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Engineered Materials for Licensing

Delphi K-Alloy/A304

Delphi's K-Alloys are suitable for a wide variety of applications.
 

Delphi's K-Alloy/A304 is a patented casting alloy engineered to protect today's most critical components from harsh operating environments. K-Alloy/A304 is designed for die casting. Millions of parts have been produced using Delphi's K-Alloy/A304 since its introduction in 2003, eliminating the need for expensive pre and post processing such as anodizing, chromating and paint.

Benefits

  • Excellent corrosion resistance offers unique engineering solutions
  • Superior finishing quality for high polish applications
  • Better thermal conductivity for improved cooling (15% over A380)
  • Eliminates pre and post processing needs such as anodizing and paint
  • Cost effective processing characteristics
    • Same castability and flow properties as standard die cast alloys
    • Same existing molds to achieve existing product dimensions
    • Same mechanical and flow properties as standard die cast alloys
    • No special tooling or process parameters required 
Delphi K-Alloy/A304 Comparison with Industry Standard (A360)

30 Day Salt Spray Results

 

K-Alloy: Housing does not show signs of corrosion however the fasteners/screws show deterioration evident from white ring around the contact point with the housing.



A360 Alloy: Housing shows signs of surface chemical reaction resulting in significant corrosion on the housing's top cover.



K-Alloy: The same housing shows the top cover removed.  The sealed surface remains intact and shows no signs of water intrusion nor surface corrosion.



A360 Alloy: Housing shows signs of water intrusion.  Corrosion to the edge of the housing is pronounced.  The raised area on the perimeter shows signs of aggressive corrosion and severe surface pitting is evident.



K-Alloy: After light blasting with glass beads to remove dispensed adhesive and salt residue from the sealing surface, the housing shows no visual corrosion, nor metal loss due to chemical reaction.



A360 Alloy: After light blasting with glass beads to remove dispensed adhesive and salt residue from the sealing surface, the housing shows material loss, pitting, and raised perimeter completely missing.

Property Comparison

Property K-Alloy As Cast K-Alloy Heat Treated Silafont - 36 Aural -2 360 380 383 413
Tensile Strength (PSI) 43,000 42,000 41,000 36,000 46,000 47,000 49,000 42,000
Yield Strength (PSI) 25,000 23,000 20,000 18,000 25,000 23,000 23,000 19,000
Elongation (%) 5.0% 8-14% heat treated 4.5% as cast, 8-11% heat treated 5.0% as cast, 8-10% heat treated 3.5 3.5 3.5 3.5
Thermal Conductivity (W/m.K @ 77°F) 120 120 120 120 113 96 96 121
Density (gms cm-3) 2.63 2.63 2.64 2.64 2.63 2.71 2.74 2.66
Corrosion Resistance (10 = best, 1 = worst) 10 10 10 10 6 3 3 6
Die Life 100% of A380 100% of A380 40% of A380 40% of A380 100% of A380 100% of A380 100% of A380 100% of A380

Typical Applications

Delphi's aluminum casting alloys are suitable for many diverse applications:
  • Electronic component housings exposed to harsh environments
  • Indoor and outdoor lighting, such as stadium lighting
  • Recreational equipment, such as boats and fishing equipment
  • Defense applications, such as drones, military radios, and antennas
  • Automotive, transportation, and harsh under hood environments

U.S. Patent Number

6,733,726 — High Corrosion Resistance Aluminum Alloy

Classification

Engineered Materials: Coating, Corrosion Resistant Alternative