High-strength 6XXX series aluminum alloy and manufacturing method thereof

Abstract

The invention relates to a high-strength 6XXX series aluminum alloy and a manufacturing method thereof. Described herein are 6xxx series aluminum alloys having unexpected properties and novel methods of producing such aluminum alloys. The aluminum alloy has a high degree of formability and exhibits high strength. The alloy is produced by continuous casting and can be hot-rolled to a final gauge and / or final state. The alloys may be used in automotive, transport, industrial, and electronic applications, listed only for several examples.

Description

[0001] This application is a divisional application of the parent application No. 201780066605.2, which was filed on September 27, 2017; the name of the invention is “High-strength 6XXX series aluminum alloy and its manufacturing method”.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims U.S. Provisional Application No. 62 / 413,740, filed on October 27, 2016, entitled “HIGH STRENGTH 6XXX SERIES ALUMINUM ALLOY AND METHODS OF MAKING THE SAME”; U.S. Provisional Application No. 62 / 529,028, filed on July 6, 2017, entitled “SYSTEMS AND METHODS FOR MAKING ALUMINUM ALLOY PLATES”; U.S. Provisional Application No. 62 / 413,591, filed on October 27, 2016, entitled “DECOUPLED CONTINUOUS CASTING AND ROLLING LINE”; and U.S. Provisional Application No. 62 / 413,592, filed on October 27, 2016, entitled “DECOUPLED CONTINUOUS CASTING AND ROLLING LINE”. ANDROLLING LINE)" which are hereby incorporated by reference in their entirety.

[0004] In addition, this application is related to U.S. non-provisional patent application No. 15 / 717,361, entitled “METAL CASTING AND ROLLING LINE,” filed by Milan Felberbaum et al. on September 27, 2017, the entire contents of which are incorporated herein by reference. Technical Field

[0005] The present disclosure relates to the fields of materials science, materials chemistry, metal fabrication, aluminum alloys, and aluminum fabrication. Background Art

[0006] Aluminum (Al) alloys are increasingly replacing steel and other metals in a variety of applications such as automotive, transportation, industrial or electronics-related applications. In some applications, such alloys may be required to exhibit high strength, high formability, corrosion resistance and / or low weight. However, producing alloys with the above properties is a challenge because conventional methods and compositions may not be able to meet the necessary requirements, specifications and / or performance required for different applications when produced by established methods. For example, aluminum alloys with high solute content, including copper (Cu), magnesium (Mg) and zinc (Zn), can cause cracking when the ingot is a direct chill (DC) casting. Summary of the invention

[0007] The covered embodiments of the present invention are defined by the claims, not by this Summary. This Summary is a high-level overview of various aspects of the present invention and introduces some concepts that are further described below in the Detailed Description section. This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used alone to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification, any or all of the drawings, and each claim.

[0008] Provided herein are aluminum alloys that exhibit high strength and high formability and do not exhibit cracking during and / or after casting, and methods of making and processing the alloys. The alloys can be used in automotive, transportation, industrial, and electronic applications, to name a few.

[0009] In some examples, a method of producing an aluminum alloy includes continuously casting an aluminum alloy to form a slab, wherein the aluminum alloy comprises approximately 0.26-2.82 wt. % Si, 0.06-0.60 wt. % Fe, 0.26–2.37 wt. % Cu, 0.06–0.57 wt. % Mn, 0.26–2.37 wt. % Mg, 0–0.21 wt. % Cr, 0–0.009 wt. % Zn, 0–0.09 wt. % Ti, 0–0.003 wt. % Zr, and up to 0.15 wt. % impurities, with the remainder being Al; and hot rolling the slab to final gauge without cold rolling the slab prior to final gauge. In some cases, the aluminum alloy includes about 0.26-2.82 wt % Si, 0.06-0.60 wt % Fe, 0.26-2.37 wt % Cu, 0.06-0.57 wt % Mn, 0.26-2.37 wt % Mg, 0.02-0.21 wt % Cr, 0.001-0.009 wt % Zn, 0.006-0.09 wt % Ti, 0.0003-0.003 wt % Zr, and up to 0.15 wt % impurities, with the remainder being Al. In some cases, the aluminum alloy includes about 0.52–1.18 wt % Si, 0.13–0.30 wt % Fe, 0.52–1.18 wt % Cu, 0.12–0.28 wt % Mn, 0.52–1.18 wt % Mg, 0.04–0.10 wt % Cr, 0.002–0.006 wt % Zn, 0.01-0.06 wt % Ti, 0.0006-0.001 wt % Zr, and up to 0.15 wt % impurities, with the remainder being Al. In some other examples, the aluminum alloy comprises about 0.70-1.0 wt % Si, 0.15-0.25 wt % Fe, 0.70-0.90 wt % Cu, 0.15-0.25 wt % Mn, 0.70-0.90 wt % Mg, 0.05-0.10 wt % Cr, 0.002-0.004 wt % Zn, 0.01-0.03 wt % Ti, 0.0006-0.001 wt % Zr and up to 0.15 wt % impurities, the remainder being Al. In some cases, the continuously cast slab is coiled prior to the step of hot rolling the slab. Optionally, the method further comprises cooling the slab as it leaves the outlet of the continuous casting machine that continuously casts the slab. Cooling may include quenching the slab with water and / or air cooling the slab. In some cases, the method may include coiling the slab into an intermediate coil prior to the step of hot rolling the slab to final gauge; preheating the intermediate coil prior to hot rolling the slab to final gauge; and homogenizing the intermediate coil prior to hot rolling the slab to final gauge.Optionally, the method may further include solutionizing the final size aluminum alloy product; quenching the final size aluminum alloy product; and aging the final size aluminum alloy product. Optionally, no cold rolling step is performed. In some cases, after the continuous casting step and before the hot rolling step, the slab has no cracks greater than about 8.0 mm in length.

[0010] In other examples, a method for producing an aluminum alloy product includes continuously casting an aluminum alloy to form a slab, wherein the aluminum alloy comprises approximately 0.26-2.82 wt. % Si, 0.06-0.60 wt. % Fe, 0.26–2.37 wt. % Cu, 0.06–0.57 wt. % Mn, 0.26–2.37 wt. % Mg, 0–0.21 wt. % Cr, 0–0.009 wt. % Zn, 0–0.09 wt. % Ti, 0–0.003 wt. % Zr, and up to 0.15 wt. % impurities, with the remainder being Al; and hot rolling the slab to final gauge and final temper. In some cases, the aluminum alloy includes about 0.26-2.82 wt % Si, 0.06-0.60 wt % Fe, 0.26-2.37 wt % Cu, 0.06-0.57 wt % Mn, 0.26-2.37 wt % Mg, 0.02-0.21 wt % Cr, 0.001-0.009 wt % Zn, 0.006-0.09 wt % Ti, 0.0003-0.003 wt % Zr, and up to 0.15 wt % impurities, with the remainder being Al. In some cases, the aluminum alloy includes about 0.52–1.18 wt % Si, 0.13–0.30 wt % Fe, 0.52–1.18 wt % Cu, 0.12–0.28 wt % Mn, 0.52–1.18 wt % Mg, 0.04–0.10 wt % Cr, 0.002–0.006 wt % Zn, 0.01-0.06 wt % Ti, 0.0006-0.001 wt % Zr, and up to 0.15 wt % impurities, with the remainder being Al. In some other examples, the aluminum alloy comprises about 0.70-1.0 wt % Si, 0.15-0.25 wt % Fe, 0.70-0.90 wt % Cu, 0.15-0.25 wt % Mn, 0.70-0.90 wt % Mg, 0.05-0.10 wt % Cr, 0.002-0.004 wt % Zn, 0.01-0.03 wt % Ti, 0.0006-0.001 wt % Zr, and up to 0.15 wt % impurities, with the remainder being Al. In some cases, the cast slab does not exhibit cracking during and / or after casting. In some cases, after the continuous casting step and before the hot rolling step, the slab has no cracks greater than about 8.0 mm in length.

[0011] In some examples, a method for producing an aluminum alloy product includes continuously casting an aluminum alloy in a continuous casting machine to form a slab, wherein the aluminum alloy contains approximately 0.26-2.82 wt. % Si, 0.06-0.60 wt. % Fe, 0.26–2.37 wt. % Cu, 0.06–0.57 wt. % Mn, 0.26–2.37 wt. % Mg, 0–0.21 wt. % Cr, 0–0.009 wt. % Zn, 0–0.09 wt. % Ti, 0–0.003 wt. % Zr, and up to 0.15 wt. % impurities, with the remainder being Al; homogenizing the slab as it exits the continuous casting machine; and hot rolling the slab to reduce the thickness of the slab by at least 50%. In some cases, the aluminum alloy includes about 0.26-2.82 wt % Si, 0.06-0.60 wt % Fe, 0.26-2.37 wt % Cu, 0.06-0.57 wt % Mn, 0.26-2.37 wt % Mg, 0.02-0.21 wt % Cr, 0.001-0.009 wt % Zn, 0.006-0.09 wt % Ti, 0.0003-0.003 wt % Zr, and up to 0.15 wt % impurities, with the remainder being Al. In some cases, the aluminum alloy includes about 0.52–1.18 wt % Si, 0.13–0.30 wt % Fe, 0.52–1.18 wt % Cu, 0.12–0.28 wt % Mn, 0.52–1.18 wt % Mg, 0.04–0.10 wt % Cr, 0.002–0.006 wt % Zn, 0.01-0.06 wt % Ti, 0.0006-0.001 wt % Zr, and up to 0.15 wt % impurities, with the remainder being Al. In some other examples, the aluminum alloy comprises about 0.70-1.0 wt % Si, 0.15-0.25 wt % Fe, 0.70-0.90 wt % Cu, 0.15-0.25 wt % Mn, 0.70-0.90 wt % Mg, 0.05-0.10 wt % Cr, 0.002-0.004 wt % Zn, 0.01-0.03 wt % Ti, 0.0006-0.001 wt % Zr and up to 0.15 wt % impurities, with the remainder being Al. Optionally, the homogenization step is performed at a temperature of about 500° C. to about 580° C.

[0012] Also provided herein is an aluminum alloy product prepared according to the method described herein. The aluminum alloy product may be an aluminum alloy sheet, an aluminum alloy plate or an aluminum alloy thin plate. The aluminum alloy product may include a long transverse tensile yield strength of at least about 365MPa under the T82 state. The aluminum alloy product may include a bending angle of about 40° to about 130° under the T4 state. Optionally, the aluminum alloy product may include an internal bending angle of about 35° to about 65° under the T4 state, an internal bending angle of about 110° to about 130° under the T82 state, and an internal bending angle of about 90° to about 130° under semi-collision conditions. The aluminum alloy product may be an automotive body part, a motor vehicle part, a transportation body part, an aerospace body part or an electronic equipment housing.

[0013] The aluminum alloys prepared according to the methods described herein have unexpected properties. For example, a continuously cast 6xxx series aluminum alloy processed without a cold rolling step exhibits the expected ductility of an aluminum alloy that has not been strain hardened by cold rolling, while also exhibiting the tensile strength typically obtained from a cold rolling step. The aluminum alloys described herein produced by continuous casting also exhibit crack resistance common in alloys of the compositions cast by a discontinuous direct chill (DC) process.

[0014] Other objects and advantages of the present invention will become apparent from the following detailed description of embodiments of the present invention and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1A and 1B is a process flow diagram showing two different processing routes for the different alloys described herein. Figure 1A A comparative process route is shown, in which a cast aluminum alloy ("As-Cast") is subjected to a preheating step ("Preheat"), a hot rolling step ("LabHR"), a quenching / coil cooling step ("Reroll"), a cold rolling step ("Lab CR") to produce a final specification product ("Final Specification"), subjected to a solutionizing step to produce a solution heat treated product ("SHT"), and subjected to an aging step to produce an aged product ("AA"). Figure 1B An exemplary process route is shown in which an as-cast aluminum alloy (“As-Cast”) is subjected to a preheating step (“Preheat”), a hot rolling to final gauge step (“Lab HR”) to produce a product of final gauge (“Final Gauge”), subjected to a solutionizing step to produce a solution heat treated product (“SHT”), and subjected to an aging step to produce an aged product (“AA”).

[0016] Figure 2 is shown by an exemplary route (hot rolled to gauge, referred to as "HRTG", see Figure 1B) processed by continuous casting (referred to as "CC") and by a comparative route (hot rolling and cold rolling, referred to as "HR+WQ+CR", see Figure 1A Graphs of yield strength (left shaded filled histogram bar of each pair) and bend angle (right shaded filled histogram bar of each pair) of a comparative alloy (C) of a DC cast (referred to as "DC") processed by ) . Measurements were made in the long transverse direction relative to the rolling direction.

[0017] Figure 3 The results are shown using three different solution temperatures and in the T4, T81 and T82 conditions. Figure 1A Graphs of the tensile properties of the continuously cast exemplary alloy A processed by the route ("HR+WQ+CR") described in . The left histogram column in each group represents the yield strength ("YS") of the alloys manufactured according to the different manufacturing methods. The center histogram column in each group represents the ultimate tensile strength ("UTS") of the alloys manufactured according to the different manufacturing methods. The right histogram column in each group represents the bending angle ("VDA") of the alloys manufactured according to the different manufacturing methods. The elongation is represented by the unfilled point marks. The diamonds in each group represent the total elongation ("TE") of the alloys manufactured according to the different manufacturing methods, and the circles in each group represent the uniform elongation ("UE") of the alloys manufactured according to the different manufacturing methods.

[0018] Figure 4 The results are shown in the table below using three different solution temperatures and in the T4, T81 and T82 conditions. Figure 1B Graphs of the tensile properties of the continuously cast exemplary alloy A processed by the route described in ("HRTG") . The left histogram column in each group represents the yield strength of the alloys made according to the different manufacturing methods. The center histogram column in each group represents the ultimate tensile strength of the alloys made according to the different manufacturing methods. The right histogram column in each group represents the bending angle of the alloys made according to the different manufacturing methods. The elongation is represented by the unfilled point marks. The diamonds in each group represent the total elongation of the alloys made according to the different manufacturing methods, and the circles in each group represent the uniform elongation of the alloys made according to the different manufacturing methods.

[0019] Figure 5 The results are shown in the table below using three different solution temperatures and in the T4, T81 and T82 conditions. Figure 1AGraphs of tensile properties of the continuously cast exemplary alloy B processed by the route HR+WQ+CR described in . The left histogram column in each group represents the yield strength of the alloys manufactured according to the different manufacturing methods. The center histogram column in each group represents the ultimate tensile strength of the alloys manufactured according to the different manufacturing methods. The right histogram column in each group represents the bending angle of the alloys manufactured according to the different manufacturing methods. The elongation is represented by the unfilled point marks. The diamonds in each group represent the total elongation of the alloys manufactured according to the different manufacturing methods, and the circles in each group represent the uniform elongation of the alloys manufactured according to the different manufacturing methods.

[0020] Figure 6 The results are shown in the table below using three different solution temperatures and in the T4, T81 and T82 conditions. Figure 1B Graphs of the tensile properties of the continuously cast exemplary alloy B processed by the route described in ("HRTG") . The left histogram column in each group represents the yield strength of the alloys made according to the different manufacturing methods. The center histogram column in each group represents the ultimate tensile strength of the alloys made according to the different manufacturing methods. The right histogram column in each group represents the bending angle of the alloys made according to the different manufacturing methods. The elongation is represented by the unfilled point marks. The diamonds in each group represent the total elongation of the alloys made according to the different manufacturing methods, and the circles in each group represent the uniform elongation of the alloys made according to the different manufacturing methods.

[0021] Figure 7 Digital images of particle content and grain structure of exemplary alloys described herein are shown. The top row ("Particles") shows the particle content of exemplary alloys processed by exemplary routes ("A-HRTG", "B-HRTG") and comparative routes ("A-HR+WQ+CR", "B-HR+WQ+CR"). The bottom row ("Grains") shows the grain structure of exemplary alloys processed by exemplary and comparative routes.

[0022] Figure 8 Digital images of particle content and grain structure of exemplary and comparative alloys described herein are shown. The top row ("Particles") shows the particle content of exemplary (A, B) and comparative (C) alloys processed by comparative routes (hot and cold rolling, "A-HR+WQ+CR", "B-HR+WQ+CR", "C-HR+WQ+CR"). The bottom row ("Grains") shows the grain structure of exemplary and comparative alloys processed by comparative routes.

[0023] Fig. 9 Schematic diagrams depicting methods for producing aluminum alloy articles according to certain aspects of the present disclosure. An aluminum alloy is continuously cast into slab form, homogenized, hot rolled, quenched, coiled, cold rolled, solutionized, and / or quenched.

[0024] Fig.10 is through Fig. 9 Graph of mechanical properties of aluminum alloys processed by the routes described. VDA bend and yield strength data are shown.

[0025] Fig.11 is a schematic diagram describing a method of producing an aluminum alloy article according to certain aspects of the present disclosure. The aluminum alloy is continuously cast into slab form, homogenized, hot rolled, quenched, coiled, preheated, quenched to a temperature below the preheat temperature, warm rolled and solutionized.

[0026] Fig.12 is through Fig.11 Graph of mechanical properties of aluminum alloys processed by the routes described. VDA bend and yield strength data are shown.

[0027] Fig.13 Schematic diagram illustrating a method for producing an aluminum alloy article according to certain aspects of the present disclosure. The aluminum alloy is continuously cast into slab form, homogenized, hot rolled, quenched, coiled, preheated, hot rolled, quenched, cold rolled, and solutionized.

[0028] Fig.14 is through Fig.13 Graph of mechanical properties of aluminum alloys processed by the routes described. VDA bend and yield strength data are shown.

[0029] Fig.15 Schematic diagram illustrating a method for producing an aluminum alloy article according to certain aspects of the present disclosure. The aluminum alloy is continuously cast into slab form, homogenized, hot rolled, quenched, preheated, quenched, cold rolled, and solutionized.

[0030] Fig.16 is through Fig.15 Graph of mechanical properties of aluminum alloys processed by the routes described. VDA bend and yield strength data are shown.

[0031] Fig.17 is a graph of mechanical properties of aluminum alloys produced according to certain aspects of the present disclosure. The left histogram bar in each group represents the yield strength of the alloy. The right histogram bar in each group represents the ultimate tensile strength of the alloy. The elongation is represented by the unfilled point marks. The diamonds in each group represent the total elongation of the alloy, and the circles in each group represent the uniform elongation of the alloy. DETAILED DESCRIPTION

[0032] This paper describes the 6xxx series aluminum alloys that show high strength and high formability. In some cases, due to its high solute content, the 6xxx series aluminum alloys may be difficult to cast using traditional casting processes. The method described herein allows the 6xxx series aluminum alloys described herein to be cast into thin slabs (e.g., a thickness of about 5mm to about 50mm aluminum alloy body), as determined by visual inspection, during and / or after casting, there is no cracking (e.g., less cracks per square meter in the slab prepared according to the method described herein than in direct chill casting ingots). In some instances, as described herein, the 6xxx series aluminum alloys can be continuously cast. In some other instances, by including a water quenching step when leaving a continuous casting machine, solutes can be frozen in a matrix, rather than being precipitated from the matrix. In some cases, the freezing of solutes in the matrix can prevent the coarsening of precipitates in downstream processing.

[0033] Definition and Description

[0034] The term "invention / the invention / this invention / the present invention" as used in this document is intended to broadly refer to all subject matter of this patent application and the following claims. It should be understood that statements containing these terms do not limit the subject matter described herein or limit the meaning or scope of the following patent claims.

[0035] As used herein, the meanings of "a," "an," and "the" include both singular and plural references unless the context clearly dictates otherwise.

[0036] As used herein, unless the context clearly dictates otherwise, the meaning of "metal" includes pure metals, alloys, and metal solid solutions.

[0037] In this specification, reference is made to alloys identified by AA numbers and other related designations, such as "Series" or "6xxx." To understand the numerical designation system most commonly used to name and identify aluminum and its alloys, refer to "International Alloy Designations and Chemical Composition Limitations for Wrought Aluminum and Wrought Aluminum Alloys" or "Aluminum Association Register of Alloy Designations and Chemical Composition Limitations for Cast Aluminum and Aluminum Alloys in Ingot Form," both published by The Aluminum Association.

[0038] Reference is made to alloy tempers or conditions throughout this application. For a description of the most commonly used alloy tempers, see "American National Standard (ANSI) H35 for Alloy and Temper Designation System." The F condition or temper refers to the aluminum alloy as manufactured. The O condition or state refers to the aluminum alloy after annealing. The T1 condition or state refers to the aluminum alloy after being hot worked, cooled, and naturally aged (e.g., at room temperature). The T2 condition or state refers to the aluminum alloy after being hot worked, cooled, cold worked, and naturally aged (e.g., at room temperature). The T3 condition or state refers to the aluminum alloy after solution heat treatment (i.e., solubilization), cold working, and natural aging. The T4 condition or state refers to the aluminum alloy after solution heat treatment followed by natural aging. The T5 condition or state refers to the aluminum alloy after being hot worked, cooled, and artificially aged. The T6 condition or state refers to the aluminum alloy after solution heat treatment followed by artificial aging (AA). The T7 condition or state refers to the aluminum alloy after solution heat treatment and then artificial over-aging. The T8x condition or state refers to the aluminum alloy after solution heat treatment, followed by cold working, and then artificially aged. The T9 condition or temper refers to an aluminum alloy after solution heat treatment, followed by artificial aging, and then cold working.

[0039] As used herein, a plate generally has a thickness greater than about 15 mm. For example, a plate may refer to an aluminum article having a thickness greater than 15 mm, greater than 20 mm, greater than 25 mm, greater than 30 mm, greater than 35 mm, greater than 40 mm, greater than 45 mm, greater than 50 mm, or greater than 100 mm.

[0040] As used herein, the thickness of the thin plate (also referred to as a sheet) is generally about 4 mm to about 15 mm. For example, the thickness of the thin plate can be 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm or 15 mm.

[0041] As used herein, sheet generally refers to an aluminum product having a thickness of less than about 4 mm. For example, the thickness of the sheet may be less than 4 mm, less than 3 mm, less than 2 mm, less than 1 mm, less than 0.5 mm, less than 0.3 mm, or less than 0.1 mm.

[0042] All ranges disclosed herein should be understood to include any and all subranges contained therein. For example, the range of "1 to 10" should be considered to include any and all subranges between (including) a minimum value of 1 and a maximum value of 10; that is, all subranges starting with a minimum value of 1 or greater, such as 1 to 6.1, and ending with a maximum value of 10 or less, such as 5.5 to 10.

[0043] In the following examples, aluminum alloys are described according to their elemental composition in terms of weight percent (wt%) of the whole. In each alloy, the remainder is aluminum, with a maximum wt% of the sum of impurities of 0.15%.

[0044] Alloy composition

[0045] Alloy described herein is 6xxx series alloy containing aluminum.This alloy shows unexpected high strength and high formability.In some cases, due to the element composition of alloy, the performance of alloy can be achieved.Specifically, alloy can have the following element composition as provided in Table 1.

[0046] Table 1

[0047]

[0048] In some examples, the alloys can have the elemental compositions provided in Table 2.

[0049] Table 2

[0050]

[0051] In some examples, the alloys can have the elemental compositions provided in Table 3.

[0052] Table 3

[0053]

[0054] In some examples, the alloys may have the following elemental compositions provided in Table 4.

[0055] Table 4

[0056]

[0057] In some examples, the alloys described herein include silicon (Si) in an amount of about 0.26 wt % to about 2.82 wt % (eg, 0.52 wt % to 1.18 wt % or 0.70 wt % to 1.0 wt %), based on the total weight of the alloy. For example, the alloy may include 0.26%, 0.27%, 0.28%, 0.29%, 0.3%, 0.31%, 0.32%, 0.33%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.4%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.5%, 0.51%, 0.52%, 0.53%, %, 0.54 wt%, 0.55 wt%, 0.56 wt%, 0.57 wt%, 0.58 wt%, 0.59 wt%, 0.6 wt%, 0.61 wt%, 0.62 wt%, 0.63 wt%, 0.64 wt%, 0.65 wt%, 0.66 wt%, 0.67 wt%, 0.68 wt%, 0.69 wt%, 0.7 wt%, 0.71 wt%, 0.72 wt%, 0.73 wt%, 0.74 wt%, 0.75 wt%, 0.76 wt%, 0.77 wt%, 0.78 wt%, 0.79 wt%, 0.8 wt%, 0.81 wt%, 0.82 wt %, 0.83 wt%, 0.84 wt%, 0.85 wt%, 0.86 wt%, 0.87 wt%, 0.88 wt%, 0.89 wt%, 0.9 wt%, 0.91 wt%, 0.92 wt%, 0.93 wt%, 0.94 wt%, 0.95 wt%, 0.96 wt%, 0.97 wt%, 0.98 wt%, 0.99 wt%, 1.0 wt%, 1.01 wt%, 1.02 wt%, 1.03 wt%, 1.04 wt%, 1.05 wt%, 1.06 wt%, 1.07 wt%, 1.08 wt%, 1.09 wt%, 1.1 wt%, 1.11 %, 1.12 wt%, 1.13 wt%, 1.14 wt%, 1.15 wt%, 1.16 wt%, 1.17 wt%, 1.18 wt%, 1.19 wt%, 1.2 wt%, 1.21 wt%, 1.22 wt%, 1.23 wt%, 1.24 wt%, 1.25 wt%, 1.26 wt%, 1.27 wt%, 1.28 wt%, 1.29 wt%, 1.3 wt%, 1.31 wt%, 1.32 wt%, 1.33 wt%, 1.34 wt%, 1.35 wt%, 1.36 wt%, 1.37 wt%, 1.38 wt%, 1.39 wt%, 1.4 wt%, 1.41 wt%, 1.42 wt%, 1.43 wt%, 1.44 wt%, 1.45 wt%, 1.46 wt%, 1.47 wt%, 1.48 wt%, 1.49 wt%, 1.5 wt%, 1.51 wt%, 1.52 wt%, 1.53 wt%, 1.54 wt%, 1.55 wt%, 1.56 wt%, 1.57 wt%, 1.58 wt%, 1.59 wt%, 1.6 wt%, 1.61 wt%, 1.62 wt%, 1.63 wt%, 1.64 wt%, 1.65 wt%, 1.66 wt%, 1.67 wt%, 1.68 wt%, 1.69 wt%, 1.7 wt%, 1.71 wt% %, 1.72 wt%, 1.73 wt%, 1.74 wt%, 1.75 wt%, 1.76 wt%, 1.77 wt%, 1.78 wt%, 1.79 wt%, 1.80 wt%, 1.81 wt%, 1.82 wt%, 1.83 wt%, 1.84 wt%, 1.85 wt%, 1.86 wt%, 1.87 wt%, 1.88 wt%, 1.89 wt%, 1.9 wt%, 1.91 wt%, 1.92 wt%, 1.93 wt%, 1.94 wt%, 1.95 wt%, 1.96 wt%, 1.97 wt%, 1.98 wt%, 1.99 wt%, 2.0 wt%, 2.01 wt%, 2.02 wt%, 2. %, 2.03 wt%, 2.04 wt%, 2.05 wt%, 2.06 wt%, 2.07 wt%, 2.08 wt%, 2.09 wt%, 2.1 wt%, 2.11 wt%, 2.12 wt%, 2.13 wt%, 2.14 wt%, 2.15 wt%, 2.16 wt%, 2.17 wt%, 2.18 wt%, 2.19 wt%, 2.2 wt%, 2.21 wt%, 2.22 wt%, 2.23 wt%, 2.24 wt%, 2.25 wt%, 2.26 wt%, 2.27 wt%, 2.28 wt%, 2.29 wt%, 2.3 wt%, 2.31 wt%, 2.32 wt%, 2.33 wt%, 2.34 wt %, 2.35 wt%, 2.36 wt%, 2.37 wt%, 2.38 wt%, 2.39 wt%, 2.4 wt%, 2.41 wt%, 2.42 wt%, 2.43 wt%, 2.44 wt%, 2.45 wt%, 2.46 wt%, 2.47 wt%, 2.48 wt%, 2.49 wt%, 2.5 wt%, 2.51 wt%, 2.52 wt%, 2.53 wt%, 2.54 wt%, 2.55 wt%, 2.56 wt%, 2.57 wt%, 2.58 wt%, 2.59 wt%, 2.6 wt%, 2.61 wt%, 2.62 wt%, 2.63 wt%, 2.64 wt%, 2.65 wt%, 2.66 wt%, 2.67 wt%, 2.68 wt%, 2.69 wt%, 2.7 wt%, 2.71 wt%, 2.72 wt%, 2.73 wt%, 2.74 wt%, 2.75 wt%, 2.76 wt%, 2.77 wt%, 2.78 wt%, 2.79 wt%, 2.80 wt%, 2.81 wt% or 2.82 wt% Si.

[0058] In some examples, the alloys described herein include iron (Fe) in an amount of about 0.06 wt % to about 0.60 wt % (eg, 0.13 wt % to 0.30 wt % or 0.15 wt % to 0.25 wt %), based on the total weight of the alloy. For example, the alloy can include 0.06%, 0.07%, 0.08%, 0.09%, 0.1%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.2%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.3%, 0.31%, 0.32%, 0.33%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.40%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.60%, 0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.70%, 0.71%, 0.72%, 0.73%, 0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, 0.80%, 0.81%, 0.82%, 0.83%, 0.84%, 0.85%, 0.86%, 0.87%, 0.88%, 0.89%, %. 0.33 wt%, 0.34 wt%, 0.35 wt%, 0.36 wt%, 0.37 wt%, 0.38 wt%, 0.39 wt%, 0.4 wt%, 0.41 wt%, 0.42 wt%, 0.43 wt%, 0.44 wt%, 0.45 wt%, 0.46 wt%, 0.47 wt%, 0.48 wt%, 0.49 wt%, 0.5 wt%, 0.51 wt%, 0.52 wt%, 0.53 wt%, 0.54 wt%, 0.55 wt%, 0.56 wt%, 0.57 wt%, 0.58 wt%, 0.59 wt% or 0.6 wt% Fe.

[0059] In some examples, the alloys described herein include copper (Cu) in an amount of about 0.26 wt % to about 2.37 wt % (eg, 0.52 wt % to 1.18 wt % or 0.70 wt % to 1.0 wt %), based on the total weight of the alloy. For example, the alloy may include 0.26%, 0.27%, 0.28%, 0.29%, 0.3%, 0.31%, 0.32%, 0.33%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.4%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.5%, 0.51%, 0.52%, 0.53%, %, 0.54 wt%, 0.55 wt%, 0.56 wt%, 0.57 wt%, 0.58 wt%, 0.59 wt%, 0.6 wt%, 0.61 wt%, 0.62 wt%, 0.63 wt%, 0.64 wt%, 0.65 wt%, 0.66 wt%, 0.67 wt%, 0.68 wt%, 0.69 wt%, 0.7 wt%, 0.71 wt%, 0.72 wt%, 0.73 wt%, 0.74 wt%, 0.75 wt%, 0.76 wt%, 0.77 wt%, 0.78 wt%, 0.79 wt%, 0.8 wt%, 0.81 wt%, 0.82 wt %, 0.83 wt%, 0.84 wt%, 0.85 wt%, 0.86 wt%, 0.87 wt%, 0.88 wt%, 0.89 wt%, 0.9 wt%, 0.91 wt%, 0.92 wt%, 0.93 wt%, 0.94 wt%, 0.95 wt%, 0.96 wt%, 0.97 wt%, 0.98 wt%, 0.99 wt%, 1.0 wt%, 1.01 wt%, 1.02 wt%, 1.03 wt%, 1.04 wt%, 1.05 wt%, 1.06 wt%, 1.07 wt%, 1.08 wt%, 1.09 wt%, 1.1 wt%, 1.11 %, 1.12 wt%, 1.13 wt%, 1.14 wt%, 1.15 wt%, 1.16 wt%, 1.17 wt%, 1.18 wt%, 1.19 wt%, 1.2 wt%, 1.21 wt%, 1.22 wt%, 1.23 wt%, 1.24 wt%, 1.25 wt%, 1.26 wt%, 1.27 wt%, 1.28 wt%, 1.29 wt%, 1.3 wt%, 1.31 wt%, 1.32 wt%, 1.33 wt%, 1.34 wt%, 1.35 wt%, 1.36 wt%, 1.37 wt%, 1.38 wt%, 1.39 wt%, 1.4 wt%, 1.41 wt%, 1.42 wt%, 1.43 wt%, 1.44 wt%, 1.45 wt%, 1.46 wt%, 1.47 wt%, 1.48 wt%, 1.49 wt%, 1.5 wt%, 1.51 wt%, 1.52 wt%, 1.53 wt%, 1.54 wt%, 1.55 wt%, 1.56 wt%, 1.57 wt%, 1.58 wt%, 1.59 wt%, 1.6 wt%, 1.61 wt%, 1.62 wt%, 1.63 wt%, 1.64 wt% %, 1.65 wt%, 1.66 wt%, 1.67 wt%, 1.68 wt%, 1.69 wt%, 1.7 wt%, 1.71 wt%, 1.72 wt%, 1.73 wt%, 1.74 wt%, 1.75 wt%, 1.76 wt%, 1.77 wt%, 1.78 wt%, 1.79 wt%, 1.80 wt%, 1.81 wt%, 1.82 wt%, 1.83 wt%, 1.84 wt%, 1.85 wt%, 1.86 wt%, 1.87 wt%, 1.88 wt%, 1. 89 wt%, 1.9 wt%, 1.91 wt%, 1.92 wt%, 1.93 wt%, 1.94 wt%, 1.95 wt%, 1.96 wt%, 1.97 wt%, 1.98 wt%, 1.99 wt%, 2.0 wt%, 2.01 wt%, 2.02 wt%, 2.03 wt%, 2.04 wt%, 2.05 wt%, 2.06 wt%, 2.07 wt%, 2.08 wt%, 2.09 wt%, 2.1 wt%, 2.11 wt%, 2.12 wt%, 2.13 wt% %, 2.14 wt%, 2.15 wt%, 2.16 wt%, 2.17 wt%, 2.18 wt%, 2.19 wt%, 2.2 wt%, 2.21 wt%, 2.22 wt%, 2.23 wt%, 2.24 wt%, 2.25 wt%, 2.26 wt%, 2.27 wt%, 2.28 wt%, 2.29 wt%, 2.3 wt%, 2.31 wt%, 2.32 wt%, 2.33 wt%, 2.34 wt%, 2.35 wt%, 2.36 wt% or 2.37 wt% Cu.

[0060] In some examples, the alloys described herein include manganese (Mn) in an amount of about 0.06 wt % to about 0.57 wt % (eg, 0.12 wt % to 0.28 wt % or 0.15 wt % to 0.25 wt %), based on the total weight of the alloy. For example, the alloy may include 0.06%, 0.07%, 0.08%, 0.09%, 0.1%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.2%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.3%, 0.31%, 0.32%, 0.33%, 0.34%, 0.36%, 0.37%, 0.38%, 0.39%, 0.40%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.60%, 0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.70%, 0.71%, 0.72%, 0.73%, 0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, 0.80%, 0.81%, 0.82%, %, 0.54 wt%, 0.55 wt%, 0.56 wt% or 0.57 wt% Mn.

[0061] In some examples, the alloys described herein include magnesium (Mg) in an amount of about 0.26 wt % to about 2.37 wt % (eg, 0.52 wt % to 1.18 wt % or 0.70 wt % to 0.90 wt %), based on the total weight of the alloy. For example, the alloy may include 0.26%, 0.27%, 0.28%, 0.29%, 0.3%, 0.31%, 0.32%, 0.33%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.4%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.5%, 0.51%, 0.52%, 0.53%, %, 0.54 wt%, 0.55 wt%, 0.56 wt%, 0.57 wt%, 0.58 wt%, 0.59 wt%, 0.6 wt%, 0.61 wt%, 0.62 wt%, 0.63 wt%, 0.64 wt%, 0.65 wt%, 0.66 wt%, 0.67 wt%, 0.68 wt%, 0.69 wt%, 0.7 wt%, 0.71 wt%, 0.72 wt%, 0.73 wt%, 0.74 wt%, 0.75 wt%, 0.76 wt%, 0.77 wt%, 0.78 wt%, 0.79 wt%, 0.8 wt%, 0.81 wt%, 0.82 wt %, 0.83 wt%, 0.84 wt%, 0.85 wt%, 0.86 wt%, 0.87 wt%, 0.88 wt%, 0.89 wt%, 0.9 wt%, 0.91 wt%, 0.92 wt%, 0.93 wt%, 0.94 wt%, 0.95 wt%, 0.96 wt%, 0.97 wt%, 0.98 wt%, 0.99 wt%, 1.0 wt%, 1.01 wt%, 1.02 wt%, 1.03 wt%, 1.04 wt%, 1.05 wt%, 1.06 wt%, 1.07 wt%, 1.08 wt%, 1.09 wt%, 1.1 wt%, 1.11 %, 1.12 wt%, 1.13 wt%, 1.14 wt%, 1.15 wt%, 1.16 wt%, 1.17 wt%, 1.18 wt%, 1.19 wt%, 1.2 wt%, 1.21 wt%, 1.22 wt%, 1.23 wt%, 1.24 wt%, 1.25 wt%, 1.26 wt%, 1.27 wt%, 1.28 wt%, 1.29 wt%, 1.3 wt%, 1.31 wt%, 1.32 wt%, 1.33 wt%, 1.34 wt%, 1.35 wt%, 1.36 wt%, 1.37 wt%, 1.38 wt%, 1.39 wt%, 1.4 wt%, 1.41 wt%, 1.42 wt%, 1.43 wt%, 1.44 wt%, 1.45 wt%, 1.46 wt%, 1.47 wt%, 1.48 wt%, 1.49 wt%, 1.5 wt%, 1.51 wt%, 1.52 wt%, 1.53 wt%, 1.54 wt%, 1.55 wt%, 1.56 wt%, 1.57 wt%, 1.58 wt%, 1.59 wt%, 1.6 wt%, 1.61 wt%, 1.62 wt%, 1.63 wt%, 1.64 wt% %, 1.65 wt%, 1.66 wt%, 1.67 wt%, 1.68 wt%, 1.69 wt%, 1.7 wt%, 1.71 wt%, 1.72 wt%, 1.73 wt%, 1.74 wt%, 1.75 wt%, 1.76 wt%, 1.77 wt%, 1.78 wt%, 1.79 wt%, 1.80 wt%, 1.81 wt%, 1.82 wt%, 1.83 wt%, 1.84 wt%, 1.85 wt%, 1.86 wt%, 1.87 wt%, 1.88 wt%, 1. 89 wt%, 1.9 wt%, 1.91 wt%, 1.92 wt%, 1.93 wt%, 1.94 wt%, 1.95 wt%, 1.96 wt%, 1.97 wt%, 1.98 wt%, 1.99 wt%, 2.0 wt%, 2.01 wt%, 2.02 wt%, 2.03 wt%, 2.04 wt%, 2.05 wt%, 2.06 wt%, 2.07 wt%, 2.08 wt%, 2.09 wt%, 2.1 wt%, 2.11 wt%, 2.12 wt%, 2.13 wt% %, 2.14 wt%, 2.15 wt%, 2.16 wt%, 2.17 wt%, 2.18 wt%, 2.19 wt%, 2.2 wt%, 2.21 wt%, 2.22 wt%, 2.23 wt%, 2.24 wt%, 2.25 wt%, 2.26 wt%, 2.27 wt%, 2.28 wt%, 2.29 wt%, 2.3 wt%, 2.31 wt%, 2.32 wt%, 2.33 wt%, 2.34 wt%, 2.35 wt%, 2.36 wt% or 2.37 wt% of Mg.

[0062] In some examples, the alloys described herein include chromium (Cr) in an amount of up to about 0.20 wt % (e.g., about 0.02 wt % to about 0.20 wt %, 0.04 wt % to 0.10 wt %, or 0.05 wt % to 0.10 wt %). For example, the alloy may include 0.02 wt %, 0.03 wt %, 0.04 wt %, 0.05 wt %, 0.06 wt %, 0.07 wt %, 0.08 wt %, 0.09 wt %, 0.1 wt %, 0.11 wt %, 0.12 wt %, 0.13 wt %, 0.14 wt %, 0.15 wt %, 0.16 wt %, 0.17 wt %, 0.18 wt %, 0.19 wt %, or 0.2 wt % Cr. In certain aspects, Cr is absent from the alloy (i.e., 0 wt %).

[0063] In some examples, the alloys described herein include zinc (Zn) in an amount of up to about 0.009 wt % (e.g., about 0.001 wt % to about 0.009 wt %, 0.002 wt % to 0.006 wt %, or 0.002 wt % to 0.004 wt %), based on the total weight of the alloy. For example, the alloy may include 0.001 wt %, 0.002 wt %, 0.003 wt %, 0.004 wt %, 0.005 wt %, 0.006 wt %, 0.007 wt %, 0.008 wt %, or 0.009 wt % Zn. In certain aspects, Zn is absent from the alloy (i.e., 0 wt %).

[0064] In some examples, the alloys described herein include titanium (Ti) in an amount of up to about 0.09 wt % (e.g., about 0.006 wt % to about 0.09 wt %, 0.01 wt % to 0.06 wt %, or 0.01 wt % to 0.03 wt %), based on the total weight of the alloy. For example, the alloy may include 0.006 wt%, 0.007 wt%, 0.008 wt%, 0.009 wt%, 0.01 wt%, 0.011 wt%, 0.012 wt%, 0.013 wt%, 0.014 wt%, 0.015 wt%, 0.016 wt%, 0.017 wt%, 0.018 wt%, 0.019 wt%, 0.02 wt%, 0.021 wt%, 0.022 wt%, 0.023 wt%, 0.024 wt%, 0.025 wt%, 0.026 wt%, %, 0.027 wt%, 0.028 wt%, 0.029 wt%, 0.03 wt%, 0.031 wt%, 0.032 wt%, 0.033 wt%, 0.034 wt%, 0.035 wt%, 0.036 wt%, 0.037 wt%, 0.038 wt%, 0.039 wt%, 0.04 wt%, 0.041 wt%, 0.042 wt%, 0.043 wt%, 0.044 wt%, 0.045 wt%, 0.046 wt%, 0.047 wt%, 0 0.048 wt%, 0.049 wt%, 0.05 wt%, 0.051 wt%, 0.052 wt%, 0.053 wt%, 0.054 wt%, 0.055 wt%, 0.056 wt%, 0.057 wt%, 0.058 wt%, 0.059 wt%, 0.06 wt%, 0.061 wt%, 0.062 wt%, 0.063 wt%, 0.064 wt%, 0.065 wt%, 0.066 wt%, 0.067 wt%, 0.068 wt%, 0.069 wt% %, 0.084 wt %, 0.085 wt %, 0.086 wt %, 0.087 wt %, 0.088 wt %, 0.089 wt %, 0.09 wt %. In certain aspects, Ti is absent from the alloy (i.e., 0 wt %).

[0065] In some examples, the alloys described herein include zirconium (Zr) in an amount of up to about 0.20 wt % (e.g., from about 0.0003 wt % to about 0.003 wt %, 0.0006 wt % to 0.001 wt %, or 0.0009 wt % to 0.001 wt %), based on the total weight of the alloy. For example, the alloy may include 0.0001%, 0.0002%, 0.0003%, 0.0004%, 0.0005%, 0.0006%, 0.0007%, 0.0008%, 0.0009%, 0.001%, 0.0011%, 0.0012%, 0.0013%, 0.0014%, 0.0015%, 0.0016%, 0.0017%, 0.0018%, 0.0019%, 0.002%, 0.0021%, 0.0022%, 0.0023%, 0.0024%, 0.0025%, 0.0 % , 0.02% by weight, 0.0027% by weight, 0.0028% by weight, 0.0029% by weight, 0.003% by weight, 0.004% by weight, 0.005% by weight, 0.006% by weight, 0.007% by weight, 0.008% by weight, 0.009% by weight, 0.01% by weight, 0.02% by weight, 0.03% by weight, 0.04% by weight, 0.05% by weight, 0.06% by weight, 0.07% by weight, 0.08% by weight, 0.09% by weight, 0.1% by weight, 0.11% by weight, 0.12% by weight, 0.13% by weight, 0.14% by weight, 0.15% by weight, 0.16% by weight, 0.17% by weight, 0.18% by weight, 0.19% by weight or 0.2% by weight of Zr. In certain aspects, Zr is absent from the alloy (ie, 0 wt %).

[0066] Optionally, the alloy compositions described herein may also include other trace elements, sometimes referred to as impurities, in amounts of 0.05 wt % or less, 0.04 wt % or less, 0.03 wt % or less, 0.02 wt % or less, 0.01 wt % or less, respectively. These impurities may include, but are not limited to, V, Ni, Sn, Ga, Ca, or combinations thereof. Thus, the amount of V, Ni, Sn, Ga, or Ca in the alloy may be 0.05 wt % or less, 0.04 wt % or less, 0.03 wt % or less, 0.02 wt % or less, or 0.01 wt % or less. In some instances, the sum of all impurities does not exceed 0.15 wt % (e.g., 0.10 wt %). The remaining percentage of the alloy is aluminum.

[0067] In some examples, the aluminum alloy includes 0.79 wt% Si, 0.20 wt% Fe, 0.79 wt% Cu, 0.196 wt% Mn, 0.79 wt% Mg, 0.07 wt% Cr, 0.003 wt% Zn, 0.02 wt% Ti, 0.001 wt% Zr, and up to 0.15 wt% impurities, with the remainder being Al.

[0068] In some examples, the aluminum alloy includes 0.94 wt% Si, 0.20 wt% Fe, 0.79 wt% Cu, 0.196 wt% Mn, 0.79 wt% Mg, 0.07 wt% Cr, 0.003 wt% Zn, 0.03 wt% Ti, 0.001 wt% Zr, and up to 0.15 wt% impurities, with the remainder being Al.

[0069] Optionally, the aluminum alloy as described herein can be a 6xxx aluminum alloy according to one of the following aluminum alloy designations: AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA6206, AA6306, 06. AA6008, AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA601 5. AA6016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027, A A6028, AA6031, AA6032, AA6033, AA6040, AA6041, AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA6 053, AA6055, AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560, AA6660, AA6061, AA6061 A. AA6261, AA6361, AA6162, AA6262, AA6262A, AA6063, AA6063A, AA6463, AA6463A, AA6763, A6963, AA6064, AA6064 A. AA6065, AA6066, AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A, AA6182, AA6091 or AA6092.

[0070] Manufacturing method

[0071] Also described herein is a method of producing aluminum sheet. The aluminum alloy may be cast and then may be subjected to further processing steps. In some examples, the processing steps include a preheating and / or homogenizing step, a hot rolling step, a solutionizing step, an optional quenching step, an artificial aging step, an optional painting step, and an optional paint baking step.

[0072] In some examples, the method includes casting a slab; hot rolling the slab to produce a hot rolled aluminum alloy in the form of a sheet, thin plate or plate; solid solution aluminum sheet, aluminum sheet or aluminum plate; and aging the aluminum sheet, aluminum sheet or aluminum plate. In some examples, the hot rolling step includes hot rolling the slab to the final specification and / or final state. In some examples, the cold rolling step is canceled (i.e., excluded). In some examples, the slab is thermally quenched when leaving the continuous casting machine. In some other examples, the slab is coiled when leaving the continuous casting machine outlet. In some cases, the coiled slab is cooled in the air. In some cases, the method also includes preheating the coiled slab. In some examples, the method also includes painting aged aluminum sheet, aluminum sheet or aluminum plate. In some other examples, the method also includes baking the painted aluminum sheet, aluminum sheet or aluminum plate. The method steps are further described below.

[0073] Casting

[0074] The alloys described herein may be cast into slabs using a continuous casting (CC) process. The continuous casting apparatus may be any suitable continuous casting apparatus. The CC process may include, but is not limited to, the use of a block caster, a twin roll caster, or a twin belt caster. Surprisingly desirable results have been achieved using twin belt casting apparatus, such as the belt casting apparatus described in U.S. Pat. No. 6,755,236, entitled "BELT-COOLING AND GUIDING MEANS FOR CONTINUOUSBELT CASTING OF METAL STRIP", the disclosure of which is hereby incorporated by reference in its entirety. In some instances, particularly desirable results may be achieved by using a belt casting apparatus having a belt made of a metal having a high thermal conductivity, such as copper. The belt casting apparatus may include a belt made of a metal having a thermal conductivity of up to 400 watts per meter Kelvin (W / m·K). For example, at the casting temperature, the thermal conductivity of the strip may be 50 W / m·K, 100 W / m·K, 150 W / m·K, 250 W / m·K, 300 W / m·K, 350 W / m·K, or 400 W / m·K, although metals having other thermal conductivity values ​​may be used, including carbon steel or mild steel. CC may be performed at a rate of up to about 12 meters per minute (m / min). For example, CC may be performed at a rate of 12 m / min or less, 11 m / min or less, 10 m / min or less, 9 m / min or less, 8 m / min or less, 7 m / min or less, 6 m / min or less, 5 m / min or less, 4 m / min or less, 3 m / min or less, 2 m / min or less, or 1 m / min or less.

[0075] Quenching

[0076] When leaving the continuous casting machine, the resulting slab can be optionally hot quenched. In some instances, quenching is performed with water. Optionally, the water quenching step can be performed at a rate of up to about 200°C / s (e.g., 10°C / s to 190°C / s, 25°C / s to 175°C / s, 50°C / s to 150°C / s, 75°C / s to 125°C / s, or 10°C / s to 50°C / s). The room temperature can be about 20°C to about 75°C (e.g., about 25°C, about 30°C, about 35°C, about 40°C, about 45°C, about 50°C, about 55°C, about 60°C, about 65°C, about 70°C or about 75°C). Optionally, the air cooling step can be performed at a rate of about 1°C / s to about 300°C / day. The resulting slab may have a thickness of about 5 mm to about 50 mm (e.g., about 10 mm to about 45 mm, about 15 mm to about 40 mm, or about 20 mm to about 35 mm), such as about 10 mm. For example, the resulting slab may be 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm, 20 mm, 21 mm, 22 mm, 23 mm, 24 mm, 25 mm, 26 mm, 27 mm, 28 mm, 29 mm, 30 mm, 31 mm, 32 mm, 33 mm, 34 mm, 35 mm, 36 mm, 37 mm, 38 mm, 39 mm, 40 mm, 41 mm, 42 mm, 43 mm, 44 mm, 45 mm, 46 mm, 47 mm, 48 mm, 49 mm, or 50 mm thick.

[0077] In some examples, the slab is water quenched when leaving the continuous casting machine to produce an aluminum alloy slab in T4 state. After the optional water quenching, the slab in T4-state can then be optionally coiled into an intermediate coil and stored for up to 90 days. Unexpectedly, water quenching the slab when leaving the continuous casting machine does not cause the slab to crack, which is determined by visual inspection so that the slab can be free of cracks. For example, compared with direct chilled ingots, the cracking tendency of the slab produced according to the method described herein is significantly reduced. In some examples, there are about 8 or less cracks per square meter, and its length is less than about 8.0mm (for example, about 7 or less cracks per square meter, about 6 or less cracks, about 5 or less cracks, about 4 or less cracks, about 3 or less cracks, about 2 or less cracks, or about 1 crack).

[0078] Winding

[0079] Optionally, the slab can be wound into an intermediate coil when leaving the continuous casting machine. In some examples, the slab is wound into an intermediate coil when leaving the continuous casting machine to produce an F-state. In some other examples, the coil is cooled in air. In some other examples, the air-cooled coil is stored for a period of time. In some examples, the intermediate coil is maintained at a temperature of about 100° C. to about 350° C. (e.g., about 200° C. or about 300° C.). In some other examples, the intermediate coil is kept refrigerated to prevent natural aging from producing an F-state.

[0080] Preheating and / or homogenization

[0081] When stored, the intermediate coil can be optionally reheated in the preheating step. In some examples, the reheating step may include preheating the intermediate coil for the hot rolling step. In some other examples, the reheating step may include preheating the intermediate coil at a rate of up to about 100°C / h (e.g., about 10°C / h or about 50°C / h). The intermediate coil can be heated to a temperature of about 350°C to about 580°C (e.g., about 375°C to about 570°C, about 400°C to about 550°C, about 425°C to about 500°C, or about 500°C to about 580°C). The intermediate coil can be soaked for about 1 minute to about 120 minutes, preferably about 60 minutes.

[0082] Optionally, the intermediate coils after storage and / or preheating the coils or slabs upon exiting the caster may be homogenized. The homogenization step may include heating the slab or intermediate coils to obtain a peak metal temperature (PMT) of about or at least about 450°C or at least about 450°C (e.g., at least 460°C, at least 470°C, at least 480°C, at least 490°C, at least 500°C, at least 510°C, at least 520°C, at least 530°C, at least 540°C, at least 550°C, at least 560°C, at least 570°C, or at least 580°C). For example, the coils or slabs may be heated to a temperature of about 450°C to about 580°C, about 460°C to about 575°C, about 470°C to about 570°C, about 480°C to about 565°C, about 490°C to about 555°C, or about 500°C to about 550°C. In some cases, the rate of heating to the PMT can be about 100°C / hour or less, 75°C / hour or less, 50°C / hour or less, 40°C / hour or less, 30°C / hour or less, 25°C / hour or less, 20°C / hour or less, or 15°C / hour or less. In other cases, the rate of heating to the PMT can be about 10°C / minute to about 100°C / minute (e.g., about 10°C / minute to about 90°C / minute, about 10°C / minute to about 70°C / minute, about 10°C / minute to about 60°C / minute, about 20°C / minute to about 90°C / minute, about 30°C / minute to about 80°C / minute, about 40°C / minute to about 70°C / minute, or about 50°C / minute to about 60°C / minute).

[0083] The coil or slab is then allowed to soak (ie, maintained at a specified temperature) for a period of time. According to a non-limiting example, the coil or slab is allowed to soak for up to about 36 hours (e.g., about 30 minutes to about 36 hours, including 30 minutes and 36 hours). For example, the coils or slabs may be soaked at temperature for 10 seconds, 15 seconds, 30 seconds, 45 seconds, 1 minute, 2 minutes, 5 minutes, 10 minutes, 15 minutes, 20 minutes, 25 minutes, 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 6 hours, 7 hours, 8 hours, 9 hours, 10 hours, 11 hours, 12 hours, 13 hours, 14 hours, 15 hours, 16 hours, 17 hours, 18 hours, 19 hours, 20 hours, 21 hours, 22 hours, 23 hours, 24 hours, 25 hours, 26 hours, 27 hours, 28 hours, 29 hours, 30 hours, 31 hours, 32 hours, 33 hours, 34 hours, 35 hours, 36 hours, or any time therebetween.

[0084] Hot Rolling

[0085] After the preheating and / or homogenizing step, a hot rolling step may be performed. The hot rolling step may include a hot reversible rolling mill operation and / or a hot tandem rolling mill operation. The hot rolling step may be performed at a temperature of about 250°C to about 500°C (e.g., about 300°C to about 400°C or about 350°C to about 500°C). For example, the hot rolling step may be performed at a temperature of about 250°C, 260°C, 270°C, 280°C, 290°C, 300°C, 310°C, 320°C, 330°C, 340°C, 350°C, 360°C, 370°C, 380°C, 390°C, 400°C, 410°C, 420°C, 430°C, 440°C, 450°C, 460°C, 470°C, 480°C, 490°C or 500°C.

[0086] In the hot rolling step, the metal product can be hot rolled to a thickness of 10 mm gauge or less (e.g., about 2 mm to about 8 mm). For example, the metal product can be hot rolled to about 10 mm gauge or less, 9 mm gauge or less, 8 mm gauge or less, 7 mm gauge or less, 6 mm gauge or less, 5 mm gauge or less, 4 mm gauge or less, 3 mm gauge or less, or 2 mm gauge or less. In some cases, the percentage reduction in thickness caused by the hot rolling step can be about 35% to about 80% (e.g., 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, or 80%). Optionally, the hot rolled metal product is quenched at the end of the hot rolling step (e.g., when leaving the tandem mill). Optionally, at the end of the hot rolling step, the hot rolled metal product is coiled.

[0087] Optionally, the hot rolled metal is provided in a final gauge and / or final condition. In some non-limiting examples, the hot rolling step can provide a final product with desired mechanical properties such that no further downstream processing is required. For example, the final product can be hot rolled and delivered in a final gauge and condition without any cold rolling, solutionizing, post-solutionizing quenching, natural aging, and / or artificial aging. Hot rolling to final gauge and condition, also referred to as "HRTGT", can provide a metal product with optimized mechanical properties at a significantly reduced cost.

[0088] Optionally, further processing steps may be performed, such as cold rolling, warm rolling, solutionizing, solutionizing followed by quenching and / or aging. These steps are further described below.

[0089] Cold rolled - optional

[0090] Optionally, the hot rolled metal product can be cold rolled. For example, an aluminum alloy plate or sheet can be cold rolled to a specification of about 0.1 mm to about 4 mm thick (e.g., a specification of about 0.5 mm to about 3 mm thick), which is referred to as a sheet. For example, a cast aluminum alloy product can be cold rolled to a thickness of less than about 4 mm. For example, the thickness of the sheet can be less than 4 mm, less than 3 mm, less than 2 mm, less than 1 mm, less than 0.9 mm, less than 0.8 mm, less than 0.7 mm, less than 0.6 mm, less than 0.5 mm, less than 0.4 mm, less than 0.3 mm, less than 0.2 mm, or less than 0.1 mm. The state of the rolled sheet is referred to as the F-state.

[0091] Optionally, the cold rolling step is eliminated. In some examples, the cold rolling step can increase the strength and hardness of the aluminum alloy while concomitantly reducing the formability of the aluminum alloy sheet, plate or sheet. Eliminating the cold rolling step can maintain the ductility of the aluminum alloy sheet, plate or sheet. Surprisingly, eliminating the cold rolling step has no adverse effect on the strength of the aluminum alloy described herein, which will be described in detail in the following examples.

[0092] Warm rolling

[0093] Optionally, the hot rolled metal product can be warm rolled to the final specification. The warm rolling step can be carried out at a temperature lower than the hot rolling temperature. Optionally, the warm rolling temperature can be about 300°C to about 400°C (e.g., 300°C, 310°C, 320°C, 330°C, 340°C, 350°C, 360°C, 370°C, 380°C, 390°C, 400°C or any temperature therebetween). In some cases, the hot rolled product can be warm rolled to a specification of about 0.1 mm to about 4 mm thick (e.g., a specification of about 0.5 mm to about 3 mm thick), which is referred to as a sheet. For example, a cast aluminum alloy product can be warm rolled to a thickness of less than about 4 mm. For example, the thickness of the sheet can be less than 4 mm, less than 3 mm, less than 2 mm, less than 1 mm, less than 0.9 mm, less than 0.8 mm, less than 0.7 mm, less than 0.6 mm, less than 0.5 mm, less than 0.4 mm, less than 0.3 mm, less than 0.2 mm, or less than 0.1 mm.

[0094] As described herein, the quenching step can be performed before the warm rolling step, after the warm rolling step, or before or after the warm rolling step. Optionally, the hot rolled product can be coiled and / or stored before the warm rolling step. In these cases, the coiled and / or stored hot rolled product can be reheated in a preheating step as described above.

[0095] Solid solution

[0096] Then the hot rolled metal product or the cold rolled metal product can be subjected to a solutionizing step. The solutionizing step can be carried out at a temperature of about 420°C to about 560°C (e.g., about 480°C to about 550°C or about 500°C to about 530°C). The solutionizing step can be carried out for about 0 minutes to about 1 hour (e.g., about 1 minute or about 30 minutes). Optionally, at the end of the solutionizing step (e.g., when leaving the furnace), the sheet is subjected to a thermal quenching step. The thermal quenching step can be carried out using air and / or water. The room temperature can be about 20°C to about 75°C (e.g., about 25°C, about 30°C, about 35°C, about 40°C, about 45°C, about 50°C, about 55°C, about 60°C, about 65°C, about 70°C or about 75°C).

[0097] aging

[0098] Optionally, the metal product is subjected to an artificial aging step. The artificial aging step develops the high strength properties of the alloy and optimizes other desired properties in the alloy. The mechanical properties of the final product can be controlled by various aging conditions according to the desired use. In some cases, the metal product described herein can be delivered to the customer in a Tx state (e.g., a T1 state, a T4 state, a T5 state, a T6 state, a T7 state, a T81 state, or a T82 state), a W state, an O state, or an F state. In some instances, an artificial aging step can be performed. The artificial aging step can be performed at a temperature of about 100°C to about 250°C (e.g., at about 180°C or about 225°C). The aging step can be performed for a period of time of about 10 minutes to about 36 hours (e.g., about 30 minutes or about 24 hours). In some instances, the artificial aging step can be performed at 180°C for 30 minutes to produce a T81 state. In some instances, the artificial aging step can be performed at 185°C for 25 minutes to produce a T81 state. In some other examples, an artificial aging step may be performed at 225°C for 30 minutes to produce a T82 temper. In some other examples, the alloy is subjected to a natural aging step. The natural aging step may produce a T4 temper.

[0099] Painting and / or lacquer baking

[0100] Optionally, the metal product is subjected to a painting step. Optionally, the painting step may include zinc phosphating (Zn-phosphating) and / or electrocoating (E-painting). Zn-phosphating and E-painting are performed according to standards commonly used in the aluminum industry known to those skilled in the art. Optionally, the painting step may be followed by a paint baking step. The paint baking step may be performed at a temperature of about 150° C. to about 230° C. (e.g., about 180° C. or about 210° C.). The paint baking step may be performed for a period of time of about 10 minutes to about 60 minutes (e.g., about 30 minutes or about 45 minutes).

[0101] Exemplary Methods

[0102] Figure 1BAn exemplary method is described. An aluminum alloy is continuously cast from a twin-belt continuous caster into a form of a slab (e.g., an aluminum alloy having a thickness of about 5 mm to about 50 mm, preferably about 10 mm). In some instances, upon leaving the continuous caster, the slab may be optionally quenched with water, and the resulting quenched slab may be coiled and stored for up to 90 days. In another instance, upon leaving the continuous caster, the slab may be optionally coiled, and the resulting coil may be cooled in air. The resulting cooling coil may be stored for a period of time. In some cases, the slab may be further processed. In some instances, the coil may be optionally preheated and / or homogenized. The resulting optionally preheated and / or homogenized coil may be expanded. The expanded slab may be hot rolled into an aluminum alloy product of final specification. The aluminum alloy product of final specification may be a plate, sheet, or thin plate. The resulting aluminum alloy product may be optionally solid solutionized (SHT). The resulting solid solution aluminum alloy product may be optionally quenched. The resulting solution and / or quenched aluminum alloy product may optionally be subjected to an aging step. The aging step may include natural and / or artificial aging (AA).

[0103] Fig. 9 Another exemplary method is depicted. An aluminum alloy is continuously cast into slab form, homogenized, hot rolled to produce a hot rolled aluminum alloy having an intermediate specification (i.e., an intermediate specification aluminum alloy product), quenched and coiled. The coiled material is then cold rolled, optionally after a period of time, to provide an aluminum alloy product of final specification. The resulting aluminum alloy product may optionally be solutionized and / or quenched. The resulting quenched and / or solutionized aluminum alloy product may optionally be subjected to an aging step. The aging step may include natural and / or artificial aging (AA).

[0104] Fig.11 Another production method as described herein is depicted. An aluminum alloy is continuously cast into slab form, homogenized, hot rolled to produce a hot rolled aluminum alloy with intermediate specifications (i.e., an intermediate specification aluminum alloy product), quenched and coiled. The coiled material is then optionally preheated after a period of time, quenched to a temperature below the preheating temperature, and hot rolled to provide an aluminum alloy product of final specifications. The resulting aluminum alloy product may optionally be quenched and / or solutionized. The resulting quenched and / or solutionized aluminum alloy product may optionally be subjected to an aging step. The aging step may include natural and / or artificial aging (AA).

[0105] Fig.13An exemplary production method as described herein is depicted. An aluminum alloy is continuously cast into a slab form, homogenized, hot rolled to produce a hot rolled aluminum alloy having a first intermediate specification (i.e., a first intermediate specification aluminum alloy product), quenched and coiled. Then, optionally after a period of time, the coiled material is preheated, hot rolled to produce a hot rolled aluminum alloy having a second intermediate specification (i.e., a second intermediate specification aluminum alloy product), quenched and cold rolled to provide an aluminum alloy product of final specification. The resulting aluminum alloy product may optionally be quenched and / or solutionized. The resulting quenched and / or solutionized aluminum alloy product may optionally be subjected to an aging step. The aging step may include natural and / or artificial aging (AA).

[0106] Fig.15 An exemplary production method as described herein is depicted. The aluminum alloy is continuously cast into slab form, homogenized, hot rolled, quenched, preheated, quenched and cold rolled to provide an aluminum alloy product of final specification. The resulting aluminum alloy product may optionally be quenched and / or solutionized. The resulting quenched and / or solutionized aluminum alloy product may optionally be subjected to an aging step. The aging step may include natural and / or artificial aging (AA).

[0107] performance

[0108] The resulting metal products as described herein have a combination of desirable properties, including high strength and high formability in a variety of temper conditions, including Tx-temper conditions (wherein the Tx temper may include T1, T4, T5, T6, T7, T81, or T82 tempers), W temper, O temper, or F temper. In some examples, the resulting metal products have a yield strength of about 150-500 MPa (e.g., 300 MPa to 500 MPa, 350 MPa to 475 MPa, or 374 MPa to 460 MPa). For example, the yield strength may be approximately 150 MPa, 160 MPa, 170 MPa, 180 MPa, 190 MPa, 200 MPa, 210 MPa, 220 MPa, 230 MPa, 240 MPa, 250 MPa, 260 MPa, 270 MPa, 280 MPa, 290 MPa, 300 MPa, 310 MPa, 320 MPa, 330 MPa, 340 MPa, 350 MPa, 360 MPa, 370 MPa, 380 MPa, 390 MPa, 400 MPa, 410 MPa, 420 MPa, 430 MPa, 440 MPa, 450 MPa, 460 MPa, 470 MPa, 480 MPa, 490 MPa, or 500 MPa. Optionally, the metal product having a yield strength between 150-500 MPa may be in the T4, T81 or T82 temper.

[0109] In some examples, the resulting metal product has a bend angle between approximately 35° and 130°. For example, the resulting metal product may have a bend angle of approximately 35°, 36°, 37°, 38°, 39°, 40°, 41°, 42°, 43°, 44°, 45°, 46°, 47°, 48°, 49°, 50°, 51°, 52°, 53°, 54°, 55°, 56°, 57°, 58°, 59°, 60°, 61°, 62°, 63°, 64°, 65°, 66°, 67°, 68°, 69°, 70°, 71°, 72°, 73°, 74°, 75°, 76°, 77°, 78°, 79°, 80°, 81°, 82°, 83°, 84°, 85°, 86°, 87°, 88°, 89°, 90°, 91°, 92°, 93°, 94°, 95°, 96°, 97°, 98°, 99°, 9°, 90°, 91°, 92°, 93°, 94°, 95°, 96°, 97°, 98°, 99°, 100°, 101°, 102°, 103°, 104°, 105°, 106°, 107°, 108°, 109°, 110°, 111°, 112°, 113°, 114°, 115°, 116°, 117°, 118°, 119°, 120°, 121°, 122°, 123°, 124°, 125°, 126°, 127°, 128°, 129° or 130° Optionally, the metal product having a bend angle between 40° and 130° can be in T4, T81 or T82 temper. In some examples, the metal product has an internal bend angle of about 35° to about 65° when in the T4 temper. In other examples, the metal product has an internal bend angle of about 110° to about 130° when in the T82 temper. Optionally, in semi-crash applications, the aluminum alloy product includes internal bend angles of about 90° to about 130° and about 100° to about 130° when in the T82 temper.

[0110] How to use

[0111] The alloys and methods described herein can be used in automotive and / or transportation applications, including motor vehicles, aircraft and railroad applications, or any other desired application. In some examples, the alloys and methods can be used to prepare automotive body parts products, such as bumpers, inner panels, outer panels, side panels, inner covers, outer covers, or trunk covers. The aluminum alloys and methods described herein can also be used in aircraft or railroad vehicle applications to prepare, for example, outer panels and inner panels.

[0112] The alloys and methods described herein can also be used in electronic device applications. For example, the alloys and methods described herein can be used to prepare housings for electronic devices, including mobile phones and tablet computers. In some examples, the alloys can be used to prepare housings for mobile phones (e.g., smart phones) and tablet computer chassis.

[0113] In some cases, the alloys and methods described herein can be used in industrial applications. For example, the alloys and methods described herein can be used to prepare products for general distribution markets.

[0114] Reference has been made in detail to various examples of the disclosed subject matter, one or more examples of which are set forth above. Each example is provided by way of illustration of the subject matter, not limitation thereof. Indeed, it will be apparent to those skilled in the art that various modifications and variations may be made to the subject matter without departing from the scope or spirit of the present disclosure. For example, features illustrated or described as part of one embodiment may be used together with another embodiment to yield yet another embodiment.

[0115] The following examples will be used to further illustrate the present invention, but, at the same time, do not constitute any limitation to it. On the contrary, it should be clearly understood that after reading the description of this article, those skilled in the art can adopt various embodiments, its modification and equivalent without departing from the spirit of the present invention.

[0116] Example

[0117] Example 1

[0118] Various alloys were prepared for strength, elongation and formability testing. The chemical compositions of these alloys are provided in Table 5 below.

[0119] Table 5

[0120]

[0121]

[0122] All values ​​are expressed as a percentage by weight of the whole

[0123] Alloys A and B (exemplary alloys) were continuously cast using the exemplary methods described herein. Specifically, a twin-belt continuous caster was used to produce continuously cast aluminum alloy slabs. Alloys A and B were each produced according to Figure 1B Exemplary processing routes (A-HRTG and B-HRTG) and according to Figure 1A Alloy C (comparative alloy) was cast using a laboratory-scale DC continuous casting machine according to methods known to those skilled in the art, and then Figure 1A The following describes how Figure 1A and 1B The processing route described in .

[0124] Figure 1Ais a process flow diagram describing a comparative processing route. The comparative route (referred to as "HR+WQ+CR") includes a conventional slow preheating and homogenizing step (Preheat), followed by hot rolling (HR), coiling / water quenching (Reroll), cold rolling (CR) to final gauge (Final gauge, solution heat treatment (SHT), and artificial aging (AA) to obtain T8x-temper properties or natural aging (not shown) to obtain T4-temper properties. Figure 1B is a process flow diagram describing an exemplary processing route according to the methods described herein. The exemplary route (referred to as "HRTG") includes preheating and homogenizing the slab (Preheat) and hot rolling (HR) to final gauge (Final Gauge), followed by coiling, solutionizing (SHT), optional quenching, and optional artificial aging (AA) to obtain T8x-temper properties or natural aging (not shown) to obtain T4-temper properties.

[0125] Mechanical properties were determined according to ASTM B5572" GL for tensile tests. Formability was determined according to the 3-point bend test of the German Association of the Automotive Industry (VDA) without prestraining the specimens. Figure 2 Graphs showing the yield strength (YS, filled histogram) and bend angle (VDA, shaded histogram) of each alloy (A, B and C) tested in the long transverse (L) orientation relative to the rolling direction. Comparison of the tensile strength and bend properties of the continuously cast alloys A and B and the DC cast alloy C after natural aging (T4 temper) and artificial aging (T82 temper aging) is shown in Figure 1. Figure 2 shown. Figure 2 In the table, “CC” stands for continuous casting and “DC” stands for direct chill casting.

[0126] like Figure 2 As shown, the continuously cast exemplary alloys A and B processed by the exemplary HRTG route can provide similar tensile strength results (YS ~ 370 MPa) with improved bend angles (about 10-15° less) compared to the DC cast alloy C processed by the comparative HR+WQ+CR route. The smaller the bend angle, the higher the formability.

[0127] The mechanical properties of the exemplary alloy A are as follows: Figure 3 and 4 shown. Figure 3 The mechanical properties of the continuously cast exemplary Alloy A obtained from process route HR+WQ+CR are presented. Figure 4The mechanical properties of the continuously cast exemplary alloy A obtained from the process route HRTG are presented. Yield strength (YS) (left histogram, filled hatching), ultimate tensile strength (UTS) (center histogram, filled cross hatching) and bend angle (VDA) (right histogram, filled vertical line) are represented by histograms and uniform elongation (UE) (unfilled circles) and total elongation (TE) (unfilled diamonds) are represented by unfilled point marks. The alloys were tested after natural aging (T4) and after artificial aging (T81 and T82) steps as described herein. Similar tensile strengths were obtained from the two processing routes, while the HRTG route provided a 10-15° smaller bend angle compared to the more traditional HR+WQ+CR route. Solid solution (SHT) at 550°C (peak metal temperature, PMT) without immersion provides the highest bendability for the exemplary and comparative aluminum alloys under T4-temper conditions, and provides the highest strength (~365MPa) for the exemplary and comparative alloys under T82-temper conditioning. For samples solutionized at lower PMT (520°C and 500°C), strength decreases and bend is improved. However, for the continuously cast 6xxx alloys, a high YS of about 350 MPa can be achieved when solutionized at 520°C without soaking.

[0128] The mechanical properties of the continuously cast exemplary alloy B are as follows: Figure 5 and 6 shown. Figure 5 The mechanical properties of the continuously cast exemplary Alloy B obtained from process route HR+WQ+CR are presented. Figure 6 The mechanical properties of the exemplary alloy B obtained from the continuous casting of the process route HRTG are presented. Yield strength (YS) (left histogram, filled hatching), ultimate tensile strength (UTS) (center histogram, filled cross hatching) and bending angle (VDA) (right histogram, filled vertical line) are represented by histograms and uniform elongation (UE) (no filled circles) and total elongation (TE) (no filled diamonds) are represented by no filled point marks. The alloy is tested after natural aging (T4) and after artificial aging (T81 and T82) steps as described herein. Compared with alloy A with slightly higher tensile strength and slightly reduced bending angle, alloy B has similar properties. The slight difference in mechanical properties can be attributed to the higher Si content of alloy B (0.14 weight % higher than alloy A).

[0129] The increases in strength and formability provided by continuously casting 6xxx series aluminum alloys A and B can be attributed to differences in microstructure. Figure 7Magnesium silicide (Mg2Si) particle size and morphology (top row, "Particles") and grain structure (bottom row, "Grains") are shown. Elongated grain structures and smaller, undissolved Mg2Si particles are observed in the continuously cast alloys (A and B) subjected to the exemplary processing route HRTG when compared to the continuously cast exemplary alloys (A and B) processed by the more traditional HR+WQ+CR route. The HR+WQ+CR route provides a more equiaxed recrystallized grain structure and a larger amount of coarse, undissolved Mg2Si particles.

[0130] Figure 8 The microstructures of the continuously cast exemplary alloys A and B are presented in comparison with the microstructure of the DC cast comparative alloy C. Each alloy was subjected to conventional hot rolling, cold rolling processing procedures and natural aging to obtain the T4-temper condition. Images were obtained from the longitudinal cross-section of each sample. The DC cast alloy C showed coarse Mg2Si particles and a recrystallized grain structure consisting of a single smaller grain. The differences in microstructure can be attributed to the higher solute content (Mg and Si) and the cold rolling step during processing.

[0131] Compared with comparative alloy C, exemplary alloys A and B have low solute content, which can help improve the formability of the aluminum alloy sheet, plate or thin plate produced. Specifically, compared with the 6xxx series aluminum alloys cast by conventional DC, the main alloying elements of the 6xxx series aluminum alloys, Mg and Si and Cu are significantly reduced, and the resulting aluminum alloys show equal strength and excellent formability. The 6xxx aluminum alloys cast by conventional DC contain higher amounts of Mg, Si and / or Cu solutes, and often these solutes cause undissolved precipitates to exist in the aluminum matrix. However, in CC aluminum alloys, the solutes present in the aluminum matrix will be precipitated from the aluminum matrix during the artificial aging step after the exemplary HRTG processing route. The aluminum alloys processed by the comparative HR+WQ+CR route show solute precipitation, regardless of casting technology. The exemplary alloys A and B described herein contain finer component Mg2Si particles and produce a supersaturated solid solution matrix (SSSS). Hot rolling continuously cast alloys to final specifications (HRTG) can produce superior performance aluminum alloys with high strength and better bendability compared to conventional hot-rolled and cold-rolled DC alloys.

[0132] Example 2

[0133] Various alloys were prepared for strength, elongation and formability testing. The chemical compositions of these alloys are provided in Table 6 below.

[0134] Table 6

[0135]

[0136]

[0137] It is expressed as a weight percentage (wt%) of the whole.

[0138] Example 2A

[0139] The alloy having the composition of alloy DI is subjected to the following production method, which includes casting a slab; homogenizing the slab before hot rolling; hot rolling the slab to produce a hot rolled aluminum alloy having an intermediate specification (e.g., an intermediate specification aluminum alloy product); quenching the intermediate specification aluminum alloy product; cold rolling the intermediate specification aluminum alloy product to provide a final specification aluminum alloy product; solutionizing the final specification aluminum alloy product; and artificially aging the final specification aluminum alloy product. This method is called "Flash -> WQ -> CR", such as Fig. 9 The method steps are further described below.

[0140] By adopting the above method and optional artificial aging, exemplary alloys DI in T81 and T82 conditions are provided (see Table 6). Each of the exemplary alloys DI is produced by the following steps: casting an aluminum alloy product 910 so that the aluminum alloy product leaving the continuous casting machine 920 has a continuous casting machine outlet temperature of about 450°C, homogenizing at a temperature of about 550°C to about 570°C for 2 minutes in a tunnel furnace 930, reducing the aluminum alloy product 910 by about 50% to about 70% in a rolling mill 940 at a temperature of about 530°C to 580°C, and water quenching the aluminum alloy product 910 with a quenching device 950. The aluminum alloy product 910 is then cold rolled in a cold rolling mill 960 to a final specification of 2.0 mm.

[0141] For the T81 temper, the exemplary aluminum alloy was artificially aged at 185°C for 20 minutes after pre-straining the exemplary aluminum alloy by 2%. For the T82 temper, the exemplary aluminum alloy was artificially aged at 225°C for 30 minutes. For the semi-crash condition, the exemplary aluminum alloy was artificially aged at 185°C for 20 minutes after pre-straining the exemplary aluminum alloy by 10%. The mechanical properties of the exemplary aluminum alloy are shown in FIG. Fig.10 As shown. Open symbols represent exemplary alloys with T81 temper and T82 temper. Filled symbols represent exemplary alloys with semi-crash performance. The bending angle data is normalized to 2.0 mm thickness according to specification VDA 239-200, and VDA bending tests are performed according to VDA specification 238-100. Exemplary alloys D, E and F exhibit high strength and excellent deformability (e.g., exhibiting a bending angle greater than 60°).

[0142] Example 2B

[0143] The alloy having the composition of alloy DI (see Table 6) is subjected to the following production method, which includes casting slabs; homogenizing the slabs before hot rolling; quenching the slabs before hot rolling; hot rolling the slabs to produce a hot rolled aluminum alloy having an intermediate specification (e.g., an intermediate specification aluminum alloy product); quenching the intermediate specification aluminum alloy product; preheating the intermediate specification aluminum alloy; quenching the preheated intermediate specification aluminum alloy; warm rolling the intermediate specification aluminum alloy product to provide a final specification aluminum alloy product; quenching the final specification aluminum alloy product; solutionizing the final specification aluminum alloy product; and artificially aging the final specification aluminum alloy product. This method is called "flash-->WQ-->HO-->WQ to 350°C-->WR", such as Fig.11 The method steps are further described below.

[0144] By adopting the above method and optional artificial aging, exemplary alloys DI in T81 and T82 conditions are provided (see Table 6). Each of the exemplary alloys DI is produced by the following steps: casting an exemplary aluminum alloy product 910 so that the aluminum alloy product leaving the continuous casting machine 920 has a continuous casting machine outlet temperature of about 450°C, homogenizing at a temperature of about 550°C to about 570°C in a tunnel furnace 930 for 2 minutes, water quenching the aluminum alloy product 910, reducing the aluminum alloy product 910 by about 50% to about 70% at a temperature of about 530°C to 580°C in a rolling mill 940, and water quenching the aluminum alloy product 910 with a quenching device 950. The aluminum alloy product 910 is then preheated in a box furnace 1110 at a temperature of about 530°C to about 560°C for 1 to 2 hours. The aluminum alloy product 910 is then water quenched to a temperature of about 350°C using a quenching device 1120 before cold rolling. The aluminum alloy product 910 is then cold rolled in a cold rolling mill 1130 to a final specification of 2.0 mm and water quenched to 50° C. using a quenching device 1140 .

[0145] For the T81 temper, the exemplary aluminum alloy was artificially aged at 185°C for 20 minutes after pre-straining the exemplary aluminum alloy by 2%. For the T82 temper, the exemplary aluminum alloy was artificially aged at 225°C for 30 minutes. For the semi-crash condition, the exemplary aluminum alloy was artificially aged at 185°C for 20 minutes after pre-straining the exemplary aluminum alloy by 10%. The mechanical properties of the exemplary aluminum alloy are shown in FIG. Fig.12 As shown. Open symbols represent exemplary alloys with T81 temper and T82 temper. Filled symbols represent exemplary alloys with semi-crash performance. The bending angle data is normalized to 2.0 mm thickness according to specification VDA 239-200, and VDA bend testing is performed according to VDA specification 238-100. Exemplary alloys D, E and F exhibit high strength and excellent deformability (e.g., having a bend angle greater than 60°).

[0146] Example 2C

[0147] An alloy having the composition of alloy DI (see Table 6) is subjected to the following production method, which includes casting a slab; homogenizing the slab before hot rolling; quenching the slab before hot rolling; hot rolling the slab to produce a hot rolled aluminum alloy having a first intermediate specification (e.g., an aluminum alloy product of a first intermediate specification); quenching the aluminum alloy product of the first intermediate specification; preheating the aluminum alloy of the first intermediate specification; hot rolling the aluminum alloy product of the first intermediate specification to provide an aluminum alloy product of a second intermediate specification; quenching the aluminum alloy product of the second intermediate specification; cold rolling the aluminum alloy product of the second intermediate specification to provide an aluminum alloy product of a final specification; quenching the aluminum alloy product of the final specification; solutionizing the aluminum alloy product of the final specification; and artificially aging the aluminum alloy product of the final specification. This method is called "flash-->WQ-->HO-->HR-->WQ-->CR", such as Fig.13 The method steps are further described below.

[0148] By adopting the above method and optional artificial aging, exemplary alloys DI in T81 and T82 conditions are provided (see Table 6). Each of the exemplary alloys DI is produced by the following steps: casting an exemplary aluminum alloy product 910 so that the aluminum alloy product leaving the continuous casting machine 920 has a continuous casting machine outlet temperature of about 450°C, homogenizing at a temperature of about 550°C to about 570°C for 2 minutes in a tunnel furnace 930, water quenching the homogenized aluminum alloy product 910, reducing the thickness of the aluminum alloy product 910 by about 50% at a temperature of about 530°C to 580°C in a rolling mill 940, and water quenching the aluminum alloy product 910 with a quenching device 950. The aluminum alloy product 910 is then preheated in a box furnace 1110 at a temperature of about 530°C to about 560°C for 1 to 2 hours. The aluminum alloy article is then further hot rolled at a temperature of about 530° C. to 580° C. in a rolling mill 940 to reduce the thickness by about 70%, and water quenched using a quenching device 950. The aluminum alloy article 910 is then cold rolled in a cold rolling mill 1130 to a final gauge of 2.0 mm, and water quenched to 50° C. using a quenching device 1140.

[0149] For the T81 temper, the exemplary aluminum alloy was artificially aged at 185°C for 20 minutes after pre-straining the exemplary aluminum alloy by 2%. For the T82 temper, the exemplary aluminum alloy was artificially aged at 225°C for 30 minutes. For the semi-crash condition, the exemplary aluminum alloy was artificially aged at 185°C for 20 minutes after pre-straining the exemplary aluminum alloy by 10%. The mechanical properties of the exemplary aluminum alloy are shown in FIG. Fig.14As shown. Open symbols represent exemplary alloys with T81 temper and T82 temper. Filled symbols represent exemplary alloys with semi-crash performance. The bending angle data is normalized to 2.0 mm thickness according to specification VDA 239-200, and the VDA bend test is performed according to VDA specification 238-100. Exemplary alloys D and F exhibit high strength and excellent deformability (e.g., having a bend angle greater than 60°).

[0150] Example 2D

[0151] An alloy having the composition of alloy DI (see Table 6) is subjected to the following production method, which includes casting a slab; homogenizing the slab before hot rolling; quenching the slab before hot rolling; hot rolling the slab to produce a hot rolled aluminum alloy having an intermediate specification (e.g., an intermediate specification aluminum alloy product); quenching the intermediate specification aluminum alloy product; preheating the intermediate specification aluminum alloy; quenching the preheated intermediate specification aluminum alloy; cold rolling the intermediate specification aluminum alloy product to provide a final specification aluminum alloy product; solutionizing the final specification aluminum alloy product; and artificially aging the final specification aluminum alloy product. This method is called "Flash-->WQ-->HO-->WQ-->CR", such as Fig.15 The method steps are further described below.

[0152] By adopting the above method and optional artificial aging, exemplary alloys DI in T81 and T82 conditions are provided (see Table 6). Each of the exemplary alloys DI is produced by the following steps: casting an exemplary aluminum alloy product 910 so that the aluminum alloy product leaving the continuous caster 920 has a continuous caster outlet temperature of about 450°C, homogenizing at a temperature of about 550°C to about 570°C in a tunnel furnace 930 for 2 minutes, water quenching the rapidly homogenized aluminum alloy product 910, reducing the aluminum alloy product 910 by about 50% to about 70% at a temperature of about 530°C to 580°C in a rolling mill 940, and water quenching the aluminum alloy product 910 with a quenching device 950. The aluminum alloy product 910 is then preheated in a box furnace 1110 at a temperature of about 530°C to about 560°C for 1 to 2 hours. The aluminum alloy product 910 is then water quenched to a temperature of about 50°C using a quenching device 1120 before cold rolling. The aluminum alloy article 910 is then cold rolled in a cold rolling mill 1130 to a final gauge of 2.0 mm.

[0153] For the T81 temper, the exemplary aluminum alloy was artificially aged at 185°C for 20 minutes after pre-straining the exemplary aluminum alloy by 2%. For the T82 temper, the exemplary aluminum alloy was artificially aged at 225°C for 30 minutes. For the semi-crash condition, the exemplary aluminum alloy was artificially aged at 185°C for 20 minutes after pre-straining the exemplary aluminum alloy by 10%. The mechanical properties of the exemplary aluminum alloy are shown in FIG. Fig.16As shown. Open symbols represent exemplary alloys with T81 temper and T82 temper. Filled symbols represent exemplary alloys with semi-crash performance. The bending angle data is normalized to 2.0 mm thickness according to specification VDA 239-200, and the VDA bend test is performed according to VDA specification 238-100. Exemplary alloys D and F exhibit high strength and excellent deformability (e.g., having a bend angle greater than 60°).

[0154] Example 2E

[0155] An alloy having the composition of alloy DI (see Table 6) is subjected to the following production method, which includes casting a slab; homogenizing the slab before hot rolling; hot rolling the slab to produce a hot-rolled aluminum alloy having an intermediate specification (e.g., an aluminum alloy product of an intermediate specification); quenching the aluminum alloy product of the intermediate specification; cold rolling the aluminum alloy product of the intermediate specification to provide an aluminum alloy product of a final specification; and solutionizing the aluminum alloy product of the final specification. Fig. 9 The method steps are depicted in and further described below.

[0156] By adopting the above method and optional natural aging, exemplary alloys DI in T4 state are provided (see Table 6). Each of the exemplary alloys DI is produced by the following steps: casting an exemplary aluminum alloy product 910 so that the aluminum alloy product leaving the continuous casting machine 920 has a casting outlet temperature of about 450°C, homogenizing at a temperature of about 550°C to about 570°C in a tunnel furnace 930 for 2 minutes, reducing the aluminum alloy product 910 by about 50% to about 70% at a temperature of about 530°C to 580°C in a rolling mill 940, and water quenching the aluminum alloy product 910 with a quenching device 950. The aluminum alloy product 910 is then cold rolled in a cold rolling mill 960 to a final specification of 2.0 mm. For the T4 state, the exemplary aluminum alloy is naturally aged for about 3 weeks to about 4 weeks. The mechanical properties of the exemplary aluminum alloys are as follows Fig.17 For the exemplary alloys in the T4 temper, yield strength (left vertical striped histogram in each group), ultimate tensile strength (right horizontal striped histogram in each group), uniform elongation (open circles), and total elongation (open diamonds) are shown. Exemplary alloys E and G exhibit high strength and excellent deformability.

[0157] Various embodiments of the present invention have been described to achieve the various objects of the present invention. It should be appreciated that these embodiments are merely illustrative of the principles of the present invention. Many modifications and adaptations thereof will be apparent to those of ordinary skill in the art without departing from the spirit and scope of the present invention as defined in the following claims.

Claims

1. A method for producing an aluminum alloy product, comprising: Continuously casting an aluminum alloy in a continuous casting machine to form a slab, wherein the aluminum alloy comprises 0.26-2.82 wt% Si, 0.06-0.60 wt% Fe, 0.26-2.37 wt% Cu, 0.06-0.57 wt% Mn, 0.26-2.37 wt% Mg, 0-0.21 wt% Cr, 0-0.009 wt% Zn, 0-0.09 wt% Ti, 0-0.003 wt% Zr and up to 0.15 wt% impurities, with the remainder being Al; homogenizing the slab at a temperature of 500° C. to 580° C. upon exiting the continuous casting machine; hot rolling the slab to final gauge without cold rolling prior to reaching the final gauge; and Solutionizing the final aluminum alloy product at a temperature of 500°C to 520°C; The continuously cast slab is coiled and then cooled in air before the step of hot rolling the slab.

2. The method of claim 1, wherein the aluminum alloy comprises 0.52-1.18 wt. % Si, 0.13–0.30 wt. % Fe, 0.52–1.18 wt. % Cu, 0.12-0.28 wt. % Mn, 0.52-1.18 wt. % Mg, 0.04-0.10 wt. % Cr, 0.002-0.006 wt. % Zn, 0.01-0.06 wt. % Ti, 0.0006-0.001 wt. % Zr, and up to 0.15 wt. % impurities, with the remainder being Al.

3. The method according to claim 1, wherein the aluminum alloy comprises 0.70-1.0 wt. % Si, 0.15-0.25 wt. % Fe, 0.70-0.90 wt. % Cu, 0.15-0.25 wt. % Mn, 0.70-0.90 wt. % Mg, 0.05-0.10 wt. % Cr, 0.002-0.004 wt. % Zn, 0.01-0.03 wt. % Ti, 0.0006-0.001 wt. % Zr and up to 0.15 wt. % impurities, with the remainder being Al.

4. The method according to any one of claims 1 to 3, further comprising cooling the slab when leaving an outlet of a continuous casting machine in which the slab is continuously cast.

5. The method of claim 4, wherein the cooling step comprises quenching the slab with water.

6. A method according to claim 4 or 5, wherein the cooling step comprises air cooling the slab.

7. The method according to any one of claims 1 to 3, further comprising: Prior to the step of hot rolling the slab to final gauge, coiling the slab into an intermediate coil; preheating the intermediate coil prior to hot rolling the slab to final gauge; and The intermediate coil is homogenized before hot rolling the slab to final gauge.

8. The method according to any one of claims 1 to 3, further comprising: quenching the aluminum alloy product of the final specification; and The final specification aluminum alloy product is aged.

9. The method according to any one of claims 1 to 3, wherein no cold rolling step is performed.

10. The method according to any one of claims 1 to 3, wherein after the continuous casting and before the hot rolling, the slab has no cracks having a length greater than 8.0 mm.

11. An aluminum alloy product prepared according to the method of any one of claims 1 to 3. 12 . The aluminum alloy product according to claim 11 , wherein the aluminum alloy product is an aluminum alloy sheet, an aluminum alloy plate or an aluminum alloy thin plate.

13. The aluminum alloy product of claim 11, wherein the aluminum alloy product comprises a long transverse tensile yield strength of at least 365 MPa in the T82 temper.

14. The aluminum alloy product of claim 11, wherein the aluminum alloy product comprises an internal bend angle of 35° to 65° in the T4 state, an internal bend angle of 110° to 130° in the T82 state, and an internal bend angle of 90° to 130° in the semi-crash condition.

15. The aluminum alloy product according to claim 11, wherein the aluminum alloy product is an automobile body part, an automobile part, a transportation body part, an aerospace body part, or an electronic equipment housing.

16. A method for producing an aluminum alloy, comprising: Continuously casting an aluminum alloy in a continuous casting machine to form a slab, wherein the aluminum alloy comprises 0.26-2.82 wt% Si, 0.06-0.60 wt% Fe, 0.26-2.37 wt% Cu, 0.06-0.57 wt% Mn, 0.26-2.37 wt% Mg, 0-0.21 wt% Cr, 0-0.009 wt% Zn, 0-0.09 wt% Ti, 0-0.003 wt% Zr and up to 0.15 wt% impurities, with the remainder being Al; homogenizing the slab at a temperature of 500° C. to 580° C. upon exiting the continuous casting machine; hot rolling the slab into final size and final condition; and Solutionizing the final aluminum alloy product at a temperature of 500°C to 520°C; The continuously cast slab is coiled and then cooled in air before the step of hot rolling the slab.

17. The method of claim 16, wherein after the continuous casting and before the hot rolling, the slab has no cracks having a length greater than 8.0 mm.

18. A method for producing an aluminum alloy product, comprising: Continuously casting an aluminum alloy in a continuous casting machine to form a slab, wherein the aluminum alloy comprises 0.26-2.82 wt% Si, 0.06-0.60 wt% Fe, 0.26-2.37 wt% Cu, 0.06-0.57 wt% Mn, 0.26-2.37 wt% Mg, 0-0.21 wt% Cr, 0-0.009 wt% Zn, 0-0.09 wt% Ti, 0-0.003 wt% Zr and up to 0.15 wt% impurities, with the remainder being Al; homogenizing the slab at a temperature of 500° C. to 580° C. upon exiting the continuous casting machine; hot rolling the slab to reduce the thickness of the slab by at least 50%; and Solutionizing the final aluminum alloy product at a temperature of 500°C to 520°C; The continuously cast slab is coiled and then cooled in air before the step of hot rolling the slab.

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