 2   
                 ening % 
                 500) 
                 ° C. 
                 Time h 
                 ° C. 
                 Time h 
                 ° C. 
                 Time h 
               
               
                   
               
               
                 As cast 
                 AC8A-F 
                 ≧170 
                 — 
                 Appx. 85 
                 — 
                 — 
                 — 
                 — 
                 — 
                 — 
               
               
                 Age hardening 
                 AC8A- 
                 ≧190 
                 — 
                 Appx. 90 
                 — 
                 — 
                 — 
                 — 
                 Appx. 
                 Appx. 4 
               
               
                   
                 T5 
                   
                   
                   
                   
                   
                   
                   
                 200 
               
               
                 Solution treat- 
                 AC8A- 
                 ≧270 
                 — 
                 Appx. 
                 — 
                 — 
                 Appx. 
                 Appx. 4 
                 Appx. 
                 Appx. 10 
               
               
                 ment + age 
                 T6 
                   
                   
                 110 
                   
                   
                 510 
                   
                 170 
               
               
                 hardening 
               
               
                 As cast 
                 AC8B-F 
                 ≧170 
                 — 
                 Appx. 85 
                 — 
                 — 
                 — 
                 — 
                 — 
                 — 
               
               
                 Age hardening 
                 AC8B- 
                 ≧180 
                 — 
                 Appx. 90 
                 — 
                 — 
                 — 
                 — 
                 Appx 
                 Appx. 4 
               
               
                   
                 T5 
                   
                   
                   
                   
                   
                   
                   
                 200 
               
               
                 Solution treat- 
                 AC8B- 
                 ≧270 
                 — 
                 Appx. 
                 — 
                 — 
                 Appx. 
                 Appx. 4 
                 Appx. 
                 Appx. 10 
               
               
                 ment + age 
                 T6 
                   
                   
                 110 
                   
                   
                 510 
                   
                 170 
               
               
                 hardening 
               
               
                 As cast 
                 AC8C-F 
                 ≧170 
                 — 
                 Appx. 85 
                 — 
                 — 
                 — 
                 — 
                 — 
                 — 
               
               
                 Age hardening 
                 AC8C- 
                 ≧180 
                 — 
                 Appx. 90 
                 — 
                 — 
                 — 
                 — 
                 Appx. 
                 Appx. 4 
               
               
                   
                 T5 
                   
                   
                   
                   
                   
                   
                   
                 200 
               
               
                 Solution treat- 
                 AC8C- 
                 ≧270 
                 — 
                 Appx. 
                 — 
                 — 
                 Appx. 
                 Appx. 4 
                 Appx. 
                 Appx. 10 
               
               
                 ment + age 
                 T6 
                   
                   
                 110 
                   
                   
                 510 
                   
                 170 
               
               
                 hardening 
               
               
                   
               
            
           
         
       
     
     Table 3 lists the mechanical properties of die cast test samples and provides information on whether or not any treatment is applied, and, if so, what type of treatment. For example, the “F” suffix that comes after the AC8A, AC8B and AC8C codes indicates that the alloy has only gone through a casting process. A “T5” suffix indicates that the alloy has been age hardened. A “T6” suffix indicates that the alloy has been age hardened after a solution treatment. For example, the AC8C-T6 alloy in the lower-most row goes through a solution treatment for approximately four hours at approximately 510° C., followed by approximately 10 hours of age hardening at approximately 170° C. The third column on Table 3 lists the tensile strengths. Tensile strength is lower for “F” compared with “T5”, while tensile strength is higher for “T6” compared with “T5”. Therefore, “T5” or “T6” treatment may be used for enhancing strength. These treatments are also effective for improving the dimensional stability during annealing. 
     
       
         
           
               
             
               
                 TABLE 4 
               
             
            
               
                   
               
               
                 JIS HS5302 Al Alloy Die Cast 
               
               
                 Reference Table 1: Mechanical properties of 
               
               
                 as-cast die cast test samples 
               
            
           
           
               
               
            
               
                   
                 Tensile Tests 
               
            
           
           
               
               
               
            
               
                   
                 Tensile Strength N/mm 2   
                 Lengthening % 
               
            
           
           
               
               
               
               
               
               
            
               
                   
                   
                   
                 Standard 
                 Average 
                 Standard 
               
               
                 Types 
                 Codes 
                 Average Value 
                 Deviation 
                 Value 
                 Deviation 
               
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 Type 10 
                 ADC10 
                 245 
                 20 
                 2.0 
                 0.6 
               
               
                 Type 12 
                 ADC12 
                 225 
                 39 
                 1.5 
                 0.6 
               
               
                   
               
            
           
         
       
     
     Table 4 is a Reference Table 1 found in JIS H 5302 (1990). ADC10 and ADC12 are both Al—Si—Cu alloys, which do not contain Mg. Their compositions are given in JIS H 5302 (1990) and will not be listed here. ADC10 and ADC12 are Al alloy die cast metals whose compositions are different from the AC8A, AC8B and AC8C metals discussed above. 
     ADC10, which is an as-cast metal, has a tensile strength of 245 N/mm 2 , as shown in the third column of Table 4. ADC10 has a different composition and a much greater tensile strength than the AC8A-F, AC8B-F and AC8C-F metals mentioned above, whose tensile strengths are greater than or equal to 170 N/mm 2 . ADC12 exhibits similar properties. 
     While regular cast metals are produced by gravity casting, die cast metals are manufactured by high pressure casting. High pressure casting results in a more dense casting structure, which also results in higher strength. 
     The inventors of this invention assumed that it would be possible to achieve a much higher strength by treating die cast metals, if “T5” age hardening on the AC8A alloy increases the tensile strength from 170 N/mm 2 , to 190 N/mm 2 , and “T6” solvent treatment, followed by age hardening, increases AC8A&#39;s tensile strength from 170 N/mm2 to 270 N/mm 2 . 
     The inventors first performed an experiment in which an AC8A die cast metal was manufactured and treated with T6 solution treatment, followed by age hardening. 
     The resulting AC8A-T6 metal was covered by blisters and unusable. It is believed that the alloy incorporates air and other gases during the casting process and remain in the die cast metal as bubbles. These bubbles expand under 510° C. of heat during solvent treatment and lifted the Al alloy, which was softened under high heat. 
     Annealing temperature for the T5 age hardening, on the other hand, is around 200° C. Nevertheless, even a die cast AC8A-T5 metal shows blistering to a lesser degree. This experiment has confirmed that the ADC compositions are made different from the AC compositions in the JIS in order to avoid this phenomenon. 
     SUMMARY OF THE INVENTION 
     The inventors of this invention, however, believed it would be possible to perform the T5 age hardening on die cast metals with AC compositions by modifying the AC compositions. As a result of various research projects, the inventors discovered compositions that would make the AC die cast metal amenable to the T5 treatment. 
     This invention provides heat resistant Al die cast material that contains 12.5% to 14.0% of Si, 3.0% to 4.5% of Cu, 1.4% to 2.0% of Mg, and 1.12% to 2.4% of Zn. This die cast material is age hardened after die casting. 
     Because the die cast material having the above composition is amenable to age hardening, the material offers a much higher mechanical strength and seizure resistance. When Zn content is less than 1.12%, the die cast metal is prone to anneal cracks. When Zn content is more than 2.4%, the material exhibits less toughness. Therefore, Zn content should preferably be 1.12% to 2.4%. 
     Appropriate amounts of Mg and Zn added to an Al—Si—Cu alloy has resulted in a die cast metal that is amenable to annealing. This type of alloy has not been previously commercialized because the material was too susceptible to anneal cracks—an important consideration for a die cast alloy. 
     For example, a thick cast metal having the ADC14 “die cast Al alloy” composition (16.0% to 18.0% Si, 4.0% to 5.0% Cu, and 0.45% to 0.65% Mg), defined in JIS H 5302 (1990), tends to show many micro-cracks after casting. 
     Similarly, an alloy with 14.0% Si, 3.3% Cu, and 1.4% Mg contents also exhibits micro-cracks after casting. 
     This problem is caused by a reduced eutectic temperature, as low as 536° C., depending on Cu and Mg contents. Because the eutectic temperature is lower, compressive stress concentrates where thick and thin parts of the die cast metal meet with each other before the annealed material becomes strong enough, as the molten metal in the metal cast in the shape of the end product solidifies and shrinks. As a result, the metal exhibits anneal cracks. 
     Zn has been added in an effort to prevent these micro-cracks. As a result, it was discovered that the eutectic temperature would go up to 547 to 554° C., if equal amounts of Mg and Zn are added to Al at the same time as other elements. Further studies revealed that similar effects would be achieved as long as Zn concentration was 80% to 120% of the Mg content. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Certain preferred embodiments of the present invention will be described in detail hereinbelow, by way of example only, with reference to the accompanying drawings, in which: 
     FIG. 1 is a graph showing seizure characteristics of the die cast metal of this invention 
     FIG.  2 A and FIG. 2B are graphs showing relationships between temperature and hardness degradation over time 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following description is merely exemplary in nature and is in no way intended to limit the invention, its application or uses. 
     
       
         
           
               
               
             
               
                   
                 TABLE 5 
               
             
            
               
                   
                   
               
               
                   
                 Rockwell Hardness (HRB) 
               
            
           
           
               
               
               
               
            
               
                   
                 Main Additives (%) 
                   
                 Age 
               
            
           
           
               
               
               
               
               
               
               
            
               
                   
                 Cu 
                 Si 
                 Mg 
                 Zn 
                 As Cast 
                 Hardened 
               
               
                   
                   
               
            
           
           
               
               
               
               
               
               
               
            
               
                 Reference 
                 3.3 
                 14.0 
                 0.8 
                 0.8 
                 40 
                 50 
               
               
                 Sample 1 
               
               
                 Reference 
                 3.3 
                 14.0 
                 1.4 
                 0.8 
                 62 
                 70 
               
               
                 Sample 2 
               
               
                 Inventive 
                 3.3 
                 14.0 
                 1.6 
                 1.7 
                 70 
                 80 
               
               
                 Sample 1 
               
               
                   
               
            
           
         
       
     
     Die cast metals with the AC compositions listed in Table 4 (translator—meaning Table 5?) are prepared by simultaneously adding Mg and Zn to Al alloys containing 3.3% of Cu and 14.0% of Si. The resulting die cast metals with the AC compositions were tested for Rockwell hardness (B scale). (Hardness is designated as HRB). 
     Age hardening treatment takes place at 250° C. for approximately 20 minutes. 
     Reference Sample 1 This sample includes 0.8% of Mg and 0.8% of Zn and has the as-cast hardness (HRB) of 40 and post-age hardening treatment hardness (HRB) of 50. 
     Reference Sample 2 This sample includes 1.4% of Mg and 0.8% of Zn and has the as-cast hardness (HRB) of 62 and post-age hardening treatment hardness (HRB) of 70. This sample shows that an increased amount of Mg increases hardness. 
     Inventive Sample 1 This sample includes 1.6% of Mg and 1.7% of Zn and has the as-cast hardness (HRB) of 70 and post-age hardening treatment hardness (HRB) of 80. Increased amounts of Mg and Zn make this sample harder. 
     Following observations have been made on the age hardened charactertics of the various samples: 
     With the alloy of the Reference Sample 1, CuAl 2  is a primary intermetallic compound that determines the age hardening characteristics, while Mg 2 Si is a secondary intermetallic compound. 
     With the alloy of the Reference Sample 2, CuAl 2  and Mg 2 Si are both primary intermetallic compounds that determine the age hardening characteristics. 
     With the Inventive Sample 1, CuAl 2 , Mg 2 Si, and MgZn 2  are all primary intermetallic compounds that contribute to the age hardening effect. As a result, the inventive sample, with approximately the same amounts of Zn and Mg, offers very high hardness. 
     Because a piston moves back and forth at high speed in an internal combustion cylinder, the piston must not seize up in the cylinder. A chip-on-disk type abrasion tester was used for testing seizure characteristics using the following steps. 
     A rotating disk rotates at a rate of 16 m/sec, and drops of oil are added to this rotating disk at a rate of 240 cm 3 /min. A test sample (die cast metal with the AC composition) is pressed against this rotating disk under a prescribed load for three minutes for preconditioning. Next, the supply of oil is stopped, and the test sample continues to be pressed against the rotating disk, rotating at a rate of 16 m/sec under a pressure P. Measurement is taken on the amount of time it takes for the sample to get seized on the rotating disk. Test results are recorded as the PV value (kgf/mm 2 ×m/sec) which is a product of pressure P (kgf/mm 2 ) and rate of rotation V (m/sec). 
     
       
         
           
               
               
               
               
             
               
                   
                 TABLE 6 
               
             
            
               
                   
                   
               
               
                   
                   
                   
                 Seizure 
               
               
                   
                 Main Additives (%) 
                 Heat 
                 Characteristics 
               
            
           
           
               
               
               
               
               
               
               
            
               
                   
                 Cu 
                 Si 
                 Mg 
                 Zn 
                 Treatment 
                 (kgf/mm 2  × m/sec) 
               
               
                   
                   
               
            
           
           
               
               
               
               
               
               
               
            
               
                 Inventive 
                 3.3 
                 14.0 
                 2.0 
                 1.8 
                 T5 
                 10 
               
               
                 Sample 2 
               
               
                 Inventive 
                 3.3 
                 13.0 
                 1.4 
                 1.6 
                 T5 
                 5 
               
               
                 Sample 3 
               
               
                 Reference 
                 3.3 
                 13.0 
                 0.8 
                 0.6 
                 T5 
                 3 
               
               
                 Sample 3 
               
               
                   
               
            
           
         
       
     
     The left half of Table 6 lists the compositions of Samples 2 and 3 of the present embodiment and Reference Sample 3, on which the seizure tests were performed. All test samples have been exposed to the T5 age hardening treatment. 
     FIG. 1 is a graph showing the seizure test results for the die cast metal of this invention. Inventive Sample 2 in this graph designates a curve that plots multiple points representing PV values at which Inventive Sample 2 shows seizure. Similar curves have been drawn for Inventive Sample 3 and Reference Sample 3. At 1200 seconds (20 minutes), the PV values are 10 for Inventive Sample 2, 5 for Inventive Sample 3, and 3 for Reference Sample 3. 
     These values, 10, 5, 3, respectively, have been entered into the right-hand column of Table 6. As shown in this Table, Inventive Sample 3, which includes 1.4% of Mg and 1.6% of Zn, shows superior seizure characteristics, compared with Reference Sample 3, which includes 0.8% of Mg and 0.6% of Zn. Inventive Sample 2, which includes 1.0% of Mg and 1.8% of Zn, offers even superior seizure characteristics. These results show that seizure characteristics are improved by adding appropriate amounts of Mg and Zn. 
     High temperature characteristics of the die cast metals of this invention were next examined. 
     
       
         
           
               
               
               
               
             
               
                   
                 TABLE 7 
               
             
            
               
                   
                   
               
               
                   
                   
                   
                 Time- 
               
               
                   
                   
                   
                 Dependent 
               
               
                   
                   
                   
                 Hardness 
               
               
                   
                 Main Additives (%) 
                 Heat 
                 Degradation 
               
            
           
           
               
               
               
               
               
               
               
            
               
                   
                 Cu 
                 Si 
                 Mg 
                 Zn 
                 Treatment 
                 at 240° C. 
               
               
                   
                   
               
            
           
           
               
               
               
               
               
               
               
            
               
                 Inventive 
                 3.3 
                 13.0 
                 1.4 
                 1.6 
                 T5 
                 Small 
               
               
                 Sample 3 
               
               
                 Reference 
                 2.0-4.0 
                 8.5-10.5 
                 0.5-1.3 
                 — 
                 T7 
                 Large 
               
               
                 Sample 4 
               
               
                 (AC8B) 
               
               
                   
               
            
           
         
       
     
     A significant aspect of this invention is that die cast metals with the AC composition are amenable to annealing. T5 age hardening treatment was performed on die cast metals having the composition shown in Table 7 for Inventive Sample 3. 
     T7 solution treatment followed by a stabilizing treatment was performed on the AC8B alloy (composition shown in Table 2) for Reference Sample 4. 
     FIG.  2 A and FIG. 2B are graphs showing relationships between temperature and time-dependent degradation in hardness. While the x-axis represents time, the y-axis represents Rockwell hardness (HRB). 
     FIG. 2A shows changes in hardness in Inventive Sample 3 and Reference Sample 4, when temperature is 220° C. Inventive Sample 3 of is always much harder than Reference Sample 4, which has gone through a T7 treatment. 
     FIG. 2B shows changes in hardness with Inventive Sample 3 and Reference Sample 4, when temperature is 240° C. Reference Sample 4 degrades much more than Inventive Sample 3. In other words, Inventive Sample 3 shows superior heat resistance characteristics. These results are shown in the right hand column of Table 7 under a column title “Time-Dependent Hardness Degradation at 240 degrees C.” Entry for Sample 3 of this embodiment in this column is “Small,” while entry for the Reference Sample 4 is “Large.” 
     
       
         
           
               
               
               
             
               
                   
                 TABLE 8 
               
               
                   
                   
               
               
                   
                 Reference Sample 5 
                   
               
               
                   
                 (AC8A-T7) 
                 Inventive Sample 3 
               
               
                   
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
            
               
                 Coefficient of Thermal Expansion 
                   
                 19.2 × 10 −6 -20.8 × 10 −6   
                 19.4 × 10 −6 -20.3 × 10 −6   
               
               
                 (Room Temperature to 100° C.) 
               
               
                 Thermal Conductance 
                   
                 0.32 × 10 −6 -0.34 × 10 −6   
                 0.24 × 10 −6 -0.25 × 10 −6   
               
               
                 (cal/cm* sec ° C.) 
               
               
                 Young&#39;s Module 
                   
                 7500-7900 
                 7620 
               
               
                 (kg/mm 2 ) 
               
               
                 Density 
                   
                 2.27 
                 2.26-2.71 
               
               
                 (g/cm 3 ) 
               
               
                 Hardness 
                   
                 64-68 
                 68-82 
               
               
                 (HRB) 
               
               
                 Tensile Strength 
                 200° C. 
                 2.16-26.5 
                 23.5-28.6 
               
               
                 (kgf/mm 2 ) 
                 300° C. 
                 7.5 
                 13.2-14.5 
               
               
                 0.2 % Yield Strength 
                 200° C. 
                 20.2-20.9 
                 20.3-24.5 
               
               
                 (kgf/mm 2 ) 
                 300° C. 
                 5.8 
                 10.2-12.1 
               
               
                 High-Temperature Fatigue 
                 200° C. 
                 7.5- 8.0 
                 8.5-9.0 
               
               
                 Strength 
                 300° C. 
                 3.4 
                 4.3 
               
               
                 (kgf/mm 2 ) 
               
               
                   
               
            
           
         
       
     
     Table 8 compares various characteristics of Inventive Sample 3, as shown in Table 7, against Reference Sample 5 (AC8A-T7). Inventive Sample 3 shows comparable or superior characteristics with respect to the Reference Sample 5 in terms of tensile strength, 0.2% yield strength, and high temperature fatigue strength. In other words, Inventive Sample 3 (a die cast metal with T5 age hardening treatment) is comparable to the T7 treated (515° C. for four hours of solution treatment and 230° C. for five hours of stabilization treatment) AC8A alloy, which is a superior Al alloy cast metal in terms of heat resistance and widely used for pistons and other applications. 
     Next, pistons manufactured with the die cast metal having the AC composition of this invention were built into engines to evaluate the seizure characteristics. 
     Tests were performed on engines with 580 cm 3  capacity. 380 cm 3  of oil is added to the engine at the time when the engine starts. As the engine runs, 10-20 cm 3  of engine oil is drained every 10 minutes. The engine starts to seize up, when the amount of engine oil is much lower than the minimum required amount or close to zero. If the piston offers superior seizure characteristics, there would be extra time before seizure starts. The results of this test are recorded in terms of the amount of the engine oil remaining when the engine stops running due to seizure. 
     
       
         
           
               
               
               
               
               
             
               
                   
                 TABLE 9 
               
             
            
               
                   
                   
               
               
                   
                   
                   
                 Amount of 
                 Size of 
               
               
                   
                   
                   
                 Oil Remain- 
                 Damages 
               
               
                   
                   
                 Heat 
                 ing at the 
                 on Piston 
               
               
                   
                 Main Additives (%) 
                 Treat- 
                 Time of 
                 Caused by 
               
            
           
           
               
               
               
               
               
               
               
               
            
               
                   
                 Cu 
                 Si 
                 Mg 
                 Zn 
                 ment 
                 Seizure 
                 Seizure 
               
               
                   
                   
               
            
           
           
               
               
               
               
               
               
               
               
            
               
                 Inventive 
                 3.3 
                 13.0 
                 1.6 
                 1.7 
                 T5 
                 58 cm 3   
                 Small 
               
               
                 Sample 4 
               
               
                 Reference 
                 0.8- 
                 11.0- 
                 0.7- 
                 — 
                 T7 
                 70 cm 3   
                 Large 
               
               
                 Sample 6 
                 1.3 
                 13.0 
                 1.3 
               
               
                 (AC8A) 
               
               
                   
               
            
           
         
       
     
     Inventive Sample 4, which is a die cast metal of this invention undergoing the T5 treatment, showed 58 cm 3  of remaining engine oil. Only small seizure damages were observed on the surface of the piston, when the engine was taken apart. On the other hand, Reference Sample 6, representing the AC8A-T7 alloy, showed 70 cm 3  of remaining engine oil. Large seizure damages were observed on the surface of the piston, when the engine was taken apart. These results show that a piston consisting of the T5 treated die cast metal, having the AC composition, offers superior seizure characteristics compared with a piston consisting of the conventional AC8A-T7 alloy. 
     According to the JIS, Si content in the gravity die cast and annealed AC8A alloy must be at least 11.0% (see Table 2). When the same type of alloy is die cast, Si concentration in the primary crystals and eutectic cells ends up being approximately 1.5% lower than the gravity die cast and treated AC8A alloy, because of rapid cooling and solidification during the die cast process. In other words, approximately 1.5% of Si apparently “disappears,” because of the die cast process. 
     To address this issue, the die cast metal of this invention must have at least 12.5% of Si, which is comparable to 11.0% plus 1.5%. Because excessive amount of Si would adversely impacts toughness of the alloy, the die cast metal of this invention must have less than 14.0% of Si. In other words, Si content in this invention ranges between 12.5% to 14.0%. 
     When Cu content is less than 3.0%, the resulting die cast metal does not offer adequate hardness initially after cooling. Furthermore, the metal will not harden adequately underage hardening. When Cu content is more than 4.5%, the resulting metal becomes less tough, creating a problem for machining. For these reasons, Cu content should be 3.0% to 4.5%. 
     Similar to Cu, when Mg content is less than 1.4%, the resulting metal does not harden adequately under age hardening. When Mg content is more than 2.0%, the resulting metal is less tough and causes a problem with machining. For these reasons, Mg content should be between 1.4% and 2.0%. 
     When Zn content is less than 1.12%, the resulting die cast metal becomes prone to cracks. When Zn content is more than 2.4%, the resulting metal is less tough. For these reasons, Zn content should be between 1.12% and 2.24%. 
     In summary, the heat resistant Al die cast material of this invention is an Al—Si—Cu die cast alloy having 12.5% to 14.0% of Si, 3.0% to 4.5% of Cu, 1.5% to 2.0% of Mg, and 1.12% to 2.4% of Zn. 
     Furthermore, the Al die cast metal of this invention may include trace amounts of Fe, Mn, Ni, and other elements. 
     While the heat resistant Al die cast material of this invention is suited for pistons, the material may also be widely used in other applications that require light weight, heat resistant, abrasion resistant materials. 
     The present disclosure relates to the subject matter of Japanese Patent Application No. 2001-094368, filed Mar. 8, 2001, the disclosure of which is incorporated herein by reference in its entirety.