Novel scrap-based aluminum alloy products

Abstract

Novel aluminum alloys are disclosed. The novel aluminum alloy may include 1.05 to 1.55 wt% of Si, 0.85 to 2.10 wt% of Mg, 0.15 to 0.75 wt% of Cu, 0.20 to 0.90 wt% of Fe, 0.5 to 1.5 wt% of Mn, 0.01 to 0.15 wt% of Ti, up to 0.4 wt% of Zn, up to 0.25 wt% of any one of Cr, Zr, and V, and up to 0.05 wt% of Ni, the balance being aluminum, even elements, and impurities. The novel aluminum alloy may be derived, at least in part, from scrap material, such as UBC or brazing scrap. The novel aluminum alloy can be processed into an H-tempered sheet product. The novel aluminum alloy may achieve an improved combination of at least two of strength, elongation, and corrosion resistance.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Application No. 63 / 344,968, filed on May 23, 2022, entitled “NEW SCRAP-BASED ALUMINUM ALLOY PRODUCTS,” which is incorporated herein by reference in its entirety. Background Art

[0003] As described in U.S. Patent Application Publication No. 2021 / 0087664, aluminum may contribute to a portion of the carbon footprint. One effective way to reduce the carbon footprint and aluminum mining is to increase the use of recycled aluminum, especially post-consumer recycled (PCR) aluminum. One of the main sources of PCR aluminum is used beverage can (UBC) scrap. Increasing recycling can have a large impact on reducing the carbon footprint and primary aluminum consumption. Summary of the invention

[0004] Broadly speaking, the present patent application relates to a novel aluminum alloy. The novel aluminum alloy can be derived from scrap, thereby reducing its manufacturing cost. Although derived from scrap, the novel aluminum alloy can achieve excellent mechanical properties and corrosion resistance. In one embodiment, the novel aluminum alloy comprises 1.05 to 1.55 wt % Si, 0.85 to 2.10 wt % Mg, 0.15 to 0.75 wt % Cu, 0.20 to 0.90 wt % Fe, 0.5 to 1.5 wt % Mn, 0.01 to 0.15 wt % Ti, up to 0.4 wt % Zn, up to 0.25 wt % Cr, any one of Zr and V and up to 0.05 wt % Ni, the remainder being aluminum, incidental elements and impurities. In one method, the novel aluminum alloy is in the form of a sheet product having a thickness of 0.4 to 4 mm. In one embodiment, the aluminum alloy sheet product achieves at least one of the following microstructural characteristics: (i) no more than 50 volume percent recrystallized grains, (ii) at least 0.5% Mg2Si area percentage, (iii) at least 0.5 particles / square micron average Mg2Si particle area, (iv) at least 0.5% constituent area percentage, and (v) at least 0.5 particles / square micron average constituent particle area. Methods for determining these microstructural characteristics are described in the Microstructural Evaluation Procedure described below.

[0005] i. Composition

[0006] As described above, the new aluminum alloy generally contains 1.05 to 1.55 weight % Si. Such silicon levels can promote, for example, increased scrap utilization and / or improved mechanical properties. In one embodiment, the new aluminum alloy contains at least 1.10 weight % Si. In another embodiment, the new aluminum alloy contains at least 1.15 weight % Si. In one embodiment, the new aluminum alloy contains no more than 1.45 weight % Si. In another embodiment, the new aluminum alloy contains no more than 1.40 weight % Si.

[0007] As described above, the new aluminum alloy generally includes 0.85 to 2.10 weight % Mg. Such magnesium levels can promote, for example, improved mechanical properties (e.g., strain hardening). In one embodiment, the new aluminum alloy includes at least 0.90 weight % Mg. In another embodiment, the new aluminum alloy includes at least 0.95 weight % Mg. In one embodiment, the new aluminum alloy includes no more than 2.05 weight % Mg. In another embodiment, the new aluminum alloy includes no more than 2.00 weight % Mg. In yet another embodiment, the new aluminum alloy includes no more than 1.95 weight % Mg. In another embodiment, the new aluminum alloy includes no more than 1.90 weight % Mg.

[0008] As described above, the new aluminum alloy generally includes 0.15 to 0.75 wt. % Cu. Such copper levels can, for example, promote improved mechanical properties without unnecessarily reducing corrosion resistance. In one embodiment, the new aluminum alloy includes at least 0.20 wt. % Cu. In another embodiment, the new aluminum alloy includes at least 0.25 wt. % Cu. In yet another embodiment, the new aluminum alloy includes at least 0.30 wt. % Cu. In one embodiment, the new aluminum alloy includes no more than 0.70 wt. % Cu. In another embodiment, the new aluminum alloy includes no more than 0.65 wt. % Cu. In yet another embodiment, the new aluminum alloy includes no more than 0.60 wt. % Cu.

[0009] As described above, the new aluminum alloy generally contains 0.20 to 0.90 wt % Fe. Such iron levels can, for example, promote high scrap tolerance and / or dispersoid formation. In one embodiment, the new aluminum alloy contains at least 0.25 wt % Fe. In another embodiment, the new aluminum alloy contains at least 0.30 wt % Fe. In one embodiment, the new aluminum alloy contains no more than 0.85 wt % Fe. In another embodiment, the new aluminum alloy contains no more than 0.80 wt % Fe. In yet another embodiment, the new aluminum alloy contains no more than 0.75 wt % Fe.

[0010] As described above, the new aluminum alloy generally contains 0.5 to 1.5 wt. % Mn. Such manganese levels can, for example, promote high scrap tolerance and / or dispersoid formation. In one embodiment, the new aluminum alloy contains at least 0.55 wt. % Mn. In another embodiment, the new aluminum alloy contains at least 0.60 wt. % Mn. In yet another embodiment, the new aluminum alloy contains at least 0.65 wt. % Mn. In another embodiment, the new aluminum alloy contains at least 0.70 wt. % Mn. In yet another embodiment, the new aluminum alloy contains at least 0.75 wt. % Mn. In another embodiment, the new aluminum alloy contains at least 0.80 wt. % Mn. In yet another embodiment, the new aluminum alloy contains at least 0.85 wt. % Mn. In another embodiment, the new aluminum alloy contains at least 0.90 wt. % Mn. In yet another embodiment, the new aluminum alloy contains at least 0.95 wt. % Mn. In another embodiment, the new aluminum alloy contains at least 1.0 wt. % Mn. In one embodiment, the new aluminum alloy includes no more than 1.45 wt. % Mn. In another embodiment, the new aluminum alloy includes no more than 1.40 wt. % Mn. In yet another embodiment, the new aluminum alloy includes no more than 1.35 wt. % Mn. In another embodiment, the new aluminum alloy includes no more than 1.30 wt. % Mn. In yet another embodiment, the new aluminum alloy includes no more than 1.25 wt. % Mn. In another embodiment, the new aluminum alloy includes no more than 1.20 wt. % Mn.

[0011] As described above, the new aluminum alloy generally contains 0.01 to 0.15 wt. % Ti. Titanium can, for example, promote grain refinement. In one embodiment, the new aluminum alloy contains at least 0.02 wt. % Ti. In another embodiment, the new aluminum alloy contains at least 0.03 wt. % Ti. In yet another embodiment, the new aluminum alloy contains at least 0.04 wt. % Ti. In yet another embodiment, the new aluminum alloy contains at least 0.05 wt. % Ti. In one embodiment, the new aluminum alloy contains no more than 0.12 wt. % Ti. In another embodiment, the new aluminum alloy contains no more than 0.10 wt. % Ti. In yet another embodiment, the new aluminum alloy contains no more than 0.08 wt. % Ti. In yet another embodiment, the new aluminum alloy contains no more than 0.05 wt. % Ti.

[0012] As described above, the new aluminum alloy may contain up to 0.40 wt. % Zn, which may promote high scrap tolerance. In one embodiment, the new aluminum alloy contains no more than 0.35 wt. % Zn. In another embodiment, the new aluminum alloy contains no more than 0.30 wt. % Zn. In yet another embodiment, the new aluminum alloy contains no more than 0.25 wt. % Zn. In another embodiment, the new aluminum alloy contains no more than 0.20 wt. % Zn. In one embodiment, the new aluminum alloy contains at least 0.01 wt. % Zn. In another embodiment, the new aluminum alloy contains at least 0.05 wt. % Zn.

[0013] As described above, the new aluminum alloy may contain up to 0.25% by weight of any one of Cr, Zr and V, which can be used to control recrystallization. In one method, the new aluminum alloy contains no more than 0.20% by weight of Zr. In another method, the new aluminum alloy contains no more than 0.15% by weight of Zr. In one embodiment, the new aluminum alloy contains no more than 0.10% by weight of Zr. In another embodiment, the new aluminum alloy contains no more than 0.08% by weight of Zr. In yet another embodiment, the new aluminum alloy contains no more than 0.05% by weight of Zr. In another embodiment, the new aluminum alloy contains no more than 0.04% by weight of Zr. In yet another embodiment, the new aluminum alloy contains no more than 0.03% by weight of Zr. In one embodiment, the new aluminum alloy contains at least 0.01% by weight of Zr.

[0014] In one approach, the new aluminum alloy contains no more than 0.20 wt. % Cr. In one embodiment, the new aluminum alloy contains no more than 0.15 wt. % Cr. In another embodiment, the new aluminum alloy contains no more than 0.10 wt. % Cr. In another embodiment, the new aluminum alloy contains no more than 0.08 wt. % Cr. In yet another embodiment, the new aluminum alloy contains no more than 0.05 wt. % Cr. In another embodiment, the new aluminum alloy contains no more than 0.04 wt. % Cr. In yet another embodiment, the new aluminum alloy contains no more than 0.03 wt. % Cr. In one embodiment, the new aluminum alloy contains at least 0.01 wt. % Cr.

[0015] In one method, the new aluminum alloy contains no more than 0.20 wt. % V. In one embodiment, the new aluminum alloy contains no more than 0.15 wt. % V. In another embodiment, the new aluminum alloy contains no more than 0.10 wt. % V. In another embodiment, the new aluminum alloy contains no more than 0.08 wt. % V. In yet another embodiment, the new aluminum alloy contains no more than 0.05 wt. % V. In another embodiment, the new aluminum alloy contains no more than 0.04 wt. % V. In yet another embodiment, the new aluminum alloy contains no more than 0.03 wt. % V. In one embodiment, the new aluminum alloy contains at least 0.01 wt. % V.

[0016] The novel aluminum alloy generally comprises the alloy composition stated, and the balance is aluminum, optional incidental elements and impurities. As used herein, "incidental elements" means, in addition to the elements listed above, elements or materials that can be optionally added to the alloy to help alloy production. Examples of incidental elements include casting aids, such as deoxidizers. Optional incidental elements can be included in the alloy in an accumulated amount of up to 1.0 weight %. As a non-limiting example, one or more incidental elements can be added to the alloy during casting to reduce or limit (and in some cases, eliminate) ingot cracking caused by, for example, oxide folding, pits and oxide patches. These types of incidental elements are generally referred to as deoxidizers in this article. Examples of some deoxidizers include Ca, Sr and Be. When calcium (Ca) is included in the alloy, it is generally present in an amount of up to about 0.05 weight % or up to about 0.03 weight %. In some embodiments, the alloy contains Ca in an amount of about 0.001-0.03 wt. % or about 0.05 wt. %, for example, 0.001-0.008 wt. % (or 10 to 80 ppm). Strontium (Sr) may be included in the alloy as a substitute for Ca (completely or partially), and may therefore be included in the alloy in the same or similar amount as Ca. Traditionally, the addition of beryllium (Be) helps to reduce the tendency of ingot cracking, but for environmental, health and safety reasons, some embodiments of the alloy are substantially free of Be. When Be is included in the alloy, it is generally present in an amount of up to about 20 ppm. Incidental elements may be present in trace amounts, or may be present in large amounts, and may be added to desired or other features without departing from the alloy described herein, as long as the alloy maintains the desired features described herein. However, it should be understood that the scope of the present disclosure must not be circumvented by adding only one or more elements in an amount that does not otherwise affect the desired and obtained characteristic combinations herein.

[0017] The new aluminum alloy may contain a small amount of impurities. In one embodiment, the new aluminum alloy contains no more than 0.15% by weight of impurities in total, and wherein the aluminum alloy contains no more than 0.05% by weight of each impurity. In another embodiment, the new aluminum alloy contains no more than 0.10% by weight of impurities in total, and wherein the aluminum alloy contains no more than 0.03% by weight of each impurity.

[0018] The new aluminum alloy is generally substantially free of nickel, that is, nickel is only contained as an impurity, and generally contains less than 0.04 weight % Ni or less than 0.01 weight % Ni. The new aluminum alloy is generally substantially free of lithium, that is, lithium is only contained as an impurity, and generally contains less than 0.04 weight % Li or less than 0.01 weight % Li. The new aluminum alloy is generally substantially free of silver, that is, silver is only contained as an impurity, and generally contains less than 0.04 weight % Ag or less than 0.01 weight % Ag. The new aluminum alloy is generally substantially free of lead, that is, lead is only contained as an impurity, and generally contains less than 0.04 weight % Pb or less than 0.01 weight % Pb. The new aluminum alloy is generally substantially free of cadmium, that is, cadmium is only contained as an impurity, and generally contains less than 0.04 weight % Cd or less than 0.01 weight % Cd. The new aluminum alloy is generally substantially free of thallium, that is, thallium is only contained as an impurity, and generally contains less than 0.04 weight % Tl or less than 0.01 weight % Tl. The new aluminum alloy is typically substantially free of scandium, ie scandium is contained only as an impurity, and typically contains less than 0.04 wt. % Sc or less than 0.01 wt. % Sc.

[0019] ii. Production method

[0020] The novel aluminum alloy can be prepared in a forged form and in an appropriate temper. In one embodiment, the novel aluminum alloy can be produced as an ingot or strip by casting (e.g., direct chill casting or continuous casting), and then appropriately processed to achieve various tempers, such as H-tempering according to ANSI H35.1 (2009), for example, H1, H2 or H3 tempering. In one embodiment, the novel aluminum alloy is processed to "H1 tempering". In another embodiment, the novel aluminum alloy is processed to "H2 tempering". In yet another embodiment, the novel aluminum alloy is processed to "H3 tempering".

[0021] In one embodiment, the novel aluminum alloy is direct chill (DC) cast into ingot form. After conventional scalping, lathing or peeling (if necessary) and homogenization (if necessary) of the ingot, these ingots can be further processed by hot working the product, wherein the homogenization can be done before or after scalping. The product can then be optionally cold worked and / or optionally annealed. In one embodiment, processing into an H-tempered sheet product includes cold rolling to final specifications and then partial annealing to achieve H2 temper.

[0022] When processing new aluminum alloys to the H temper, their production methods usually do not include (are not present) solution heat treatment or artificial aging. These steps add unnecessary cost, and the H temper can achieve the necessary properties without such steps.

[0023] In other embodiments, the new aluminum alloy may be processed to a T temper, which would include solution heat treatment followed by natural and / or artificial aging. The high magnesium silicide (Mg2Si) content of the new alloy may promote strength improvements in the T4 (natural aging) or T6 (artificial aging) tempers as well as other T tempers.

[0024] The new aluminum alloy product may have any suitable final gauge thickness. In one embodiment, the new aluminum alloy is in the form of a sheet having a thickness of 0.4 to 4 mm. Other wrought product forms (e.g., plates, extrusions, forgings) may be used.

[0025] As described above, the ingots used to produce the novel aluminum alloys described herein may be derived at least in part from aluminum alloy scrap. For example, a method may include (a) producing an aluminum alloy ingot from aluminum-based scrap and (b) processing the aluminum alloy ingot into a suitable wrought product form and temper, such as an H-tempered sheet product having a thickness of 0.4 to 4.0 mm.

[0026] With respect to the above step (a) (i.e., producing an aluminum alloy ingot), the step (a) may include (i) mixing a first aluminum scrap material with another aluminum material to obtain a target ingot composition, (ii) before or after the mixing step, heating the first aluminum scrap material and the other aluminum material to produce a molten aluminum alloy, and (iii) casting the molten aluminum alloy into an aluminum alloy ingot, wherein the aluminum alloy ingot obtains the target ingot composition. The other aluminum material may be at least one of (A) a second aluminum scrap material, (B) raw aluminum, and (C) a mixture thereof. The target ingot composition may be any composition disclosed herein, including those disclosed in the composition and examples section.

[0027] In one embodiment, at least one of the first aluminum scrap material and the second aluminum scrap material is 3xxx aluminum alloy scrap, 4xxx aluminum alloy scrap, 5xxx aluminum alloy scrap, or 6xxx aluminum alloy scrap. In one embodiment, at least one of the first aluminum scrap material and the second aluminum scrap material is 3004 and / or 3104 aluminum alloy scrap. In another embodiment, at least one of the first aluminum scrap material and the second aluminum scrap material is 4343 aluminum alloy scrap. In yet another embodiment, at least one of the first aluminum scrap material and the second aluminum scrap material is 5052 and / or 5182 aluminum alloy scrap. In another embodiment, at least one of the first aluminum scrap material and the second aluminum scrap material is 6061, 6063, 6022, 6111, and / or 6013 aluminum alloy scrap.

[0028] In one embodiment, at least one of the first aluminum scrap material and the second aluminum scrap material is brazing scrap. Suitable brazing scrap materials may include composite alloys having a core and a liner. The composite alloy may have, for example, a 3xxx aluminum alloy core and a 4xxx aluminum alloy liner, or a 3xxx core and a 7xxx aluminum alloy liner, etc. For example, the brazing scrap may come from tubing, headers, or other heat exchanger materials.

[0029] In one embodiment, at least one of the first aluminum scrap material and the second aluminum scrap material is UBC (used beverage can) scrap. Suitable UBC scrap materials include those made of 3104 and / or 5182 aluminum alloys. In one embodiment, the UBC scrap material includes at least 3104 scrap. In another embodiment, the UBC scrap material includes at least 5182 scrap.

[0030] In one embodiment, at least one of the first and second aluminum scrap materials is automotive or industrial scrap (eg, scrap of aluminum alloys 6061, 6063, 6022, 6111, and / or 6013).

[0031] In one embodiment, the first aluminum scrap material is at least one of brazing scrap, used beverage can (UBC) scrap, and mixtures thereof, and the other aluminum material is a second aluminum scrap material, such as 3xxx, 4xxx, 5xxx, or 6xxx aluminum alloy scrap. In another embodiment, the first aluminum scrap material is at least one of brazing scrap, used beverage can (UBC) scrap, and mixtures thereof, and the other aluminum material is raw aluminum. In one embodiment, the first aluminum scrap material is brazing scrap, and the second aluminum scrap material is UBC scrap.

[0032] Due to the use of scrap, the aluminum alloy ingot may contain a considerable amount of scrap material. In one embodiment, at least 30% of the ingot is derived from the first aluminum scrap material (i.e., at least 30% of the ingot contains the first aluminum scrap material), and the balance of the ingot is raw aluminum and / or other scrap materials. In another embodiment, at least 35% of the ingot is derived from the first aluminum scrap material. In yet another embodiment, at least 40% of the ingot is derived from the first aluminum scrap material. In another embodiment, at least 45% of the ingot is derived from the first aluminum scrap material. In yet another embodiment, at least 50% of the ingot is derived from the first aluminum scrap material. In another embodiment, at least 55% of the ingot is derived from the first aluminum scrap material. In yet another embodiment, at least 60% of the ingot is derived from the first aluminum scrap material. In another embodiment, at least 65% of the ingot is derived from the first aluminum scrap material.

[0033] In one embodiment, the aluminum alloy ingot contains at least two aluminum scrap materials (first and second scrap materials). In one embodiment, at least 50% of the ingot is derived from the first and second aluminum scrap materials (i.e., at least 50% of the ingot contains the first and second aluminum scrap materials). In another embodiment, at least 55% of the ingot is derived from the first and second aluminum scrap materials. In yet another embodiment, at least 60% of the ingot is derived from the first and second aluminum scrap materials. In another embodiment, at least 65% of the ingot is derived from the first and second aluminum scrap materials. In yet another embodiment, at least 70% of the ingot is derived from the first and second aluminum scrap materials. In another embodiment, at least 75% of the ingot is derived from the first and second aluminum scrap materials. In yet another embodiment, at least 80% of the ingot is derived from the first and second aluminum scrap materials. In another embodiment, at least 85% of the ingot is derived from the first and second aluminum scrap materials. In yet another embodiment, at least 90% of the ingot is derived from the first and second aluminum scrap materials. In another embodiment, at least 94% of the ingot is derived from the first and second aluminum scrap materials. Additional scrap materials (third, fourth, fifth, etc.) may be used to produce any of the aluminum alloy ingots described in this paragraph.

[0034] Raw aluminum can be used with any mixture of scrap to prepare aluminum alloy ingots. In one embodiment, the aluminum alloy ingot contains at least 1% raw aluminum. In another embodiment, the aluminum alloy ingot contains at least 2% raw aluminum. In yet another embodiment, the aluminum alloy ingot contains at least 3% raw aluminum. In another embodiment, the aluminum alloy ingot contains at least 4% raw aluminum. In yet another embodiment, the aluminum alloy ingot contains at least 5% raw aluminum. In another embodiment, the aluminum alloy ingot contains at least 6% raw aluminum. In one embodiment, the aluminum alloy ingot contains no more than 60% raw aluminum. In another embodiment, the aluminum alloy ingot contains no more than 55% raw aluminum. In yet another embodiment, the aluminum alloy ingot contains no more than 50% raw aluminum. In another embodiment, the aluminum alloy ingot contains no more than 45% raw aluminum. In yet another embodiment, the aluminum alloy ingot contains no more than 40% raw aluminum. In another embodiment, the aluminum alloy ingot contains no more than 30% raw aluminum. In yet another embodiment, the aluminum alloy ingot contains no more than 35% raw aluminum. In another embodiment, the aluminum alloy ingot contains no more than 30% primary aluminum. In yet another embodiment, the aluminum alloy ingot contains no more than 25% primary aluminum.

[0035] iii. Microstructure

[0036] As mentioned above, the new aluminum alloy can achieve a unique microstructure. For example, as described below Recrystallization Set procedures As determined, the new aluminum alloy may contain 50 volume % or less recrystallized grains. In one embodiment, the new aluminum alloy contains no more than 45 volume % recrystallized grains. In another embodiment, the new aluminum alloy contains no more than 40 volume % recrystallized grains. In yet another embodiment, the new aluminum alloy contains no more than 35 volume % recrystallized grains. In another embodiment, the new aluminum alloy product contains no more than 30 volume % recrystallized grains. In yet another embodiment, the new aluminum alloy contains no more than 25 volume % recrystallized grains. In another embodiment, the new aluminum alloy product contains no more than 20 volume % recrystallized grains. In yet another embodiment, the new aluminum alloy contains no more than 15 volume % recrystallized grains. In another embodiment, the new aluminum alloy product contains no more than 10 volume % recrystallized grains. In one embodiment, the new aluminum alloy contains at least 1 volume % recrystallized grains. In another embodiment, the new aluminum alloy product contains at least 3 volume % recrystallized grains. In yet another embodiment, the new aluminum alloy product contains at least 5 volume % recrystallized grains.

[0037] As described above, the new aluminum alloy can achieve an Mg2Si area percentage of at least 0.5%. In one embodiment, the new aluminum alloy achieves an Mg2Si area percentage of at least 0.6%. In another embodiment, the new aluminum alloy achieves an Mg2Si area percentage of at least 0.7%. In yet another embodiment, the new aluminum alloy achieves an Mg2Si area percentage of at least 0.8%. In another embodiment, the new aluminum alloy achieves an Mg2Si area percentage of at least 0.9%. In yet another embodiment, the new aluminum alloy achieves an Mg2Si area percentage of at least 1.0%. In another embodiment, the new aluminum alloy achieves an Mg2Si area percentage of at least 1.1%. In yet another embodiment, the new aluminum alloy achieves an Mg2Si area percentage of at least 1.2%.

[0038] As described above, the new aluminum alloy can achieve an average Mg2Si particle area of ​​at least 0.5 particles / square micron. In one embodiment, the new aluminum alloy achieves an average Mg2Si particle area of ​​at least 0.75 particles / square micron. In another embodiment, the new aluminum alloy achieves an average Mg2Si particle area of ​​at least 1.0 particles / square micron. In yet another embodiment, the new aluminum alloy achieves an average Mg2Si particle area of ​​at least 1.25 particles / square micron. In another embodiment, the new aluminum alloy achieves an average Mg2Si particle area of ​​at least 1.5 particles / square micron. In yet another embodiment, the new aluminum alloy achieves an average Mg2Si particle area of ​​at least 1.75 particles / square micron. In another embodiment, the new aluminum alloy achieves an average Mg2Si particle area of ​​at least 2.0 particles / square micron. In yet another embodiment, the new aluminum alloy achieves an average Mg2Si particle area of ​​at least 2.25 particles / square micron. In another embodiment, the new aluminum alloy achieves an average Mg2Si particle area of ​​at least 2.5 particles / square micron. In yet another embodiment, the new aluminum alloy achieves an average Mg2Si particle area of ​​at least 2.75 particles / square micron. In another embodiment, the new aluminum alloy achieves an average Mg2Si particle area of ​​at least 3.0 particles / square micron. In yet another embodiment, the new aluminum alloy achieves an average Mg2Si particle area of ​​at least 3.25 particles / square micron. In another embodiment, the new aluminum alloy achieves an average Mg2Si particle area of ​​at least 3.5 particles / square micron.

[0039] As described above, the new aluminum alloy can achieve a component area percentage of at least 0.5%. In one embodiment, the new aluminum alloy achieves a component area percentage of at least 0.75%. In another embodiment, the new aluminum alloy achieves a component area percentage of at least 1.0%. In yet another embodiment, the new aluminum alloy achieves a component area percentage of at least 1.25%. In another embodiment, the new aluminum alloy achieves a component area percentage of at least 1.5%. In yet another embodiment, the new aluminum alloy achieves a component area percentage of at least 1.75%. In another embodiment, the new aluminum alloy achieves a component area percentage of at least 2.0%. In yet another embodiment, the new aluminum alloy achieves a component area percentage of at least 2.25%. In another embodiment, the new aluminum alloy achieves a component area percentage of at least 2.5%. In yet another embodiment, the new aluminum alloy achieves a component area percentage of at least 2.75%.

[0040] As described above, the new aluminum alloy can achieve an average component particle area of ​​at least 0.5 particles / square micron. In one embodiment, the new aluminum alloy achieves an average component particle area of ​​at least 0.75 particles / square micron. In another embodiment, the new aluminum alloy achieves an average component particle area of ​​at least 1.0 particles / square micron. In yet another embodiment, the new aluminum alloy achieves an average component particle area of ​​at least 1.25 particles / square micron. In another embodiment, the new aluminum alloy achieves an average component particle area of ​​at least 1.5 particles / square micron. In yet another embodiment, the new aluminum alloy achieves an average component particle area of ​​at least 1.75 particles / square micron. In another embodiment, the new aluminum alloy achieves an average component particle area of ​​at least 2.0 particles / square micron. In yet another embodiment, the new aluminum alloy achieves an average component particle area of ​​at least 2.25 particles / square micron. In another embodiment, the new aluminum alloy achieves an average component particle area of ​​at least 2.5 particles / square micron. In yet another embodiment, the new aluminum alloy achieves an average component particle area of ​​at least 2.75 particles / square micron. In another embodiment, the novel aluminum alloy achieves an average component particle area of ​​at least 3.0 particles / square micron. In yet another embodiment, the novel aluminum alloy achieves an average component particle area of ​​at least 3.25 particles / square micron. In another embodiment, the novel aluminum alloy achieves an average component particle area of ​​at least 3.5 particles / square micron. In yet another embodiment, the novel aluminum alloy achieves an average component particle area of ​​at least 3.75 particles / square micron.

[0041] As described above, the new aluminum alloy can achieve at least one of the following microstructural characteristics: (i) no more than 50% by volume of recrystallized grains, (ii) at least 0.5% Mg2Si area percentage, (iii) at least 0.5 particles / square micron average Mg2Si particle area, (iv) at least 0.5% component area percentage, and (v) at least 0.5 particles / square micron average component particle area. In one embodiment, the new aluminum alloy achieves at least two of the microstructural characteristics (i)-(v). In another embodiment, the new aluminum alloy achieves at least three of the microstructural characteristics (i)-(v). In another embodiment, the new aluminum alloy achieves at least four of the microstructural characteristics (i)-(v). In another embodiment, the new aluminum alloy achieves all of the microstructural characteristics (i)-(v).

[0042] iv. Microstructural Evaluation Procedure

[0043] The following procedures and definitions apply to measuring the microstructural characteristics (eg, percent recrystallization, composition, and Mg2Si content) of products manufactured according to the present patent application.

[0044] a. Mg2Si and component particle measurement

[0045] The "constituent area fraction" (cf) and the "Mg2Si area fraction" are the fraction of the area occupied by the constituent particles or Mg2Si, respectively, divided by the total area examined in a two-dimensional cross section prepared by standard metallographic sample preparation methods.

[0046] The "composition area percentage" and the "Mg2Si area percentage" are determined by multiplying their respective area fractions by 100%.

[0047] "Constituent particle area" and "Mg2Si particle area" are the areas of the constituent particles and Mg2Si particles, respectively, measured in the sample.

[0048] The "average component particle area" and the "average Mg2Si particle area" are the average areas of each component particle or Mg2Si particle, respectively.

[0049] To measure the composition and Mg2Si area fraction and particle area, backscattered electron images should be taken at 500x on an Apreo S field emission gun (Thermo Fisher Scientific (Waltham, MA, USA)) scanning electron microscope or equivalent to image the composition and Mg2Si particles. Images should be taken using an accelerating voltage of 10 kV. The beam current should be 3.2 nanoamperes. The working distance should be 10 mm, the dwell time should be 5 microseconds, and the line average should be 3. For each alloy, thirty images should be collected from the metallographic polished specimen at t / 2. Image analysis should be used to quantify the images. The pixel size used to quantify the composition and MgSi particles is 0.083 microns. For the composition, only particles containing at least 50 pixels were counted, with a threshold of 99 and a minimum intensity average of 115. For each composition particle, the number of pixels was converted into particle area and particle effective diameter. For Mg2Si particles, only particles containing at least 15 pixels were counted, with a threshold of 73, and the average intensity of all pixels in the particle was not less than 65. For each Mg2Si particle, the number of pixels was converted to particle area and particle effective diameter. For average particle based calculations, only particles that were completely included in the image area were included in the calculations.

[0050] b. Recrystallization determination procedure

[0051] "Recrystallized percentage" and the like refer to the volume percentage of the wrought aluminum alloy product having recrystallized grains. The amount of recrystallized grains is determined based on the Recrystallization Determination Procedure Determined by performing EBSD (Electron Backscatter Diffraction) analysis on a suitable number of SEM micrographs of the wrought aluminium alloy product. Normally at least 5 micrographs should be analysed.

[0052] "Recrystallized grains" means grains that meet the "first grain criteria" defined below and whose crystalline microstructure is measured using the OIM (Oriented Imaging Microscope) sampling procedure described below.

[0053] OIM analysis will be done through the full thickness of the sheet sample in the L-ST plane using the following OIM sample procedure. The size of the sample to be analyzed will typically vary by specification. Prior to measurement, the OIM sample is prepared by standard metallographic sample preparation methods. For example, the OIM sample is metallographically prepared and then vibratory polished (e.g., using 0.05 micron colloidal silica).

[0054] The "OIM Sample Procedure" is as follows:

[0055] The software used was APEX EBSD Collection Software Version 2 (EDAX Inc., New Jersey, USA) or equivalent, connected to a Velocity EBSD Camera (EDAX Inc., New Jersey, USA) or equivalent. The SEM was an APREO S field emission gun (Thermo Fisher Scientific. Waltham, MA, USA) or equivalent.

[0056] The OIM run conditions were 68° tilt with a working distance of 18 mm and an accelerating voltage of 15 kV with dynamic focusing and a beam current of 51 nA (nanoamperes) specified by the instrument. The collection mode was a hexagonal grid. A selection was made so that orientation was collected in the analysis (i.e., Hough peak information was not collected). For a 2 mm specification sample at 80X with a step of 0.25 microns, the area size of each scan (i.e., frame) was 2.0 mm×1 mm. Depending on the specification, different frame sizes can be used. The collected data is exported in the form of an *.osc file. This data can be used to calculate the volume fraction of the first type of grains, as described below.

[0057] · Calculation of the volume fraction of the first type of grains : The volume fraction of the first type of grains is calculated using the data from the *.osc file and OIM Analysis software (EDAX, Inc., New Jersey, USA) version 8.1.0 or equivalent. Prior to the calculation, a two-step data cleanup can be performed. First, for any point with a confidence index below a threshold of 0.08, an adjacent direction correlation cleanup is performed. Second, a grain size expansion cleanup is performed for any grain with less than 3 data points. The amount of the first type of grains is then calculated by the software using the first grain standard (as follows).

[0058] · First Die Standard : The average grain misorientation (GAM) is calculated. All "Apply partitioning before calculation", "Include edge grains" and "Ignore twin boundary definition" should be required. Any grain with GAM ≤ 1° is a first type grain.

[0059] "First grain volume" (FGV) refers to the volume fraction of a first type of grains of a crystalline material.

[0060] The "percentage of recrystallization" is determined by the following formula: FGV*100%.

[0061] The term "grain" has the meaning defined in ASTM E112 §3.2.2, namely, "the area within the original (primary) boundaries observed on a two-dimensional polished surface, or the volume enclosed by the original (primary) boundaries in a three-dimensional object."

[0062] "Particle size" is calculated by the following equation:

[0063]

[0064] ·A i is the area of ​​a single grain measured using the commercial software OIM Analysis Software Version 8.1.0 or equivalent; and

[0065] · Among them d i is a single grain size calculated assuming that the grains are round.

[0066] The "area weighted average particle size" is calculated by the following equation:

[0067]

[0068] ·A i is the area of ​​each individual grain measured using the commercial software OIM Analysis Software Version 8.1.0 or equivalent;

[0069] · Among them d i is the calculated individual grain size assuming that the grains are round; and

[0070] Where d-bar is the area-weighted average particle size.

[0071] v. nature

[0072] As noted above, despite being potentially scrap based, the novel aluminum alloy products described herein may achieve relatively high mechanical properties and / or good corrosion resistance.

[0073] In one embodiment, the novel aluminum alloy sheet product achieves a tensile yield strength (longitudinal) of at least 35 ksi. In another embodiment, the novel aluminum alloy sheet product achieves a tensile yield strength (longitudinal) of at least 36 ksi. In yet another embodiment, the novel aluminum alloy sheet product achieves a tensile yield strength (longitudinal) of at least 37 ksi. In another embodiment, the novel aluminum alloy sheet product achieves a tensile yield strength (longitudinal) of at least 38 ksi. In yet another embodiment, the novel aluminum alloy sheet product achieves a tensile yield strength (longitudinal) of at least 39 ksi. In another embodiment, the novel aluminum alloy sheet product achieves a tensile yield strength (longitudinal) of at least 40 ksi.

[0074] In one embodiment, the novel aluminum alloy sheet product achieves a longitudinal (L) elongation of at least 3.0%. In another embodiment, the novel aluminum alloy sheet product achieves a longitudinal (L) elongation of at least 3.5%. In yet another embodiment, the novel aluminum alloy sheet product achieves a longitudinal (L) elongation of at least 4.0%. In another embodiment, the novel aluminum alloy sheet product achieves a longitudinal (L) elongation of at least 4.5%. In yet another embodiment, the novel aluminum alloy sheet product achieves a longitudinal (L) elongation of at least 5.0%.

[0075] In one embodiment, the new aluminum alloy sheet product achieves at least equivalent ASTM G85 corrosion resistance compared to a conventional AA3004 sheet product of equivalent specification.

[0076] vi. Application

[0077] The new aluminum alloy described herein can be used in various product applications, such as automotive and / or industrial sheet products. In one embodiment, the new aluminum alloy is a sheet product for building a box trailer (e.g., a dry box or refrigerated box trailer for commercial transportation).

[0078] vii. definition

[0079] The “wrought aluminum alloy product” means an aluminum alloy product that is hot-worked after casting, and includes a rolled product (sheet or plate), a forged product, and an extruded product.

[0080] "Hot working" such as hot rolling means working the aluminum alloy product at elevated temperatures, and generally at least 121.1°C (250°F). Strain hardening is limited / avoided during hot working, which generally distinguishes hot working from cold working.

[0081] "Cold working" such as cold rolling means working the aluminum alloy product at temperatures that are not considered hot working temperatures, generally below about 121.1°C (250°F), such as at ambient temperature.

[0082] Temper definitions are in accordance with ANSI H35.1 (2009) published by The Aluminum Association, entitled "American National Standard Alloy and Temper Designation Systems for Aluminum."

[0083] Strength and elongation are measured according to ASTM E8 / E8M-21 and B557-15.

[0084] viii. other

[0085] These and other aspects, advantages, and novel features of the new technology are set forth in part in the description that follows and will become apparent to those skilled in the art upon examination of the description herein or may be learned by practicing one or more embodiments of the technology provided by this disclosure.

[0086] Among those benefits and improvements that have been disclosed, other objects and advantages of the present invention will become apparent from the description herein. Detailed embodiments of the present invention are disclosed herein; however, it should be understood that the disclosed embodiments are merely illustrative of the present invention that can be embodied in various forms. In addition, each example given together with the various embodiments of the present invention is intended to be illustrative rather than limiting.

[0087] Throughout the specification and claims, unless the context clearly dictates otherwise, the following terms take the meanings explicitly associated herein. As used herein, the phrases "in one embodiment" and "in some embodiments" do not necessarily refer to the same embodiment, although they may be. In addition, as used herein, the phrases "in another embodiment" and "in some other embodiments" do not necessarily refer to different embodiments, although they may be. Therefore, the various embodiments of the present invention can be easily combined without departing from the scope or spirit of the present invention.

[0088] In addition, unless the context clearly indicates otherwise, as used herein, the term "or" is an inclusive "or" operator and is equivalent to the term "and / or". Unless the context clearly indicates otherwise, the term "based on" is not exclusive and allows for being based on additional factors that are not described. In addition, throughout this specification, unless the context clearly indicates otherwise, the meaning of "a", "an", and "the" includes plural referents. Unless the context clearly indicates otherwise, the meaning of "in..." includes "in..." and "on...".

[0089] Although multiple embodiments of the present invention have been described, it should be understood that these embodiments are illustrative only and non-restrictive, and that various modifications may be apparent to those skilled in the art. Furthermore, unless the context clearly requires otherwise, the various steps may be performed in any desired order, and any applicable steps may be added and / or eliminated. DETAILED DESCRIPTION

[0090] Example 1

[0091] Several laboratory scale aluminum alloy ingots were produced, the compositions of which are shown in Table 1 below. Alloys XA39-XA46 are experimental alloys. Aluminum alloy 3004 (AA3004) is a conventional alloy. Alloy 0437 is a conventional alloy sold by Arconic Corp. under the same name.

[0092] Table 1 - Composition of Example 1 Alloy (wt%)*

[0093]

[0094]

[0095] *The balance of the alloy is aluminum and inevitable impurities.

[0096] After casting, the alloy is conventionally peeled / stripped and homogenized. The alloy is then hot rolled to an intermediate gauge and then cold rolled to a final gauge of approximately 1 mm and then partially annealed to achieve the H291 temper.

[0097] As described in ANSI H35.1 (2009), H-temper is defined as "Strain Hardening (Wrought Products Only)". According to ANSI H35.1, the H-temper designation "applies to products whose strength has been increased by strain hardening, with or without supplemental heat treatment to produce some reduction in strength. The H is always followed by two or more digits". In other words, H-tempered aluminum alloy products are not subjected to precipitation hardening (e.g., by solution heat treatment, followed by quenching, and then natural or artificial aging), which is a heat treatment that increases strength.

[0098] "H2 temper" is defined as "strain hardened and partially annealed". According to ANSI H35.1, the "H2 temper" designation applies to products that are strain hardened beyond the desired final amount and then reduced in strength to the desired level by partial annealing - the number following the designation indicates the degree of strain hardening remaining after the product has been partially annealed. The H291 temper is a common H2 temper and is used to achieve certain minimum strength and elongation values ​​for conventional alloys such as AA3004 and AA5052. See U.S. Patent Application Publication No. 2009 / 0159160.

[0099] The mechanical properties of the H291 tempered alloy were tested and the results are shown in Table 2 below.

[0100] Table 2 - Mechanical properties of H291 tempered example 1 alloy

[0101]

[0102]

[0103] As shown, despite having compositions useful for using scrap, the alloys XA41-XA43 of the present invention show comparable strength-elongation relationships to AA3004. The strength-elongation relationships of alloys XA44-X A46 are slightly lower. The strength of alloys XA39-40 is lower compared to AA3004.

[0104] The paint corrosion resistance of the alloy samples was also tested. Specifically, the alloy was cleaned and then painted according to the conventional aluminum alloy painting procedure. The painted alloy was then subjected to a 28-day MASTMAASIS test according to ASTM G85 Appendix A2 "Cyclic Acidified Salt Spray (Spray) Test". Overall, the new alloy achieved similar or better corrosion performance than conventional AA3004. These results are unexpected considering the copper content of the new alloy, which is typically over 0.30 wt. % Cu.

[0105] The scrap friendliness evaluation was also performed by comparing the possible aluminum alloy scraps that could be used to produce the alloys with the target alloy compositions for each of the alloys XA41-XA46. The most scrap-friendly alloys were XA42-43, each of which could be produced using 48-85% (XA42) or 48-96% (by weight) of common scrap such as brazing scrap and / or common 6xxx aluminum alloy scrap (e.g., AA6061 and / or AA6063 scrap).

[0106] An analysis of free silicon (free Si) and its effect on performance was also performed. The amount of free silicon (free Si) was determined by estimating the amount of silicon occupied by iron (Fe), manganese (Mn) and chromium (Cr) in the alloy using the following formula:

[0107] Free Si (wt%) = Total Si (wt%) – ([Fe+Mn+Cr)] / 4)

[0108] The results are shown in Table 3 below.

[0109] Table 3 - Comparison of Mg:free Si ratio and mechanical properties

[0110]

[0111] As shown, alloys with Mg:free Si ratios above 1:1 and closer to a 1.73:1 weight ratio of Mg:free Si can achieve improved performance. Alloys with lower silicon (e.g., around 0.77 wt. % Si) and / or lower free Si can achieve lower mechanical properties. Additional copper can contribute to improved mechanical properties.

[0112] Example 2

[0113] Based on the results of Example 1, alloy XA42-43 was screened for plant scale testing. Plant scale XA42-43 alloy was processed to H291 temper and processed in much the same manner as described in Example 1, but using industrial scale ingot casting and rolling equipment. The composition and mechanical properties of the alloy are provided in Tables 4-5 below. Results from conventional AA3004 samples are also shown below.

[0114] Table 4 - Composition of Example 2 Alloy (wt%)*

[0115]

[0116] Table 5 - Mechanical properties of H291 tempered example 2 alloy

[0117]

[0118] Likewise, despite having a composition that can be used to employ scrap, the XA42-43 alloy achieves mechanical properties that are generally similar to conventional AA3004. It is expected that the mill-produced alloy (XA42-XA43) will also achieve similar or better corrosion performance than conventional AA3004, which is unexpected given the copper content of the new alloy. Thus, when made from scrap, the new alloy can achieve significant cost advantages over conventional alloys while still achieving commercially valuable properties.

[0119] Microscopic analysis was also completed for the Example 2 alloy according to the microstructural evaluation procedures described herein. The results are shown in Table 6 below.

[0120] Table 6 - Microscopy data

[0121]

[0122]

[0123] As shown, the alloy of the present invention has little recrystallization but has large Mg2Si and component area fractions and grain areas.

[0124] Although various embodiments of the present disclosure have been described in detail, it is obvious that those skilled in the art will modify and adjust these embodiments. However, it should be clearly understood that such modifications and adjustments are within the spirit and scope of the present disclosure.

Claims

1. An aluminum alloy sheet product, comprising: 1.05 to 1.55 wt% Si; 0.85 to 2.10 wt. % Mg; 0.15 to 0.75 wt. % Cu; 0.20 to 0.90 wt.% Fe; 0.5 to 1.5 wt% Mn; 0.01 to 0.15 wt.% Ti; Up to 0.4 wt. % Zn; Up to 0.25 wt% of any one of Cr, Zr and V; and Up to 0.05 wt.% Ni; The balance is aluminum, incidental elements and impurities; wherein the aluminum alloy sheet product has a thickness of 0.4 to 4 mm; The aluminum alloy sheet product achieves at least one of the following: (i) not more than 50% by volume of recrystallized grains; (ii) an area percentage of Mg2Si of at least 0.5%; (iii) an average Mg2Si particle area of ​​at least 0.5 particles / μm2; (iv) a composition area percentage of at least 0.5%; and (v) an average constituent particle area of ​​at least 0.5 particles per square micron.

2. The aluminum alloy sheet product of claim 1, wherein the aluminum alloy sheet product comprises at least 1.10 wt. % Si, or at least 1.15 wt. % Si.

3. The aluminium alloy sheet product according to any one of the preceding claims, wherein the aluminium alloy sheet product comprises no more than 1.45 wt. % Si, or no more than 1.40 wt. % Si.

4. The aluminium alloy sheet product according to any one of the preceding claims, wherein the aluminium alloy sheet product comprises at least 0.90 wt. % Mg, or at least 0.95 wt. % Mg.

5. The aluminum alloy sheet product according to any one of the preceding claims, wherein the aluminum alloy sheet product comprises no more than 2.05 wt. % Mg, or no more than 2.00 wt. % Mg, or no more than 1.95 wt. % Mg, or no more than 1.90 wt. % Mg.

6. The aluminium alloy sheet product according to any one of the preceding claims, wherein the aluminium alloy sheet product comprises at least 0.20 wt. % Cu, or at least 0.25 wt. % Cu, or at least 0.30 wt. % Cu.

7. The aluminium alloy sheet product according to any one of the preceding claims, wherein the aluminium alloy sheet product comprises no more than 0.70 wt. % Cu, or no more than 0.65 wt. % Cu, or no more than 0.60 wt. % Cu.

8. The aluminium alloy sheet product according to any one of the preceding claims, wherein the aluminium alloy sheet product comprises at least 0.25 wt% Fe, or at least 0.30 wt% Fe.

9. The aluminium alloy sheet product according to any one of the preceding claims, wherein the aluminium alloy sheet product comprises no more than 0.85 wt % Fe, or no more than 0.80 wt % Fe, or no more than 0.75 wt % Fe.

10. The aluminum alloy sheet product of any one of the preceding claims, wherein the aluminum alloy sheet product comprises at least 0.55 wt. % Mn, or at least 0.60 wt. % Mn, or at least 0.65 wt. % Mn, or at least 0.70 wt. % Mn, or at least 0.75 wt. % Mn, or at least 0.80 wt. % Mn, or at least 0.85 wt. % Mn, or at least 0.90 wt. % Mn, or at least 0.95 wt. % Mn, or at least 1.0 wt. % Mn.

11. The aluminum alloy sheet product according to any one of the preceding claims, wherein the aluminum alloy sheet product comprises no more than 1.45 wt. % Mn, or no more than 1.40 wt. % Mn, or no more than 1.35 wt. % Mn, or no more than 1.30 wt. % Mn, or no more than 1.25 wt. % Mn, or no more than 1.20 wt. % Mn.

12. The aluminium alloy sheet product according to any one of the preceding claims, wherein the aluminium alloy sheet product comprises no more than 0.12 wt. % Ti, or no more than 0.10 wt. % Ti.

13. The aluminium alloy sheet product according to any one of the preceding claims, wherein the aluminium alloy sheet product comprises at least 0.02 wt. % Ti, or at least 0.05 wt. % Ti.

14. The aluminum alloy sheet product according to any one of the preceding claims, wherein the aluminum alloy sheet product comprises no more than 0.35 wt. % Zn, or no more than 0.30 wt. % Zn, or no more than 0.25 wt. % Zn, or no more than 0.20 wt. % Zn.

15. The aluminium alloy sheet product according to any one of the preceding claims, wherein the aluminium alloy sheet product comprises at least 0.01 wt. % Zn.

16. The aluminum alloy sheet product according to any one of the preceding claims, wherein the aluminum alloy sheet product comprises no more than 0.15 wt. % Zr, or no more than 0.10 wt. % Zr, or no more than 0.08 wt. % Zr, or no more than 0.05 wt. % Zr, or no more than 0.03 wt. % Zr.

17. The aluminium alloy sheet product according to any one of the preceding claims, wherein the aluminium alloy sheet product comprises at least 0.01 wt. % Zr.

18. The aluminum alloy sheet product according to any one of the preceding claims, wherein the aluminum alloy sheet product comprises no more than 0.15 wt. % V, or no more than 0.10 wt. % V, or no more than 0.08 wt. % V, or no more than 0.05 wt. % V, or no more than 0.03 wt. % V.

19. The aluminum alloy sheet product of claim 1, wherein the aluminum alloy sheet product comprises at least 0.01 wt. % V.

20. The aluminum alloy sheet product of any one of the preceding claims, wherein the aluminum alloy sheet product comprises no more than 0.18 wt. % Cr, or no more than 0.15 wt. % Cr, or no more than 0.12 wt. % Cr, or no more than 0.10 wt. % Cr, or no more than 0.08 wt. % Cr, or no more than 0.05 wt. % Cr, or no more than 0.03 wt. % Cr.

21. The aluminium alloy sheet product according to any one of the preceding claims, wherein the aluminium alloy sheet product comprises at least 0.01 wt. % Cr.

22. The aluminium alloy sheet product according to any one of the preceding claims, wherein the aluminium alloy sheet product comprises no more than 0.03 wt% Ni, or no more than 0.01 wt% Ni.

23. An aluminum alloy sheet product according to any one of the preceding claims, wherein the aluminum alloy sheet product achieves no more than 45 volume % recrystallized grains, or no more than 40 volume % recrystallized grains, or no more than 35 volume % recrystallized grains, or no more than 30 volume % recrystallized grains, or no more than 25 volume % recrystallized grains, or no more than 20 volume % recrystallized grains, or no more than 15 volume % recrystallized grains.

24. The aluminum alloy sheet product of any one of the preceding claims, wherein the aluminum alloy sheet product realizes an Mg2Si area percentage of at least 0.6%, or at least 0.7%, or at least 0.8%, or at least 0.9%, or at least 1.0%, or at least 1.1%, or at least 1.2%.

25. An aluminum alloy sheet product according to any one of the preceding claims, wherein the aluminum alloy sheet product achieves an average Mg2Si particle area of ​​at least 0.75 particles / square micron, or at least 1.0 particles / square micron, or at least 1.25 particles / square micron, or at least 1.5 particles / square micron, or at least 1.75 particles / square micron, or at least 2.0 particles / square micron, or at least 2.25 particles / square micron, or at least 2.5 particles / square micron, or at least 2.75 particles / square micron, or at least 3.0 particles / square micron, or at least 3.25 particles / square micron, or at least 3.5 particles / square micron.

26. An aluminum alloy sheet product according to any one of the preceding claims, wherein the aluminum alloy sheet product achieves a composition area percentage of at least 0.75%, or at least 1.0%, or at least 1.25%, or at least 1.5%, or at least 1.75%, or at least 2.0%, or at least 2.25%, or at least 2.50%, or at least 2.75%.

27. An aluminum alloy sheet product according to any one of the preceding claims, wherein the aluminum alloy sheet product achieves an average constituent particle area of ​​at least 0.75 particles / square micron, or at least 1.0 particles / square micron, or at least 1.25 particles / square micron, or at least 1.5 particles / square micron, or at least 1.75 particles / square micron, or at least 2.0 particles / square micron, or at least 2.25 particles / square micron, or at least 2.5 particles / square micron, or at least 2.75 particles / square micron, or at least 3.0 particles / square micron, or at least 3.25 particles / square micron, or at least 3.5 particles / square micron, or at least or at least 3.75 particles / square micron.

28. An aluminum alloy sheet product according to any one of the preceding claims, wherein the aluminum alloy sheet product achieves at least two of the following: (i) no more than 50 volume % recrystallized grains; (ii) an Mg2Si area percentage of at least 0.5%; (iii) an average Mg2Si particle area of ​​at least 0.5 particles / square micron; (iv) a constituent area percentage of at least 0.5%; and (v) an average constituent particle area of ​​at least 0.5 particles / square micron.

29. An aluminum alloy sheet product according to any one of the preceding claims, wherein the aluminum alloy sheet product achieves at least three of the following: (i) no more than 50 volume % recrystallized grains; (ii) an Mg2Si area percentage of at least 0.5%; (iii) an average Mg2Si particle area of ​​at least 0.5 particles / square micron; (iv) a constituent area percentage of at least 0.5%; and (v) an average constituent particle area of ​​at least 0.5 particles / square micron.

30. An aluminum alloy sheet product according to any one of the preceding claims, wherein the aluminum alloy sheet product achieves at least four of the following: (i) no more than 50 volume % recrystallized grains; (ii) an Mg2Si area percentage of at least 0.5%; (iii) an average Mg2Si particle area of ​​at least 0.5 particles / square micron; (iv) a constituent area percentage of at least 0.5%; and (v) an average constituent particle area of ​​at least 0.5 particles / square micron.

31. An aluminum alloy sheet product according to any of the preceding claims, wherein the aluminum alloy sheet product achieves all of the following: (i) no more than 50 volume % recrystallized grains; (ii) an Mg2Si area percentage of at least 0.5%; (iii) an average Mg2Si particle area of ​​at least 0.5 particles / square micron; (iv) a constituent area percentage of at least 0.5%; and (v) an average constituent particle area of ​​at least 0.5 particles / square micron.

32. The aluminum alloy sheet product of any one of the preceding claims, wherein the aluminum alloy sheet product realizes a longitudinal (L) tensile yield strength of at least 35 ksi, or at least 36 ksi, or at least 37 ksi, or at least 38 ksi, or at least 39 ksi, or at least 40 ksi.

33. The aluminum alloy sheet product according to any one of the preceding claims, wherein the aluminum alloy sheet product achieves a longitudinal (L) elongation of at least 3.0%, or at least 3.5%, or at least 4.0%, or at least 4.5%, or at least 5.0%.

34. The aluminum alloy sheet product of any one of the preceding claims, wherein the aluminum alloy sheet product achieves at least equivalent ASTM G85 corrosion resistance compared to a conventional AA3004 sheet product of equivalent specification.

35. A method of manufacturing an aluminum alloy sheet product, the method comprising: (a) producing an aluminum alloy ingot from aluminum-based scrap, wherein the producing comprises: (i) mixing a first aluminum scrap material with another aluminum material to obtain a target ingot composition, wherein the other aluminum material is at least one of (A) a second aluminum scrap material and (B) raw aluminum; (ii) before or after the mixing step, heating the first aluminium scrap material and the another aluminium material to produce a molten aluminium alloy; and (iii) casting the molten aluminum alloy into the aluminum alloy ingot, wherein the aluminum alloy ingot obtains the target ingot composition, wherein the target ingot composition is: 1.05 to 1.55 wt% Si; 0.85 to 2.10 wt. % Mg; 0.15 to 0.75 wt. % Cu; 0.20 to 0.90 wt.% Fe; 0.5 to 1.5 wt% Mn; 0.01 to 0.15 wt.% Ti; Up to 0.4 wt. % Zn; Up to 0.25 wt% of any one of Cr, Zr and V; and Up to 0.05 wt.% Ni; The balance is aluminum, incidental elements and impurities; and (b) processing the aluminum alloy ingot into an H-tempered sheet product having a thickness of 0.4 to 4.0 mm.

36. The method of claim 35, wherein processing the aluminum alloy ingot into an H-temper sheet product comprises cold rolling to final gauge and then partially annealing to achieve an H2 temper.

37. The method according to any one of claims 35-36, wherein the first aluminum scrap material is selected from the group consisting of brazing scrap, used beverage can (UBC) scrap, and mixtures thereof.

38. The method of claim 37, wherein the another aluminum material is primary aluminum.

39. The method of claim 37, wherein the another aluminum material is a second aluminum scrap material.

40. The method of claim 39, wherein the second aluminum scrap material comprises at least one of 3xxx, 4xxx, 5xxx, or 6xxx aluminum alloy scrap.

41. The method of claim 39, wherein the second aluminum scrap material comprises at least one of industrial or automotive scrap.

42. The method of any one of claims 35-41, wherein at least 30% of the ingot comprises the first aluminum scrap material, or at least 35% of the ingot comprises the first aluminum scrap material, or at least 40% of the ingot comprises the first aluminum scrap material, or at least 45% of the ingot comprises the first aluminum scrap material, or at least 50% of the ingot comprises the first aluminum scrap material, or at least 55% of the ingot comprises the first aluminum scrap material, or at least 60% of the ingot comprises the first aluminum scrap material, or at least 65% of the ingot comprises the first aluminum scrap material.

43. The method of any one of claims 35-41, wherein at least 50% of the ingot comprises the first aluminum scrap material and the second aluminum scrap material, or at least 55% of the ingot comprises the first aluminum scrap material and the second aluminum scrap material, or at least 60% of the ingot comprises the first aluminum scrap material and the second aluminum scrap material, or at least 65% of the ingot comprises the first aluminum scrap material and the second aluminum scrap material, or at least 70% of the ingot comprises the first aluminum scrap material and the second aluminum scrap material, or at least 75% of the ingot comprises the first aluminum scrap material and the second aluminum scrap material, or at least 80% of the ingot comprises the first aluminum scrap material and the second aluminum scrap material, or at least 85% of the ingot comprises the first aluminum scrap material and the second aluminum scrap material, or at least 90% of the ingot comprises the first aluminum scrap material and the second aluminum scrap material, or at least 94% of the ingot comprises the first aluminum scrap material and the second aluminum scrap material.

44. The method of any one of claims 35-43, wherein the H-tempered sheet product is neither solution heat treated nor artificially aged.

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