Novel 6XXX aluminum alloy

Abstract

Novel 6xxx aluminum alloy products are disclosed. The novel 6xxx aluminum alloy product may include tin and may achieve an improved combination of characteristics, such as an improved combination of two or more of strength, ductility (elongation), extrudability, extrusion temperature, extrusion speed, and without the appearance of macroscopic surface defects.

Description

BACKGROUND OF THE INVENTION

[0001] 6xxx aluminum alloys are aluminum alloys having silicon and magnesium to produce a magnesium silicide (Mg 2 Si) phase. Alloy 6061 has been used in various applications for decades. However, it is difficult to improve one or more properties of aluminum alloys without degrading other properties.

[0002] 6xxx high-speed cutting aluminum alloys (such as tin-containing aluminum alloys) are described in co-owned U.S. Patents 5,522,950 and 7,422,645. SUMMARY OF THE INVENTION

[0003] Broadly speaking, the present patent application relates to novel 6xxx aluminum alloys and methods for making the same. The novel 6xxx aluminum alloys generally comprise from 0.5 wt% to 1.5 wt% Sn, from 0.4 wt% to 1.6 wt% Si, from 0.6 wt% to 1.2 wt% Mg, wherein the weight ratio of (wt% of Si) to (wt% of Mg) is at least 0.75:1, from 0.5 wt% to 1.1 wt% Cu, from 0.15 wt% to 1.5 wt% Mn, from 0.10 wt% to 0.80 wt% Fe, wherein (wt% of Si)+(wt% of Mn)+(wt% of Fe) is at least 0.95 wt%, up to 1.2 wt% Bi, up to 1.2 wt% In, up to 1.0 wt% Zn, up to 0.35 wt% Cr; up to 0.25 wt% V, up to 0.25 wt% Zr; up to 0.15 wt% Ti and up to 0.04 wt% Pb, with the balance being aluminum, optional incidental elements and impurities. In one embodiment, the novel 6xxx aluminum alloy is in the form of an extruded product.

[0004] Products made from the novel 6xxx aluminum alloys can achieve an improved combination of properties, such as an improved combination of two or more of strength, ductility (elongation), extrudability, extrusion temperature, extrusion speed, and do not exhibit surface defects visible to the naked eye (e.g., do not crack, hot tear, etc.). The novel aluminum alloy can be used in a variety of applications, such as for lead-free (Pb-free) machining applications.

[0005] In one embodiment, the novel 6xxx aluminum alloy product has a dispersed phase area fraction (f) of at least 0.30%, wherein the dispersed phase comprises at least FeMn 3 Si 2 dispersed phase. A high volume fraction of the dispersed phase can, for example, be beneficial for producing improved products having high strength, ductility, extrudability, lower extrusion temperature and / or higher extrusion speed, etc., without substantially sacrificing machinability.

[0006] i. Composition

[0007] As described above, the novel 6xxx aluminum alloy typically contains (and in some cases consists essentially of or consists of) 0.5 wt% to 1.5 wt% of Sn, 0.4 wt% to 1.6 wt% of Si, 0.6 wt% to 1.2 wt% of Mg, where the weight ratio of (wt% of Si) to (wt% of Mg) is at least 0.75:1, 0.5 wt% to 1.1 wt% of Cu, 0.15 wt% to 1.5 wt% of Mn, 0.10 wt% to 0.80 wt% of Fe, where (wt% of Si) + (wt% of Mn) + (wt% of Fe) is at least 0.95 wt%, up to 1.2 wt% of Bi, up to 1.2 wt% of In, up to 1.0 wt% of Zn, up to 0.35 wt% of Cr; up to 0.25 wt% of V, up to 0.25 wt% of Zr; up to 0.15 wt% of Ti and up to 0.04 wt% of Pb, with the balance being aluminum, optional incidental elements and impurities.

[0008] As described above, the novel 6xxx aluminum alloy typically contains 0.5 wt% to 1.5 wt% of Sn. Tin can be beneficial for the machinability of especially novel 6xxx aluminum alloy products. In one embodiment, the novel 6xxx aluminum alloy product contains at least 0.55 wt% of Sn. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.60 wt% of Sn. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 0.65 wt% of Sn. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.70 wt% of Sn. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 0.75 wt% of Sn.

[0009] In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.80 wt% of Sn. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 0.85 wt% of Sn. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.90 wt% of Sn. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 0.95 wt% of Sn.

[0010] In another embodiment, the novel 6xxx aluminum alloy product contains at least 1.0 wt% of Sn. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 1.05 wt% of Sn.

[0011] In another embodiment, the novel 6xxx aluminum alloy product contains at least 1.10 wt% of Sn.

[0012] In one embodiment, the novel 6xxx aluminum alloy product contains no more than 1.45 wt% Sn. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.40 wt% Sn. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.35 wt% Sn. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.30 wt% Sn.

[0013] As described above, the novel 6xxx aluminum alloy typically contains 0.4 wt% to 1.6 wt% Si. The combination of silicon and magnesium can be beneficial for the presence of, in particular, the Mg 2 Si phase. Increasing the silicon level can also be beneficial for producing a higher volume fraction of FeMn 3 Si 2 dispersion phase without substantially affecting the volume fraction of the Mg 2 Si phase. In one embodiment, the novel 6xxx aluminum alloy product contains at least 0.45 wt% Si. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.50 wt% Si. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 0.55 wt% Si. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.60 wt% Si. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 0.65 wt% Si. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.70 wt% Si. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 0.75 wt% Si. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.80 wt% Si.

[0014] In one embodiment, the novel 6xxx aluminum alloy product contains no more than 1.55 wt% Si. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.50 wt% Si. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.45 wt% Si. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.40 wt% Si. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.35 wt% Si. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.30 wt% Si. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.25 wt% Si. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.20 wt% Si. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.15 wt% Si. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.10 wt% Si. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.05 wt% Si. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.0 wt% Si. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.95 wt% Si. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.90 wt% Si.

[0015] As described above, the novel 6xxx aluminum alloy typically contains 0.6 wt% to 1.2 wt% Mg (e.g., to achieve an appropriate volume fraction of Mg 2 Si phase and / or work hardening effect). In one embodiment, the novel 6xxx aluminum alloy product contains at least 0.65 wt% Mg. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.70 wt% Mg.

[0016] In one embodiment, the novel 6xxx aluminum alloy product contains no more than 1.15 wt% Mg. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.10 wt% Mg. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.05 wt% Mg. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.0 wt% Mg. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.95 wt% Mg. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.90 wt% Mg. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.85 wt% Mg.

[0017] In one embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the novel 6xxx aluminum alloy product is at least 0.80:1 (the ratio of (weight % of Si) to (weight % of Mg)). In another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the novel 6xxx aluminum alloy product is at least 0.85:1. In yet another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the novel 6xxx aluminum alloy product is at least 0.90:1. In another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the novel 6xxx aluminum alloy product is at least 0.95:1. In yet another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the novel 6xxx aluminum alloy product is at least 1.0:1. In another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the novel 6xxx aluminum alloy product is at least 1.05:1. In yet another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the novel 6xxx aluminum alloy product is at least 1.10:1. In another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the novel 6xxx aluminum alloy product is at least 1.15:1.

[0018] In one embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the novel 6xxx aluminum alloy product is not greater than 2.2:1. In another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the novel 6xxx aluminum alloy product is not greater than 2.1:1. In yet another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the novel 6xxx aluminum alloy product is not greater than 2.0:1. In another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the novel 6xxx aluminum alloy product is not greater than 1.9:1. In another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the novel 6xxx aluminum alloy product is not greater than 1.8:1. In yet another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the novel 6xxx aluminum alloy product is not greater than 1.7:1. In another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the novel 6xxx aluminum alloy product is not greater than 1.6:1. In yet another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the novel 6xxx aluminum alloy product is not greater than 1.5:1. In another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the novel 6xxx aluminum alloy product is not greater than 1.4:1. In yet another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the novel 6xxx aluminum alloy product is not greater than 1.3:1. In another embodiment, the weight ratio of silicon to magnesium (Si:Mg) of the novel 6xxx aluminum alloy product is not greater than 1.2:1.

[0019] In one embodiment, the total amount of silicon and magnesium in the novel 6xxx aluminum alloy product (by weight percentage) is at least 1.3 wt% (i.e., (wt% of Si) + (wt% of Mg) ≥ 1.3 wt%). In another embodiment, the total amount of silicon and magnesium in the novel 6xxx aluminum alloy product is at least 1.35 wt%. In yet another embodiment, the total amount of silicon and magnesium in the novel 6xxx aluminum alloy product is at least 1.40 wt%. In another embodiment, the total amount of silicon and magnesium in the novel 6xxx aluminum alloy product is at least 1.45 wt%. In yet another embodiment, the total amount of silicon and magnesium in the novel 6xxx aluminum alloy product is at least 1.50 wt%. In another embodiment, the total amount of silicon and magnesium in the novel 6xxx aluminum alloy product is at least 1.55 wt%. In yet another embodiment, the total amount of silicon and magnesium in the novel 6xxx aluminum alloy product is at least 1.60 wt%. In another embodiment, the total amount of silicon and magnesium in the novel 6xxx aluminum alloy product is at least 1.65 wt%. In yet another embodiment, the total amount of silicon and magnesium in the novel 6xxx aluminum alloy product is at least 1.70 wt%.

[0020] In one embodiment, the total amount of silicon and magnesium in the novel 6xxx aluminum alloy product (by weight percentage) is not greater than 2.6 wt% (i.e., (wt% of Si) + (wt% of Mg) ≤ 2.6 wt%). In another embodiment, the total amount of silicon and magnesium in the novel 6xxx aluminum alloy product is not greater than 2.5 wt%. In yet another embodiment, the total amount of silicon and magnesium in the novel 6xxx aluminum alloy product is not greater than 2.4 wt%. In another embodiment, the total amount of silicon and magnesium in the novel 6xxx aluminum alloy product is not greater than 2.3 wt%. In another embodiment, the total amount of silicon and magnesium in the novel 6xxx aluminum alloy product is not greater than 2.2 wt%. In yet another embodiment, the total amount of silicon and magnesium in the novel 6xxx aluminum alloy product is not greater than 2.1 wt%. In another embodiment, the total amount of silicon and magnesium in the novel 6xxx aluminum alloy product is not greater than 2.0 wt%. In yet another embodiment, the total amount of silicon and magnesium in the novel 6xxx aluminum alloy product is not greater than 1.9 wt%. In another embodiment, the total amount of silicon and magnesium in the novel 6xxx aluminum alloy product is not greater than 1.85 wt%. In yet another embodiment, the total amount of silicon and magnesium in the novel 6xxx aluminum alloy product is not greater than 1.80 wt%. In another embodiment, the total amount of silicon and magnesium in the novel 6xxx aluminum alloy product is not greater than 1.75 wt%.

[0021] As described above, the novel 6xxx aluminum alloy typically contains from 0.5 wt% to 1.1 wt% of Cu. Copper can be beneficial for, for example, the production of strengthening phases such as the Q phase. In one embodiment, the novel 6xxx aluminum alloy product contains at least 0.55 wt% of Cu. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.60 wt% of Cu. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 0.65 wt% of Cu.

[0022] In one embodiment, the novel 6xxx aluminum alloy product contains no more than 1.05 wt% of Cu. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.0 wt% of Cu. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.95 wt% of Cu. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.90 wt% of Cu. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.85 wt% of Cu. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.80 wt% of Cu. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.75 wt% of Cu.

[0023] As described above, the novel 6xxx aluminum alloy typically contains from 0.15 wt% to 1.5 wt% of Mn. Manganese can be beneficial for, for example, the production of a high volume fraction of FeMn 3 Si 2 and other dispersoid phases. In one embodiment, the novel 6xxx aluminum alloy product contains at least 0.18 wt% of Mn. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.20 wt% of Mn. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 0.22 wt% of Mn. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.24 wt% of Mn. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 0.26 wt% of Mn. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.28 wt% of Mn. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 0.30 wt% of Mn. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.32 wt% of Mn.

[0024] In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 0.34 wt% of Mn.

[0025] In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.36 wt% of Mn.

[0026] In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 0.38 wt% of Mn.

[0027] In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.40 wt% of Mn.

[0028] In one embodiment, the novel 6xxx aluminum alloy product contains no more than 1.45 wt% of Mn. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.40 wt% of Mn. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.35 wt% of Mn. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.30 wt% of Mn. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.25 wt% of Mn. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.20 wt% of Mn. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.15 wt% of Mn. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.10 wt% of Mn. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.05 wt% of Mn. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 1.0 wt% of Mn. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.95 wt% of Mn. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.90 wt% of Mn. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.85 wt% of Mn. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.80 wt% of Mn. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.75 wt% of Mn. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.70 wt% of Mn. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.65 wt% of Mn. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.60 wt% of Mn. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.55 wt% of Mn. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.50 wt% of Mn. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.45 wt% of Mn. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.42 wt% of Mn.

[0029] As described above, the novel 6xxx aluminum alloy typically contains 0.10 wt% to 0.80 wt% of Fe. Iron can be beneficial for, for example, the production of a high volume fraction of FeMn 3 Si 2 and other dispersoids. In one embodiment, the novel 6xxx aluminum alloy product contains at least 0.15 wt% of Fe. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.20 wt% of Fe. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 0.25 wt% of Fe. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.30 wt% of Fe. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 0.35 wt% of Fe. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.40 wt% of Fe. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 0.45 wt% of Fe. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.50 wt% of Fe.

[0030] In one embodiment, the novel 6xxx aluminum alloy product contains no more than 0.75 wt% of Fe. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.70 wt% of Fe. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.65 wt% of Fe. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.60 wt% of Fe. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.55 wt% of Fe. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.52 wt% of Fe.

[0031] As described above, the total amount of silicon, manganese, and iron (by weight percentage) in the novel 6xxx aluminum alloy is at least 0.95 wt% (i.e., (wt% of Si) + (wt% of Mn) + (wt% of Fe) ≥ 0.95 wt%). In one embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is at least 1.0 wt%. In another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is at least 1.05 wt%. In yet another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is at least 1.10 wt%. In another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is at least 1.15 wt%. In yet another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is at least 1.20 wt%. In another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is at least 1.25 wt%. In yet another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is at least 1.30 wt%. In another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is at least 1.35 wt%. In yet another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is at least 1.40 wt%. In another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is at least 1.45 wt%. In yet another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is at least 1.50 wt%. In another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is at least 1.55 wt%. In yet another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is at least 1.60 wt%.

[0032] In one embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product (by weight percentage) is not greater than 3.1 wt% (i.e., (wt% of Si) + (wt% of Mn) + (wt% of Fe) ≤ 3.1 wt%). In another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is not greater than 3.0 wt%. In yet another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is not greater than 2.9 wt%. In another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is not greater than 2.8 wt%. In another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is not greater than 2.7 wt%. In yet another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is not greater than 2.6 wt%. In another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is not greater than 2.5 wt%. In another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is not greater than 2.4 wt%. In yet another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is not greater than 2.3 wt%. In another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is not greater than 2.2 wt%. In yet another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is not greater than 2.1 wt%. In another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is not greater than 2.0 wt%. In yet another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is not greater than 1.9 wt%. In another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is not greater than 1.8 wt%. In yet another embodiment, the total amount of silicon, manganese, and iron in the novel 6xxx aluminum alloy product is not greater than 1.7 wt%.

[0033] As mentioned above, the novel 6xxx aluminum alloy product may contain up to 1.2 wt% of Bi. In some alloy systems, bismuth can completely or partially substitute for tin. However, the preference for the bismuth phase is generally lower than that for the tin phase. Thus, in some embodiments, the novel 6xxx aluminum alloy product contains less than 0.25 wt% of Bi. In one embodiment, the novel 6xxx aluminum alloy product contains no more than 0.20 wt% of Bi. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.15 wt% of Bi. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.10 wt% of Bi. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.08 wt% of Bi. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.05 wt% of Bi. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.03 wt% of Bi. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.01 wt% of Bi. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.005 wt% of Bi.

[0034] In embodiments where bismuth is used, the novel 6xxx aluminum alloy product generally contains 0.25 wt% to 1.2 wt% of Bi.

[0035] As mentioned above, the novel 6xxx aluminum alloy product may contain up to 1.2 wt% of In. In some alloy systems, indium can completely or partially substitute for tin. However, the preference for the indium phase is generally lower than that for the tin phase. Thus, in some embodiments, the novel 6xxx aluminum alloy product contains less than 0.25 wt% of In. In one embodiment, the novel 6xxx aluminum alloy product contains no more than 0.20 wt% of In. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.15 wt% of In. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.10 wt% of In. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.08 wt% of In. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.05 wt% of In. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.03 wt% of In. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.01 wt% of In. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.005 wt% of In.

[0036] In embodiments where indium is used, the novel 6xxx aluminum alloy product generally contains 0.25 wt% to 1.2 wt% of In.

[0037] In one embodiment, the novel 6xxx aluminum alloy product contains 0.5 to 1.5 wt% of Sn, such as any of the tin levels listed herein, and the novel 6xxx aluminum alloy product contains less than 0.05 wt% of Bi and less than 0.05 wt% of In. In another embodiment, the novel 6xxx aluminum alloy product contains 0.5 to 1.5 wt% of Sn, such as any of the tin levels listed herein, and the novel 6xxx aluminum alloy product contains less than 0.03 wt% of Bi and less than 0.03 wt% of In. In yet another embodiment, the novel 6xxx aluminum alloy product contains 0.5 to 1.5 wt% of Sn, such as any of the tin levels listed herein, and the novel 6xxx aluminum alloy product contains less than 0.01 wt% of Bi and less than 0.01 wt% of In.

[0038] In one embodiment, the novel 6xxx aluminum alloy product contains at least 0.25 wt% of each of at least two of tin, bismuth, and indium. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.25 wt% of each of all of tin, bismuth, and indium.

[0039] As mentioned above, the novel 6xxx aluminum alloy product may contain up to 1.0 wt% of Zn. Zinc can be beneficial for solid solution strengthening. In one embodiment, the novel 6xxx aluminum alloy product contains at least 0.01 wt% of Zn. In one embodiment, the novel 6xxx aluminum alloy product contains no more than 0.9 wt% of Zn. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.8 wt% of Zn. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.7 wt% of Zn. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.6 wt% of Zn. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.50 wt% of Zn. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.40 wt% of Zn. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.30 wt% of Zn. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.20 wt% of Zn. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.15 wt% of Zn. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.10 wt% of Zn. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.08 wt% of Zn. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.05 wt% of Zn. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.03 wt% of Zn.

[0040] As mentioned above, the novel 6xxx aluminum alloy product may contain up to 0.35 wt% of Cr. Chromium can be beneficial for the formation of, for example, chromium-containing dispersoids. In one embodiment, the novel 6xxx aluminum alloy product contains at least 0.01 wt% of Cr. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.03 wt% of Cr. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 0.06 wt% of Cr. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.08 wt% of Cr. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 0.10 wt% of Cr. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.12 wt% of Cr. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 0.14 wt% of Cr. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.16 wt% of Cr. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 0.18 wt% of Cr.

[0041] In one embodiment, the novel 6xxx aluminum alloy product contains no more than 0.30 wt% of Cr. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.25 wt% of Cr. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.22 wt% of Cr. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.20 wt% of Cr.

[0042] As mentioned above, the novel 6xxx aluminum alloy product may contain up to 0.25 wt% of V. V can be a complete or partial substitute for Cr. In one embodiment, the novel 6xxx aluminum alloy product contains at least 0.01 wt% of V. In one embodiment, the novel 6xxx aluminum alloy product contains no more than 0.15 wt% of V. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.10 wt% of V. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.08 wt% of V. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.05 wt% of V. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.03 wt% of V. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.01 wt% of V. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.005 wt% of V.

[0043] As mentioned above, the novel 6xxx aluminum alloy product may contain up to 0.25 wt% of Zr. Zr may fully or partially substitute for Cr. In one embodiment, the novel 6xxx aluminum alloy product contains at least 0.01 wt% of Zr. In one embodiment, the novel 6xxx aluminum alloy product contains no more than 0.15 wt% of Zr. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.10 wt% of Zr. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.08 wt% of Zr. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.05 wt% of Zr. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.03 wt% of Zr. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.01 wt% of Zr. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.005 wt% of Zr.

[0044] In one embodiment, at least one of Zr and V partially substitutes for Ct.

[0045] As described above, the novel 6xxx aluminum alloy typically contains no more than 0.15 wt% of Ti. Titanium can be used for grain refinement during casting. The titanium content in the alloy should be restricted such that large primary particles are avoided / restricted / limited during the production of alloy products. In one embodiment, the novel 6xxx aluminum alloy product contains at least 0.005 wt% of Ti. In another embodiment, the novel 6xxx aluminum alloy product contains at least 0.01 wt% of Ti. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 0.02 wt% of Ti. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 0.05 wt% of Ti. In one embodiment, the novel 6xxx aluminum alloy product contains no more than 0.12 wt% of Ti. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.10 wt% of Ti. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.08 wt% of Ti. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.05 wt% of Ti. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.03 wt% of Ti. In one embodiment, the novel 6xxx aluminum alloy product contains 0.005 to 0.10 wt% of Ti. In another embodiment, the novel 6xxx aluminum alloy product contains 0.01 to 0.05 wt% of Ti. In yet another embodiment, the novel 6xxx aluminum alloy product contains 0.01 to 0.03 wt% of Ti. Titanium can be in elemental form or in compound form (e.g., TiB 2 or TiC).

[0046] As described above, the novel 6xxx aluminum alloy typically contains no more than 0.04 wt% of Pb. In some countries, lead may be regarded as a dangerous substance. In one embodiment, the novel 6xxx aluminum alloy contains no more than 0.03 wt% of Pb. In another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.01 wt% of Pb. In yet another embodiment, the novel 6xxx aluminum alloy product contains no more than 0.005 wt% of Pb.

[0047] As mentioned above, the balance of the novel aluminum alloy is typically aluminum, optional incidental elements, and impurities. As used herein, "incidental element" means an element or material that may optionally be added to the alloy to assist in alloy fabrication, in addition to the elements listed above. Examples of incidental elements include foundry aids such as grain refiners and deoxidizers. Up to 1.0 wt% cumulative amount of optional incidental elements may be included in the alloy. As a non-limiting example, during casting, one or more incidental elements may be added to the alloy to reduce or constrain (and in some cases, eliminate) ingot cracking caused by, for example, oxide wrinkles, depressions, and oxide spots. These types of incidental elements are generally referred to herein as deoxidizers. Some examples of deoxidizers include Ca, Sr, and Be. When calcium (Ca) is included in the alloy, it is typically present in an amount of up to about 0.05 wt% or up to about 0.03 wt%. In some embodiments, the alloy includes an amount of Ca of about 0.001 - 0.03 wt% or about 0.05 wt%, such as 0.001 - 0.008 wt% (or 10 to 80 ppm). Strontium (Sr) may be included in the alloy as an alternative to Ca (fully or partially) and may thus be included in the same or a similar amount as Ca. Traditionally, adding beryllium (Be) helps 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 typically present in an amount of up to about 20 ppm. Incidental elements may be present in trace amounts or in large amounts and may add desired or other characteristics without departing from the alloys described herein, provided that the alloy maintains the desired characteristics described herein. However, it should be understood that the scope of this disclosure cannot be circumvented by adding only one or more elements in amounts that do not otherwise affect the combination of characteristics desired and obtained herein.

[0048] The novel 6xxx aluminum alloy may contain a small amount of impurities. In one embodiment, the novel 6xxx aluminum alloy product contains a total of no more than 0.15 wt% of impurities, and each of the impurities in the novel aluminum alloy is no more than 0.05 wt%. In another embodiment, the novel 6xxx aluminum alloy product contains a total of no more than 0.10 wt% of impurities, and each of the impurities in the novel aluminum alloy is no more than 0.03 wt%.

[0049] ii. Processing

[0050] The novel aluminum alloy can be applicable to a variety of product forms, including, for example, ingots or billets, forged product forms (plates, forgings, and extrusions), shaped castings, additive manufacturing products, and powder metallurgy products. For example, the novel aluminum alloy can be processed into various forged forms, such as in a rolled form (sheets, plates), in an extruded form, or in a forged form, as well as in a variety of temper forms. In this regard, the novel aluminum alloy can be cast (e.g., direct chill casting or continuous casting), and then processed (hot and / or cold worked) into a suitable product form (sheets, plates, extrusions, or forgings). After processing, the novel aluminum alloy can be processed to one of T temper, W temper, O temper, or F temper according to ANSI H35.1 (2009). In one example, the novel aluminum alloy is processed to "T temper" (heat treatment). In this regard, the novel aluminum alloy can be processed to one of T1 temper, T2 temper, T3 temper, T4 temper, T5 temper, T6 temper, T7 temper, T8 temper, T9 temper, or T10 temper according to ANSI H35.1 (2009). In one embodiment, the product is processed to T1 temper. In another embodiment, the product is processed to T2 temper. In yet another embodiment, the product is processed to T3 temper. In another embodiment, the product is processed to T4 temper. In another embodiment, the product is processed to T5 temper. In yet another embodiment, the product is processed to T6 temper. In another embodiment, the product is processed to T7 temper. In yet another embodiment, the product is processed to T8 temper. In another embodiment, the product is processed to T9 temper. In yet another embodiment, the product is processed to T10 temper. In other embodiments, the novel aluminum alloy is processed to "W temper" (solution heat treated). In another example, after the aluminum alloy is processed into a suitable product form, solution heat treatment is not applied, and thus the novel aluminum alloy can be processed to "F temper" (as fabricated) or "O temper" (annealed).

[0051] In one embodiment, the novel 6xxx aluminum alloy product is an extruded product. In one embodiment, the extruded product is processed to a T1, T2, T3, T4, T5, T6, T7, T8, T9 or T10 temper. For example, the extruded product can be produced by casting an ingot of any of the 6xxx aluminum alloys described herein, then scalping / skinning and homogenizing (in any order), and then extruding (directly or indirectly) at an extrusion temperature. Any suitable extrusion technique can be utilized, including hydrostatic extrusion. The extruded product can be in any suitable form, such as a rod, bar, shape or any other geometric shape / profile. The extruded product can be an intermediate or final product. Soon after extrusion, the product can be subjected to targeted quenching to produce a press quenched product, followed by natural aging, i.e., a T1 temper, and / or then artificial aging, i.e., a T5 temper product. Alternatively, the extruded product can be solution heat treated (e.g., in a separate furnace), quenched, and then naturally aged, i.e., a T4 temper product, and / or then artificially aged, i.e., a T6 temper product. In another embodiment, the extruded product is further cold worked and / or artificially aged after extrusion. For a T8 temper, cold working is first completed, followed by artificial aging. For a T9 temper, artificial aging is first completed, followed by cold working.

[0052] Different from the extrusion conditions described in the co-owned U.S. Patent No. 7,422,645, the ingots prepared from the novel 6xxx aluminum alloy products described herein can be homogenized at any suitable homogenization temperature (e.g., 1010°F to 1040°F), and then (a) immediately extruded or (b) air or water quenched and then extruded. In either case, the preheat temperature (i.e., the temperature at which the ingot enters the extruder) can be significantly higher than the preferred maximum temperature of 800°F described in U.S. Patent No. 7,422,645. In one aspect, the preheat temperature is greater than 800°F. In one method, the preheat temperature ranges from 810°F to 960°F. In one embodiment, the preheat temperature is at least 820°F. In another embodiment, the preheat temperature is at least 830°F. In yet another embodiment, the preheat temperature is at least 840°F. In another embodiment, the preheat temperature is at least 850°F. In yet another embodiment, the preheat temperature is at least 860°F. In another embodiment, the preheat temperature is at least 870°F. In yet another embodiment, the preheat temperature is at least 880°F. In another embodiment, the preheat temperature is at least 890°F. In yet another embodiment, the preheat temperature is at least 900°F. In another embodiment, the preheat temperature is at least 905°F. In yet another embodiment, the preheat temperature is at least 910°F. In another embodiment, the preheat temperature is at least 915°F. In yet another embodiment, the preheat temperature is at least 920°F. In one embodiment, the preheat temperature is not greater than 950°F.

[0053] In one embodiment, the preheat temperature is from 900°F to 960°F. In another embodiment, the preheat temperature is from 905°F to 960°F. In yet another embodiment, the preheat temperature is from 910°F to 960°F. In another embodiment, the preheat temperature is from 915°F to 960°F. In yet another embodiment, the preheat temperature is from 920°F to 960°F.

[0054] In one embodiment, the extrusion speed is 40 to 70 feet per minute.

[0055] As described above, the novel 6xxx aluminum alloy described herein can facilitate colder extrusion and / or faster extrusion without accompanying loss of the mechanical properties of the material and / or without visible surface defects (e.g., no cracking, hot tearing, etc.). Therefore, higher production rates can be achieved without substantially sacrificing quality.

[0056] In one embodiment, the extrusion process is initiated at a preheat temperature, and the extrusion method includes extruding a billet into an extruded product. In one embodiment, the method includes quenching the extruded piece during the extrusion step (e.g., immediately as the extruded piece exits the extrusion equipment). In another embodiment, the method includes: after the extrusion step, solution heat treating in a separate furnace and then quenching the extruded product. In one embodiment, the method includes artificially aging the extruded product. In one embodiment, the method includes cold working the extruded product and then artificially aging the extruded product. In one embodiment, the method includes artificially aging the extruded product and then cold working the extruded product. Natural aging can be used in place of artificial aging, or natural aging can be performed prior to artificial aging.

[0057] iii. Microstructure

[0058] As described above, the novel 6xxx aluminum alloy product can achieve a unique microstructure, such as a high volume fraction of dispersoids and / or a high volume fraction of <111> microtexture, as defined below. The volume fraction of the dispersoids and / or the volume fraction of the <111> microtexture shall be determined according to the microstructure evaluation procedure, as described below.

[0059] In one embodiment, and as described above, the novel 6xxx aluminum alloy product has a dispersoid area fraction (f) of at least 0.30%, where the dispersoids include FeMn 3 Si 2Dispersed phase. In another embodiment, the novel 6xxx aluminum alloy product has a dispersed phase area fraction (f) of at least 0.35%. In yet another embodiment, the novel 6xxx aluminum alloy product has a dispersed phase area fraction (f) of at least 0.40%. In another embodiment, the novel 6xxx aluminum alloy product has a dispersed phase area fraction (f) of at least 0.45%. In yet another embodiment, the novel 6xxx aluminum alloy product has a dispersed phase area fraction (f) of at least 0.50%. In another embodiment, the novel 6xxx aluminum alloy product has a dispersed phase area fraction (f) of at least 0.55%. In yet another embodiment, the novel 6xxx aluminum alloy product has a dispersed phase area fraction (f) of at least 0.60%. In another embodiment, the novel 6xxx aluminum alloy product has a dispersed phase area fraction (f) of at least 0.65%. In yet another embodiment, the novel 6xxx aluminum alloy product has a dispersed phase area fraction (f) of at least 0.70%. In another embodiment, the novel 6xxx aluminum alloy product has a dispersed phase area fraction (f) of at least 0.75%. In yet another embodiment, the novel 6xxx aluminum alloy product has a dispersed phase area fraction (f) of at least 0.80%. In another embodiment, the novel 6xxx aluminum alloy product has a dispersed phase area fraction (f) of at least 0.85%. In yet another embodiment, the novel 6xxx aluminum alloy product has a dispersed phase area fraction (f) of at least 0.90%. In another embodiment, the novel 6xxx aluminum alloy product has a dispersed phase area fraction (f) of at least 0.95%. In yet another embodiment, the novel 6xxx aluminum alloy product has a dispersed phase area fraction (f) of at least 1.0%. In another embodiment, the novel 6xxx aluminum alloy product has a dispersed phase area fraction (f) of at least 1.05%. In yet another embodiment, the novel 6xxx aluminum alloy product has a dispersed phase area fraction (f) of at least 1.10%.

[0060] In one embodiment, the novel 6xxx aluminum alloy product achieves a mean (average) dispersed phase particle size of 0.05 to 0.20 microns.

[0061] In one embodiment, the D90 of the dispersed phase is not greater than 0.30 microns. In another embodiment, the D90 of the dispersed phase is not greater than 0.27 microns. In yet another embodiment, the D90 of the dispersed phase is not greater than 0.24 microns. In another embodiment, the D90 of the dispersed phase is not greater than 0.21 microns. In yet another embodiment, the D90 of the dispersed phase is not greater than 0.19 microns. In another embodiment, the D90 of the dispersed phase is not greater than 0.18 microns.

[0062] In one embodiment, the D10 of the dispersed phase is at least 0.02 microns. In another embodiment, the D10 of the dispersed phase is at least 0.03 microns. In yet another embodiment, the D10 of the dispersed phase is at least 0.04 microns.

[0063] In one embodiment, the novel 6xxx aluminum alloy product contains at least 3 vol% of <111> microtexture. In another embodiment, the novel 6xxx aluminum alloy product contains at least 5 vol% of <111> microtexture. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 7 vol% of <111> microtexture. In another embodiment, the novel 6xxx aluminum alloy product contains at least 9 vol% of <111> microtexture. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 11 vol% of <111> microtexture. In another embodiment, the novel 6xxx aluminum alloy product contains at least 13 vol% of <111> microtexture. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 15 vol% of <111> microtexture. In another embodiment, the novel 6xxx aluminum alloy product contains at least 17 vol% of <111> microtexture. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 19 vol% of <111> microtexture. In another embodiment, the novel 6xxx aluminum alloy product contains at least 21 vol% of <111> microtexture. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 23 vol% of <111> microtexture. In another embodiment, the novel 6xxx aluminum alloy product contains at least 25 vol% of <111> microtexture. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 27 vol% of <111> microtexture. In another embodiment, the novel 6xxx aluminum alloy product contains at least 29 vol% of <111> microtexture. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 31 vol% of <111> microtexture. In another embodiment, the novel 6xxx aluminum alloy product contains at least 33 vol% of <111> microtexture. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 35 vol% of <111> microtexture. In another embodiment, the novel 6xxx aluminum alloy product contains at least 37 vol% of <111> microtexture. In yet another embodiment, the novel 6xxx aluminum alloy product contains at least 39 vol% of <111> microtexture.

[0064] iv. Properties

[0065] As mentioned above, the novel aluminum alloy can achieve an improved combination of properties. For example, products made from the novel 6xxx aluminum alloy can achieve an improved combination of two or more of strength, ductility (elongation), extrudability, extrusion temperature, and extrusion speed, and do not exhibit surface defects visible to the naked eye (e.g., do not crack, hot tear, etc.).

[0066] In one embodiment, the novel 6xxx aluminum alloy product achieves a tensile yield strength (LT) of at least 40 ksi. In another embodiment, the novel 6xxx aluminum alloy product achieves a tensile yield strength (LT) of at least 41 ksi. In yet another embodiment, the novel 6xxx aluminum alloy product achieves a tensile yield strength (LT) of at least 42 ksi. In another embodiment, the novel 6xxx aluminum alloy product achieves a tensile yield strength (LT) of at least 43 ksi. In yet another embodiment, the novel 6xxx aluminum alloy product achieves a tensile yield strength (LT) of at least 44 ksi. In another embodiment, the novel 6xxx aluminum alloy product achieves a tensile yield strength (LT) of at least 45 ksi. In yet another embodiment, the novel 6xxx aluminum alloy product achieves a tensile yield strength (LT) of at least 46 ksi. In another embodiment, the novel 6xxx aluminum alloy product achieves a tensile yield strength (LT) of at least 47 ksi. In yet another embodiment, the novel 6xxx aluminum alloy product achieves a tensile yield strength (LT) of at least 48 ksi. In another embodiment, the novel 6xxx aluminum alloy product achieves a tensile yield strength (LT) of at least 49 ksi. In yet another embodiment, the novel 6xxx aluminum alloy product achieves a tensile yield strength (LT) of at least 50 ksi. In another embodiment, the novel 6xxx aluminum alloy product achieves a tensile yield strength (LT) of at least 51 ksi. In yet another embodiment, the novel 6xxx aluminum alloy product achieves a tensile yield strength (LT) of at least 52 ksi. In another embodiment, the novel 6xxx aluminum alloy product achieves a tensile yield strength (LT) of at least 53 ksi. In yet another embodiment, the novel 6xxx aluminum alloy product achieves a tensile yield strength (LT) of at least 54 ksi. The properties determined in this paragraph can be achieved in a variety of tempers, including T5 and T8 tempers.

[0067] In one embodiment, the novel 6xxx aluminum alloy product achieves a minimum ultimate tensile strength (LT) of at least 43 ksi. In another embodiment, the novel 6xxx aluminum alloy product achieves a minimum ultimate tensile strength (LT) of at least 44 ksi. In another embodiment, the novel 6xxx aluminum alloy product achieves a minimum ultimate tensile strength (LT) of at least 45 ksi. In yet another embodiment, the novel 6xxx aluminum alloy product achieves a minimum ultimate tensile strength (LT) of at least 46 ksi. In another embodiment, the novel 6xxx aluminum alloy product achieves a minimum ultimate tensile strength (LT) of at least 47 ksi. In yet another embodiment, the novel 6xxx aluminum alloy product achieves a minimum ultimate tensile strength (LT) of at least 48 ksi. In another embodiment, the novel 6xxx aluminum alloy product achieves a minimum ultimate tensile strength (LT) of at least 49 ksi. In yet another embodiment, the novel 6xxx aluminum alloy product achieves a minimum ultimate tensile strength (LT) of at least 50 ksi. In another embodiment, the novel 6xxx aluminum alloy product achieves a minimum ultimate tensile strength (LT) of at least 51 ksi. In yet another embodiment, the novel 6xxx aluminum alloy product achieves a minimum ultimate tensile strength (LT) of at least 52 ksi. In another embodiment, the novel 6xxx aluminum alloy product achieves a minimum ultimate tensile strength (LT) of at least 53 ksi. In yet another embodiment, the novel 6xxx aluminum alloy product achieves a minimum ultimate tensile strength (LT) of at least 54 ksi. In another embodiment, the novel 6xxx aluminum alloy product achieves a minimum ultimate tensile strength (LT) of at least 55 ksi. In yet another embodiment, the novel 6xxx aluminum alloy product achieves a minimum ultimate tensile strength (LT) of at least 56 ksi. The properties determined in this paragraph can be achieved in a variety of temper forms, including T5 and T8 tempers.

[0068] In one embodiment, the novel 6xxx aluminum alloy product achieves a minimum elongation (LT) of at least 8%. In another embodiment, the novel 6xxx aluminum alloy product achieves a minimum elongation (LT) of at least 9%. In yet another embodiment, the novel 6xxx aluminum alloy product achieves a minimum elongation (LT) of at least 10%. In another embodiment, the novel 6xxx aluminum alloy product achieves a minimum elongation (LT) of at least 11%. In yet another embodiment, the novel 6xxx aluminum alloy product achieves a minimum elongation (LT) of at least 12%. In another embodiment, the novel 6xxx aluminum alloy product achieves a minimum elongation (LT) of at least 13%. In yet another embodiment, the novel 6xxx aluminum alloy product achieves a minimum elongation (LT) of at least 14%. The properties determined in this paragraph can be achieved in a variety of temper forms, including T5 and T8 tempers.

[0069] v. Product Application

[0070] The novel 6xxx aluminum alloy described herein can be used in a variety of applications, such as in applications that require high-speed machining, i.e., the novel 6xxx aluminum alloy can be used as a high-speed machining alloy. In one embodiment, the novel 6xxx aluminum alloy is in the form of an extruded bar.

[0071] vi. Definition

[0072] "Forged aluminum alloy products" means aluminum alloy products that are hot-worked after casting and include rolled products (sheets or plates), forged products, and extruded products.

[0073] "Hot working" such as hot rolling means working the aluminum alloy product at a high temperature, and is typically at least 121.1 °C (250 °F). Strain hardening is restricted / avoided during hot working, which generally distinguishes hot working from cold working.

[0074] "Cold working" such as cold rolling means working the aluminum alloy product at a temperature that is not considered a hot working temperature, generally below about 121.1 °C (250 °F) (e.g., at ambient temperature).

[0075] The temper definition conforms to ANSI H35.1 (2009) published by The Aluminum Association, titled "American National Standard Alloy and Temper Designation Systems for Aluminum".

[0076] Strength and elongation are measured in accordance with ASTM E8 / E8M-16a and B557-15.

[0077] vii. Microstructure Evaluation Procedure

[0078] The following procedures and definitions are used to measure the microstructural features (e.g., dispersion phase content and particle size, volume fraction of <111> microtexture) of products prepared according to this patent application.

[0079] A. Dispersed Phase

[0080] The "dispersion phase area fraction" f is the fraction of the area occupied by the dispersion phase particles divided by the total area examined in a two-dimensional cross-section prepared by standard metallographic sample preparation methods.

[0081] The "dispersion phase area %" is determined via the formula f x 100.

[0082] The "dispersion phase average diameter" is the average of all measured dispersion phase diameters, d i, where each diameter is an equivalent diameter calculated based on the following assumption: each dispersed phase area measured on a two-dimensional cross-section is a circle with an effective diameter:

[0083]

[0084] To measure the dispersed phase area fraction f and the average diameter of the dispersed phase, backscattered electron images should be taken at different magnifications and contrast / brightness settings to determine the lowest magnification at which the smallest-sized dispersed phase can be adequately captured. The brightness / contrast setting is determined to be acceptable when the dispersed phase is significantly brighter than the background matrix and the edges of the particles are easily recognizable. Typically, the magnification on the screen is from 1000× to 10000×. For the images of Example 1 below, the magnification on the screen is 5000×. A scanning electron microscope such as an Apreo S field emission gun (Thermo Fisher Scientific, Waltham, MA, U.S.A.) or an equivalent product is used to image the dispersed phase. The images should be taken using an accelerating voltage of 5 kV. The beam current should be 0.8 nanoamperes. The working distance should be 5 mm. The dwell time should be 5 microseconds. The line average should be 3. Depending on the situation, at least twenty images should be collected from the metallographically polished samples of each alloy at the T / 2 or D / 2 position or near the T / 2 or D / 2 position. For each sample, images should be captured from several different random positions so that the overall analysis can represent the microstructure. Although the minimum number required for analysis remains twenty acceptable images, any images with scratches, foreign feature parts, or focus problems should be excluded. MIPAR version 3.3.4 or an equivalent version should be used to perform image analysis to quantify the images. The pixel size used to quantify the dispersed phase will vary depending on the magnification and image resolution. The image analysis of Example 1 uses a pixel size of 0.008 microns. For an 8-bit image ranging from 0 (black) to 255 (white), the peak (mode) of the image histogram corresponding to the average background level is 69 - 71. Only when the gray value of a pixel is 40% greater than the background (i.e., the global threshold is 100) is the pixel considered to belong to the dispersed phase. If the area of a particle consists of fewer than 20 consecutive pixels, or if the particle is larger than 1500 pixels, or if the mean intensity of all pixels in the particle does not exceed 10% of the minimum threshold defined above, the particle is not considered a dispersed phase. Before analysis, each image frame is inspected and any non-dispersed phase particles are manually erased; non-dispersed phase particles can include debris on the surface, such as polishing compounds, or image artifacts, such as charging. A data file (e.g., EXCEL, Microsoft, U.S.A.) showing the statistical information of each particle is generated. Calculations are performed based on the data file. By obtaining the total particle area and calculating the diameter when the particle is a perfect circle, the equivalent diameter of each particle can be generated.

[0085] Figure 1B Shows an exemplary image of particle size analysis. Figure 1A Is a SEM processed according to the above program that generates Figure 1B the above.

[0086] B. Volume Fraction of <111> Microtexture

[0087] "Percentage <111>-microtexture", etc. means the volume percentage (fraction) of the <111> crystal direction of a forged aluminum alloy product that is closely aligned with the L direction (e.g., the extrusion direction of an extruded product). The amount of <111> microtexture is determined by performing EBSD (electron backscatter diffraction) analysis on an appropriate area of the forged aluminum alloy product. A larger amount of <111> microtexture indicates a non-recrystallized microstructure, while a smaller amount of <111> microtexture indicates a recrystallized microstructure.

[0088] The following EBSD sample procedure should be used to perform EBSD analysis on the entire width of a sample of a forged product in the LT-ST plane. The particle size of the sample to be analyzed will generally vary with the particle size and shape of the forged product (e.g., the particle size and shape of an extruded profile). Before measurement, the EBSD sample is prepared by standard metallographic sample preparation methods. For example, the EBSD sample is metallographically prepared and then polished (e.g., using 0.05 micron colloidal silica). The sample is then anodized in Barker's reagent (a dilute fluoboric acid solution) for 90 seconds. The sample is then etched using an aqueous phosphoric acid solution containing chromium trioxide, and then rinsed and dried.

[0089] The "EBSD sample procedure" is as follows:

[0090] ● The software used is APEX EBSD collection software version 2 (EDAX Inc., New Jersey, U.S.A.) or equivalent, which is connected to a Velocity EBSD camera (EDAX Inc., New Jersey, U.S.A.) or equivalent. The SEM is an APREO S field emission gun (Thermo Fisher Scientific, Waltham, MA, U.S.A.) or equivalent.

[0091] ● The EBSD operating conditions are tilt 68°, working distance 18 mm, accelerating voltage 20 kV, dynamic focus, and the beam current specified by the instrument is 26 nA (nanoampere). The collection mode is a grid. Selection is made such that orientations are collected in the analysis (i.e., Hough peak information is not collected). Scans are collected at 3-micron step size, 120× over multiple frames to cover the entire sample width. The APEX software merges these frames together. If the entire sample cannot be scanned, e.g., the profile size is too large, then several discrete positions can be mapped provided that, when performing the global analysis, the results represent the average of the entire extrudate. The data collected is output in the form of a *.osc file. This data can be used to calculate the volume fraction of the <111> microtexture, as described below.

[0092] ● Calculation of Volume Fraction of <111> Microtexture : Use the data from the *.osc file and OIM analysis software (EDAX Inc., New Jersey, U.S.A.), version 8.5.1 or equivalent, to calculate the volume fraction of the <111> microtexture. Two steps of data cleaning can be performed before the calculation. First, for any points with a confidence index less than the threshold of 0.10, nearest neighbor orientation correlation cleaning is performed, requiring 5 nearest neighbors with similar orientations [out of the possible 8]. Second, grain dilation cleaning is performed on any grains with less than 3 data points (confidence index less than the threshold of 0.15). Then, the number of <111> microtextures is calculated using the <111> microtexture criteria (described below) through the software.

[0093] ● <111> Microtexture Standard : Generate a crystal orientation map for <111> aligned within 10° of the longitudinal axis (e.g., the extrusion axis), which corresponds to the normal direction of the EBSD scan of the LT-ST plane. The software calculates the area fraction of all points contained within this partition. Since the crystal texture measurement results are three-dimensional, calculating the area fraction is equivalent to the volume fraction (volume percentage).

[0094] viii. Others

[0095] These and other aspects, advantages, and novel features of this new technology are partially described in the following description, and will become apparent to those skilled in the art upon examination of the following description and the drawings, or can be learned by practicing one or more embodiments of the technology provided by this disclosure.

[0096] Among the benefits and improvements already disclosed, other objects and advantages of the present invention will become apparent from the following description taken in conjunction with the accompanying drawings. Specific embodiments of the invention are disclosed herein; however, it is to be understood that the disclosed embodiments merely illustrate the invention which can be embodied in various forms. Additionally, each example given along with the various embodiments of the invention is intended to be illustrative and not limiting.

[0097] 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 can. Additionally, as used herein, the phrases "in another embodiment" and "in some other embodiments" do not necessarily refer to different embodiments, although they can. Thus, the various embodiments of the invention can be readily combined without departing from the scope or spirit of the invention.

[0098] Furthermore, 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 additional factors not described. Additionally, throughout this specification, unless the context clearly dictates otherwise, the meanings of "a", "an", and "the" include plural referents. Unless the context clearly dictates otherwise, the meaning of "in" includes "in" and "on".

[0099] Although multiple embodiments of the invention have been described, it should be understood that these embodiments are illustrative only and not restrictive, and various modifications may be apparent to those skilled in the art. Still further, unless the context clearly requires, the various steps can be performed in any desired order, and any applicable steps can be added and / or eliminated. Description of the Drawings

[0100] Figure 1A is an SEM image of a representative alloy of Alloy 4-6 of Example 1.

[0101] Figure 1B is a processed form of the SEM image for Figure 1A particle (dispersion phase) size analysis.

[0102] Figure 2 is an image showing the dispersion phase particle size distribution of the alloy of Example 1.

[0103] Figure 3Ais a representative microstructure of the standard 6020 alloy from Example 1, which was taken across the entire width of the extruded bar and centered at D / 2; this microstructure is a <111> crystal orientation map generated from EBSD data of points aligned within 10° of the extrusion axis.

[0104] Figure 3B is a representative microstructure of Alloy 1-3 from Example 1, which was taken across the entire width of the extruded bar and centered at D / 2; this microstructure is a <111> crystal orientation map generated from EBSD data of points aligned within 10° of the extrusion axis.

[0105] Figure 3C is a representative microstructure of Alloys 4-6 from Example 1, which was taken across the entire width of the extruded bar and centered at D / 2; this microstructure is a <111> crystal orientation map generated from EBSD data of points aligned within 10° of the extrusion axis. Detailed Description

[0106] Example 1

[0107] Six industrial-grade ingots (11 inches (D) × 40 inches (L); 27.9 cm (D) × 101.6 cm (L)) of the new aluminum alloy shown in Table 1 were cast. Three conventional 6020 ingots of the same grain size were also cast, and the average composition of the ingots is provided in Table 1 below.

[0108] Table 1 - Composition of the alloy of Example 1 (wt%) *

[0109]

[0110]

[0111] * The balance of the alloy is incidental elements and impurities, where the alloy contains no more than 0.03 wt% of any one impurity, and where the total percentage of all impurities contained in the alloy does not exceed 0.10 wt%.

[0112] After casting, the billets are homogenized and then extruded into wire rods with a diameter of 0.637 inches (16.17 mm) at a nominal temperature of 940°F (504°C) (furnace temperature set point) and an extrusion speed of 38.5 ft / min (11.58 m / min), and then water quenched. The extruded rods are then drawn to a final diameter of 0.539 inches (13.7 mm) at 28.4% ROA (reduction of area), and then aged at 355°F (179.4°C) for 8 hours to produce T8 tempered rods. The mechanical properties of the rods are then measured by obtaining tensile samples from the front and rear of each rod. The mechanical property results are summarized in Table 2 below. (Values are the average of two samples.)

[0113] Table 2 - Stretch and Artificial Aging Practice of Alloy in Example 1

[0114]

[0115] As shown, the new alloy achieves significantly higher strength than the conventional 6020 alloy, and the ductility is roughly similar. Alloys 4 - 6 with higher silicon (≥0.8 wt%) and manganese (≥0.3 wt%) contents achieve significantly higher strength than the conventional 6020 alloy.

[0116] SEM images were also taken and particle counting was performed according to the above Microstructure Evaluation Procedure The particle counting results are shown in Table 3 below. Figure 2 The particle size distribution is shown. The mean and D10 - D90 values provided below are in microns.

[0117] Table 3 – Dispersed Phase Analysis – Alloy in Example 1

[0118]

[0119] Particle counting represents the volume of the dispersed phase in the alloy product, including FeMn 3 Si 2 volume of the dispersed phase. As shown, the new alloy contains significantly more dispersed phase than the conventional 6020 alloy, but the dispersed phase particle size is roughly similar. It is believed that the higher manganese, iron, and / or silicon content at least partially contributes to the formation of a higher volume fraction of the dispersed phase in the new aluminum alloy product. This high number of dispersed phases can be beneficial especially for the production of forged aluminum alloy products in a partially non - recrystallized or fully non - recrystallized form. Thus, improved properties can be achieved.

[0120] Microstructural analysis was also performed on the produced rods. Specifically, one rod of alloys 1 - 3, one rod of alloys 4 - 6, and one rod of 6020 alloy were subjected to EBSD imaging according to the above Microstructure Evaluation Procedure As Figure 3A - 3CAs shown, the standard 6020 alloy contains very little <111> microtexture, where the <111> microtexture is less than 3% by volume, which is consistent with a fully recrystallized microstructure. In contrast, the new alloy has at least 0.15 wt% Mn and 0.40 wt% Fe, achieving significantly more <111> microtexture. Alloys 1 - 3 have approximately 0.66 wt% Si, 0.42 wt% Fe, and 0.18 wt% Mn, containing approximately 20% by volume of <111> microtexture, which is consistent with a partially non-recrystallized microstructure. Alloys 4 - 6 have approximately 0.81 wt% Si, 0.45 wt% Fe, and 0.32 wt% Mn, containing approximately 40% by volume of <111> microtexture, which is consistent with a fully non-recrystallized microstructure.

[0121] Example 2

[0122] Additional industrial-grade ingots were cast according to Example 1 and these ingots were homogenized. The compositions of these ingots are shown in Table 4 below.

[0123] Table 4 - Composition (wt%) of Alloy in Example 2*

[0124] Alloy Si Fe Cu Mn Mg Cr Zn Ti Sn 7 0.86 0.46 0.67 0.31 0.86 0.12 0.05 0.06 1.08

[0125] * The balance of the alloy is incidental elements and impurities, where the alloy contains no more than 0.03 wt% of any one impurity, and where the total percentage of all impurities contained in the alloy does not exceed 0.10 wt%.

[0126] The first group of homogenized ingots was preheated from room temperature to 940°F (504°C), then extruded at an extrusion speed of 50 ft / min (15.24 m / min) to a diameter of 1.031 inches (26.2 mm), and then water quenched. Then the extruded rod was stretched to a final diameter of 0.952 inches (24.2 mm) at 14.6% ROA (reduction of area), and then aged at 355°F (179.4°C) for 8 hours to produce the first group of T8 tempered rods (Alloy 7A).

[0127] The second group of homogenized ingots was preheated from room temperature to 870°F (465.6°C), then extruded at an extrusion speed of 50 ft / min (15.24 m / min) to a diameter of 1.077 inches (27.3 mm), and then water quenched. Then the extruded rod was stretched to a final diameter of 0.953 inches (24.2 mm) at 21.7% ROA (reduction of area), and then aged at 355°F (179.4°C) for 8 hours to produce the T8 tempered rods (Alloy 7B).

[0128] Then, the mechanical properties of the bars were measured by obtaining tensile samples from the front and rear of each bar. The results of the mechanical properties are summarized in Table 5 below. (Values are the average of at least three samples.) Table 5 - Mechanical Properties of the Alloy of Example 2

[0129]

[0130] It is believed that a higher number of dispersion phases is beneficial, especially for the production of partially non-recrystallized bars or fully non-recrystallized bars, thereby improving the mechanical properties. For example, Alloy 7 contains 0.12 wt% of Cr, while Alloys 1 - 6 contain 0.05 wt% to 0.06 wt% of Cr. The increase in the chromium content in Alloy 7 can at least partially result in a significant improvement in its strength properties.

[0131] Although the various embodiments of the present disclosure have been described in detail, it is obvious that those skilled in the art will make modifications and adjustments to 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. A 6xxx aluminum alloy product, the 6xxx aluminum alloy product comprising: 0.5 to 1.5% by weight of Sn; 0.4 to 1.6% by weight of Si; 0.6 to 1.2% by weight of Mg; wherein the weight ratio of (wt% of Si) to (wt% of Mg) is at least 0.75:1; 0.5 to 1.1% by weight of Cu; 0.15 to 1.5% by weight of Mn; 0.10 to 0.80% by weight of Fe; wherein (wt% of Si) + (wt% of Mn) + (wt% of Fe) is at least 0.95% by weight; up to 1.2% by weight of Bi; up to 1.2% by weight of In; up to 1.0% by weight of Zn; up to 0.35% by weight of Cr; up to 0.25% by weight of V; up to 0.25% by weight of Zr; up to 0.15% by weight of Ti; up to 0.04% by weight of Pb; the balance being aluminum, optionally incidental elements and impurities; wherein the 6xxx aluminum alloy product has a dispersed phase area fraction (f) of at least 0.30%, and wherein the dispersed phase comprises FeMn 3 Si 2 dispersed phase 2. The 6xxx aluminum alloy product according to claim 1, wherein the 6xxx aluminum alloy product comprises at least 0.55% by weight of Sn, or at least 0.60% by weight of Sn, or at least 0.65% by weight of Sn, or at least 0.70% by weight of Sn, or at least 0.75% by weight of Sn, or at least 0.80% by weight of Sn, or at least 0.85% by weight of Sn, or at least 0.90% by weight of Sn, or at least 0.95% by weight of Sn, or at least 1.0% by weight of Sn, or at least 1.05% by weight of Sn, or at least 1.10% by weight of Sn.

3. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product comprises not more than 1.45% by weight of Sn or not more than 1.40% by weight of Sn or not more than 1.35% by weight of Sn or not more than 1.30% by weight of Sn.

4. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product comprises at least 0.45% by weight of Si or at least 0.50% by weight of Si or at least 0.55% by weight of Si or at least 0.60% by weight of Si or at least 0.65% by weight of Si, or at least 0.70% by weight of Si or at least 0.75% by weight of Si, or at least 0.80% by weight of Si.

5. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product comprises not more than 1.55% by weight of Si or not more than 1.50% by weight of Si or not more than 1.45% by weight of Si, or not more than 1.40% by weight of Si or not more than 1.35% by weight of Si, or not more than 1.30% by weight of Si, or not more than 1.25% by weight of Si, or not more than 1.20% by weight of Si, or not more than 1.15% by weight of Si, or not more than 1.10% by weight of Si, or not more than 1.05% by weight of Si or not more than 1.0% by weight of Si or not more than 0.95% by weight of Si or not more than 0.90% by weight of Si.

6. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product contains at least 0.65 wt% of Mg or at least 0.70 wt% of Mg.

7. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product contains no more than 1.15 wt% of Mg, or no more than 1.10 wt% of Mg, or no more than 1.05 wt% of Mg, or no more than 1.0 wt% of Mg, or no more than 0.95 wt% of Mg, or no more than 0.90 wt% of Mg, or no more than 0.85 wt% of Mg.

8. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the weight ratio of (wt% of Si) to (wt% of Mg) is at least 0.80:1, or at least 0.85:1, or at least 0.90:1, or at least 0.95:1, or at least 1.0:1, or at least 1.05:1, or at least 1.10:1, or at least 1.15:

1.

9. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the weight ratio of (wt% of Si) to (wt% of Mg) is not greater than 2.2:1, or not greater than 2.1:1, or not greater than 2.0:1, or not greater than 1.9:1, or not greater than 1.8:1, or not greater than 1.7:1, or not greater than 1.6:1, or not greater than 1.5:1, or not greater than 1.4:1, or not greater than 1.3:1, or not greater than 1.2:

1.

10. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein (wt% of Si) + (wt% of Mg) is at least 1.3 wt%, or at least 1.35 wt%, or at least 1.40 wt%, or at least 1.45 wt%, or at least 1.50 wt%, or at least 1.55 wt%, or at least 1.60 wt%, or at least 1.65 wt%, or at least 1.70 wt%.

11. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein (wt% of Si) + (wt% of Mg) is not greater than 2.6 wt%, or not greater than 2.5 wt%, or not greater than 2.4 wt%, or not greater than 2.3 wt%, or not greater than 2.2 wt%, or not greater than 2.1 wt%, or not greater than 2.0 wt%, or not greater than 1.9 wt%, or not greater than 1.85 wt%, or not greater than 1.8 wt%, or not greater than 1.75 wt%.

12. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product contains at least 0.55 wt% of Cu, or at least 0.60 wt% of Cu, or at least 0.65 wt% of Cu.

13. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product contains no more than 1.05 wt% of Cu, or no more than 1.0 wt% of Cu, or no more than 0.95 wt% of Cu, or no more than 0.90 wt% of Cu, or no more than 0.85 wt% of Cu, or no more than 0.80 wt% of Cu, or no more than 0.75 wt% of Cu.

14. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product contains at least 0.18 wt% of Mn, or at least 0.20 wt% of Mn, or at least 0.22 wt% of Mn, or at least 0.24 wt% of Mn, or at least 0.26 wt% of Mn, or at least 0.28 wt% of Mn, or at least 0.30 wt% of Mn, or at least 0.32 wt% of Mn, or at least 0.34 wt% of Mn, or at least 0.36 wt% of Mn, or at least 0.38 wt% of Mn, or at least 0.40 wt% of Mn.

15. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product contains no more than 1.45 wt% of Mn, or no more than 1.40 wt% of Mn, or no more than 1.35 wt% of Mn, or no more than 1.30 wt% of Mn, or no more than 1.25 wt% of Mn, or no more than 1.20 wt% of Mn, or no more than 1.15 wt% of Mn, or no more than 1.10 wt% of Mn, or no more than 1.05 wt% of Mn, or no more than 1.0 wt% of Mn, or no more than 0.95 wt% of Mn, or no more than 0.90 wt% of Mn, or no more than 0.85 wt% of Mn, or no more than 0.80 wt% of Mn, or no more than 0.75 wt% of Mn, or no more than 0.70 wt% of Mn, or no more than 0.65 wt% of Mn, or no more than 0.60 wt% of Mn, or no more than 0.55 wt% of Mn, or no more than 0.50 wt% of Mn, or no more than 0.45 wt% of Mn, or no more than 0.42 wt% of Mn.

16. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product contains at least 0.15 wt% of Fe, or at least 0.20 wt% of Fe, or at least 0.25 wt% of Fe, or at least 0.30 wt% of Fe, or at least 0.35 wt% of Fe, or at least 0.40 wt% of Fe, or at least 0.45 wt% of Fe, or at least 0.50 wt% of Fe.

17. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product contains no more than 0.75 wt% of Fe, or no more than 0.70 wt% of Fe, or no more than 0.65 wt% of Fe, or no more than 0.60 wt% of Fe, or no more than 0.55 wt% of Fe, or no more than 0.52 wt% of Fe.

18. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein (wt% of Si) + (wt% of Mn) + (wt% of Fe) is at least 1.0 wt%, or at least 1.05 wt%, or at least 1.10 wt%, or at least 1.15 wt%, or at least 1.20 wt%, or at least 1.25 wt%, or at least 1.30 wt%, or at least 1.35 wt%, or at least 1.40 wt%, or at least 1.45 wt%, or at least 1.50 wt%, or at least 1.55 wt% or at least 1.60 wt%.

19. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein (wt% of Si) + (wt% of Mn) + (wt% of Fe) is not more than 3.1 wt%, or not more than 3.0 wt%, or not more than 2.9 wt%, or not more than 2.8 wt%, or not more than 2.7 wt%, or not more than 2.6 wt%, or not more than 2.5 wt%, or not more than 2.4 wt%, or not more than 2.3 wt%, or not more than 2.2 wt%, or not more than 2.1 wt%, or not more than 2.0 wt%, or not more than 1.9 wt%, or not more than 1.8 wt% or not more than 1.7 wt%.

20. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product contains no more than 1.1 wt% of Bi, or no more than 1.0 wt% of Bi, or no more than 0.9 wt% of Bi, or no more than 0.8 wt% of Bi, or no more than 0.7 wt% of Bi, or no more than 0.6 wt% of Bi, or no more than 0.50 wt% of Bi, or no more than 0.40 wt% of Bi, or no more than 0.30 wt% of Bi, or no more than 0.20 wt% of Bi, or no more than 0.15 wt% of Bi, or no more than 0.10 wt% of Bi, or no more than 0.08 wt% of Bi, or no more than 0.05 wt% of Bi, or no more than 0.03 wt% of Bi, or no more than 0.01 wt% or no more than 0.005 wt% of Bi.

21. The 6xxx aluminum alloy according to any one of the preceding claims, wherein the 6xxx aluminum alloy product contains at least 0.25 wt% of bismuth, and wherein the bismuth at least partially replaces tin.

22. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product contains no more than 1.1 wt% of In, or no more than 1.0 wt% of In, or no more than 0.9 wt% of In, or no more than 0.8 wt% of In, or no more than 0.7 wt% of In, or no more than 0.6 wt% of In, or no more than 0.50 wt% of In, or no more than 0.40 wt% of In, or no more than 0.30 wt% of In, or no more than 0.20 wt% of In, or no more than 0.15 wt% of In, or no more than 0.10 wt% of In, or no more than 0.08 wt% of In, or no more than 0.05 wt% of In, or no more than 0.03 wt% of In, or no more than 0.01 wt% or no more than 0.005 wt% of In.

23. The 6xxx aluminum alloy according to any one of the preceding claims, wherein the 6xxx aluminum alloy product contains at least 0.25 wt% of In, and wherein indium at least partially replaces tin.

24. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product contains no more than 0.9 wt% of Zn, or no more than 0.8 wt% of Zn, or no more than 0.7 wt% of Zn, or no more than 0.6 wt% of Zn, or no more than 0.5 wt% of Zn, or no more than 0.4 wt% of Zn, or no more than 0.3 wt% of Zn, or no more than 0.20 wt% of Zn, or no more than 0.15 wt% of Zn, or no more than 0.10 wt% of Zn, or no more than 0.08 wt% of Zn, or no more than 0.05 wt% of Zn, or no more than 0.03 wt% of Zn.

25. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product contains at least 0.01 wt% of Zn.

26. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product contains at least 0.01 wt% of Cr, or at least 0.03 wt% of Cr, or at least 0.06 wt% of Cr, or at least 0.08 wt% of Cr, or at least 0.10 wt% of Cr, or at least 0.12 wt% of Cr, or at least 0.14 wt% of Cr, or at least 0.16 wt% of Cr, or at least 0.18 wt% of Cr.

27. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product contains no more than 0.30 wt% of Cr, or no more than 0.25 wt% of Cr, or no more than 0.22 wt% of Cr, or no more than 0.20 wt% of Cr.

28. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product contains V not exceeding 0.15% by weight, or V not exceeding 0.10% by weight, or V not exceeding 0.08% by weight, or V not exceeding 0.05% by weight, or V not exceeding 0.03% by weight, or V not greater than 0.01% by weight, or V not greater than 0.005% by weight.

29. The 6xxx aluminum alloy product according to claim 1, wherein the 6xxx aluminum alloy product contains at least 0.01% by weight of V.

30. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product contains Zr not exceeding 0.15% by weight, or Zr not exceeding 0.10% by weight, or Zr not exceeding 0.08% by weight, or Zr not exceeding 0.05% by weight, or Zr not exceeding 0.03% by weight, or Zr not exceeding 0.01% by weight, or Zr not exceeding 0.005% by weight.

31. The 6xxx aluminum alloy product according to claim 1, wherein the 6xxx aluminum alloy product contains at least 0.01% by weight of Zr.

32. The 6xxx aluminum alloy product according to any one of claims 28 to 31, wherein at least one of Zr and V partially replaces Cr.

33. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product contains Ti not exceeding 0.12% by weight, or Ti not exceeding 0.10% by weight, or Ti not exceeding 0.08% by weight, or Ti not exceeding 0.07% by weight, or Ti not exceeding 0.06% by weight, or Ti not exceeding 0.05% by weight.

34. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product contains at least 0.01% by weight of Ti, or at least 0.02% by weight of Ti, or at least 0.03% by weight of Ti.

35. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product contains Pb not exceeding 0.03% by weight, or Pb not exceeding 0.01% by weight, or Pb not exceeding 0.005% by weight.

36. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product contains a total of not more than 0.15% by weight of the impurities, and wherein the 6xxx aluminum alloy product contains not more than 0.05% by weight of each of the impurities, or wherein the 6xxx aluminum alloy product contains a total of not more than 0.10% by weight of the impurities, and wherein the 6xxx aluminum alloy product contains not more than 0.03% by weight of each of the impurities.

37. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the area fraction (f) of the dispersed phase is at least 0.35%, or at least 0.40, or at least 0.45, or at least 0.50, or at least 0.55, or at least 0.60, or at least 0.65, or at least 0.70, or at least 0.75, or at least 0.80, or at least 0.85, or at least 0.90, or at least 0.95, or at least 1.0, or at least 1.05 or at least 1.

10.

38. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the mean (average) grain size of the dispersed phase is from 0.05 to 0.20 microns.

39. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein D90 of the dispersed phase is not greater than 0.30 microns, or not greater than 0.27 microns, or not greater than 0.24 microns, or not greater than 0.21 microns, or not greater than 0.19 microns or not greater than 0.18 microns.

40. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein D10 of the dispersed phase is at least 0.02 microns, or at least 0.03 microns or at least 0.04 microns.

41. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product comprises at least 3 vol% of <111> microtexture, or at least 5 vol% of <111> microtexture, or at least 7 vol% of <111> microtexture, or at least 9 vol% of <111> microtexture, or at least 11 vol% of <111> microtexture, or at least 13 vol% of <111> microtexture, or at least 15 vol% of <111> microtexture, or at least 17 vol% of <111> microtexture, or at least 19 vol% of <111> microtexture, or at least 21 vol% of <111> microtexture, or at least 23 vol% of <111> microtexture, or at least 25 vol% of <111> microtexture, or at least 27 vol% of <111> microtexture, or at least 29 vol% of <111> microtexture, or at least 31 vol% of <111> microtexture, or at least 33 vol% of <111> microtexture, or at least 35 vol% of <111> microtexture, or at least 37 vol% of <111> microtexture or at least 39 vol% of <111> microtexture.

42. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product achieves a tensile yield strength (LT) of at least 40 ksi, or at least 41 ksi, or at least 42 ksi, or at least 43 ksi, or at least 44 ksi, or at least 45 ksi, or at least 46 ksi, or at least 47 ksi, or at least 48 ksi, or at least 49 ksi, or at least 50 ksi, or at least 51 ksi, or at least 52 ksi or at least 53 ksi.

43. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product achieves an ultimate tensile strength (LT) of at least 43 ksi, or at least 44 ksi, or at least 45 ksi, or at least 46 ksi, or at least 47 ksi, or at least 48 ksi, or at least 49 ksi, or at least 50 ksi, or at least 51 ksi, or at least 52 ksi, or at least 53 ksi, or at least 54 ksi, or at least 55 ksi or at least 56 ksi.

44. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product achieves an elongation (LT) of at least 8%, or at least 9%, or at least 10%, or at least 11%, or at least 12%, or at least 13% or at least 14%.

45. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product is a sheet, plate, extrusion or forging.

46. The 6xxx aluminum alloy product according to any one of the preceding claims, wherein the 6xxx aluminum alloy product is an extrusion.

47. The 6xxx aluminum alloy product according to claim 44, wherein the extrusion is a rod.

48. A method, the method comprising: casting an ingot of 6xxx aluminum alloy according to any one of claims 1 to 41; preheating the ingot to an extrusion temperature, wherein the extrusion temperature is from 810°F to 960°F; and extruding the ingot into an extruded product.

49. The method according to claim 48, the method comprising quenching the extruded product during the extrusion step.

50. The method according to claim 48, the method comprising, after the extrusion step, solution heat treating the extruded product and then quenching the extruded product.

51. The method according to any one of claims 49 to 50, the method comprising artificially aging the extruded product.

52. The method according to any one of claims 48 to 50, the method comprising cold working the extruded product and then artificially aging the extruded product.

53. The method according to any one of claims 48 to 50, the method comprising artificially aging the extruded product and then cold working the extruded product.

54. The method according to any one of claims 48 to 53, wherein the extrusion speed is from 40 to 70 feet per minute.

55. The method according to claim 54, wherein the extruded product has no surface defects visible to the naked eye.

56. The method according to any one of claims 48 to 55, wherein the extrusion temperature is at least 820°F, or at least 830°F, or at least 840°F, or at least 850°F, or at least 860°F, or at least 870°F, or at least 880°F, or at least 8980°F, or at least 900°F, or at least 905°F, or at least 910°F, or at least 915°F or at least 920°F.

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