Corrosion-Resistant Aluminum

Die Casting Alloy

K-Alloy
Delphi K-Alloy Enhances Therm al Conduct ivit y
Tested by Thermophysical Properties Research Laboratory, Inc., the Delphi
K-Alloy nets a 15% improvement in thermal conductivity properties when
compared to an industry standard die casting alloy. By controlling the chemistry Corrosion-Resistant Aluminum
of the elements in Delphi K-Alloy, a better performing compound results.
Die Casting Alloy
Therm al Conduct ivit y Test Result s
Delphi K-Alloy is protected under U.S. Patent Number 6,733,725 B2 A New, M ore Robust Die alloys require expensive coatings or
Sam ple Te m p e ra t u re Co n d u ct i v i t y Re si st i v i t y Co n d u ct i v i t y Te m p e ra t u re Casting Alloy special designs to meet customer
D e si g n a t i o n ( C) (W cm K )
-1 -1
(m i cr o h m s cm ) ( B T U i n h r -1f t -2F -1) ( F)
Delphi has developed and patented performance specifications. The
25.9 1.0012 8.103 694.64 79
a new aluminum alloy (U. S. Patent unique properties of the Delphi
42.0 1.0118 8.375 702.00 108
62.4 1.0293 8.775 714.15 144 6,733,726 B2) w ith more robust K-Alloy allow castings to be
A380 Alloy 73.7 1.0346 8.974 717.82 165 corrosion performance. The Delphi designed not only for optimal
87.9 1.0463 9.222 725.90 190 K-Alloy substantially improves corrosion resistance but at a lower
96.1 1.0520 9.362 729.86 205 corrosion resistance w hen cost.
109.3 1.0628 9.591 737.39 229 compared to today's best
122.0 1.0727 9.809 744.26 252 Delphi K-Alloy Resists
commercially available alloys and
Sam ple Te m p e ra t u re Co n d u ct i v i t y Re si st i v i t y Co n d u ct i v i t y Te m p e ra t u re has the additional advantage of Corrosion
( B T U i n h r -1f t -2F -1) ( F)
D e si g n a t i o n ( C) (W cm K )
-1 -1
(m i cr o h m s cm )
enhanced thermal conductivity. It The Delphi-K Alloy helps provide the
26.3 1.1742 6.548 814.67 79 corrosion resistance you require. Its
can also help reduce production
41.0 1.1821 6.823 820.15 106
and warranty costs. exceptional performance, evidenced
48.1 1.1867 6.966 823.36 119
after prolonged exposure to a highly
Delphi 58.4 1.1915 7.132 826.64 137
K-Alloy
74.7 1.2030 7.398 834.67 166
Why Use Delphi K-Alloy corrosive environment exceeds that
83.8 1.2055 7.546 836.42 183 Die cast aluminum housings are of even today's best commercially
95.2 1.2144 7.732 842.54 203 often used in extremely harsh available die casting alloys.
106.8 1.2195 7.921 846.09 224 environments. Prolonged exposure Comprehensive testing compared
121.8 1.2305 8.165 853.72 251
to corrosive agents like moisture the effects of a cyclic schedule of
Thermophysical Properties Research Laboratory, Inc.
Kohlrausch M ethod and salt as well as shock and w ide salt and heat exposure over a 30-
October 2004
temperature extremes often day cycle to both the Delphi K-Alloy
M echanical Propert ies produces undesirable levels of and A360 Alloy cast housings and
U l t i m a t e Te n si l e Yi e l d S t re n g t h % corrosion and sealing-surface covers. While the screw fasteners
A l l oy S t re n g t h ( p si ) El o n ga t i o n
( p si ) degradation. The result — water on the housing cast of Delphi K-
Delphi K-Alloy 43,000 25,000 5.1
intrusion and potentially, product Alloy showed corrosion, the
A380 (NADCA) 47,000 23,000 3.5
failure. housing itself did not. In the same
For more information... salt spray test, the surface of the
MDW Technologies,
MDW Technologies, LLC - WestLLC
MDW Technologies, LLC - East Even the best of today's A360 Alloy housing was attacked
20101 SW Birch St. Ste. 130-D
20101
NewportS.W.
Beach,Birch
CA 92660St. Suite77 Norwood St
130-D
Sharon, MA 02067 commercially available, corrosion- and showed signs of severe
Newport Beach, CA 92660781.583.7550
949.757.0341
Delphi Elect ronics & Safet y
World Headquart ers resistant aluminum die casting corrosion.
disaacs@mdwtech.com
(949) 757-0341 - info@mdwtech.commnewman@mdwtech.com P.O. Box 9005 Kokom o, IN 46904-9005
www.mdwtech.com/kalloy

w w w.delphi.com
Printed on Recycled Paper ©2005 Delphi. All Rights Reserved DD05E0177
A360 Alloy
Housing was exposed to
30-day salt spray test cycle
and show s signs of a
surface chemical reaction,
corrosion on the housing’s
top cover.
The same housing shows the
top cover removed. The
surface with dispensed
adhesive 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 while
water intrusion around the
entire sealing surface is
revealed. Severe surface
pitting is also visible on all
surfaces.
After light blasting w ith
glass beads to remove the
dispensed adhesive and
aluminum oxide from the
sealing surface, the housing
show s that the prolonged
salt spray has removed
aluminum material. Pitting
on the housing surface is
uniform and the raised
perimeter is completely
missing in some places.
Delphi K-Alloy
Housing was exposed to the
same 30-day salt spray test
cycle. Pronounced
deterioration of the screw
fasteners is evident from the
w hite ring around the contact
point on the housing; however,
the housing itself does not
show signs of corrosion.
The same housing show s
the top cover removed. The
sealed surface remains intact
and show s neither signs of
water intrusion nor surface
corrosion.
After light blasting w ith glass
beads to remove dispensed
adhesive and salt residue from
the sealing surface, the same
housing show s neither visual
damage from corrosion, nor
metal loss due to a salt spray
reaction.