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WO2024186360A1 - Procédés de fabrication et d'utilisation d'un alliage d'aluminium à haute teneur en recyclage pour peinture d'automobile - Google Patents

Procédés de fabrication et d'utilisation d'un alliage d'aluminium à haute teneur en recyclage pour peinture d'automobile Download PDF

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Publication number
WO2024186360A1
WO2024186360A1 PCT/US2023/073726 US2023073726W WO2024186360A1 WO 2024186360 A1 WO2024186360 A1 WO 2024186360A1 US 2023073726 W US2023073726 W US 2023073726W WO 2024186360 A1 WO2024186360 A1 WO 2024186360A1
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WIPO (PCT)
Prior art keywords
product
aluminum alloy
mpa
metal product
hot
Prior art date
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PCT/US2023/073726
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English (en)
Inventor
Guillaume Hubert FLOREY
Jonathan FRIEDLI
Aurele Blaise MARIAUX
Loïc ARON
Nicolas Chevrier
Sebastien EBENEGGER
Zeqin LIANG
Milan FELBERBAUM
Claudio BACCIARINI
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Novelis Inc.
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Application filed by Novelis Inc. filed Critical Novelis Inc.
Publication of WO2024186360A1 publication Critical patent/WO2024186360A1/fr

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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/06—Alloys based on aluminium with magnesium as the next major constituent
    • C22C21/08—Alloys based on aluminium with magnesium as the next major constituent with silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/05—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys of the Al-Si-Mg type, i.e. containing silicon and magnesium in approximately equal proportions

Definitions

  • the present disclosure relates to metallurgy generally and more specifically to aluminum alloys having high recycled content.
  • High-forming aluminum alloys are used in many different applications, particularly in applications where strength and durability are required.
  • 6xxx series aluminum alloys have been widely used in automobile applications, due to their superior combination of properties including strength-to-weight ratio, formability, weldability, and general corrosion resistance.
  • 6xxx series aluminum alloys are commonly used for automotive structural and closure panel applications in place of steel. Because aluminum alloys are generally about 2.8 times less dense than steel, the use of such materials reduces the weight of the vehicle and allows for substantial improvements in its fuel economy. Even so, the use of currently available aluminum alloys in automotive applications poses certain challenges.
  • Described herein are aluminum alloys and metal products generated using those aluminum alloys. In certain aspects, methods of preparing metal products are also described. In some examples, a method of producing a metal product can include casting a 6xxx aluminum alloy to generate a cast product.
  • the 6xxx aluminum alloy can comprise about 0.30 wt.% to 0.64 wt.% Si, up to about 0.35 wt.% Fe, up to about 0.25 wt.% Cu, about 0.05 wt.% to 0.20 wt.% Mn, about 0.40 wt.% to 0.80 wt.% Mg, up to about 0.20 wt.% Cr, up to about 0.15 wt.% Zn, up to about 0.10 wt.% Ti, up to about 0.20 wt.% V, and up to about 0.05 wt.% impurities.
  • Aluminum may be present as a remainder in the aluminum alloy (e.g., an amount of the aluminum alloy besides any alloying elements and impurities).
  • the 6xxx aluminum alloy can comprise recycled aluminum alloy content.
  • the 6xxx aluminum alloy can comprise up to 100% recycled aluminum content or more than 20% recycled aluminum content (e.g., by weight).
  • the aluminum alloys described may include from 20% to 100% recycled aluminum alloy content (e.g., by weight), such as from 20% to 25%, from 25% to 30%, from 30% to 35%, from 35% to 40%, from 40% to 45%, from 45% to 50%, from 50% to 55%, from 55% to 60%, from 60% to 65%, from 65% to 70%, from 70% to 75%, from 75% to 80%, from 80% to 85%, from 85% to 90%, from 90% to 95%, or from 95% to 100%.
  • the method of producing the metal produce can further include homogenizing the cast product to generate a homogenized product, hot rolling the homogenized product to generate a hot-rolled product, and subjecting the hot-rolled product to a final cold rolling process to produce the metal product.
  • the cast product or the homogenized product can have a thickness of about 400 mm to 600 mm.
  • the cast product or the homogenized product can have a thickness of from 400 mm to 410 mm, from 410 mm to 420 mm, from 420 mm to 430 mm, from 430 mm to 440 mm, from 440 mm to 450 mm, from 450 mm to 460 mm, from 460 mm to 470 mm, from 470 mm to 480 mm, from 480 mm to 490 mm, from 490 mm to 500 mm, from 500 mm to 510 mm, from 510 mm to 520 mm, from 520 mm to 530 mm, from 530 mm to 540 mm, from 540 mm to 550 mm, from 550 mm to 560 mm, from 560 mm to 570 mm, from 570 mm to 580 mm, from 580 mm to 590 mm, or from 590 mm to 600 mm.
  • the hot rolling may achieve a thickness reduction between the homogenized product and the hot-rolled product from 90% to 99%.
  • the hot rolling may achieve a thickness reduction from 90% to 91 %, from 91% to 92%, from 92% to 93%, from 93% to 94%, from 94% to 95%, from 95% to 96%, from 96% to 97%, from 97% to 98%, or from 98% to 99%.
  • the hot rolling can be conducted at an entry temperature of from about 450 °C to about 550 °C and an exit temperature of from about 350 °C to about 450 °C .
  • the method can include subjecting the hot-rolled product to a recrystallization process to generate a recrystallized product.
  • the final cold rolling process can then include rolling the recrystallized product to produce the metal product.
  • the recrystallization process can occur between the hot rolling and the final cold rolling process.
  • the method can include subjecting the rolled product to a preliminary cold rolling process subsequent to the hot rolling and prior to the recrystallization process. The recrystallization process can thus happen between the preliminary cold rolling process and the final cold rolling process.
  • the recrystallization process can include annealing the hot-rolled product to generate a recrystallized product. Annealing can include heating the metal product to a temperature between about 400 °C and about 500 °C for a soaking time of up to about 120 minutes.
  • the recrystallization process can also include quenching the recrystallized product. The quenching can be performed using water or air.
  • the metal product can be subjected to an aging or an artificial aging process to generate an aged metal product.
  • the aging can include heating the metal product to a temperature of about 180 °C to about 225 °C for a period of time.
  • the metal product can be subjected to a solutionizing process to generate a solutionized metal product.
  • the aluminum alloy can contain Si in amounts from about 0.30 wt.% to 0.64 wt.%.
  • Si may be present in the aluminum alloy in amounts from 0.30 wt.% to 0.31 wt.%, from 0.31 wt.% to 0.32 wt.%, from 0.32 wt.% to 0.33 wt.%, from 0.33 wt.% to 0.34 wt.%, from 0.34 wt.% to 0.35 wt.%, from 0.35 wt.% to 0.36 wt.%, from 0.36 wt.% to 0.37 wt.%, from 0.37 wt.% to 0.38 wt.%, from 0.38 wt.% to 0.39 wt.%, from 0.39 wt.% to 0.40 wt.%, from 0.40 wt.% to 0.41 wt.%, from 0.41 wt.% to 0.42 wt.%, from 0.42 wt.%, from 0.42
  • the aluminum alloy can contain Fe in amounts up to about 0.35 wt.%.
  • Fe may be present in the aluminum alloy in amounts from 0.0 wt.% to 0.01 wt.%, from 0.01 wt.% to 0.02 wt.%, from 0.02 wt.% to 0.03 wt.%, from 0.03 wt.% to
  • 0.04 wt.% from 0.04 wt.% to 0.05 wt.%, from 0.05 wt.% to 0.06 wt.%, from 0.06 wt.% to
  • the aluminum alloy can contain Cu in amounts up to about 0.25 wt.%.
  • Cu may be present in the aluminum alloy in amounts from 0.0 wt.% to 0.01 wt.%, from 0.01 wt.% to 0.02 wt.%, from 0.02 wt.% to 0.03 wt.%, from 0.03 wt.% to 0.04 wt.%, from 0.04 wt.% to 0.05 wt.%, from 0.05 wt.% to 0.06 wt.%, from 0.06 wt.% to
  • 0.22 wt.% from 0.22 wt.% to 0.23 wt.%, from 0.23 wt.% to 0.24 wt.%, or from 0.24 wt.% to 0.25 wt.%.
  • the aluminum alloy can contain Mn in amounts from 0.05 wt.% to 0.20 wt.%.
  • Mn may be present in the aluminum alloy in amounts from 0.05 wt.% to 0.06 wt.%, from 0.06 wt.% to 0.07 wt.%, from 0.07 wt.% to 0.08 wt.%, from
  • the aluminum alloy can contain Mg in amounts from 0.40 wt.% to 0.80 wt.%.
  • Mg may be present in the aluminum alloy in amounts from 0.40 wt.% to 0.41 wt.%, from 0.41 wt.% to 0.42 wt.%, from 0.42 wt.% to 0.43 wt.%, from
  • the aluminum alloy can contain Cr in amounts up to about 0.20 wt.%.
  • Cr may be present in the aluminum alloy in amounts from 0.0 wt.% to 0.005 wt.%, from 0.005 wt.% to 0.010 wt.%, from 0.010 wt.% to 0.015 wt.%, from 0.015 wt.% to 0.020 wt.%, from 0.020 wt.% to 0.025 wt.%, from 0.025 wt.% to 0.03 wt.%, from 0.03 wt.% to 0.04 wt.%, from 0.04 wt.% to 0.05 wt.%, from 0.05 wt.% to 0.06 wt.%, from
  • the aluminum alloy can contain Zn in amounts up to about 0.15 wt.%.
  • Zn may be present in the aluminum alloy in amounts from 0.0 wt.% to 0.01 wt.%, from 0.01 wt.% to 0.02 wt.%, from 0.02 wt.% to 0.03 wt.%, from 0.03 wt.% to
  • 0.04 wt.% from 0.04 wt.% to 0.05 wt.%, from 0.05 wt.% to 0.06 wt.%, from 0.06 wt.% to
  • the aluminum alloy can contain Ti in amounts up to about 0.10 wt.%.
  • Ti may be present in the aluminum alloy in amounts from 0.0 wt.% to 0.01 wt.%, from 0.01 wt.% to 0.02 wt.%, from 0.02 wt.% to 0.03 wt.%, from 0.03 wt.% to 0.04 wt.%, from 0.04 wt.% to 0.05 wt.%, from 0.05 wt.% to 0.06 wt.%, from 0.06 wt.% to
  • 0.07 wt.% from 0.07 wt.% to 0.08 wt.%, from 0.08 wt.% to 0.09 wt.%, or from 0.09 wt.% to
  • the aluminum alloy can contain Ni in amounts up to about 0.030 wt.%.
  • Ni may be present in the aluminum alloy in amounts from 0.0 wt.% to 0.005 wt.%, from 0.005 wt.% to 0.010 wt.%, from 0.010 wt.% to 0.015 wt.%, from 0.015 wt.% to 0.020 wt.%, from 0.020 wt.% to 0.025 wt.%, or from 0.025 wt.% to 0.030 wt.%.
  • the aluminum alloy can contain impurities in amounts of up to 0.05 wt.%.
  • impurities may be present in the aluminum alloy in amounts from 0.0 wt.% to 0.01 wt.%, from 0.01 wt.% to 0.02 wt.%, from 0.02 wt.% to 0.03 wt.%, from 0.03 wt.% to 0.04 wt.%, or from 0.04 wt.% to 0.05 wt.%.
  • aluminum may be present as or comprise a remainder or balance of any alloy aside from any specified alloying elements or impurities.
  • metal products such as metal products comprising an aluminum alloy, such as those described herein.
  • the disclosed metal products can be processed into any desirable shape or form.
  • the metal product comprises a transportation body part.
  • the disclosed metal products can be made using any suitable processing where the aluminum alloy is processed using various processing steps to generate the metal product.
  • the metal product is a rolled metal product.
  • the metal product is a dual-recrystallized metal product.
  • the metal product can exhibit suitable properties, such as mechanical or physical properties or characteristics, which may be advantageous for various end uses or implementations.
  • the metal product exhibits an fl0% bending factor after 10% pre-straining along a transverse direction of from about 0.4 to 0.8, such as from 0.4 to 0.5, from 0.5 to 0.6, from 0.6 to 0.7, or from 0.7 to 0.8.
  • fl0% is the bending factor after pre-straining of 10% in the transverse direction.
  • the metal product exhibits a yield strength of from about 90 MPa to 135 MPa when in a T4 temper, such as from 90 MPa to 95 MPa, from 95 MPa to 100 MPa, from 100 MPa to 105 MPa, from 105 MPa to 110 MPa, from 110 MPa to 115 MPa, from 115 MPa to 120 MPa, from 125 MPa to 130 MPa, or from 130 MPa to 135 MPa.
  • the metal product exhibits a yield strength of from about 200 MPa to about 245 MPa when in a T8X temper, such as from 200 MPa to 205 MPa, from 205 MPa to 210 MPa, from 210 MPa to 215 MPa, from 215 MPa to 220 MPa, from 220 MPa to 225 MPa, from 225 MPa to 230 MPa, from 230 MPa to 235 MPa, from 235 MPa to 240 MPa, or from 240 MPa to 245 MPa.
  • a T8X temper such as from 200 MPa to 205 MPa, from 205 MPa to 210 MPa, from 210 MPa to 215 MPa, from 215 MPa to 220 MPa, from 220 MPa to 225 MPa, from 225 MPa to 230 MPa, from 230 MPa to 235 MPa, from 235 MPa to 240 MPa, or from 240 MPa to 245 MPa.
  • the metal product exhibits an ultimate tensile strength of from 190 MPa to 250 MPa when in a T4 temper, such as from 190 MPa to 195 MPa, from 195 MPa to 200 MPa, from 200 MPa to 205 MPa, from 205 MPa to 210 MPa, from 210 MPa to 215 MPa, from 215 MPa to 220 MPa, from 220 MPa to 225 MPa, from 225 MPa to 230 MPa, from 230 MPa to 235 MPa, from 235 MPa to 240 MPa, from 240 MPa to 245 MPa, or from 245 MPa to 250 MPa.
  • a T4 temper such as from 190 MPa to 195 MPa, from 195 MPa to 200 MPa, from 200 MPa to 205 MPa, from 205 MPa to 210 MPa, from 210 MPa to 215 MPa, from 215 MPa to 220 MPa, from 220 MPa to 225 MPa, from 225 MPa to 230
  • the metal product exhibits an ultimate tensile strength of from 260 MPa to 290 MPa when in a T8X temper, such as from 260 MPa to 265 MPa, from 265 MPa to 270 MPa, from 270 MPa to 275 MPa, from 275 MPa to 280 MPa, from 280 MPa to 285 MPa, or from 285 MPa to 290 MPa.
  • the metal product exhibits a total elongation of from 20% to 26% when in a T4 temper, such as from 20% to 21%, from 21% to 22%, from 22% from 23%, from 23% to 24%, from 24% to 25%, or from 25% to 26%.
  • FIG. 1 provides a schematic overview of an example method for making a rolled aluminum alloy product.
  • FIG. 3 shows measured yield strength of various aluminum alloy samples in a T4 temper.
  • FIG. 4 shows measured ultimate tensile strength of various aluminum alloy samples in a T4 temper.
  • FIG. 5 shows measured uniform elongation of various aluminum alloy samples in a T4 temper.
  • FIG. 6 shows measured total elongation of various aluminum alloy samples in a T4 temper.
  • FIG. 8 shows measured ultimate tensile strength of various aluminum alloy samples in a T8X temper.
  • FIG. 10 shows measured fl0% bending factors of various aluminum alloy samples.
  • the disclosed alloys can be prepared using large amounts of recycled aluminum alloy content, such as up to 100% recycled content.
  • the disclosed aluminum alloys include amounts of iron and manganese in excess of comparable aluminum alloys commonly made by alloying prime aluminum. Performing hot rolling and recrystallization processes on the disclosed aluminum alloys can contribute, at least partly, to desirable bending, forming, and surface properties and characteristics of metal products made using the disclosed aluminum alloys.
  • the disclosed alloys can be used to prepare automotive and structural panels such that these products are generated using large amounts of recycled aluminum alloy content.
  • Aluminum alloys used for recycling can contain a mixture or unknown amounts of various aluminum alloys. In some cases, contaminants can also be present in aluminum alloys used for recycling.
  • aluminum alloys used for recycling may correspond to scrap source aluminum, such as end of life automotive aluminum or industrial scrap source, such as remelt scrap ingot (RSI), extrusion profile, aluminum plate, brazing scrap, as well as casting alloy scrap.
  • RSI remelt scrap ingot
  • the energy requirements and carbon footprint for preparing the metal products can be significantly reduced.
  • the alloys and processing techniques described herein are useful for generating aluminum alloy sheet metal, or other metal products, with desirable bending characteristics, strength characteristics, forming characteristics (e.g., isotropic forming properties), and the like.
  • 6xxx series aluminum alloys are commonly used in automotive or structural applications. In general, aluminum alloys falling under various designations (e.g., AA6014) are not prepared using large amounts of recycled aluminum. For example, the elemental limits on some 6xxx series aluminum alloy products are typically lower for certain elements (e.g., Fe and Mn) than may be commonly found in recycled aluminum alloy material. Stated another way, adding amounts of recycled aluminum content to an aluminum alloy that is destined to become a particular 6xxx series aluminum alloy product (e.g., a AA6014 product) may necessitate use of large amounts of prime aluminum to ensure that certain elements (e.g., Fe and Mn) are not included in excess of those limits defined by the product or alloy designation.
  • AA6014 6xxx series aluminum alloys
  • the alloy designation can be different than that commonly used for certain applications.
  • 6xxx series aluminum alloys with large amounts of recycled content are processed according to techniques commonly used to prepare products using products containing alloys including no or low amounts of recycled material (e.g., AA6014)
  • the resultant products can have mechanical and physical characteristics different from those made using the reference alloy (e.g., AA6014).
  • increased amounts of Fe and Mn present when using large amounts of recycled content can cause increased intermetallic particles in the aluminum alloy, preventing the effectiveness of recrystallization processes, and causing modifications to strength, formability, or other characteristics when the alloy is prepared according to common processing techniques.
  • the alloys described herein overcome these challenges by including certain elements (e.g., iron and manganese) in particular amounts while still retaining beneficial properties, allowing use of high amounts of recycled content material.
  • certain elements e.g., iron and manganese
  • particular processing schemes such as those employing one or more hot rolling or other heated processing steps prior to final cold rolling steps, can be used to impart desirable properties (e.g., bending properties, forming properties, strength properties, and/or surface characteristics) to the resultant aluminum alloy products even when large amounts of recycled content are used for their preparation.
  • these alloys can reduce an overall carbon footprint of an end product by being prepared using large amounts of recycled content, as compared to the same end product being prepared using large amounts of prime aluminum.
  • invention As used herein, the terms “invention,” “the invention,” “this invention” and “the present invention” are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.
  • a plate generally has a thickness of greater than about 15 mm.
  • a plate may refer to an aluminum product having a thickness of greater than about 15 mm, greater than about 20 mm, greater than about 25 mm, greater than about 30 mm, greater than about 35 mm, greater than about 40 mm, greater than about 45 mm, greater than about 50 mm, or greater than about 100 mm.
  • a shate (also referred to as a sheet plate) generally has a thickness of from about 4 mm to about 15 mm.
  • a shate may have a thickness of about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm, or about 15 mm.
  • a sheet generally refers to an aluminum product having a thickness of less than about 4 mm.
  • a sheet may have a thickness of less than about 4 mm, less than about 3 mm, less than about 2 mm, less than about 1 mm, less than about 0.5 mm, or less than about 0.3 mm (e.g., about 0.2 mm).
  • An F condition or temper refers to an aluminum alloy as fabricated.
  • An O condition or temper refers to an aluminum alloy after annealing.
  • An Hxx condition or temper also referred to herein as an H temper, refers to a non-heat treatable aluminum alloy after cold rolling with or without thermal treatment (e.g., annealing). Suitable H tempers include HX1, HX2, HX3 HX4, HX5, HX6, HX7, HX8, or HX9 tempers.
  • a T1 condition or temper refers to an aluminum alloy cooled from hot working and naturally aged (e.g., at room temperature).
  • a T2 condition or temper refers to an aluminum alloy cooled from hot working, cold worked and naturally aged.
  • a T3 condition or temper refers to an aluminum alloy solution heat treated, cold worked, and naturally aged.
  • a T4 condition or temper refers to an aluminum alloy solution heat treated and naturally aged.
  • a T5 condition or temper refers to an aluminum alloy cooled from hot working and artificially aged (at elevated temperatures).
  • a T6 condition or temper refers to an aluminum alloy solution heat treated and artificially aged.
  • a T7 condition or temper refers to an aluminum alloy solution heat treated and artificially overaged.
  • a T8x condition or temper refers to an aluminum alloy solution heat treated, cold worked, and artificially aged.
  • a T9 condition or temper refers to an aluminum alloy solution heat treated, artificially aged, and cold worked.
  • a W condition or temper refers to an aluminum alloy after solution heat treatment.
  • cast metal product As used herein, terms such as “cast metal product,” “cast product,” “cast aluminum alloy product,” and the like may be used interchangeably herein, in some examples, to refer to a product produced by direct chill casting (including direct chill cocasting) or semi-continuous casting, continuous casting (including, for example, by use of a twin belt caster, a twin roll caster, a block caster, or any other continuous caster), electromagnetic casting, hot top casting, or any other casting method.
  • direct chill casting including direct chill cocasting
  • semi-continuous casting continuous casting
  • continuous casting including, for example, by use of a twin belt caster, a twin roll caster, a block caster, or any other continuous caster
  • electromagnetic casting hot top casting, or any other casting method.
  • room temperature can include a temperature of from about 15 °C to about 30 °C, for example about 15 °C, about 16 °C, about 17 °C, about 18 °C, about 19 °C, about 20 °C, about 21 °C, about 22 °C, about 23 °C, about 24 °C, about 25 °C, about 26 °C, about 27 °C, about 28 °C, about 29 °C, or about 30 °C.
  • ambient conditions can include temperatures of about room temperature, relative humidity of from about 20% to about 100%, and barometric pressure of from about 975 millibar (mbar) to about 1050 mbar.
  • relative humidity can be about 20%, about 21%, about 22%, about 23%, about 24%, about 25%, about 26%, about 27%, about 28%, about 29%, about 30%, about 31%, about 32%, about 33%, about 34%, about 35%, about 36%, about 37%, about 38%, about 39%, about 40%, about 41%, about 42%, about 43%, about 44%, about 45%, about 46%, about 47%, about 48%, about 49%, about 50%, about 51%, about 52%, about 53%, about 54%, about 55%, about 56%, about 57%, about 58%, about 59%, about 60%, about 61%, about 62%, about 63%, about 64%, about 65%, about 66%, about 67%, about 68%, about 69%, about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%
  • barometric pressure can be about 975 mbar, about 980 mbar, about 985 mbar, about 990 mbar, about 995 mbar, about 1000 mbar, about 1005 mbar, about 1010 mbar, about 1015 mbar, about 1020 mbar, about 1025 mbar, about 1030 mbar, about 1035 mbar, about 1040 mbar, about 1045 mbar, about 1050 mbar, or anywhere in between.
  • aluminum alloy products and their components may be described in terms of their elemental composition in weight percent (wt.%). In each alloy, the remainder is aluminum, with a maximum wt.% of 0.25%, or in some cases 0.15%, for the sum of all impurities.
  • Incidental elements such as grain refiners and deoxidizers, or other additives may be present in the invention and may add other characteristics on their own without departing from or significantly altering the alloy described herein or the characteristics of the alloy described herein.
  • Unavoidable impurities including materials or elements may be present in an alloy in minor amounts due to inherent properties of aluminum or leaching from contact with processing equipment. Some alloys, as described, may contain no more than about 0.25 wt.% of any element besides the alloying elements, incidental elements, and unavoidable impurities.
  • the aluminum alloy products described herein can be prepare using suitable methods.
  • aluminum alloys may be cast, homogenized, hot-rolled using breakdown mill following by tandem mill or using break-down mill only, cold-rolled, heat treated, formed, or the like to generate aluminum alloy products.
  • FIG. 1 provides an overview of an example method of making aluminum alloy products.
  • the method of FIG. 1 begins at 105, where an aluminum alloy 106 is cast to form a cast aluminum alloy product 107, such as an ingot or other cast product.
  • the cast aluminum alloy product 107 is homogenized to form a homogenized aluminum alloy product
  • the homogenized aluminum alloy product 111 is subjected to one or more hot rolling passes and/or one or more cold rolling passes to form a rolled aluminum alloy product
  • the rolled aluminum alloy product 112 is subjected to additional processing steps, as described below, to form an aluminum alloy article.
  • the casting process can include a direct chill (DC) casting process, a fusion casting process, or a continuous casting (CC) process.
  • FIG. 1 depicts a schematic illustration of a DC casting process at 105, but other casting processes can be used.
  • the continuous casting system can include a pair of moving opposed casting surfaces (e.g., moving opposed belts, rolls or blocks), a casting cavity between the pair of moving opposed casting surfaces, and a molten metal injector.
  • the molten metal injector can have an end opening from which molten metal can exit the molten metal injector and be injected into the casting cavity.
  • a cast aluminum alloy product such as a cast ingot, cast slab, or other cast product can be processed by any suitable means. Such processing steps include, but are not limited to, homogenization, hot rolling, cold rolling, solution heat treatment, and an optional pre-aging step.
  • the cast aluminum alloy product is homogenized to form a homogenized aluminum alloy product.
  • a cast product may be heated to a temperature ranging from about 400 °C to about 565 °C.
  • the cast product can be heated to a temperature of about 400 °C, about 410 °C, about 420 °C, about 430 °C, about 440 °C, about 450 °C, about 460 °C, about 470 °C, about 480 °C, about 490 °C, about 500 °C, about 510 °C, about 520 °C, about 530 °C, or about 540 °C up to 565 °C.
  • the product may then be allowed to soak (i.e., held at the indicated temperature) for a period of time to form a homogenized product.
  • the total time for the homogenization step can be up to 72 hours.
  • the product can be heated up to 500 °C to 565 °C, and soaked, for a total time of up to 18 hours for the homogenization step.
  • the product can be heated to below 490 °C and soaked, for a total time of greater than 18 hours for the homogenization step.
  • the homogenization step comprises multiple processes.
  • the homogenization step includes heating a cast product to a first temperature for a first period of time followed by heating to a second temperature for a second period of time.
  • a cast product can be heated to about 465 °C for about 3.5 hours and then heated to about 480 °C for about 6 hours.
  • the homogenization process and casting process are combined as casting with in-situ homogenization.
  • the homogenized aluminum alloy product is subjected to one or more roll bonding passes and/or one or more hot rolling passes to form a rolled aluminum alloy product, which may correspond to an aluminum alloy article, such as an aluminum alloy plate, an aluminum alloy shate, or an aluminum alloy sheet.
  • a roll bonding process can be carried out in different manners.
  • a roll bonding process can include both hot rolling and cold rolling.
  • a roll bonding process can be a one-step process or a multi- step process in which the material is gauged down during successive rolling steps. Separate rolling steps can optionally be separated by other processing steps, including, for example, annealing steps, cleaning steps, heating steps, cooling steps, and the like.
  • the homogenized product Prior to the start of hot rolling, the homogenized product can be allowed to cool to a temperature between 380 °C to 500 °C. For example, the homogenized product can be allowed to cool to a temperature of between 400 °C to 425 °C.
  • the homogenized product can then be hot rolled at a temperature between 250 °C to 500 °C to form a hot rolled plate, a hot rolled shate or a hot rolled sheet having a gauge between 2 mm and 200 mm (e.g., 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm, or anywhere in between).
  • the cast product can be a continuously cast product that can be allowed to cool to a temperature between 300 °C to 535 °C.
  • the continuously cast product can be allowed to cool to a temperature of between 325 °C to 510 °C, from 350 °C to 485 °C, from 375 °C to 460 °C, or from 400 °C to 435 °C.
  • the continuously cast products can then be hot rolled at a temperature between 300 °C to 500 °C, for example, to form a hot rolled plate, a hot rolled shate or a hot rolled sheet having a gauge between 3 mm and 25 mm (e.g., 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, or anywhere in between).
  • temperatures and other operating parameters can be controlled so that the temperature of the hot rolled intermediate product upon exit from the hot rolling mill is no more than 470 °C, no more than 450 °C, no more than 440 °C, no more than 430 °C, no more than 420 °C, no more than 410 °C, or no more than 400 °C.
  • the cast product can be hot rolled at least one time.
  • the cast product can be hot rolled three times, with an overall entry temperature of about 500 °C and an overall exit temperature of about 400 °C.
  • one or more of the hot roll passes can have a relatively high reduction in temperature between an entry temperature and an exit temperature.
  • one or more of the hot roll passes may cause a 50% reduction in temperature.
  • the hot rolling steps can be performed at relatively high line speeds.
  • the relatively high line speeds of the hot rolling steps can cause less precipitation formation or a finer distribution of precipitation in the hot-rolled products as compared to conventional hot rolling steps performed at lower line speeds.
  • the cast product or the homogenized product can have a thickness of about 400 mm to 600 mm.
  • the cast product or the homogenized product can have a thickness of from 400 mm to 410 mm, from 410 mm to 420 mm, from 420 mm to 430 mm, from 430 mm to 440 mm, from 440 mm to 450 mm, from 450 mm to 460 mm, from 460 mm to 470 mm, from 470 mm to 480 mm, from 480 mm to 490 mm, from 490 mm to 500 mm, from 500 mm to 510 mm, from 510 mm to 520 mm, from 520 mm to 530 mm, from 530 mm to 540 mm, from 540 mm to 550 mm, from 550 mm to 560 mm, from 560 mm to 570 mm, from 570 mm to 580 mm, from 580 mm to 590
  • Hot rolling the cast can achieve a thickness reduction between the homogenized product and the hot-rolled product from 90% to 99%.
  • the hot rolling may achieve a thickness reduction from 90% to 91 %, from 91% to 92%, from 92% to 93%, from 93% to 94%, from 94% to 95%, from 95% to 96%, from 96% to 97%, from 97% to 98%, or from 98% to 99%.
  • Cast, homogenized, or hot-rolled products can optionally be subjected to a break down process or a break down and tandem process.
  • a preliminary cold rolling process may be used after a hot rolling process, a break down process, and or a break down and tandem process.
  • the preliminary cold rolling process can use cold rolling mills to cold roll the aluminum product into thinner products, such as a cold rolled sheet.
  • the cold rolled product can have a gauge between about 0.1 to 7 mm, e.g., between about 0.7 to 6.5 mm.
  • the cold rolled product can have a gauge of 0.5 mm, 1.0 mm, 1.5 mm, 2.0 mm, 2.5 mm, 3.0 mm, 3.5 mm, 4.0 mm, 4.5 mm, 5.0 mm, 5.5 mm, 6.0 mm, 6.5 mm, or 7.0 mm.
  • the preliminary cold rolling can be performed to result in a final gauge thickness that represents a gauge reduction of up to 95% (e.g., up to 10%, up to 20%, up to 30%, up to 40%, up to 50%, up to 55%, up to 60%, up to 70%, up to 75%, up to 80%, or up to 85%, or up to 90%, up to 95%, or up to 99% reduction) as compared to a gauge prior to the start of the preliminary cold rolling.
  • up to 95% e.g., up to 10%, up to 20%, up to 30%, up to 40%, up to 50%, up to 55%, up to 60%, up to 70%, up to 75%, up to 80%, or up to 85%, or up to 90%, up to 95%, or up to 99% reduction
  • a recrystallization process can be optionally used.
  • a product after a hot rolling process, a breakdown process, and/or a breakdown/tandem process is subjected to a recrystallization process.
  • the recrystallization process can be any suitable treatment (e.g., an intermediate annealing process) which results in at least partial recrystallization to generate a recrystallized aluminum product.
  • the intermediate annealing process can comprise subjecting an unrecrystallized aluminum product (e.g., a hot-rolled product or a cold-rolled product) to a heat treatment at a predefined temperature of between about 400 °C and 500 °C for a length of time less than or equal to about 120 minutes to generate a recrystallized aluminum product.
  • an unrecrystallized aluminum product e.g., a hot-rolled product or a cold-rolled product
  • a heat treatment at a predefined temperature of between about 400 °C and 500 °C for a length of time less than or equal to about 120 minutes to generate a recrystallized aluminum product.
  • the cast, homogenized, hot rolled, or cold rolled product can be heated to a temperature of up to 495 °C for a length of time up to 25 minutes as part of an annealing process or recrystallization.
  • the temperature may be from about 400 °C to about 500 °C, such as from 400 °C to 405 °C, from 405 °C to 410 °C, from 410 °C to 415 °C, from 415 °C to 420 °C, from 420 °C to 425 °C, from 425 °C to 430 °C, from 430 °C to 435 °C, from 435 °C to 440 °C, from 440 °C to 445 °C, from 445 °C to 450 °C, from 450 °C to 455 °C, from 455 °C to 460 °C, from 460 °C to 465 °C, from 465 °C to 470 °C, from 470 °C to 475 °C, from 475 °C to 480 °C, from 480 °C to 485 °C, from 485 °C to 490 °C, such as
  • any suitable temperature ramp rates may be used to heat up to and or cool down from the specified temperature.
  • the product is heated to the temperature for a length of time from about 0.1 seconds to about 25 minutes, such as from 0.1 seconds to 0.5 seconds, from 0.5 seconds to 1 second, from 1 second to 2 seconds, from 2 seconds to 3 seconds, from 3 seconds to 4 seconds, from 4 seconds to 5 seconds, from 5 seconds to 10 seconds, from 10 seconds to 15 second, from 15 seconds to 30 seconds, from 30 seconds to 45 seconds, from 45 seconds to 60 seconds, from 60 seconds to 75 seconds, from 75 seconds to 90 seconds, from 90 seconds to 105 seconds, from 105 seconds to 2 minutes, from 2 minutes to 3 minutes, from 3 minutes to 4 minutes, from 4 minutes to 5 minutes, from 5 minutes to 10 minutes, from 10 minutes to 15 minutes, from 15 minutes to 20 minutes, from 20 minutes to 25 minutes, from 25 minutes to 30 minutes, from 35 minutes to 40 minutes, from 40 minutes to 45 minutes, from 45 minutes to 50 minutes, from 55 minutes to 60 minutes, from 60 minutes to 65 minutes, from 65 minutes to
  • this may indicate that the temperature is held at or about a specified temperature or within 5 °C or within 10 °C of the specified temperature for the length of time.
  • the temperature or temperature range may be paired with a specific length of time or time range.
  • the temperature may be from 440 °C to 485 °C while the length of time is less than or equal to 10 minutes, the temperature may be from 450 °C to 475 °C while the length of time is less than 1 minute, or the temperature may be from 470 °C to 475 °C while the length of time is from 2 seconds to 35 seconds. Any variation or combination of the above-mentioned temperatures and lengths of time may be used, and certain alloys or end product configurations may benefit from a particular temperature and length of time combination or range of particular temperatures and lengths of time.
  • the recrystallization process can include passing a cast, homogenized, or rolled product through a furnace at a speed from about 10 m/min to about 150 m/min, such as from 10 m/min to 15 m/min, from 15 m/min to 20 m/min, from 20 m/min to 25 m/min, from 25 m/min to 30 m/min, from 30 m/min to 40 m/min, from 40 m/min to 45 m/min, from 45 m/min to 50 m/min, from 50 m/min to 60 m/min, from 60 m/min to 70 m/min, from 70 m/min to 80 m/min, from 80 m/min to 90 m/min, from 90 m/min to 100 m/min, from 100 m/min to 110 m/min, from 110 m/min to 120 m/min, from 120 m/min to 130 m/min, from 130 m/min to 140 m
  • the recrystallization process can include heating the cast, homogenized, or rolled product by passing the product through a gas-fired furnace.
  • the recrystallization process can include or use a magnetic heating unit with a heating rate of from 10 °C/s to 150 °C/s.
  • the recrystallization process can include or use a quenching process (e.g., a water quench or an air quench) with a cooling rate of from 5 °C/s to 150 °C/s, or more, to return the product to ambient or room temperature. Cold rolling the product after the recrystallization process may result in an unrecrystallized aluminum product with deformed grains.
  • Cold rolling can be performed to create a final gauge thickness that represents a gauge reduction from 25% to 99% (e.g., from 25% to 30%, from 30% to 35%, from 35% to 40%, from 40% to 45%, from 45% to 50%, from 50% to 55%, from 55% to 60%, from 60% to 65%, from 65% to 70%, from 70% to 75%, from 75% to 80%, from 80% to 85%, from 85% to 90%, from 90% to 95%, or from 95% to 99% reduction) as compared to the gauge prior to cold rolling.
  • a cold rolling process may achieve a cold reduction from 55% to 75%, from 25% to 90%, from 45% to 95%, or from 60% to 99%.
  • the product can optionally undergo one or more solution heat treatment steps.
  • the solution heat treatment steps can be any suitable treatment for the metal product which results in solutionizing of the soluble particles.
  • the product can be heated to a peak metal temperature (PMT) of up to 590 °C (e.g., from 400 °C to 590 °C) and soaked for a period of time at the PMT to form a hot product.
  • PMT peak metal temperature
  • the product can be soaked at 480 °C for a soak time of up to 30 minutes (e.g., 0 seconds, 60 seconds, 75 seconds, 90 seconds, 5 minutes, 10 minutes, 20 minutes, 25 minutes, or 30 minutes).
  • the hot product After heating and soaking, the hot product is rapidly cooled at rates greater than 90 °C/s to a temperature between 500 °C and room temperature to form a heat-treated product.
  • the solution heat treatment steps can be performed relatively quickly. This can be due to faster hot rolling that causes less precipitation or a finer distribution of precipitation, requiring less dissolution during the solution heat treatment steps.
  • the heat-treated product can optionally undergo a pre-aging treatment by reheating before coiling.
  • the pre-aging treatment can be performed at a temperature of from about 50 °C to about 125 °C for a period of time of up to 6 hours.
  • the pre-aging treatment can be performed at a temperature of about 50 °C, about 55 °C. about 60 °C, about 65 °C, about 70 °C, about 75 °C, about 80 °C, about 85 °C, about 90 °C, about 95 °C, about 100 °C, about 105 °C, about 110 °C, about 115 °C, about 120 °C, or about 125 °C.
  • the pre-aging treatment can be performed for about 30 minutes, about 1 hour, about 2 hours, about 3 hours, about 4 hours, about 5 hours, or about 6 hours.
  • the pre-aging treatment can be carried out by passing the heat-treated product through a heating device, such as a device that emits radiant heat, convective heat, induction heat, infrared heat, or the like.
  • FIG. 2 provides a plot showing example temperatures of a cast metal product during various stages of a manufacturing process in accordance with various aspects of the present disclosure.
  • the molten metal may be cooled and/or solidified by a process involving quenching or cooling the metal by exposing the metal to water or an aqueous solution, such as in a direct chill casting process or in a continuous casting process that includes quenching immediately after casting.
  • the metal product may be subjected to a homogenization process 210, where the metal is heated to a temperature less than the melting or solidus temperature of the metal.
  • the metal product is heated to a temperature at which the base metal and any alloying elements form a solid solution.
  • the metal product may be exposed to one or more processes that may, for example, form desirable microcrystalline structures within the metal product while elongating the metal product.
  • processes may correspond to hot rolling 215 and/or cold rolling 220, for example, such as to form shates, plates, or sheets from a metal ingot or other cast article or metal product.
  • exposing a metal product at an elevated temperature to a solution such as water, an aqueous solution, or a gas, gas mixture, or gas-phase solution, in a quenching or cooling process may be used to reduce the temperature of the metal product to a temperature desirable or useful for a subsequent process.
  • exposing the metal product to water or an aqueous solution may be useful for cooling the metal product between hot rolling process 215 and subsequent processing. Tandem and/or breakdown processing is not shown in FIG. 2 but can be performed at any suitable temperature for such processes.
  • the metal product may be subjected to an intermediate annealing heat treatment process 225, where the metal product is heated to and held at a predefined temperature for a length of time less than or equal to an hour to generate at least partial recrystallization of the metal product.
  • the metal product may be optionally subjected to an additional cold rolling process 230 after the intermediate annealing heat treatment process 225.
  • Various different peak temperatures may be used for the intermediate annealing heat treatment process 225, as shown in FIG. 2, which may be dependent on the particular alloy of the metal product and/or the particular mechanical or physical properties desired for the final product, for example.
  • the metal product may then be subjected to a solution heat treatment process 235, where the temperature of the metal product is increased to a temperature above a threshold temperature, such as a temperature at which precipitated components in the metal product dissolve into a solid solution or a temperature at which recrystallization processes occur, and held at or above the threshold temperature for a period of time.
  • a threshold temperature such as a temperature at which precipitated components in the metal product dissolve into a solid solution or a temperature at which recrystallization processes occur, and held at or above the threshold temperature for a period of time.
  • a quenching process 240 where dissolved components are fixed into place by rapidly reducing the temperature of the metal by a quenching process.
  • a quenching process 240 may involve exposing the metal product to a solution, such as a quench solution including water, an aqueous solution, or a gas or gas mixture.
  • the processes overviewed in FIG. 2 may be performed discretely or as part of one or more continuous processing lines where metal product may be transported as a coil, a film, or a web of material between processing stages.
  • the metal product may be transported between stages by rolling the metal product, which may be under tension, over or between one or more rollers, or by transporting the metal product on one or more conveyors, for example.
  • other stages not explicitly identified may be included before, between, and/or after any stage identified in FIG. 2.
  • Other example stages include, but are not limited to, a tandem and/or breakdown stage, a washing stage, a chemical treatment stage, or a finishing stage.
  • a finishing stage may correspond to a surface anodizing stage, a powder coating stage, a painting stage, a printing stage, or the like.
  • the aluminum alloy products described herein can be used in automotive applications and other transportation applications, including aircraft and railway applications.
  • the disclosed aluminum alloy products can be used to prepare automotive structural parts, such as bumpers, side beams, roof beams, cross beams, pillar reinforcements (e.g., A-pillars, B-pillars, and C -pillars), inner panels, outer panels, side panels, inner hoods, outer hoods, or trunk lid panels.
  • the aluminum alloy products and methods described herein can also be used in aircraft or railway vehicle applications, to prepare, for example, external and internal panels.
  • the aluminum alloy products and methods described herein can also be used in electronics applications.
  • the aluminum alloy products and methods described herein can be used to prepare housings for electronic devices, including mobile phones and tablet computers.
  • the aluminum alloy products can be used to prepare housings for the outer casing of mobile phones (e.g., smart phones), tablet bottom chassis, and other portable electronics.
  • Described herein are methods of treating metals and metal alloys, including aluminum, aluminum alloys, magnesium, magnesium alloys, magnesium composites, and steel, among others, and the resultant treated metals and metal alloys.
  • the metals for use in the methods described herein include aluminum alloys, for example, Ixxx series aluminum alloys, 2xxx series aluminum alloys, 3xxx series aluminum alloys, 4xxx series aluminum alloys, 5xxx series aluminum alloys, 6xxx series aluminum alloys, 7xxx series aluminum alloys, or 8xxx series aluminum alloys.
  • the materials for use in the methods described herein include non-ferrous materials, including aluminum, aluminum alloys, magnesium, magnesium-based materials, magnesium alloys, magnesium composites, titanium, titanium-based materials, titanium alloys, copper, copper-based materials, composites, sheets used in composites, or any other suitable metal, non-metal or combination of materials.
  • non-ferrous materials including aluminum, aluminum alloys, magnesium, magnesium-based materials, magnesium alloys, magnesium composites, titanium, titanium-based materials, titanium alloys, copper, copper-based materials, composites, sheets used in composites, or any other suitable metal, non-metal or combination of materials.
  • Monolithic as well as non-monolithic such as roll-bonded materials, cladded alloys, clad layers, composite materials, such as but not limited to carbon fiber-containing materials, or various other materials are also useful with the methods described herein.
  • aluminum alloys containing iron are useful with the methods described herein.
  • exemplary Ixxx series aluminum alloys for use in the methods described herein can include AA1100, AA1100A, AA1200, AA1200A, AA1300, AA1110, AA1120, AA1230, AA1230A, AA1235, AA1435, AA1145, AA1345, AA1445, AA1150, AA1350, AA1350A, AA1450, AA1370, AA1275, AA1185, AA1285, AA1385, AA1188, AA1190, AA1290, AA1193, AA1198, or AA1199.
  • Non-limiting exemplary 2xxx series aluminum alloys for use in the methods described herein can include AA2001, A2002, AA2004, AA2005, AA2006, AA2007, AA2007A, AA2007B, AA2008, AA2009, AA2010, AA2011, AA2011A, AA2111, AA2111A, AA2111B, AA2012, AA2013, AA2014, AA2014A, AA2214, AA2015, AA2016, AA2017, AA2017A, AA2117, AA2018, AA2218, AA2618, AA2618A, AA2219, AA2319, AA2419, AA2519, AA2021, AA2022, AA2023, AA2024, AA2024A, AA2124, AA2224, AA2224A, AA2324, AA2424, AA2524, AA2624, AA2724, AA2824, AA2025, AA
  • Non-limiting exemplary 3xxx series aluminum alloys for use in the methods described herein can include AA3002, AA3102, AA3003, AA3103, AA3103A, AA3103B, AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, AA3005A, AA3105, AA3105A, AA3105B, AA3007, AA3107, AA3207, AA3207A, AA3307, AA3009, AA3010, AA3110, AA3011, AA3012, AA3012A, AA3013, AA3014, AA3015, AA3016, AA3017, AA3019, AA3020, AA3021, AA3025, AA3026, AA3030, AA3130, or AA3065.
  • Non-limiting exemplary 4xxx series aluminum alloys for use in the methods described herein can include AA4004, AA4104, AA4006, AA4007, AA4008, AA4009, AA4010, AA4013, AA4014, AA4015, AA4015A, AA4115, AA4016, AA4017, AA4018, AA4019, AA4020, AA4021, AA4026, AA4032, AA4043, AA4043A, AA4143, AA4343, AA4643, AA4943, AA4044, AA4045, AA4145, AA4145A, AA4046, AA4047, AA4047A, or AA4147.
  • Non-limiting exemplary 5xxx series aluminum alloys for use in the methods described herein product can include AA5182, AA5183, AA5005, AA5005A, AA5205, AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110, AA5110A, AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A, AA5119, AA5119A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5040, AA5140, AA5041, AA5042, AA5043, AA5049, AA5149, AA5249, AA5349, AA5449, AA5449A, AA5050, AA5050A, AA5050C, AA5150,
  • Non-limiting exemplary 6xxx series aluminum alloys for use in the methods described herein can include AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA6206, AA6306, AA6008, AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, AA6016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027,
  • Non-limiting exemplary 7xxx series aluminum alloys for use in the methods described herein can include AA7011, AA7019, AA7020, AA7021, AA7039, AA7072, AA7075, AA7085, AA7108, AA7108A, AA7015, AA7017, AA7018, AA7019A, AA7024, AA7025, AA7028, AA7030, AA7031, AA7033, AA7035, AA7035A, AA7046, AA7046A, AA7003, AA7004, AA7005, AA7009, AA7010, AA7011, AA7012, AA7014, AA7016, AA7116, AA7122, AA7023, AA7026, AA7029, AA7129, AA7229, AA7032, AA7033, AA7034, AA7036, AA7136, AA7034,
  • Non-limiting exemplary 8xxx series aluminum alloys for use in the methods described herein can include AA8005, AA8006, AA8007, AA8008, AA8010, AA8011, AA8011A, AA8111, AA8211, AA8112, AA8014, AA8015, AA8016, AA8017, AA8018, AA8019, AA8021, AA8021A, AA8021B, AA8022, AA8023, AA8024, AA8025, AA8026, AA8030, AA8130, AA8040, AA8050, AA8150, AA8076, AA8076A, AA8176, AA8077, AA8177, AA8079, AA8090, AA8091, or AA8093.
  • FIG. 3 shows measured yield strength of various aluminum alloy samples in a T4 temper.
  • the yield strength of the aluminum alloy samples was measured between 90 MPa and 135 MPa.
  • FIG. 4 shows measured ultimate tensile strength of various aluminum alloy samples in a T4 temper.
  • the ultimate tensile strength of the aluminum alloy samples was measured between 190 MPa and 250 MPa.
  • FIG. 5 shows measured uniform elongation of various aluminum alloy samples in a T4 temper.
  • the uniform elongation of the aluminum alloy samples was measured between about 19% and 23%.
  • FIG. 6 shows measured total elongation of various aluminum alloy samples in a T4 temper.
  • the total elongation of the aluminum alloy samples was measured between 21% to 26%.
  • FIG. 7 shows measured yield strength of various aluminum alloy samples in a T8X temper. For example, the yield strength of the aluminum alloy samples was measured between 200 MPa and 230 MPa.
  • FIG. 8 shows measured ultimate tensile strength of various aluminum alloy samples in a T8X temper. For example, the ultimate tensile strength of the aluminum alloy samples was measured between 260 MPa and 290 MPa.
  • FIG. 9 shows measured total elongation of various aluminum alloy samples in a T8X temper. For example, the total elongation of the aluminum alloy samples was measured between 16% and 21%.
  • FIG. 10 shows measured fl0% bending factor of various aluminum alloy samples, where the samples are pre-strained 10% in the transverse direction from T4 temper prior to bending.
  • the fl0% bending factor along a transverse direction was measured between 0.4 and 0.8.
  • any reference to a series of aspects e.g., “Aspects 1-4” or nonenumerated group of aspects (e.g., “any previous or subsequent aspect”) is to be understood as a reference to each of those aspects disjunctively (e.g., “Aspects 1-4” is to be understood as “Aspects 1, 2, 3, or 4 ”).
  • Aspect l is a method of producing a metal product, the method comprising: casting a 6xxx aluminum alloy to generate a cast product, wherein the 6xxx aluminum alloy comprises Al and about 0.30 wt.% to 0.64 wt.% Si, up to about 0.35 wt.% Fe, up to about 0.25 wt.% Cu, about 0.05 wt.% to 0.20 wt.% Mn, about 0.40 wt.% to 0.80 wt.% Mg, up to about 0.20 wt.% Cr, up to about 0.15 wt.% Zn, up to about 0.10 wt.% Ti, up to about 0.20 wt.% V, up to about 0.05 wt.% impurities, wherein at least a portion of the 6xxx aluminum alloy comprises recycled aluminum content; homogenizing the cast product to generate a homogenized product; hot rolling the homogenized product to generate a hot-rolled product; and subjecting the hot-rolled product to a final
  • Aspect 2 is the method of any previous or subsequent aspect, wherein the hot rolling is conducted at an entry temperature of from about 450 °C to about 550 °C and an exit temperature of from about 350 °C to about 450 °C.
  • Aspect 3 is the method of any previous or subsequent aspect, further comprising: subsequent to the hot rolling, subjecting the hot-rolled product to a recrystallization process to generate a recrystallized product, wherein the final cold rolling process comprising cold rolling the recrystallized product to produce the metal product.
  • Aspect 4 is the method of any previous or subsequent aspect, wherein the recrystallization process occurs between the hot rolling and the final cold rolling process.
  • Aspect 5 is the method of any previous or subsequent aspect, further comprising: subjecting the hot-rolled product to a preliminary cold rolling process subsequent to the hot rolling and prior to the recrystallization process, wherein the recrystallization process occurs between the preliminary cold rolling process and the final cold rolling process.
  • Aspect 6 is the method of any previous or subsequent aspect, wherein the recrystallization process comprises: annealing the hot-rolled product to generate a recrystallized product; and quenching the recrystallized product.
  • Aspect 7 is the method of any previous or subsequent aspect, wherein the quenching is performed using water or air.
  • Aspect 8 is the method of any previous or subsequent aspect, wherein the annealing step comprises heating the metal product to a temperature between about 400 °C and about 500 °C for a soaking time of up to about 120 minutes.
  • Aspect 9 is the method of any previous or subsequent aspect, wherein the cast product or the homogenized product has a thickness of about 400 mm to 600 mm and wherein the hot rolling achieves a thickness reduction between the homogenized product and the hot-rolled product from 90% to 99%.
  • Aspect 10 is the method of any previous or subsequent aspect, further comprising: subjecting the metal product to an aging or artificial aging process to generate an aged metal product.
  • Aspect 11 is the method of any previous or subsequent aspect, wherein the aging comprises heating the metal product to a temperature of about 180 °C to about 225 °C for a period of time.
  • Aspect 12 is the method of any previous or subsequent aspect, further comprising: subjecting the metal product to a solutionizing process to generate a solutionized metal product.
  • Aspect 13 is the method of any previous or subsequent aspect, wherein the 6xxx series aluminum alloy comprises up to 100% recycled aluminum content or more than 20% recycled aluminum content.
  • Aspect 14 is a metal product made according to the method of any previous aspect.
  • Aspect 15 is a transportation body part comprising the metal product of any previous or subsequent aspect.
  • Aspect 16 is an aluminum alloy, comprising Al and about 0.30 wt.% to 0.64 wt.% Si, up to about 0.35 wt.% Fe, up to about 0.25 wt.% Cu, about 0.05 wt.% to 0.20 wt.% Mn, about 0.40 wt.% to 0.80 wt.% Mg, up to about 0.20 wt.% Cr, up to about 0.15 wt.% Zn, up to about 0.10 wt.% Ti, up to about 0.20 wt.% V, up to about 0.05 wt.% impurities, wherein at least a portion of the aluminum alloy comprises recycled aluminum content.
  • Aspect 17 is the aluminum alloy of any previous or subsequent aspect, comprising about 0.30 wt.% to 0.61 wt.% Si, up to about 0.24 wt.% Fe, up to about 0.13 wt.% Cu, about 0.05 wt.% to 0.12 Mn, about 0.40 wt.% to 0.56 wt.% Mg, up to about 0.015 wt.% Cr, up to about 0.012 wt.% Zn, and up to about 0.020 wt.% Ti.
  • Aspect 18 is the aluminum alloy of any previous or subsequent aspect, comprising about 0.30-0.32 wt.% Fe, up to about 0.14 wt.% Cu, about 0.05 wt.% to 0.17 wt.% Mn, about 0.40 wt.% to 0.65 wt.% Mg, up to about 0.03 wt.% Cr, up to about 0.021 wt.% Zn, and up to about 0.020 wt.% Ti.
  • Aspect 19 is the aluminum alloy of any previous or subsequent aspect, further comprising up to about 0.030 wt.% Ni.
  • Aspect 20 is the aluminum alloy of any previous aspect prepared according to the method of any previous aspect.
  • Aspect 21 is a metal product comprising the aluminum alloy of any previous aspect.
  • Aspect 22 is the metal product of any previous or subsequent aspect, wherein the metal product exhibits an fl0% bending factor after 10% pre-straining along a transverse direction of from about 0.4 to 0.8.
  • Aspect 23 is the metal product of any previous or subsequent aspect, wherein the metal product exhibits a yield strength of from 90 MPa to 135 MPa when in a T4 temper or from 200 MPa to 245 MPa when in a T8X temper.
  • Aspect 24 is the metal product of any previous or subsequent aspect, wherein the metal product exhibits an ultimate tensile strength of from 190 MPa to 250 MPa when in a T4 temper or from 260 MPa to 290 MPa when in a T8X temper.
  • Aspect 25 is the metal product of any previous aspect, wherein the metal product exhibits a total elongation of from 20% to 26% when in a T4 temper or from 16% to 21% when in a T8x temper.

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  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Continuous Casting (AREA)

Abstract

Des alliages d'aluminium, des produits métalliques fabriqués à l'aide des alliages d'aluminium, et des procédés de traitement des alliages d'aluminium sont divulgués. Les alliages divulgués peuvent être préparés à l'aide de grandes quantités d'alliage d'aluminium recyclé, par exemple jusqu'à 100 % de contenu recyclé, ou plus. Les alliages d'aluminium divulgués comprennent des quantités de fer et de manganèse en excès d'alliages d'aluminium comparables généralement fabriqués par alliage d'aluminium primaire. Les alliages d'aluminium divulgués peuvent être produits par coulée d'un alliage d'aluminium 6xxx pour générer un produit coulé, qui peut ensuite être traité pour générer des produits laminés.
PCT/US2023/073726 2023-03-07 2023-09-08 Procédés de fabrication et d'utilisation d'un alliage d'aluminium à haute teneur en recyclage pour peinture d'automobile WO2024186360A1 (fr)

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2000052216A1 (fr) * 1999-03-03 2000-09-08 Alusuisse Technology & Management Ag COMPOSANT STRUCTURAL CONSTITUE D'UN ALLIAGE D'ALUMINIUM DU TYPE AlMgSi
US10190196B2 (en) * 2014-01-21 2019-01-29 Arconic Inc. 6XXX aluminum alloys
WO2021211696A1 (fr) * 2020-04-15 2021-10-21 Novelis Inc. Alliages d'aluminium produits à partir de déchets d'alliage d'aluminium recyclés

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2000052216A1 (fr) * 1999-03-03 2000-09-08 Alusuisse Technology & Management Ag COMPOSANT STRUCTURAL CONSTITUE D'UN ALLIAGE D'ALUMINIUM DU TYPE AlMgSi
US10190196B2 (en) * 2014-01-21 2019-01-29 Arconic Inc. 6XXX aluminum alloys
WO2021211696A1 (fr) * 2020-04-15 2021-10-21 Novelis Inc. Alliages d'aluminium produits à partir de déchets d'alliage d'aluminium recyclés

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
ENGLER OLAF ET AL: "Effect of Natural Ageing on Strength and Anisotropy in Aluminium Alloy AA 6005C", MATERIALS SCIENCE FORUM, vol. 877, 1 November 2016 (2016-11-01), CH, pages 688 - 694, XP093108017, ISSN: 1662-9752, Retrieved from the Internet <URL:https://www.scientific.net/MSF.877.688.pdf?casa_token=dmrAOIisvigAAAAA:7AN7QZnkHYIniV4bFXcLFr1N2pD2SgzBOGfDiSoZmltFik9hABC5hlROuG9ol_Tovo3ORstCUEE> DOI: 10.4028/www.scientific.net/MSF.877.688 *
THE ALUMINUM ASSOCIATION: "International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys", REGISTRATION RECORD SERIES TEAL SHEETS, 1 February 2009 (2009-02-01), XP055722574, Retrieved from the Internet <URL:https://www.aluminum.org> [retrieved on 20200814] *

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