High recovery content aluminum alloys and methods of making and using same

Abstract

Aluminum alloys, metal products made using the aluminum alloys, and methods of processing the aluminum alloys are disclosed. The disclosed alloys can be prepared using a large amount of recovered aluminum alloy content, such as a recovered content or more of up to 100%. The disclosed aluminum alloys comprise more iron, manganese, chromium and / or silicon in amounts than similar aluminum alloys typically made by alloying primary aluminum. Further, the disclosed alloys include a ratio of the total amount of manganese and chromium to iron of greater than or about 0.60 or 0.70, which may at least in part contribute to desired bending, forming, and surface properties and characteristics of metal products made using the aluminum alloys. The disclosed alloys can be used to make automotive and structural panels, such that these products can be produced using high amounts of recovered aluminum alloy content.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of and priority to U.S. Provisional Application No. 63 / 375,093, filed on September 9, 2022, which is hereby incorporated by reference in its entirety. Technical Field

[0003] The present disclosure relates generally to metallurgy and, more particularly, to aluminum alloys having high recycled content. Background Art

[0004] High forming aluminum alloys are used in many different applications, particularly in applications requiring strength and durability. For example, 6xxx series aluminum alloys are widely used in automotive applications due to their excellent property combination (including strength to weight ratio, formability, weldability and general corrosion resistance). 6xxx series aluminum alloys are usually used in automotive structures and closed plate applications instead of steel. Since the density of aluminum alloys is usually about 2.8 times lower than that of steel, the use of such materials can reduce the weight of the vehicle and significantly improve its fuel economy. Even so, currently available aluminum alloys are still faced with certain challenges in automotive applications. Summary of the invention

[0005] The term embodiment and similar terms are intended to refer broadly to the subject matter of the present disclosure and the entirety of the following claims. Statements containing these terms should not be understood to limit the subject matter described herein, or to limit the meaning or scope of the following claims. The embodiments of the present disclosure covered herein are defined by the following claims rather than by this disclosure. This disclosure is a high-level overview of various aspects of the present disclosure and introduces some of the concepts further described in the following detailed description section. This disclosure is neither intended to identify the key or essential features of the claimed subject matter nor to be used independently to determine the scope of the claimed subject matter. The subject matter should be understood with reference to appropriate portions of the entire specification of the present disclosure, any or all drawings, and each claim.

[0006] Aluminum alloys and metal products produced using these aluminum alloys are described herein. In some aspects, a method for preparing a metal product is also described. In some instances, the aluminum alloy comprises Al and about 1 wt % to 1.5 wt % Si, up to about 0.35 wt % Fe, up to about 0.25 wt % Cu, about 0.05 wt % to 0.25 wt % Mn, about 0.2 wt % to 0.60 wt % Mg, up to about 0.10 wt % Cr, up to about 0.10 wt % Ni, up to about 0.20 wt % Zn, up to about 0.15 wt % Ti and up to about 0.20 wt % V. Aluminum may exist as the remainder in the aluminum alloy (e.g., an aluminum alloy in an amount other than any alloying elements and impurities). In some instances, the aluminum alloy comprises up to 0.05 wt % of any individual impurities and up to 0.25 wt % of all impurities. Optionally, certain elements in the aluminum alloy described herein are included with specific concentrations relative to other elements in the aluminum alloy. In some instances, the ratio of the total amount of Mn and Cr to the amount of Fe in the aluminum alloy is greater than or about 0.6 or greater than or about 0.7, such as 0.6 to 2.5, such as 0.6 to 0.65, 0.65 to 0.7, 0.7 to 0.75, 0.75 to 0.8, 0.8 to 0.9, 0.9 to 1.0, 1.0 to 1.1, 1.1 to 1.2, 1.2 to 1.3, 1.3 to 1.4, 1.4 to 1.5, 1.5 to 1.6, 1.6 to 1.7, 1.7 to 1.8, 1.8 to 1.9, 1.9 to 2.0, 2.0 to 2.1, 2.1 to 2.2, 2.2 to 2.3, 2.3 to 2.4, 2.4 to 2.5 or more. In some instances, the aluminum alloy comprises a 6xxx series aluminum alloy. Optionally, at least a portion of the aluminum alloy comprises recycled aluminum alloy content.

[0007] These concentrations and relationships between concentrations can provide the ability to include relatively high amounts of recycled aluminum alloy content in the disclosed aluminum alloys while still retaining useful and / or beneficial physical and mechanical properties in products generated using the aluminum alloys. In some examples, the aluminum alloys include up to 100% recycled aluminum alloy content (e.g., by weight). In some examples, the aluminum alloys include more than 20% recycled aluminum alloy content (e.g., by weight). Without limitation, the aluminum alloy may include 20% to 100% recycled aluminum alloy content (e.g., by weight), such as 20% to 25%, 25% to 30%, 30% to 35%, 35% to 40%, 40% to 45%, 45% to 50%, 50% to 55%, 55% to 60%, 60% to 65%, 65% to 70%, 70% to 75%, 75% to 80%, 80% to 85%, 85% to 90%, 90% to 95%, or 95% to 100%.

[0008] In some examples, the aluminum alloy may contain Si in an amount of about 1 wt % to 1.5 wt %. For example, Si may be 1.00 wt % to 1.01 wt %, 1.01 wt % to 1.02 wt %, 1.02 wt % to 1.03 wt %, 1.03 wt % to 1.04 wt %, 1.04 wt % to 1.05 wt %, 1.05 wt % to 1.06 wt %, 1.06 wt % to 1.07 wt %, 1.07 wt % to 1.08 wt %, 1.08 wt % to 1.09 wt %, 1.09 wt % to 1.10 wt %, 1.10 wt % to 1.11 wt %, 1.11 wt % to 1.12 wt %, 1.13 wt % to 1.14 wt %, 1.15 wt % to 1.16 wt %, 1.17 wt % to 1.18 wt %, 1.19 wt % to 1.20 wt %, 1.21 wt % to 1.22 wt %, 1.23 wt % to 1.24 wt %, 1.25 wt % to 1.26 wt %, 1.27 wt % to 1.28 wt %, 1.29 wt % to 1.30 wt %, 1.31 wt % to 1.32 wt %, 1.33 wt % to 1.34 wt %, 1.35 wt % to 1.36 wt %, 1.37 wt % to 1.38 wt %, 1.12 wt % to 1.13 wt %, 1.13 wt % to 1.14 wt %, 1.14 wt % to 1.15 wt %, 1.15 wt % to 1.16 wt %, 1.16 wt % to 1.17 wt %, 1.17 wt % to 1.18 wt %, 1.18 wt % to 1.19 wt %, 1.19 wt % to 1.20 wt %, 1.20 wt % to 1.21 wt %, 1.21 wt % to 1.22 wt %, 1.22 wt % to 1.23 wt %, 1.23 wt % to 1.24 wt %, 1.24 wt % to 1.26 wt %. %. 1.25 wt %, 1.25 wt % to 1.26 wt %, 1.26 wt % to 1.27 wt %, 1.27 wt % to 1.28 wt %, 1.28 wt % to 1.29 wt %, 1.29 wt % to 1.30 wt %, 1.30 wt % to 1.31 wt %, 1.31 wt % to 1.32 wt %, 1.32 wt % to 1.33 wt %, 1.33 wt % to 1.34 wt %, 1.34 wt % to 1.35 wt %, 1.36 wt % to 1.37 wt %, 1.37 wt % to 1.38 wt %, 1.39 wt % to 1.40 wt %, 1.41 wt % to 1.42 wt %, 1.43 wt % to 1.44 wt %, .38 wt % to 1.39 wt %, 1.39 wt % to 1.40 wt %, 1.40 wt % to 1.41 wt %, 1.41 wt % to 1.42 wt %, 1.42 wt % to 1.43 wt %, 1.43 wt % to 1.44 wt %, 1.44 wt % to 1.45 wt %, 1.45 wt % to 1.46 wt %, 1.46 wt % to 1.47 wt %, 1.47 wt % to 1.48 wt %, 1.48 wt % to 1.49 wt % or 1.49 wt % to 1.50 wt % is present in the aluminum alloy.

[0009] In some examples, the aluminum alloy may contain Fe in an amount up to about 0.35 wt % Fe. For example, Fe may be 0 wt % to 0.01 wt %, 0.01 wt % to 0.02 wt %, 0.02 wt % to 0.03 wt %, 0.03 wt % to 0.04 wt %, 0.04 wt % to 0.05 wt %, 0.05 wt % to 0.06 wt %, 0.06 wt % to 0.07 wt %, 0.07 wt % to 0.08 wt %, 0.08 wt % to 0.09 wt %, 0.10 wt % to 0.11 wt %, 0.11 wt % to 0.12 wt %, 0.13 wt % to 0.14 wt %, 0.15 wt % to 0.16 wt %, 0.17 wt % to 0.18 wt %, 0.19 wt % to 0.20 wt %, 0.21 wt % to 0.22 wt %, 0.23 wt % to 0.24 wt %, 0.25 wt % to 0.26 wt %, 0.27 wt % to 0.28 wt %, 0.29 wt % to 0.30 wt %, 0.31 wt % to 0.32 wt %, 9 wt%, 0.09 wt% to 0.10 wt%, 0.10 wt% to 0.11 wt%, 0.11 wt% to 0.12 wt%, 0.12 wt% to 0.13 wt%, 0.13 wt% to 0.14 wt%, 0.14 wt% to 0.15 wt%, 0.15 wt% to 0.16 wt%, 0.16 wt% to 0.17 wt%, 0.17 wt% to 0. %, 0.18 wt % to 0.19 wt %, 0.19 wt % to 0.20 wt %, 0.20 wt % to 0.21 wt %, 0.21 wt % to 0.22 wt %, 0.22 wt % to 0.23 wt %, 0.23 wt % to 0.24 wt %, 0.24 wt % to 0.25 wt %, 0.25 wt % to 0.26 wt %, 0.26 wt % to 0. %. 0.27 wt %, 0.27 wt % to 0.28 wt %, 0.28 wt % to 0.29 wt %, 0.29 wt % to 0.30 wt %, 0.30 wt % to 0.31 wt %, 0.31 wt % to 0.32 wt %, 0.32 wt % to 0.33 wt %, 0.33 wt % to 0.34 wt % or 0.34 wt % to 0.35 wt % is present in the aluminum alloy.

[0010] In some examples, the aluminum alloy may contain Cu in an amount of up to 0.25 wt%. For example, Cu may be 0 wt% to 0.01 wt%, 0.01 wt% to 0.02 wt%, 0.02 wt% to 0.03 wt%, 0.03 wt% to 0.04 wt%, 0.04 wt% to 0.05 wt%, 0.05 wt% to 0.06 wt%, 0.06 wt% to 0.07 wt%, 0.07 wt% to 0.08 wt%, 0.08 wt% to 0.09 wt%, 0.09 wt% to 0.10 wt%, 0.10 wt% to 0.11 wt%, 0.11 wt% to 0.12 wt%, 0.12 wt% to 0. %, 0.13 wt % to 0.14 wt %, 0.14 wt % to 0.15 wt %, 0.15 wt % to 0.16 wt %, 0.16 wt % to 0.17 wt %, 0.17 wt % to 0.18 wt %, 0.18 wt % to 0.19 wt %, 0.19 wt % to 0.20 wt %, 0.20 wt % to 0.21 wt %, 0.21 wt % to 0.22 wt %, 0.22 wt % to 0.23 wt %, 0.23 wt % to 0.24 wt %, or 0.24 wt % to 0.25 wt %. Cu may be optional.

[0011] In some examples, the aluminum alloy may contain Mn in an amount of about 0.05 wt % to 0.25 wt %. For example, Mn can be present in the aluminum alloy in an amount of 0.05 wt % to 0.06 wt %, 0.06 wt % to 0.07 wt %, 0.07 wt % to 0.08 wt %, 0.08 wt % to 0.09 wt %, 0.09 wt % to 0.10 wt %, 0.10 wt % to 0.11 wt %, 0.11 wt % to 0.12 wt %, 0.12 wt % to 0.13 wt %, 0.13 wt % to 0.14 wt %, 0.14 wt % to 0.15 wt %, 0.15 wt % to 0.16 wt %, 0.16 wt % to 0.17 wt %, 0.17 wt % to 0.18 wt %, 0.18 wt % to 0.19 wt %, or 0.19 wt % to 0.20 wt %.

[0012] In some examples, the aluminum alloy may contain Mg in an amount of about 0.2 wt % to 0.60 wt %. For example, Mg may be 0.20 wt % to 0.21 wt %, 0.21 wt % to 0.22 wt %, 0.22 wt % to 0.23 wt %, 0.23 wt % to 0.24 wt %, 0.24 wt % to 0.25 wt %, 0.25 wt % to 0.26 wt %, 0.26 wt % to 0.27 wt %, 0.27 wt % to 0.28 wt %, 0.28 wt % to 0.29 wt %, 0.29 wt % to 0.30 wt %, 0.31 wt % to 0.32 wt %, 0.33 wt % to 0.34 wt %, 0.35 wt % to 0.36 wt %, 0.37 wt % to 0.38 wt %, 0.39 wt % to 0.40 wt %, 0.41 wt % to 0.42 wt %, 0.43 wt % to 0.44 wt %, 0.45 wt % to 0.46 wt %, 0.47 wt % to 0.48 wt %, 0.49 wt % to 0.49 wt %, 0.50 wt % to 0.51 wt %, 0.52 wt % to 0.53 wt %, 0.54 wt % to 0.55 wt %, 0.56 wt % to 0.57 wt %, 0.58 wt % to 0.5 %, 0.30 wt % to 0.31 wt %, 0.31 wt % to 0.32 wt %, 0.32 wt % to 0.33 wt %, 0.33 wt % to 0.34 wt %, 0.34 wt % to 0.35 wt %, 0.35 wt % to 0.36 wt %, 0.36 wt % to 0.37 wt %, 0.37 wt % to 0.38 wt %, 0.38 wt % to 0.39 wt %, 0.39 wt % to 0.40 wt %, 0. 0.40 wt % to 0.41 wt %, 0.41 wt % to 0.42 wt %, 0.42 wt % to 0.43 wt %, 0.43 wt % to 0.44 wt %, 0.44 wt % to 0.45 wt %, 0.45 wt % to 0.46 wt %, 0.46 wt % to 0.47 wt %, 0.47 wt % to 0.48 wt %, 0.48 wt % to 0.49 wt %, 0.49 wt % to 0.50 wt %, 0.50 wt % to 0.51 wt %, 0.52 wt % to 0.53 wt %, 0.54 wt % to 0.55 wt %, 0.56 wt % to 0.57 wt %, 0.58 wt % to 0.59 wt %, 0.60 wt % to 0.61 wt %, 0.62 wt % to 0.63 wt %, 0.64 wt % to 0.65 wt %, % to 0.51 wt %, 0.51 wt % to 0.52 wt %, 0.52 wt % to 0.53 wt %, 0.53 wt % to 0.54 wt %, 0.54 wt % to 0.55 wt %, 0.55 wt % to 0.56 wt %, 0.56 wt % to 0.57 wt %, 0.57 wt % to 0.58 wt %, 0.58 wt % to 0.59 wt % or 0.59 wt % to 0.60 wt % is present in the aluminum alloy.

[0013] In some examples, the aluminum alloy may contain Cr in an amount of up to 0.10 wt %. For example, Cr may be present in the aluminum alloy in an amount of 0 wt % to 0.01 wt %, 0.01 wt % to 0.02 wt %, 0.02 wt % to 0.03 wt %, 0.03 wt % to 0.04 wt %, 0.04 wt % to 0.05 wt %, 0.05 wt % to 0.06 wt %, 0.06 wt % to 0.07 wt %, 0.07 wt % to 0.08 wt %, 0.08 wt % to 0.09 wt %, or 0.09 wt % to 0.10 wt %. Cr may be optional.

[0014] In some examples, the aluminum alloy may contain Ni in an amount of up to 0.10 wt % Ni. For example, Ni may be present in the aluminum alloy in an amount of 0 wt % to 0.01 wt %, 0.01 wt % to 0.02 wt %, 0.02 wt % to 0.03 wt %, 0.03 wt % to 0.04 wt %, 0.04 wt % to 0.05 wt %, 0.05 wt % to 0.06 wt %, 0.06 wt % to 0.07 wt %, 0.07 wt % to 0.08 wt %, 0.08 wt % to 0.09 wt %, or 0.09 wt % to 0.10 wt %. Ni may be optional.

[0015] In some examples, the aluminum alloy may contain Zn in an amount up to 0.20 wt %. For example, Zn may be present in an amount of 0 wt % to 0.01 wt %, 0.01 wt % to 0.02 wt %, 0.02 wt % to 0.03 wt %, 0.03 wt % to 0.04 wt %, 0.04 wt % to 0.05 wt %, 0.05 wt % to 0.06 wt %, 0.06 wt % to 0.07 wt %, 0.07 wt % to 0.08 wt %, 0.08 wt % to 0.09 wt %, 0.09 wt % to 0.10 wt %, 0. % , 0.16 wt % to 0.17 wt %, 0.17 wt % to 0.18 wt %, 0.18 wt % to 0.19 wt %, or 0.19 wt % to 0.20 wt % is present in the aluminum alloy. Zn may be optional.

[0016] In some examples, the aluminum alloy may contain Ti in an amount of up to 0.15 wt % Ti. For example, Ti can be present in the aluminum alloy in an amount of 0 wt % to 0.01 wt %, 0.01 wt % to 0.02 wt %, 0.02 wt % to 0.03 wt %, 0.03 wt % to 0.04 wt %, 0.04 wt % to 0.05 wt %, 0.05 wt % to 0.06 wt %, 0.06 wt % to 0.07 wt %, 0.07 wt % to 0.08 wt %, 0.08 wt % to 0.09 wt %, 0.09 wt % to 0.10 wt %, 0.10 wt % to 0.11 wt %, 0.11 wt % to 0.12 wt %, 0.12 wt % to 0.13 wt %, 0.13 wt % to 0.14 wt % or 0.14 wt % to 0.15 wt %. Ti can be optional.

[0017] In some examples, the aluminum alloy may contain V in an amount of up to 0.20 wt % V. For example, V may be present in the aluminum alloy in an amount of 0 wt % to 0.01 wt %, 0.01 wt % to 0.02 wt %, 0.02 wt % to 0.03 wt %, 0.03 wt % to 0.04 wt %, 0.04 wt % to 0.05 wt %, 0.05 wt % to 0.06 wt %, 0.06 wt % to 0.07 wt %, 0.07 wt % to 0.08 wt %, 0.08 wt % to 0.09 wt %, or 0.09 wt % to 0.10 wt %. V may be optional.

[0018] In some examples, Fe present in the aluminum alloy may combine with other elements to form Fe-containing intermetallic particles. For example, Fe may combine with other elements to form α-phase Fe-containing intermetallic particles and / or β-phase Fe-containing intermetallic particles. In some cases, it may be desirable to control the amount of different Fe-containing intermetallic particles or the ratio of the amounts of different Fe-containing intermetallic particles in the aluminum alloy or a metal product comprising the aluminum alloy. For example, in some cases, the aluminum alloy, a metal product made from or comprising the aluminum alloy, contains more α-phase Fe-containing intermetallic particles than β-phase Fe-containing intermetallic particles.

[0019] Also described herein are metal products, such as metal products comprising aluminum alloys such as those described herein. The disclosed metal products can be processed into any desired shape or form. In a specific example, the metal product comprises an automotive body product. The disclosed metal products can be made using any suitable processing method, wherein the aluminum alloy is processed using various processing steps to generate the metal product. In some cases, the metal product is a rolled metal product. Optionally, the metal product is a doubly recrystallized metal product. The metal product can exhibit suitable properties, such as mechanical or physical properties or characteristics, which can be beneficial to various end uses or implementations.

[0020] In some examples, the metal product exhibits isotropic strain characteristics. For example, the metal product may exhibit a Lankford ratio of about 0.6 or greater, such as 0.6 to 1.0, 0.60 to 0.65, 0.65 to 0.70, 0.70 to 0.75, 0.75 to 0.80, 0.80 to 0.85, 0.85 to 0.90, 0.90 to 0.95, or 0.95 to 1.0, in the longitudinal, transverse, and diagonal directions at about 10% strain. In some examples, the metal product exhibits a f15% bending coefficient of about 0.3 to 1.0, such as 0.3 to 0.4, 0.4 to 0.5, 0.5 to 0.6, 0.6 to 0.7, 0.7 to 0.8, 0.8 to 0.9, or 0.9 to 1.0 in the transverse direction. The f bending factor can be measured according to ASTM E290, where for a given pre-strain, f=r / t, r is the minimum radius of the bend at which no surface visible cracks are visible to the naked eye, and t is the thickness of the sheet after straining. For example, f15% is the bending factor after 15% pre-strain in the transverse direction. In some examples, the metal product exhibits an inner bend angle of about 10° to 60° after 10% pre-strain, such as 10° to 15°, 15° to 20°, 20° to 25°, 25° to 30°, 30° to 35°, 35° to 40°, 40° to 45°, 45° to 50°, 50° to 55°, or 55° to 60°. In some instances, the metal product exhibits a surface arithmetic mean height (Sa) of at most 0.60 μm, such as less than or about 0.10 μm, less than or about 0.15 μm, less than or about 0.20 μm, less than or about 0.25 μm, less than or about 0.30 μm, less than or about 0.35 μm, less than or about 0.40 μm, less than or about 0.45 μm, less than or about 0.50 μm, less than or about 0.55 μm, or less than or about 0.60 μm. In some examples, the metal product exhibits a yield strength of about 90 MPa to about 130 MPa in the T4 temper, such as 90 MPa to 95 MPa, 95 MPa to 100 MPa, 100 MPa to 105 MPa, 105 MPa to 110 MPa, 110 MPa to 115 MPa, 115 MPa to 120 MPa, 120 MPa to 125 MPa, or 125 MPa to 130 MPa. In some examples, the metal product exhibits a yield strength of about 200 MPa to about 235 MPa in the T6 temper, such as 200 MPa to 205 MPa, 205 MPa to 210 MPa, 210 MPa to 215 MPa, 215 MPa to 220 MPa, 220 MPa to 225 MPa, 225 MPa to 230 MPa, or 230 MPa to 235 MPa.In some examples, the metal product exhibits an ultimate tensile strength of about 195 MPa to about 270 MPa in the T4 temper, such as 195 MPa to 200 MPa, 200 MPa to 205 MPa, 205 MPa to 210 MPa, 210 MPa to 215 MPa, 215 MPa to 220 MPa, 220 MPa to 225 MPa, 225 MPa to 230 MPa, 230 MPa to 235 MPa, 235 MPa to 240 MPa, 240 MPa to 245 MPa, 245 MPa to 250 MPa, 250 MPa to 255 MPa, 255 MPa to 260 MPa, 260 MPa to 265 MPa, or from 265 MPa to 270 MPa. In some examples, the metal product exhibits an ultimate tensile strength of about 240 MPa to about 300 MPa in the T6 temper, such as 240 MPa to 245 MPa, 245 MPa to 250 MPa, 250 MPa to 255 MPa, 255 MPa to 260 MPa, 260 MPa to 265 MPa, 265 MPa to 270 MPa, 270 MPa to 275 MPa, 275 MPa to 280 MPa, 280 MPa to 285 MPa, 285 MPa to 290 MPa, 290 MPa to 295 MPa, or 295 MPa to 300 MPa. In some examples, the metal product exhibits a uniform elongation of 20% to 30% in the T4 temper, such as 20% to 21%, 21% to 22%, 22% to 23%, 23% to 24%, 24% to 25%, 25% to 26%, 26% to 27%, 27% to 28%, 28% to 29%, or 29% to 30%. In some examples, the metal product exhibits a uniform elongation of 10% to 20% in the T6 temper, such as 10% to 11%, 11% to 12%, 12% to 13%, 13% to 14%, 14% to 15%, 15% to 16%, 16% to 17%, 17% to 18%, 18% to 19%, or 19% to 20%.

[0021] In one aspect, methods are also described herein, such as methods of processing aluminum alloys and methods of producing metal products. In some examples, the methods of this aspect include casting an aluminum alloy to produce a cast product, such as the aluminum alloy described herein; homogenizing the cast product to produce a homogenized product; hot rolling the homogenized product to produce a rolled product; and subjecting the rolled product to a final cold rolling process product to produce a metal product. Optionally, the outlet temperature of the hot rolling does not exceed 400°C. Optionally, the hot rolling achieves a thickness reduction of 90% or more between the homogenized product and the rolled product.

[0022] Optionally, the method of this aspect further comprises, after hot rolling, subjecting the rolled product to a recrystallization process to produce a recrystallized product, such as wherein the final cold rolling process comprises cold rolling the recrystallized product to produce a metal product. Optionally, in some example methods, the recrystallization process occurs between the hot rolling and the final cold rolling process. Optionally, the method of this aspect comprises, after hot rolling and before the recrystallization process, subjecting the rolled product to a preliminary cold rolling process, wherein the recrystallization process occurs between the preliminary cold rolling process and the final cold rolling process.

[0023] In some examples, the recrystallization process includes annealing the rolled product at a peak metal temperature of 325° C. to 425° C. for up to 1 minute to produce a recrystallized product; and quenching the recrystallized product. Further details of the recrystallization process and related methods that can be used for the aluminum alloys described herein are described in U.S. Provisional Application No. 63 / 261,042, filed on September 9, 2021, which is hereby incorporated by reference in its entirety.

[0024] Optionally, the method of this aspect further comprises subjecting the metal product to a solutionizing process to produce a solutionized metal product. Optionally, the method of this aspect further comprises subjecting the metal product to an aging or artificial aging process to produce an aged metal product. The disclosed aluminum alloys may optionally be processed using additional processing steps to produce the metal product.

[0025] Other objects and advantages will become apparent from the following detailed description given by way of non-limiting example. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The description makes reference to the following drawings, in which the use of like reference numerals in different drawings is intended to describe like or similar components.

[0027] Figure 1 A schematic diagram of an example process for producing a rolled aluminum alloy product is provided.

[0028] Figure 2 A schematic diagram of a process for preparing an aluminum alloy article is provided.

[0029] Figure 3 The measured grain size characteristics of various aluminum alloy samples are shown.

[0030] Figure 4 The measured textural features of various aluminum alloy samples are shown.

[0031] Figure 5 The measured yield strengths of various aluminum alloy samples are shown.

[0032] Figure 6 The measured ultimate tensile strengths of various aluminum alloy samples are shown.

[0033] Figure 7 The uniform elongation measured for various aluminum alloy samples is shown.

[0034] Figure 8 The total elongation measured for various aluminum alloy samples is shown.

[0035] Fig. 9 The strain hardening exponents of various aluminum alloy samples at 5% strain were measured.

[0036] Fig.10 Shown are the strain hardening exponents measured for various aluminum alloy samples at 10-20% strain. DETAILED DESCRIPTION

[0037] Aluminum alloys, metal products made using the aluminum alloys, and methods of processing the aluminum alloys are described herein. The disclosed alloys can be prepared using a large amount of recycled aluminum alloy content, such as up to 100% recycled content. The disclosed aluminum alloys contain more iron, manganese, chromium, and / or silicon than a comparable aluminum alloy typically made by alloying raw aluminum. In addition, the disclosed alloys contain a ratio of the total amount of manganese and chromium to iron greater than or about 0.70, which can at least partially contribute to the desired bending, forming, and surface properties and characteristics of the metal products made using the aluminum alloys. The disclosed alloys can be used to prepare automotive and structural panels so that these products can be produced using a large amount of recycled aluminum alloy content.

[0038] The aluminum alloy for recycling may contain a mixture of various aluminum alloys or unknown amounts of various aluminum alloys. In some cases, contaminants may also be present in the aluminum alloy for recycling. For example, the aluminum alloy for recycling may correspond to a scrap aluminum source, such as scrap automotive aluminum or an industrial scrap source, such as remelted scrap ingots (RSI), extruded profiles, aluminum sheets, brazing scrap, and casting alloy scrap.

[0039] By increasing the amount of recycled aluminum content that can be included in the aluminum alloys described herein, while still retaining good physical and mechanical properties so that the aluminum alloys can be used as metal products for specific applications (e.g., as vehicle bodies or structural panels), the energy requirements and carbon footprint for producing metal products can be significantly reduced. As an example, the alloys and processing techniques described herein can be used to produce aluminum alloy sheet metal or other metal products having desired bending characteristics, strength characteristics, forming characteristics (e.g., isotropic forming properties), etc.

[0040] Alloys referred to as AA6016 are often used in automotive or structural applications. However, generally speaking, AA6016 is not made using large amounts of recycled aluminum. For example, the element limits for certain elements (e.g., Fe) in AA6016 are generally lower than the element limits commonly found in recycled aluminum alloy materials. In other words, adding a certain amount of recycled aluminum content to an aluminum alloy destined to become AA6016 may require the use of a large amount of original aluminum to ensure that certain elements (e.g., Fe) included do not exceed the limits defined by the AA6016 name. Therefore, when an aluminum alloy contains a large amount of recycled aluminum content, its name may be different from AA6016. When this alloy is processed according to common techniques for making products using AA6016, the resulting product may have different mechanical and physical characteristics than products made using AA6016.

[0041] However, the alloys described herein overcome these challenges by including certain elements (e.g., iron, manganese, chromium, and / or silicon) in specific amounts and / or ratios, while still retaining beneficial properties. In addition, by carefully controlling the ratios of certain elements (e.g., the ratio of the total amount of manganese and chromium to iron), desired properties (e.g., mechanical properties or physical properties) can be achieved in aluminum alloy products. In addition, specific processing schemes, such as a scheme that employs a rapid low temperature annealing process before cold rolling or between cold rolling steps, can be used to impart desired properties (e.g., bending properties, forming properties, strength properties, and / or surface characteristics) to the resulting aluminum alloy product.

[0042] Definition and Description:

[0043] As used herein, the terms "invention," "the invention," "this invention," and "present invention" are intended to broadly refer to all subject matter of this patent application and the appended claims. Statements containing these terms should not be construed as limiting the subject matter described herein, or limiting the meaning or scope of the following patent claims.

[0044] In this specification, reference is made to alloys identified by AA numbers and other related designations such as "Series" or "7xxx". To understand the number designation system most commonly used to name and identify aluminum and its alloys, see "International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys" or "Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot", both published by the Aluminum Association.

[0045] As used herein, the thickness of a plate is generally greater than about 15 mm. For example, a plate may refer to an aluminum product having a thickness greater than about 15 mm, greater than about 20 mm, greater than about 25 mm, greater than about 30 mm, greater than about 35 mm, greater than about 40 mm, greater than about 45 mm, greater than about 50 mm, or greater than about 100 mm.

[0046] As used herein, the thickness of the Saudi board (also referred to as a sheet board) is generally about 4 mm to about 15 mm. For example, the thickness of the Saudi board can be about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm or about 15 mm.

[0047] As used herein, thin plate generally refers to an aluminum product having a thickness of less than about 4 mm. For example, the thickness of the thin plate may be less than about 4 mm, less than about 3 mm, less than about 2 mm, less than about 1 mm, less than about 0.5 mm, or less than about 0.3 mm (e.g., about 0.2 mm).

[0048] Reference may be made to alloy tempering or states in this application. To understand the most commonly used alloy state descriptions, please refer to "American National Standards (ANSI) H35 on Alloy and Temper Designation Systems". The F condition or state refers to a manufactured aluminum alloy. The O condition or state refers to an aluminum alloy after annealing. The Hxx condition or state (also referred to herein as the H state) refers to a non-heat-treatable aluminum alloy that has been subjected to or not subjected to heat treatment (e.g., annealing) after cold rolling. Suitable H states include HX1, HX2, HX3, HX4, HX5, HX6, HX7, HX8 or HX9 states. The T1 condition or state refers to an aluminum alloy that has been cooled from hot working and subjected to natural aging treatment (e.g., at room temperature). The T2 condition or state refers to an aluminum alloy that has been cooled from hot working, cold worked, and subjected to natural aging treatment. The T3 condition or state refers to an aluminum alloy that has been subjected to solution heat treatment, cold working, and natural aging treatment. The T4 condition or state refers to an aluminum alloy that has been subjected to solution heat treatment and natural aging treatment. The T5 condition or state refers to aluminum alloys that have been cooled from hot working and artificially aged (at elevated temperatures). The T6 condition or state refers to aluminum alloys that have been solution heat treated and artificially aged. The T7 condition or state refers to aluminum alloys that have been solution heat treated and artificially aged. The T8x condition or state refers to aluminum alloys that have been solution heat treated, cold worked, and artificially aged. The T9 condition or state refers to aluminum alloys that have been solution heat treated, artificially aged, and cold worked. The W condition or state refers to aluminum alloys that have been solution heat treated.

[0049] As used herein, terms such as "cast metal product", "cast product", "cast aluminum alloy product" and the like are interchangeable and refer to products produced by direct chill casting (including direct chill co-casting) or semi-continuous casting, continuous casting (including, for example, by using a twin-belt caster, a twin-roll caster, a block caster or any other continuous casting machine), electromagnetic casting, hot top casting or any other casting method.

[0050] As used herein, "room temperature" may include a temperature from about 15° C. to about 30° C., such as about 15° C., about 16° C., about 17° C., about 18° C., about 19° C., about 20° C., about 21° C., about 22° C., about 23° C., about 24° C., about 25° C., about 26° C., about 27° C., about 28° C., about 29° C., or about 30° C. As used herein, "ambient conditions" may include a temperature of approximately room temperature, a relative humidity of about 20% to about 100%, and an atmospheric pressure of about 975 millibars (mbar) to about 1050 mbar. For example, the relative humidity can be about 20%, about 21%, about 22%, about 23%, about 24%, about 25%, about 26%, about 27%, about 28%, about 29%, about 30%, about 31%, about 32%, about 33%, about 34%, about 35%, about 36%, about 37%, about 38%, about 39%, about 40%, about 41%, about 42%, about 43%, about 44%, about 45%, about 46%, about 47%, about 48%, about 49%, about 50%, about 51%, about 52%, about 53%, about 54%, about 55%, about 56%, about 57%, about 58%, about 59%, about 60%, about 61%, about 62%, about 63%, about 64%, about 65%, about 66%, about 67%, about 68%, about 69%, about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84%, about 85%, about 86%, about 87%, about 88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about 98%, about 99%, about 100%, about 101%, about 102%, about 103%, about 104%, about 105%, about 106%, about 107%, about 108%, about 109%, about 110%, about 111%, about 112%, about 113%, about 114%, about 115%, about 116%, about 87%, about 88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about 98%, about 99%, about 100%, about 100%, about 101%, about 102%, about 103%, about 104%, about 105%, about 106%, about 107%, about 108%, about 109%, about 110%, about 111%, about 112%, about 113%, about 114%, about 115%, about 116%, about 117%, about 118%, about 119%, about 120%, about 121%, about 122%, about 123%, about 124%, about 125%, about 126%, about 127%, about 128%, about 129%, about 130%, about 131%, about 132%, about 133%, about 134%, about 135%, about 136%, about 137%, about 138%, about 139%, about 140%, about 141%, about 142%, about 143%, about 144%, about 145%, about 146%, about 147%, about 148%, about 149%, about 150%, about For example, the atmospheric pressure may be about 975 mbar, about 980 mbar, about 985 mbar, about 990 mbar, about 995 mbar, about 1000 mbar, about 1005 mbar, about 1010 mbar, about 1015 mbar, about 1020 mbar, about 1025 mbar, about 1030 mbar, about 1035 mbar, about 1040 mbar, about 1045 mbar, about 1050 mbar, or any value therebetween.

[0051] All ranges disclosed herein should be understood to encompass any and all subranges included therein. For example, a specified range of "1 to 10" should be considered to include any and all subranges between a minimum of 1 and a maximum of 10 (and including 1 and 10); that is, all subranges start with a minimum of 1 or greater (e.g., 1 to 6.1) and end with a maximum of 10 or less (e.g., 5.5 to 10). Unless otherwise stated, when referring to the composition amount of an element, the expression "at most" means that the element is optional and includes zero percent composition of the particular element. Unless otherwise stated, all composition percentages are weight percent (wt%).

[0052] As used herein, "a," "an," and "the" include both singular and plural references unless the context clearly dictates otherwise.

[0053] In this disclosure, aluminum alloy products and their components may be described according to their elemental composition expressed as weight percent (wt %). In each alloy, the remainder is aluminum, with a maximum wt % of the sum of all impurities of 0.15% or 0.25%.

[0054] Incidental elements, such as grain refiners and deoxidizers, or other additives may be present in the disclosed alloys and may themselves add other characteristics without departing from or significantly altering the alloys described herein or the characteristics of the alloys described herein.

[0055] Small amounts of unavoidable impurities, including materials or elements, may be present in the alloy due to the inherent properties of aluminum or leaching when in contact with processing equipment. Some alloys as described may contain no more than about 0.15 wt % or 0.25 wt % of any element in addition to alloying elements, incidental elements, and unavoidable impurities.

[0056] Methods for producing and preparing alloys and aluminum alloy products

[0057] The aluminum alloy products described herein can be prepared using suitable methods. For example, the aluminum alloy can be cast, homogenized or hot rolled using a break-down mill and a tandem mill, or can be hot rolled, cold rolled, heat treated, formed, etc. using only a break-down mill to produce the aluminum alloy product.

[0058] Figure 1 An overview of example methods of making aluminum alloy products is provided. Figure 1The method begins at 105, where an aluminum alloy 106 is cast to form a cast aluminum alloy product 107, such as an ingot or other cast product. At 110, the cast aluminum alloy product 107 is homogenized to form a homogenized aluminum alloy product 111. At 115, the homogenized aluminum alloy product 111 is subjected to one or more hot rolling passes and / or one or more cold rolling passes to form a rolled aluminum alloy product 112, which may correspond to an aluminum alloy article, such as an aluminum alloy plate, an aluminum alloy slat, or an aluminum alloy sheet. Optionally, the rolled aluminum alloy product 112 is subjected to additional processing steps as described below to form an aluminum alloy article.

[0059] The alloys described herein can be cast using any suitable casting method known to those of ordinary skill in the art. As a few non-limiting examples, the casting process can include a direct cooling casting (DC) casting process, a melt casting process, or a continuous casting (CC) process. For example, Figure 1 A schematic diagram of a DC casting process is depicted at 105, but other casting processes may be used. A continuous casting system may include a pair of moving opposing casting surfaces (e.g., moving opposing belts, rollers, or blocks), a casting cavity between the pair of moving opposing casting surfaces, and a molten metal injector. The molten metal injector may have an end opening from which the molten metal may exit the molten metal injector and be injected into the casting cavity.

[0060] Cast aluminum alloy products such as ingots, billets or other cast products can be processed by suitable techniques described herein. Optionally, the processing steps can be used to produce rolled aluminum alloy products, such as aluminum alloy sheets. Exemplary optional processing steps include, but are not limited to, homogenization, hot rolling, cold rolling, annealing, solution heat treatment, and pre-aging.

[0061] In the homogenization step, the cast aluminum alloy product is homogenized to form a homogenized aluminum alloy product. During the homogenization period, the cast product can be heated to a temperature in the range of about 400°C to about 565°C. For example, the cast product can be heated to about 400°C, about 410°C, about 420°C, about 430°C, about 440°C, about 450°C, about 460°C, about 470°C, about 480°C, about 490°C, about 500°C, about 510°C, about 520°C, about 530°C or about 540°C, up to 565°C. Then the product can be allowed to be homogenized (i.e., maintained at a specified temperature) for a period of time to form a homogenized product. In some instances, the total time of the homogenization step (including the heating stage and the soaking stage) can be up to 72 hours. For example, in a homogenization step with a total time of up to 18 hours, the product can be heated to up to 500°C to 565°C and soaked. Optionally, in a homogenization step with a total time of more than 18 hours, the product may be heated to less than 490°C and homogenized. In some cases, the homogenization step includes multiple processes. In some non-limiting examples, the homogenization step includes heating the cast product to a first temperature for a first time period, and then heating to a second temperature for a second time period. For example, the cast product may be heated to about 465°C for about 3.5 hours, and then heated to about 480°C for about 6 hours. In some cases, the homogenization process and the casting process are combined as in-situ homogenization casting.

[0062] The homogenized aluminum alloy product is subjected to one or more roll bonding passes and / or one or more hot rolling passes to form a rolled aluminum alloy product, which may correspond to an aluminum alloy product, such as an aluminum alloy plate, an aluminum alloy saturated plate, or an aluminum alloy sheet. The roll bonding process can be performed in different ways. For example, the roll bonding process may include both hot rolling and cold rolling. In addition, the roll bonding process may be a one-step process or a multi-step process, wherein the material is reduced in size during the continuous rolling steps. The individual rolling steps may optionally be separated by other processing steps, including, for example, annealing steps, cleaning steps, heating steps, cooling steps, etc.

[0063] Before starting hot rolling, the homogenized product may be cooled to a temperature between 380° C. and 450° C. For example, the homogenized product may be cooled to a temperature between 400° C. and 425° C. The homogenized product may then be hot rolled at a temperature between 250° C. and 450° C. to form a hot rolled plate, hot rolled Saudi plate or hot rolled sheet having a gauge between 2 mm and 200 mm, for example, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm or any value therebetween.

[0064] Optionally, the cast product can be a continuous casting product, which can be cooled to a temperature between 300°C and 535°C. For example, the continuous casting product can be cooled to a temperature between 325°C and 510°C, 350°C and 485°C, 375°C and 460°C, or 400°C and 435°C. Then, the continuous casting product can be hot rolled at a temperature between 300°C and 450°C, for example, to form a hot rolled plate, hot rolled Saudi plate, or hot rolled sheet having a specification between 3mm and 25mm (for example, 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, 9mm, 10mm, 15mm, 20mm, 25mm, or any value therebetween). During hot rolling, the temperature and other operating parameters can be controlled so that the temperature of the hot rolled intermediate product when leaving the hot rolling mill does not exceed 470°C, 450°C, 440°C, or 430°C.

[0065] Cast products, homogenized products or hot rolled products can be subjected to a break down process or a break down and tandem process. Optionally, a cold rolling process can be used after a hot rolling process, a break down process and or a break down and tandem process. The cold rolling process can use a cold rolling mill to cold roll an aluminum product into a thinner product, such as a cold rolled sheet. The cold rolled product can have a specification between about 0.1mm and 7mm (e.g., between about 0.7mm and 6.5mm). Optionally, the cold rolled product can have a specification of 0.5mm, 1.0mm, 1.5mm, 2.0mm, 2.5mm, 3.0mm, 3.5mm, 4.0mm, 4.5mm, 5.0mm, 5.5mm, 6.0mm, 6.5mm, 7.0mm. Cold rolling may be performed to result in a final gauge thickness that represents a gauge reduction of up to 95% compared to the gauge before cold rolling commenced (e.g., up to 10%, up to 20%, up to 30%, up to 40%, up to 50%, up to 55%, up to 60%, up to 70%, up to 75%, up to 80%, or up to 85%, or up to 90%, up to 95%, or up to 99% reduction).

[0066] After the cold rolling process, an intermediate annealing process may be optionally used. In some cases, the product after the hot rolling process, the decomposition process and / or the decomposition / tandem process is subjected to an intermediate annealing process. The intermediate annealing process may be any suitable treatment that causes at least partial recrystallization to generate a recrystallized aluminum product. The intermediate annealing process may include subjecting an unrecrystallized aluminum product (e.g., a hot rolled product or a cold rolled product) to a heat treatment at a predetermined temperature of less than or equal to 495°C for a time length of less than or equal to 25 minutes to generate a recrystallized aluminum product. For example, as part of the intermediate annealing process, the cast product, the homogenized product, the hot rolled product, or the cold rolled product may be heated to a temperature of up to 495°C and for a time length of up to 25 minutes. In some examples, the temperature may be from about 300°C to about 495°C, such as 300°C to 305°C, 305°C to 310°C, 310°C to 315°C, 315°C to 320°C, 320°C to 325°C, 325°C to 330°C, 330°C to 335°C, 335°C to 340°C, 340°C to 345°C, 345°C to 350°C, 350°C to 355°C, 355°C to 360°C, 360°C to 365°C, 365°C to 370°C, 370°C to 375°C, 375°C to 380°C, 380°C to 385°C, 385°C to 390°C, 390°C to 395°C. ℃, 395℃ to 400℃, 400℃ to 405℃, 405℃ to 410℃, 410℃ to 415℃, 415℃ to 420℃, 420℃ to 425℃, 425℃ to 430℃, 430℃ to 435℃, 435℃ to 440℃, 440℃ to 445℃, 445℃ to 450℃, 450℃ to 455℃, 455℃ to 460℃, 460℃ to 465℃, 465℃ to 470℃, 470℃ to 475℃, 475℃ to 480℃, 480℃ to 485℃, 485℃ to 490℃, 490℃ to 495℃, or 490℃ to 495℃. In some examples, the temperature may be 320° C. to 495° C., 340° C. to 485° C., 350° C. to 475° C., or 370° C. to 475° C. Any suitable ramp rate may be used to heat to and / or cool from a given temperature. In some examples, the product is heated to the temperature for a period of time from about 0.1 seconds to about 25 minutes, such as 0.1 seconds to 0.5 seconds, 0.5 seconds to 1 second, 1 second to 2 seconds, 2 seconds to 3 seconds, 3 seconds to 4 seconds, 4 seconds to 5 seconds, 5 seconds to 10 seconds, 10 seconds to 15 seconds, 15 seconds to 30 seconds, 30 seconds to 45 seconds, 45 seconds to 60 seconds, 60 seconds to 75 seconds, 75 seconds to 90 seconds, 90 seconds to 105 seconds, 105 seconds to 2 minutes, 2 minutes to 3 minutes, 3 minutes to 4 minutes, 4 minutes to 5 minutes, 5 minutes to 10 minutes, 10 minutes to 15 minutes, 15 minutes to 20 minutes, or 20 minutes to 25 minutes.In some cases, this may indicate that the temperature is maintained at or about a specified temperature for a certain length of time, or within 5°C or 10°C of a specified temperature. In some instances, a temperature or temperature range may be paired with a specific length of time or time range. For example, the temperature may be 340°C to 485°C for a length of time less than or equal to 10 minutes, the temperature may be 350°C to 475°C for a length of time less than 1 minute, or the temperature may be 370°C to 475°C for a length of time of 2 seconds to 35 seconds. Any variation or combination of the above temperatures and lengths of time may be used, and certain alloys or final product configurations may benefit from a specific temperature and length of time combination or a range of specific temperatures and lengths of time.

[0067] The intermediate annealing process may include subjecting the cast product, homogenized product or rolled product to a temperature of about 10 m / min to about 150 m / min, such as 10 m / min to 15 m / min, 15 m / min to 20 m / min, 20 m / min to 25 m / min, 25 m / min to 30 m / min, 30 m / min to 40 m / min, 40 m / min to 45 m / min, 45 m / min to 50 m / min, 50 m / min to 60 m / min, m / min, 60m / min to 70m / min, 70m / min to 80m / min, 80m / min to 90m / min, 90m / min to 100m / min, 100m / min to 110m / min, 110m / min to 120m / min, 120m / min to 130m / min, 130m / min to 140m / min, or 140m / min to 150m / min. In some cases, the intermediate annealing process may include heating the product by passing the cast product, homogenized product or rolled product through a gas-fired furnace. In some cases, the intermediate annealing process may include or use a magnetic heating unit with a heating rate of 10°C / s to 150°C / s. Optionally, the intermediate annealing process may include or use a quenching process (e.g., water quenching or air quenching) with a cooling rate of 5°C / s to 150°C / s or higher to return the product to ambient temperature or room temperature. Cold rolling the product after the intermediate annealing process can produce a non-recrystallized aluminum product with deformed grains. Cold rolling can be performed to produce a final gauge thickness that represents a gauge reduction of 25% to 99% compared to the gauge before cold rolling (e.g., 25% to 30%, 30% to 35%, 35% to 40%, 40% to 45%, 45% to 50%, 50% to 55%, 55% to 60%, 60% to 65%, 65% to 70%, 70% to 75%, 75% to 80%, 80% to 85%, 85% to 90%, 90% to 95%, or 95% to 99% reduction). In some specific examples, the cold rolling process can achieve a cold reduction of 55% to 75%, 25% to 90%, 45% to 95%, or 60% to 99%.

[0068] Subsequently, the product may optionally be subjected to one or more solution heat treatment steps. The solution heat treatment step may be any treatment suitable for a metal product that results in solubilization of soluble particles. For example, the product may be heated to a peak metal temperature (PMT) of up to 590°C (e.g., 400°C to 590°C) and soaked for a period of time at the PMT to form a hot product. For example, the product may be soaked at 480°C for a soaking time of up to 30 minutes (e.g., 0 seconds, 60 seconds, 75 seconds, 90 seconds, 5 minutes, 10 minutes, 20 minutes, 25 minutes, or 30 minutes). After heating and soaking, the hot product is rapidly cooled to a temperature between 500°C and room temperature at a rate greater than 90°C / s to form a heat-treated product.

[0069] After quenching, the heat-treated product may optionally undergo a pre-aging treatment by reheating before coiling. The pre-aging treatment may be performed at a temperature of about 50°C to about 125°C for a period of up to 6 hours. For example, the pre-aging treatment may be performed at a temperature of about 50°C, about 55°C, about 60°C, about 65°C, about 70°C, about 75°C, about 80°C, about 85°C, about 90°C, about 95°C, about 100°C, about 105°C, about 110°C, about 115°C, about 120°C, or about 125°C. Optionally, the pre-aging treatment may be performed for about 30 minutes, about 1 hour, about 2 hours, about 3 hours, about 4 hours, about 5 hours, or about 6 hours. The pre-aging treatment may be performed by passing the heat-treated product through a heating device, such as a device that emits radiant heat, convection heat, induction heat, infrared heat, etc.

[0070] Figure 2 A graph is provided showing example temperatures of a cast metal product during various stages of a manufacturing process according to various aspects of the present disclosure. As part of the initial casting stage 205, in which molten metal is formed into an ingot, cast article, or other solid object or metal product, the molten metal can be cooled and / or solidified by a process involving quenching or cooling the metal by exposing the metal to water or an aqueous solution, such as in a direct chill casting process or in a continuous casting process that includes quenching immediately after casting.

[0071] After the casting stage 205, the metal product may be subjected to a homogenization process 210, wherein the metal is heated to a temperature below the melting temperature or solidus temperature of the metal. Optionally, the metal product is heated to a temperature at which the base metal and any alloying elements form a solid solution.

[0072] After the homogenization process 210, the metal product may be exposed to one or more processes that may, for example, form a desired microcrystalline structure within the metal product while elongating the metal product. Such processes may correspond to, for example, hot rolling 215 and / or cold rolling 220, for example, such as to form a slat, plate, or sheet from a metal ingot or other cast article or metal product.

[0073] In some embodiments, exposing a metal product at an elevated temperature to a solution, such as water, an aqueous solution, or a gas, a gas mixture, or a vapor phase solution, during a quenching or cooling process can be used to reduce the temperature of the metal product to a desired or usable temperature for subsequent processing. For example, exposing the metal product to water or an aqueous solution can be used to cool the metal product between the hot rolling process 215 and subsequent processing. Figure 2 , but may be carried out at any temperature suitable for such a process.

[0074] After the hot rolling process 215 and / or the cold rolling process 220 (the cold rolling process 220 may be optional), the metal product may be subjected to an intermediate annealing heat treatment process 225, wherein the metal product is heated to and maintained at a predetermined temperature for a period of time less than or equal to one hour to produce at least partial recrystallization of the metal product. The metal product may be subjected to an additional cold rolling process 230 optionally after the intermediate annealing heat treatment process 225. Various peak temperatures may be used for the intermediate annealing heat treatment process 225, such as Figure 2 As shown, for example, it may depend on the particular alloy of the metal product and / or the particular mechanical or physical properties desired in the final product.

[0075] The metal product may then be subjected to a solution heat treatment process 235, wherein the temperature of the metal product is raised to a temperature above a threshold temperature, such as a temperature at which precipitated components in the metal product dissolve into a solid solution or a temperature at which a recrystallization process occurs, and maintained at or above the threshold temperature for a period of time. At the end of the solution heat treatment process 235, the metal product may be subjected to a quenching process 240, wherein the dissolved components are fixed in place by rapidly reducing the temperature of the metal by a quenching process. Such a quenching process 240 may involve exposing the metal product to a solution, such as a quenching solution comprising water, an aqueous solution, or a gas or a mixture of gases.

[0076] In an implementation scheme, Figure 2The processes outlined in can be performed discretely or as part of one or more continuous processing lines, wherein the metal product can be transported between processing stages in the form of a coil, film, or web of material. For example, the metal product can be transported between stages by rolling the metal product on or between one or more rollers (which can be under tension) or by transporting the metal product on one or more conveyors. Additionally, other stages not explicitly identified may be included in Figure 2 Before, between and / or after any stage identified in. Other example stages include, but are not limited to, a series connection and / or decomposition stage, a washing stage, a chemical treatment stage, or a finishing stage. As an example, the finishing stage may correspond to a surface anodizing stage, a powder coating stage, a painting stage, a printing stage, etc.

[0077] Methods of using the disclosed aluminum alloy products

[0078] The aluminum alloy products described herein can be used in automotive applications and other transportation applications, including aircraft and railroad applications. For example, the disclosed aluminum alloy products can be used to prepare automotive structural parts, such as bumpers, side beams, roof beams, cross beams, pillar reinforcements (e.g., A-pillars, B-pillars, and C-pillars), inner panels, outer panels, side panels, inner covers, outer covers, or trunk lid panels. The aluminum alloy products and methods described herein can also be used in aircraft or railroad vehicle applications to prepare, for example, exterior and interior panels.

[0079] The aluminum alloy products and methods described herein can also be used in electronic applications. For example, the aluminum alloy products and methods described herein can be used to prepare housings for electronic devices including mobile phones and tablet computers. In some examples, the aluminum alloy products can be used to prepare housings for mobile phones (e.g., smart phones), tablet chassis, and other portable electronic devices.

[0080] Methods for processing metals and metal alloys

[0081] Methods for processing and using metals and metal alloys (including aluminum, aluminum alloys, magnesium, magnesium alloys, magnesium composites and steel, etc.) and the resulting processed metals and metal alloys are described herein. In some instances, the metal used for the methods described herein includes an aluminum alloy, for example, a 1xxx series aluminum alloy, a 2xxx series aluminum alloy, a 3xxx series aluminum alloy, a 4xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, a 7xxx series aluminum alloy or an 8xxx series aluminum alloy. In some instances, materials comprising a 1xxx series aluminum alloy, a 2xxx series aluminum alloy, a 3xxx series aluminum alloy, a 4xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, a 7xxx series aluminum alloy or an 8xxx series aluminum alloy can be used as a recycled source content material for aluminum alloys and metal products described herein. In some instances, materials used for the methods described herein include non-ferrous metal materials, including aluminum, aluminum alloys, magnesium, magnesium-based materials, magnesium alloys, magnesium composites, titanium, titanium-based materials, titanium alloys, copper, copper-based materials, composites, sheets used in composites, or any other suitable metal, non-metal or material combination. Monolithic materials as well as non-monolithic materials such as rolled bonded materials, clad alloys, claddings, composite materials such as but not limited to materials containing carbon fibers, or various other materials may also be used with the methods described herein. In some examples, aluminum alloys containing iron may be used with the methods described herein.

[0082] By way of non-limiting example, exemplary 1xxx series aluminum alloys for use in the methods described herein may include AA1100, AA1100A, AA1200, AA1200A, AA1300, AA1110, AA1120, AA1230, AA1230A, AA1235, AA1435, AA1145, AA1345, AA1445, AA1150, AA1350, AA1350A, AA1450, AA1370, AA1275, AA1185, AA1285, AA1385, AA1188, AA1190, AA1290, AA1193, AA1198, or AA1199.

[0083] Non-limiting exemplary 2xxx series aluminum alloys for use in the methods described herein may include AA2001, AA2002, AA2004, AA2005, AA2006, AA2007, AA2007A, AA2007B, AA2008, AA2009, AA2010, AA2011, AA2011A, AA2111, AA2111A, AA2111B, AA2012, AA2013, AA2014, AA2015, AA2016, AA2017, AA2018, AA2019, AA2020, AA2021 A2014A, AA2214, AA2015, AA2016, AA2017, AA2017A, AA2117, AA2018, AA2218, AA2618, AA2618A, AA2219, AA2319, AA2419, AA2519, AA2021, AA2022, AA2023, AA2024, AA2024A, AA2124, AA2224, AA2224A, AA2324, A A2424, AA2524, AA2624, AA2724, AA2824, AA2025, AA2026, AA2027, AA2028, AA2028A, AA2028B, AA2028C, AA2029, AA2030, AA2031, AA2032, AA2034, AA2036, AA2037, AA2038, AA2039, AA2139, AA2040, AA2041, AA 2044, AA2045, AA2050, AA2055, AA2056, AA2060, AA2065, AA2070, AA2076, AA2090, AA2091, AA2094, AA20 95, AA2195, AA2295, AA2196, AA2296, AA2097, AA2197, AA2297, AA2397, AA2098, AA2198, AA2099 or AA2199.

[0084] Non-limiting exemplary 3xxx series aluminum alloys for use in the methods described herein may include AA3002, AA3102, AA3003, AA3103, AA3103A, AA3103B, AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, AA3005A, AA3105, AA3105A, AA3105B, AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005 AA3007, AA3107, AA3207, AA3207A, AA3307, AA3009, AA3010, AA3110, AA3011, AA3012, AA3012A, AA3013, AA3014, AA3015, AA3016, AA3017, AA3019, AA3020, AA3021, AA3025, AA3026, AA3030, AA3130, or AA3065.

[0085] Non-limiting exemplary 4xxx series aluminum alloys for use in the methods described herein may include AA4045, AA4004, AA4104, AA4006, AA4007, AA4008, AA4009, AA4010, AA4013, AA4014, AA4015, AA4015A, AA4115, AA4016, AA4017, AA4018, AA4019, AA4020, AA4021, AA4026, AA4032, AA4043, AA4043A, AA4143, AA4343, AA4643, AA4943, AA4044, AA4145, AA4145A, AA4046, AA4047, AA4047A, or AA4147.

[0086] Non-limiting exemplary 5xxx series aluminum alloys for use in the methods described herein may include AA5182, AA5183, AA5005, AA5005A, AA5205, AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110, AA5110A, AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A, AA5119 ... A5119A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5040, AA5140, AA5041, AA5042, AA5043, AA504 9. AA5149, AA5249, AA5349, AA5449, AA5449A, AA5050, AA5050A, AA5050C, AA5150, AA5051, AA5051A, AA5151, AA5251, AA5251A, AA5351, AA5451, AA5052, AA5252, AA5352, AA5154, AA5154A, AA5154B, AA5154C, AA5254, AA5354, AA5454, A A5554, AA5654, AA5654A, AA5754, AA5854, AA5954, AA5056, AA5356, AA5356A, AA5456, AA5456A, AA5456B, AA5556, AA5 556A, AA5556B, AA5556C, AA5257, AA5457, AA5557, AA5657, AA5058, AA5059, AA5070, AA5180, AA5180A, AA5082, AA51 82. AA5083, AA5183, AA5183A, AA5283, AA5283A, AA5283B, AA5383, AA5483, AA5086, AA5186, AA5087, AA5187 or AA5088.

[0087] Non-limiting exemplary 6xxx series alloys for use in the methods described herein may include AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA6206, AA6306 ... 6008, AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, AA6 016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027, AA602 8. AA6031, AA6032, AA6033, AA6040, AA6041, AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA6053 ,AA6055,AA6056,AA6156,AA6060,AA6160,AA6260,AA6360,AA6460,AA6460B,AA6560,AA6660,AA6061,AA6061A, AA6261, AA6361, AA6162, AA6262, AA6262A, AA6063, AA6063A, AA6463, AA6463A, AA6763, AA6963, AA6064, AA6064A, AA6065, AA6066, AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A, AA6182, AA6091, or AA6092.

[0088] Non-limiting exemplary 7xxx series aluminum alloys for use in the methods described herein may include AA7011, AA7019, AA7020, AA7021, AA7039, AA7072, AA7075, AA7085, AA7108, AA7108A, AA7015, AA7017, AA7018, AA7019A, AA7024, AA7025, AA7028 ,AA7030,AA7031,AA7033,AA7035,AA7035A,AA7046,AA7046A,AA7003,AA7004,AA7005,AA70 09. AA7010, AA7011, AA7012, AA7014, AA7016, AA7116, AA7122, AA7023, AA7026, AA7029, AA71 29. AA7229, AA7032, AA7033, AA7034, AA7036, AA7136, AA7037, AA7040, AA7140, AA7041, AA7 049, AA7049A, AA7149, AA7204, AA7249, AA7349, AA7449, AA7050, AA7050A, AA7150, AA7250, A AA7055, AA7155, AA7255, AA7056, AA7060, AA7064, AA7065, AA7068, AA7168, AA7175, AA7475, AA7076, AA7178, AA7278, AA7278A, AA7081, AA7181, AA7185, AA7090, AA7093, AA7095, or AA7099.

[0089] Non-limiting exemplary 8xxx series aluminum alloys for use in the methods described herein may include AA8005, AA8006, AA8007, AA8008, AA8010, AA8011, AA8011A, AA8111, AA8211, AA8112, AA8014, AA8015, AA8016, AA8017, AA8018, AA8019, AA8020, AA8021A, AA8022, AA8023, AA8024, AA8025, AA8026, AA8027, AA8028, AA8029, AA8030, AA8031, AA8032, AA8033, AA8034, AA8035, AA8036, AA8037, AA8038, AA8039, AA8040, AA8041, AA8042, AA8043, AA8044, AA8045, AA8046, AA8047, AA8048, AA8049, AA8050, AA8051 1. AA8021A, AA8021B, AA8022, AA8023, AA8024, AA8025, AA8026, AA8030, AA8130, AA8040, AA8050, AA8150, AA8076, AA8076A, AA8176, AA8077, AA8177, AA8079, AA8090, AA8091, or AA8093.

[0090] The examples disclosed herein will be used to further illustrate aspects of the present invention, but will not constitute any limitation of the present invention at the same time. On the contrary, it should be clearly understood that after reading the specification of this article, those skilled in the art themselves can think of adopting various embodiments, modifications and their equivalent forms without departing from the spirit of the present invention. Unless otherwise specified, the examples and embodiments described herein can also utilize conventional procedures. Some programs are described herein for illustrative purposes.

[0091] Example 1

[0092] Aluminum alloy sheet metal samples were prepared by casting, homogenizing, hot rolling, cold rolling, solutionizing, and aging the aluminum alloy. Conventional DC casting techniques were used to prepare ingots consisting of AA6016. The aluminum alloy contained about 55% recycled aluminum content. The aluminum alloy contained about 0.23-0.30 wt. % Fe, 0.15-0.20 wt. % Mn, and 0.009-0.025 wt. % Cr, such that the ratio of Mn+Cr to Fe was about 0.67-0.73.

[0093] The ingot is homogenized at about 540°C for about 14 hours. According to conventional hot rolling, cold rolling, solution heat treatment technology, the homogenized product is subjected to hot rolling, followed by cold rolling, and then solution. The outlet temperature after hot rolling is 405°C. The thickness reduction achieved by hot rolling is about 98%, and the thickness reduction achieved by cold rolling before intermediate annealing at 355°C is 63%. Additional cold rolling is then used to generate a cold rolled product with a final specification of 1.02mm. The cold rolled product is subjected to a short (<1 minute) solution treatment at a peak metal temperature between 560°C and 570°C. Samples of the solution product are subjected to natural aging to reach the T4 state, and these samples are subjected to testing to evaluate properties. Some aged samples are also subjected to artificial aging to reach the T6 state, and these samples are also subjected to testing to evaluate properties. The measured values ​​are shown in Tables 1 and 2. The ripping characteristics (Sa and VDA 239-400RK 10%) were also evaluated and the measured values ​​are shown in Table 3.

[0094]

[0095]

[0096] Table 1. T4 status values

[0097]

[0098] Table 2. T6 status values

[0099]

[0100] Table 3. Luo Ping weave value

[0101] Example 2

[0102] Aluminum alloy sheet metal samples were prepared by casting, homogenizing, hot rolling, cold rolling and intermediate annealing recrystallization of the aluminum alloy. Conventional DC casting techniques were used to prepare ingots consisting of AA6016. The aluminum alloy contained about 55% recycled aluminum content. The aluminum alloy contained about 0.23-0.30 wt. % Fe, 0.15-0.20 wt. % Mn and 0.009-0.025 wt. % Cr, such that the ratio of Mn+Cr to Fe was about 0.67-0.73.

[0103] The ingot was homogenized at about 540°C for about 13-14 hours. The homogenized product was subjected to hot rolling, followed by cold rolling to a specification of about 3.5 mm, followed by intermediate annealing recrystallization, and then cold rolling to a final specification of about 1.0 mm. Conventional hot rolling and cold rolling techniques were used. The outlet temperature after hot rolling was about 350°C, at which fine precipitates were produced in the sample. Several different intermediate annealing recrystallization techniques were applied to the product samples after hot rolling and cold rolling. Some samples were subjected to solution heat treatment and natural aging processes after final cold rolling to T4 temper conditions, and properties were evaluated (e.g., grain characteristics, mechanical properties, crystal texture, surface characteristics, etc.). Comparative samples of different alloys (AA6016) (C1) and the same alloy (C2) not including recycled content were also evaluated for comparison, wherein the same hot rolling and cold rolling processes were used, but intermediate annealing recrystallization treatment was not used.

[0104] The first and second intermediate annealing recrystallization techniques (RX1 and RX2) included heating the sample to 350°C for 5 seconds, followed by air quenching. The third intermediate annealing recrystallization technique (RX3) included heating the sample to 365°C for 5 seconds using a magnetic induction heating system, followed by water quenching. The fourth intermediate annealing recrystallization technique (RX3) included heating the sample to 415°C for 5 seconds using a magnetic induction heating system, followed by water quenching.

[0105] Complete recrystallization of the samples was observed in all the intermediate annealing recrystallization techniques tested. The grain growth observed in the first and second intermediate annealing recrystallization techniques was different from that observed in the third and fourth intermediate annealing recrystallization techniques, but no significant grain coarsening was observed in any of the intermediate annealing recrystallization techniques.

[0106] Figure 3 The grain size characteristics of various aluminum alloy samples are shown. Figure 4 The textural features of various aluminum alloy samples are shown. Figure 5The yield strength of various aluminum alloy samples is shown. Figure 6 The ultimate tensile strength of various aluminum alloy samples is shown. Figure 7 The uniform elongation of various aluminum alloy samples is shown. Figure 8 The total elongation of various aluminum alloy samples is shown. Fig. 9 The strain hardening exponents of various aluminum alloy samples at 5% strain are shown. Fig.10 The strain hardening exponents for various aluminum alloy samples at 10-20% strain are shown.

[0107] The fine grain size and highly random texture lead to good bending and roping character features, as well as improved formability compared to processing without intermediate annealing recrystallization process. In addition, the clean microstructure with low undissolved precipitates and microporosity helps to achieve good bending characteristics.

[0108] Illustrative aspects

[0109] As used below, any reference to a series of aspects (e.g., “Aspects 1-4”) or an unlisted group of aspects (e.g., “any preceding or subsequent aspect”) should be understood as a separate reference to each of those aspects (e.g., “Aspects 1-4” should be understood as “Aspect 1, Aspect 2, Aspect 3, or Aspect 4”).

[0110] Aspect 1 is an aluminum alloy comprising Al and about 1 wt % to 1.5 wt % Si, up to about 0.35 wt % Fe, up to about 0.25 wt % Cu, about 0.05 wt % to 0.25 wt % Mn, about 0.2 wt % to 0.60 wt % Mg, up to about 0.10 wt % Cr, up to about 0.10 wt % Ni, up to about 0.20 wt % Zn, up to about 0.15 wt % Ti, and up to about 0.10 wt % V, wherein the ratio of the total amount of Mn and Cr to the amount of Fe is greater than 0.6, and wherein at least a portion of the aluminum alloy comprises recycled aluminum alloy content.

[0111] Aspect 2 is an aluminum alloy as described in any preceding or subsequent aspect, comprising up to 100% recycled aluminum alloy content or comprising more than 20% recycled aluminum alloy content.

[0112] Aspect 3 is an aluminum alloy as described in any preceding or subsequent aspect, comprising a 6xxx series aluminum alloy.

[0113] Aspect 4 is an aluminum alloy as described in any preceding or subsequent aspect, comprising approximately 1.2 wt % to 1.5 wt % Si, approximately 0.10 wt % to 0.35 wt % Fe, approximately 0.05 wt % to 0.25 wt % Cu, approximately 0.10 wt % to 0.25 wt % Mn, approximately 0.25 wt % to 0.60 wt % Mg, approximately 0.005 wt % to 0.10 wt % Cr, approximately 0.03 wt % to 0.10 wt % Ni, approximately 0.02 wt % to 0.20 wt % Zn, approximately 0.01 wt % to 0.15 wt % Ti, and approximately 0.01 wt % to 0.10 wt % V.

[0114] Aspect 5 is an aluminum alloy as described in any preceding or subsequent aspect, comprising approximately 1.35 wt. % to 1.5 wt. % Si, approximately 0.20 wt. % to 0.35 wt. % Fe, approximately 0.10 wt. % to 0.25 wt. % Cu, approximately 0.10 wt. % to 0.20 wt. % Mn, approximately 0.25 wt. % to 0.60 wt. % Mg, approximately 0.009 wt. % to 0.10 wt. % Cr, approximately 0.05 wt. % to 0.10 wt. % Ni, approximately 0.02 wt. % to 0.15 wt. % Zn, approximately 0.01 wt. % to 0.15 wt. % Ti, and approximately 0.02 wt. % to 0.10 wt. % V.

[0115] Aspect 6 is an aluminum alloy as described in any preceding or subsequent aspect, comprising up to 0.05 wt. % of any individual impurity and up to 0.25 wt. % of all impurities.

[0116] Aspect 7 is the aluminum alloy as described in any preceding or subsequent aspect, which contains more intermetallic compound particles containing α-phase Fe than intermetallic compound particles containing β-phase Fe.

[0117] Aspect 8 is a metal product comprising an aluminum alloy, wherein the aluminum alloy comprises Al and about 1 wt % to 1.5 wt % Si, up to about 0.35 wt % Fe, up to about 0.25 wt % Cu, about 0.05 wt % to 0.25 wt % Mn, about 0.2 wt % to 0.60 wt % Mg, up to about 0.10 wt % Cr, up to about 0.10 wt % Ni, up to about 0.20 wt % Zn, up to about 0.15 wt % Ti, and up to about 0.10 wt % V, wherein the ratio of the total amount of Mn and Cr to the amount of Fe is greater than 0.6, and wherein at least a portion of the aluminum alloy comprises recycled aluminum alloy content.

[0118] Aspect 9 is a metal product as described in any preceding or subsequent aspect, wherein the aluminum alloy is an aluminum alloy as described in any preceding or subsequent aspect.

[0119] Aspect 10 is the metal product of any preceding or subsequent aspect, wherein the metal product is a rolled metal product.

[0120] Aspect 11 is the metal product of any preceding or subsequent aspect, wherein the metal product is a doubly recrystallized metal product.

[0121] Aspect 12 is the metal product of any preceding or subsequent aspect, wherein the metal product exhibits isotropic strain characteristics.

[0122] Aspect 13 is the metal product of any preceding or subsequent aspect, wherein the metal product exhibits a Lankford Ratio of about 0.6 or greater in the longitudinal, transverse, and diagonal directions at about 10% strain.

[0123] Aspect 14 is the metal product of any preceding or subsequent aspect, wherein the metal product exhibits an f15% bend modulus in the transverse direction of about 0.3 to 1.0.

[0124] Aspect 15 is the metal product of any preceding or subsequent aspect, wherein the metal product exhibits an inward bend angle of about 10° to 60° after pre-straining by 10%.

[0125] Aspect 16 is the metal product of any preceding or subsequent aspect, wherein the metal product exhibits a surface arithmetic mean height (Sa) of at most 0.60 μm.

[0126] Aspect 17 is the metal product of any preceding or subsequent aspect, wherein the metal product exhibits a yield strength of 90 MPa to 130 MPa in the T4 temper or a yield strength of 200 MPa to 235 MPa in the T6 temper.

[0127] Aspect 18 is the metal product of any preceding or subsequent aspect, wherein the metal product exhibits an ultimate tensile strength of 195 MPa to 270 MPa in the T4 temper or an ultimate tensile strength of 240 MPa to 300 MPa in the T6 temper.

[0128] Aspect 19 is the metal product of any preceding or subsequent aspect, wherein the metal product exhibits a uniform elongation of 20% to 30% in the T4 temper or a uniform elongation of 10% to 20% in the T6 temper.

[0129] Aspect 19A is a metal product as described in any preceding or subsequent aspect, prepared using a method as described in any subsequent aspect.

[0130] Aspect 19B is a metal product as described in any of the preceding aspects, which is prepared using the aluminum alloy as described in any of the preceding aspects.

[0131] Aspect 20 is a method for producing a metal product, the method comprising casting an aluminum alloy to produce a cast product, wherein the aluminum alloy comprises Al and about 1 wt% to 1.5 wt% Si, up to about 0.35 wt% Fe, up to about 0.25 wt% Cu, about 0.05 wt% to 0.25 wt% Mn, about 0.2 wt% to 0.60 wt% Mg, up to about 0.10 wt% Cr, up to about 0.10 wt% Ni, up to about 0.20 wt% Zn, up to about 0.15 wt% Ti and up to about 0.10 wt% V, wherein the ratio of the total amount of Mn and Cr to the amount of Fe is greater than 0.7, and wherein at least a portion of the aluminum alloy comprises recycled aluminum alloy content; homogenizing the cast product to produce a homogenized product; hot rolling the homogenized product to produce a rolled product; and subjecting the rolled product to a final cold rolling process product to produce the metal product.

[0132] Aspect 21 is a method as described in any preceding or subsequent aspect, which further includes, after the hot rolling, subjecting the rolled product to a recrystallization process to produce a recrystallized product, wherein the final cold rolling process includes cold rolling the recrystallized product to produce the metal product.

[0133] Aspect 22 is the method of any preceding or subsequent aspect, wherein the recrystallization process occurs between the hot rolling and the final cold rolling process.

[0134] Aspect 23 is a method as described in any preceding or subsequent aspect, which also includes subjecting the rolled product to a preliminary cold rolling process after the hot rolling and before the recrystallization process, wherein the recrystallization process occurs between the preliminary cold rolling process and the final cold rolling process.

[0135] Aspect 24 is a method as described in any preceding or subsequent aspect, wherein the recrystallization process includes annealing the rolled product at a peak metal temperature of 325°C to 425°C for up to 1 minute to produce a recrystallized product; and quenching the recrystallized product.

[0136] Aspect 25 is a method as described in any preceding or subsequent aspect, wherein the outlet temperature of the hot rolling does not exceed 400°C.

[0137] Aspect 26 is the method of any preceding or subsequent aspect, wherein the hot rolling achieves a thickness reduction of 90% or more between the homogenized product and the rolled product.

[0138] Aspect 27 is a method as described in any preceding or subsequent aspect, further comprising subjecting the metal product to a solutionizing process to produce a solutionized metal product.

[0139] Aspect 28 is the method of any preceding or subsequent aspect, further comprising subjecting the metal product to an aging or artificial aging process to produce an aged metal product.

[0140] Aspect 29 is the method of any preceding or subsequent aspect, wherein the aluminum alloy comprises up to 100% recycled aluminum alloy content or greater than 20% recycled aluminum alloy content.

[0141] Aspect 30 is a method as described in any preceding or subsequent aspect, wherein the aluminum alloy product comprises a 6xxx series aluminum alloy.

[0142] Aspect 31 is a method as described in any preceding or subsequent aspect, wherein the aluminum alloy comprises approximately 1.2 wt % to 1.5 wt % Si, approximately 0.10 wt % to 0.35 wt % Fe, approximately 0.05 wt % to 0.25 wt % Cu, approximately 0.10 wt % to 0.25 wt % Mn, approximately 0.25 wt % to 0.60 wt % Mg, approximately 0.005 wt % to 0.10 wt % Cr, approximately 0.03 wt % to 0.10 wt % Ni, approximately 0.02 wt % to 0.20 wt % Zn, approximately 0.01 wt % to 0.15 wt % Ti, and approximately 0.01 wt % to 0.10 wt % V.

[0143] Aspect 32 is a method as described in any preceding or subsequent aspect, wherein the aluminum alloy comprises approximately 1.35 wt. % to 1.5 wt. % Si, approximately 0.20 wt. % to 0.35 wt. % Fe, approximately 0.10 wt. % to 0.25 wt. % Cu, approximately 0.10 wt. % to 0.20 wt. % Mn, approximately 0.25 wt. % to 0.60 wt. % Mg, approximately 0.009 wt. % to 0.10 wt. % Cr, approximately 0.05 wt. % to 0.10 wt. % Ni, approximately 0.02 wt. % to 0.15 wt. % Zn, approximately 0.01 wt. % to 0.15 wt. % Ti, and approximately 0.02 wt. % to 0.10 wt. % V.

[0144] Aspect 33 is a method as described in any preceding or subsequent aspect, wherein the aluminum alloy comprises up to 0.05 weight percent of any individual impurity and up to 0.25 weight percent of all impurities.

[0145] Aspect 34 is the method of any preceding or subsequent aspect, wherein the metal product exhibits isotropic strain characteristics.

[0146] Aspect 35 is the method of any preceding or subsequent aspect, wherein the metal product exhibits a Lankford Ratio of about 0.6 or greater in the longitudinal, transverse, and diagonal directions at about 10% strain.

[0147] Aspect 36 is the method of any preceding or subsequent aspect, wherein the metal product exhibits an f15% bend factor in the transverse direction of about 0.3 to 1.0.

[0148] Aspect 37 is the method of any preceding or subsequent aspect, wherein the metal product exhibits an inward bend angle of about 10° to 60° after prestraining by 10%.

[0149] Aspect 38 is the method of any preceding or subsequent aspect, wherein the metal product exhibits a surface arithmetic mean height (Sa) of at most 0.60 μm.

[0150] Aspect 39 is the method of any preceding or subsequent aspect, wherein the metal product exhibits a yield strength of 90 MPa to 130 MPa in the T4 temper or a yield strength of 200 MPa to 235 MPa in the T6 temper.

[0151] Aspect 40 is the method of any preceding or subsequent aspect, wherein the metal product exhibits an ultimate tensile strength of 195 MPa to 270 MPa in the T4 temper or an ultimate tensile strength of 240 MPa to 300 MPa in the T6 temper.

[0152] Aspect 41 is the method of any preceding or subsequent aspect, wherein the metal product exhibits a uniform elongation of 20% to 30% in the T4 temper or a uniform elongation of 10% to 20% in the T6 temper.

[0153] Aspect 42 is a method as described in any preceding aspect, wherein the aluminum alloy is an aluminum alloy as described in any preceding aspect.

[0154] All patents and publications cited herein are incorporated by reference in their entirety. The foregoing description of the embodiments, including the illustrated embodiments, is presented for illustration and description purposes only and is not intended to be exhaustive or limited to the precise forms disclosed. Numerous modifications, variations and uses of the present invention will be apparent to those skilled in the art.

Claims

1. An aluminum alloy comprising Al and about 1 wt% to 1.5 wt% Si, Up to about 0.35 wt. % Fe, Up to about 0.25 wt. % Cu, about 0.05 wt% to 0.25 wt% Mn, about 0.2 wt% to 0.60 wt% Mg, Up to about 0.10 wt. % Cr, Up to about 0.10 wt.% Ni, Up to about 0.20 wt. % Zn, up to about 0.15 wt. % Ti, and Up to about 0.10 wt. % V, wherein a ratio of the total amount of Mn and Cr to the amount of Fe is greater than 0.6, and wherein at least a portion of the aluminum alloy comprises recycled aluminum alloy content.

2. The aluminum alloy of claim 1 comprising up to 100% recycled aluminum alloy content or comprising more than 20% recycled aluminum alloy content.

3. The aluminum alloy of claim 1, comprising a 6xxx series aluminum alloy.

4. The aluminum alloy of claim 1, comprising: about 1.2 wt% to 1.5 wt% Si, about 0.10 wt% to 0.35 wt% Fe, About 0.05 wt % to 0.25 wt % Cu, about 0.10 wt % to 0.25 wt % Mn, about 0.25 wt % to 0.60 wt % Mg, about 0.005 wt % to 0.10 wt % Cr, about 0.03 wt % to 0.10 wt % Ni, about 0.02 wt % to 0.20 wt % Zn, about 0.01 wt % to 0.15 wt % Ti, and about 0.01 wt % to 0.10 wt % V.

5. The aluminum alloy of claim 1 comprising: about 1.35 wt. % to 1.5 wt. % Si, about 0.20 wt% to 0.35 wt% Fe, about 0.10 wt.% to 0.25 wt.% Cu, about 0.10 wt% to 0.20 wt% Mn, about 0.25 wt.% to 0.60 wt.% Mg, about 0.009 wt% to 0.10 wt% Cr, about 0.05 wt% to 0.10 wt% Ni, about 0.02 wt% to 0.15 wt% Zn, About 0.01 wt% to 0.15 wt% Ti, and about 0.02 wt% to 0.10 wt% V.

6. The aluminum alloy of claim 1, comprising up to 0.05 wt. % of any individual impurity and up to 0.25 wt. % of all impurities. 7 . The aluminum alloy of claim 1 , comprising more intermetallic compound particles containing α-phase Fe than intermetallic compound particles containing β-phase Fe.

8. A metal product comprising an aluminum alloy, wherein the aluminum alloy comprises Al and about 1 wt% to 1.5 wt% Si, Up to about 0.35 wt. % Fe, Up to about 0.25 wt. % Cu, about 0.05 wt% to 0.25 wt% Mn, about 0.2 wt% to 0.60 wt% Mg, Up to about 0.10 wt. % Cr, Up to about 0.10 wt.% Ni, Up to about 0.20 wt. % Zn, up to about 0.15 wt. % Ti, and Up to about 0.10 wt. % V, wherein a ratio of the total amount of Mn and Cr to the amount of Fe is greater than 0.6, and wherein at least a portion of the aluminum alloy comprises recycled aluminum alloy content.

9. The metal product according to claim 8, wherein the aluminum alloy is the aluminum alloy according to any one of claims 1 to 7.

10. The metal product of claim 8, wherein the metal product is a rolled metal product.

11. The metal product of claim 8, wherein the metal product is a doubly recrystallized metal product.

12. The metal product of claim 8, wherein the metal product exhibits isotropic strain characteristics.

13. The metal product of claim 8, wherein the metal product exhibits a Lankford Ratio of about 0.6 or greater in the longitudinal, transverse, and diagonal directions at about 10% strain.

14. The metal product of claim 8, wherein the metal product exhibits an f15% bend factor in the transverse direction of about 0.3 to 1.

0.

15. The metal product of claim 8, wherein the metal product exhibits an inward bend angle of about 10° to 60° after being pre-strained by 10%.

16. The metal product of claim 8, wherein the metal product exhibits an arithmetic mean surface height (Sa) of at most 0.60 μm.

17. The metal product of claim 8, wherein the metal product exhibits a yield strength of 90 MPa to 130 MPa in the T4 temper or a yield strength of 200 MPa to 235 MPa in the T6 temper.

18. The metal product of claim 8, wherein the metal product exhibits an ultimate tensile strength of 195 MPa to 270 MPa in the T4 temper or an ultimate tensile strength of 240 MPa to 300 MPa in the T6 temper.

19. The metal product of claim 8, wherein the metal product exhibits a uniform elongation of 20% to 30% in the T4 temper or a uniform elongation of 10% to 20% in the T6 temper.

20. A method of producing a metal product, the method comprising: Casting an aluminum alloy to produce a cast product, wherein the aluminum alloy comprises Al and about 1 wt% to 1.5 wt% Si, Up to about 0.35 wt. % Fe, Up to about 0.25 wt. % Cu, about 0.05 wt% to 0.25 wt% Mn, about 0.2 wt% to 0.60 wt% Mg, Up to about 0.10 wt. % Cr, Up to about 0.10 wt.% Ni, Up to about 0.20 wt. % Zn, up to about 0.15 wt. % Ti, and Up to about 0.10 wt. % V, wherein the ratio of the total amount of Mn and Cr to the amount of Fe is greater than 0.7, and wherein at least a portion of the aluminum alloy comprises recycled aluminum alloy content; homogenizing the cast product to produce a homogenized product; hot rolling the homogenized product to produce a rolled product; as well as The rolled product is subjected to a final cold rolling process to produce the metal product.

21. The method of claim 20, further comprising: After the hot rolling, the rolled product is subjected to a recrystallization process to produce a recrystallized product, wherein the final cold rolling process includes cold rolling the recrystallized product to produce the metal product.

22. The method of claim 21, wherein the recrystallization process occurs between the hot rolling and the final cold rolling process.

23. The method of claim 21, further comprising: The rolled product is subjected to a preliminary cold rolling process after the hot rolling and before the recrystallization process, wherein the recrystallization process occurs between the preliminary cold rolling process and the final cold rolling process.

24. The method of claim 21, wherein the recrystallization process comprises: annealing the rolled product at a peak metal temperature of 325°C to 425°C for up to 1 minute to produce a recrystallized product; as well as The recrystallized product is quenched.

25. The method of claim 20, wherein the outlet temperature of the hot rolling does not exceed 400°C.

26. The method of claim 20, wherein the hot rolling achieves a thickness reduction of 90% or more between the homogenized product and the rolled product.

27. The method of claim 20, further comprising: The metal product is subjected to a solutionizing process to produce a solutionized metal product.

28. The method of claim 20, further comprising: The metal product is subjected to an aging or artificial aging process to produce an aged metal product.

29. The method of claim 20, wherein the aluminum alloy comprises up to 100% recycled aluminum alloy content or greater than 20% recycled aluminum alloy content.

30. The method of claim 20, wherein the aluminum alloy product comprises a 6xxx series aluminum alloy.

31. The method of claim 20, wherein the aluminum alloy comprises: about 1.2 wt % to 1.5 wt % Si, about 0.10 wt% to 0.35 wt% Fe, about 0.05 wt.% to 0.25 wt.% Cu, about 0.10 wt% to 0.25 wt% Mn, about 0.25 wt.% to 0.60 wt.% Mg, about 0.005 wt% to 0.10 wt% Cr, about 0.03 wt. % to 0.10 wt. % Ni, about 0.02 wt% to 0.20 wt% Zn, about 0.01 wt% to 0.15 wt% Ti, and About 0.01 wt% to 0.10 wt% V.

32. The method of claim 20, wherein the aluminum alloy comprises: about 1.35 wt. % to 1.5 wt. % Si, about 0.20 wt% to 0.35 wt% Fe, about 0.10 wt.% to 0.25 wt.% Cu, about 0.10 wt% to 0.20 wt% Mn, about 0.25 wt.% to 0.60 wt.% Mg, about 0.009 wt% to 0.10 wt% Cr, about 0.05 wt% to 0.10 wt% Ni, about 0.02 wt% to 0.15 wt% Zn, about 0.01 wt% to 0.15 wt% Ti, and About 0.02 wt% to 0.10 wt% V.

33. The method of claim 20, wherein the aluminum alloy contains up to 0.05 wt. % of any individual impurity and up to 0.25 wt. % of all impurities.

34. The method of claim 20, wherein the metal product exhibits isotropic strain characteristics.

35. The method of claim 20, wherein the metal product exhibits a Lankford Ratio of about 0.6 or greater in the longitudinal, transverse, and diagonal directions at about 10% strain.

36. The method of claim 20, wherein the metal product exhibits an f15% bend factor in the transverse direction of about 0.3 to 1.

0.

37. The method of claim 20, wherein the metal product exhibits an inward bend angle of about 10° to 60° after being pre-strained by 10%.

38. The method of claim 20, wherein the metal product exhibits an arithmetic mean surface height (Sa) of at most 0.60 μm.

39. The method of claim 20, wherein the metal product exhibits a yield strength of 90 MPa to 130 MPa in the T4 temper or a yield strength of 200 MPa to 235 MPa in the T6 temper.

40. The method of claim 20, wherein the metal product exhibits an ultimate tensile strength of 195 MPa to 270 MPa in the T4 temper or an ultimate tensile strength of 240 MPa to 300 MPa in the T6 temper.

41. The method of claim 20, wherein the metal product exhibits a uniform elongation of 20% to 30% in the T4 temper or a uniform elongation of 10% to 20% in the T6 temper.

42. The method of claim 20, wherein the aluminum alloy is the aluminum alloy of any one of claims 1 to 7.

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