Cladding composite material, article formed from cladding composite material, method of forming cladding composite material, and method of forming article

Abstract

Cladding composites, articles formed from cladding composites, methods of forming cladding composites, and methods of forming articles are provided. The cladding composite includes a core layer and a first layer. The core layer includes a first aluminum alloy having a first corrosion potential. The first layer includes a second aluminum alloy having a second corrosion potential. The second aluminum alloy includes from 0 wt% to 0.5 wt% Zn. The second corrosion potential is in the range of-600 mV to-800 mV. The electronegativity of the first corrosion potential is at least 8 mV and no more than 100 mV lower than the electronegativity of the second corrosion potential.

Description

Technical Field

[0001] The present disclosure relates to a clad composite material, an article formed from the clad composite material, a method of forming the clad composite material, and a method of forming an article. Background Art

[0002] Various devices, such as, for example, heat exchangers, can be formed from tubes and fins. The working principle of a heat exchanger is to circulate a fluid inside the tubes and exchange heat with the surrounding environment through the fins. To ensure that the heat exchanger has an acceptable service life, the heat exchanger can be designed to resist corrosion attacks. Improving the corrosion resistance of heat exchangers can pose significant challenges. Summary of the Invention

[0003] According to a non-limiting aspect of the present disclosure, there is provided a clad composite material comprising a core layer and a first layer. The core layer comprises a first aluminum alloy having a first corrosion potential. The first layer comprises a second aluminum alloy having a second corrosion potential. The second aluminum alloy comprises from 0 wt% to 0.5 wt% of Zn. The second corrosion potential is in the range of -600 mV to -800 mV. The first corrosion potential is at least 8 mV and not more than 100 mV less electronegative than the second corrosion potential.

[0004] It should be understood that the inventions disclosed and described in this specification are not limited to the aspects outlined in this summary of the invention. After considering the following detailed description of various non-limiting and non-exhaustive aspects in accordance with this specification, the reader will understand the foregoing details as well as other details. Brief Description of the Drawings

[0005] The features and advantages of the examples, and the manner of achieving them, will become more apparent and the examples will be better understood by reference to the following description in conjunction with the drawings, in which:

[0006] Figure 1 is a schematic side elevation view of a non-limiting embodiment of a clad composite material according to the present disclosure;

[0007] Figure 2 is a schematic side elevation view of a non-limiting embodiment of a clad composite material according to the present disclosure;

[0008] Figure 3 is a schematic side elevation view of a non-limiting embodiment of an article comprising a clad composite material according to the present disclosure;

[0009] Figure 4 is a block diagram of a non-limiting embodiment of a method for forming a clad composite material and forming an article from the clad composite material according to the present disclosure;

[0010] Figure 5Schematic perspective view of a tube including a non - limiting embodiment of a cladding composite according to the present disclosure; and

[0011] Figure 6 Schematic perspective view of a heat exchanger including a tube comprising a non - limiting embodiment of a cladding composite according to the present disclosure.

[0012] The illustrations set forth herein show certain embodiments in one form, and such illustrations should not be construed as limiting the scope of the appended claims in any way. Detailed Description

[0013] Various embodiments are described and illustrated herein to provide an overall understanding of the structure, function, and use of the disclosed articles and methods. The various embodiments described and illustrated herein are non - limiting and non - exhaustive. Thus, the present invention is not limited by the description of the various non - limiting and non - exhaustive embodiments disclosed herein. Instead, the present invention is defined only by the claims. Features and characteristics described and / or illustrated in connection with various embodiments may be combined with the features and characteristics of other embodiments. Such modifications and variations are intended to be included within the scope of this specification. Accordingly, the claims may be modified to recite any feature or characteristic that is expressly or inherently described or otherwise expressly or inherently supported in this specification. Additionally, the applicant reserves the right to modify the claims to affirmatively disclaim features or characteristics that may exist in the prior art. The various embodiments disclosed and described in this specification may include, consist of, or consist essentially of the various features and characteristics described herein.

[0014] Any reference in this document to "various non - limiting embodiments", "some non - limiting embodiments", "a non - limiting embodiment", "non - limiting embodiments", or similar phrases means that the particular feature, structure, or characteristic described in connection with the example is included in at least one embodiment. Thus, the phrases "in various non - limiting embodiments", "in some non - limiting embodiments", "in a non - limiting embodiment", "in non - limiting embodiments", or similar phrases that appear in the specification do not necessarily refer to the same embodiment. Additionally, in one or more embodiments, the particular features, structures, or characteristics described may be combined in any suitable manner. Thus, the particular features, structures, or characteristics shown or described in connection with a non - limiting embodiment may be combined, in whole or in part, with the features, structures, or characteristics of one or more other non - limiting embodiments without limitation. Such modifications and variations are intended to be included within the scope of the non - limiting embodiments of the present disclosure.

[0015] The various non-limiting embodiments of the alloys discussed in connection with the present disclosure optionally include inadvertently added incidental elements that may, for example, assist in the production of the alloy and / or improve one or more properties or characteristics of the alloy. For example, certain non-limiting embodiments of the alloys according to the present disclosure may include one or more grain refining elements and / or one or more deoxidizing elements added inadvertently. In various non-limiting embodiments, based on the total weight of the alloy, the total concentration of the incidental elements in the alloys according to the present disclosure is preferably not more than 1 wt%, and based on the total weight of the alloy, the concentration of any single incidental element is preferably not more than 0.2 wt%.

[0016] The various non-limiting embodiments of the alloys discussed in connection with the present disclosure may include impurities. As used herein, "impurities" are elements or other materials that may be present in the alloys according to the present disclosure in relatively small concentrations but are not intentionally added to enhance production or affect the properties or characteristics of the alloy. For example, impurities in the alloys according to the present disclosure may be present in small concentrations due to, for example, the inevitable or inadvertent presence of impurities in the feed materials, ingress from the local atmosphere during melting and refining, or contamination due to contact with processing equipment. In various non-limiting embodiments, based on the total weight of the alloy, the total concentration of the impurities in the alloys discussed in the present disclosure is preferably not more than 0.15 wt%, and based on the total weight of the alloy, the concentration of any single impurity is preferably not more than 0.05 wt%.

[0017] Due to the galvanic difference between the composition of the cladding composite and the composition of the material coupled to (e.g., galvanically coupled to) the cladding composite, the cladding composite may be susceptible to galvanic corrosion. As used herein, "galvanic difference" refers to the corrosion potential difference (e.g., the corrosion potential difference) between one region (e.g., layer) and another region. The corrosion potential difference between regions may be attributed to differences in the compositions of the regions. Without being bound by a particular mechanism or theory, in some non-limiting embodiments, when two regions having a corrosion potential difference are coupled together and an electrolyte is present, one region will act as the anode of the galvanic circuit and the other region will act as the cathode of the galvanic circuit. As used herein, "anodic" or "anode" refers to a region having a composition that is more electrochemically negative than another region. As used herein, "cathodic" or "cathode" refers to a region having a composition that is less electrochemically negative than another region. As used herein, "more electrochemically negative" means that the corrosion potential value is more negative than another corrosion potential value (e.g., a corrosion potential value of -900 mV is more electrochemically negative than a corrosion potential value of -740 mV). Similarly, as used herein, "less electrochemically negative" means that the corrosion potential value is more positive than another corrosion potential value (e.g., a corrosion potential value of -740 mV is less electrochemically negative than a corrosion potential value of -900 mV). The corrosion potential may be measured in accordance with ASTM G69-20.

[0018] To improve the corrosion resistance of the cladding composite material and thereby extend the service life of articles comprising the cladding composite material, the present disclosure provides novel cladding composite materials, articles formed from the cladding composite material, methods of forming the cladding composite material, and methods of forming the articles. Embodiments of the cladding composite material according to the present disclosure comprise a core layer and a first layer. The core layer comprises a first aluminum alloy having a first corrosion potential. The first layer comprises a second aluminum alloy having a second corrosion potential. The second corrosion potential is in the range of -600 mV to -800 mV. The first corrosion potential is at least 8 mV less electronegative and not more than 100 mV less electronegative than the second corrosion potential.

[0019] As used herein, the term "core" or "core layer" refers to the substrate layer of the cladding composite material. In various non-limiting embodiments, the "core layer" may be disposed generally at the center of the cladding composite material. However, the position of the core layer in the cladding composite material according to the present disclosure is not limited to the center of the cladding composite material. The core layer may or may not be covered on both of its faces with another layer of the cladding composite material, and for example, the core layer may be disposed on one side of the cladding composite material. Thus, in various non-limiting embodiments, the core layer may be surrounded by other layers of the cladding composite material, have at least one side that is at least partially exposed or have at least one side that is fully exposed.

[0020] Reference Figure 1 , there is provided a cladding composite material 100 according to the present disclosure. The cladding composite material 100 comprises a core layer 102 and a first layer 104, and the first layer may be disposed on the core layer 102. In various non-limiting embodiments, reference Figure 1 , the core layer 102 and the first layer 104 are bonded together in the cladding composite material 100 and may be in contact with each other. Again referring to Figure 2 , optionally, in certain non-limiting embodiments, a cladding composite material 200 according to the present disclosure may comprise a core layer 102, a first layer 104, and a second layer 106 disposed intermediate the core layer 102 and the first layer 104. In various non-limiting embodiments, reference Figure 2 , the core layer 102, the first layer 104, and the second layer 106 are bonded together in the cladding composite material 200, and the second layer 106 may be in contact with the core layer 102 and the first layer 104. In certain non-limiting embodiments, the cladding composite material 100 may further comprise layers other than the core layer 102, the first layer 104, and the second layer 106.

[0021] Reference Figure 3, the article 300 may include the cladding composite material 100 and / or the cladding composite material 200 (not shown) coupled to a second material such as, for example, the fin 308. The fin 308 may include a 1XXX series aluminum alloy or a 3XXX series aluminum alloy, each such aluminum alloy including no more than 0.25 wt% Zn, such as, for example, no more than 0.2 wt% Zn, no more than 0.15 wt% Zn, no more than 0.1 wt% Zn, no more than 0.05 wt% Zn, or no more than 0.01 wt% Zn. A lower concentration of Zn may allow for more efficient fin recycling and / or the use of different grades of aluminum alloy. In some previous instances, relatively large amounts of Zn additives were included in the fins to increase the corrosion potential of the fins and increase the self-corrosion resistance of the fins.

[0022] In various non-limiting embodiments, due to the lower concentration of Zn in the fins, the corrosion potential of the fin 308 may not be as electronegative as desired and may render the fin 308 anodic with respect to the cladding composite materials 100, 200. For example, the corrosion potential of the fin 308 may be in the range of -740 millivolts (mV) to -900 mV, such as, for example, -740 mV to -850 mV, -740 mV to -800 mV, or -740 mV to -780 mV. Generally, the corrosion potential of a corrosion-resistant fin is significantly higher than -900 mV, such that a layer with a corrosion potential value more electronegative than -800 mV (e.g., -850 mV) remains cathodic with respect to the fin.

[0023] To enhance the corrosion resistance of the cladding composite materials 100, 200, the corrosion potential of each layer within the cladding composite material 100 may be selected to achieve the desired corrosion resistance. For example, the cladding composite material 100 may be cathodic with respect to the fin 308 in a galvanic circuit such that the fin 308 corrodes preferentially. In various non-limiting embodiments, a large corrosion potential difference between the fin 308 and the cladding composite materials 100, 200 may result in rapid corrosion of the fin 308, and due to, for example, a low concentration or lack of Zn, the fin 308 may have an undesirable self-corrosion resistance. The corrosion potential of the cladding composite materials 100, 200 may be selected based on the corrosion potential of the fin 308 such that the fin 308 corrodes preferentially at a suitable rate.

[0024] Reference Figures 1-3, the core layer 102 comprises a first aluminum alloy having a first corrosion potential, and the first layer 104 comprises a second aluminum alloy having a second corrosion potential. In various non-limiting embodiments, the first corrosion potential is more electrochemically negative than the second corrosion potential to achieve a galvanic gradient from the first layer 104 to the core layer 102. For example, the first corrosion potential can be at least 8 mV more electrochemically negative than the second corrosion potential, such as at least 10 mV, at least 20 mV, at least 30 mV, or at least 40 mV. The first corrosion potential can be no more than 100 mV more electrochemically negative than the second corrosion potential, such as no more than 90 mV, no more than 80 mV, no more than 70 mV, no more than 60 mV, no more than 50 mV, no more than 40 mV, or no more than 30 mV.

[0025] The second corrosion potential can be selected according to the desired application, such as if the cladding composite materials 100, 200 are to be attached to the fin 308. For example, in various non-limiting embodiments, the second corrosion potential can be in the range of -600 mV to -800 mV, such as -680 mV to -740 mV, -690 mV to -730 mV, -700 mV to -730 mV, -715 mV to -730 mV, or -720 mV to -730 mV. In various non-limiting embodiments, the first corrosion potential can be in the range of -590 mV to -750 mV, such as -620 mV to -730 mV, -630 mV to -720 mV, -650 mV to -720 mV, -690 mV to -720 mV, -690 mV to -710 mV, or -695 mV to less than -720 mV.

[0026] Reference Figure 2 , the second layer 106 comprises a third aluminum alloy having a third corrosion potential. The third corrosion potential can be selected to be more electrochemically positive than the first corrosion potential and more electrochemically negative than the second corrosion potential. In various non-limiting embodiments, regardless of the number of layers in the cladding composite material 100, a galvanic potential gradient can be configured within the cladding composite material 100, where the core layer 102 is the most cathodic among the layers and the first layer 104 is the most anodic among the layers. In various non-limiting embodiments, the third corrosion potential can be in the range of -600 mV to -800 mV, such as -680 mV to -740 mV, -690 mV to -730 mV, -700 mV to -730 mV, or -715 mV to -730 mV.

[0027] Again reference Figures 1-3, to configure a galvanic circuit within the cladding composite 100, the core layer 102 includes a first concentration of a first cathodic material, the first layer 104 includes a second concentration of a second cathodic material, and the second layer 106 includes a third concentration of a third cathodic material. The first concentration can be greater than the second concentration. The third concentration can be greater than the second concentration and less than the first concentration. As used herein, "cathodic material" can be an element or combination of elements that, when present in a layer, can make the corrosion potential of the corresponding layer more electronegative.

[0028] The first cathodic material, the second cathodic material, and the third cathodic material can be the same or different, and in various non-limiting embodiments, the first cathodic material, the second cathodic material, and the third cathodic material are each independently selected from Cu, Mg, Mn, Si, Fe, Cr, Ti, Zr, V, Li, and combinations of two or more thereof. In various instances, the first cathodic material, the second cathodic material, and the third cathodic material can be the same to limit interdiffusion between the layers in the brazing sheet during the brazing cycle. In various non-limiting embodiments, the first cathodic material, the second cathodic material, and the third cathodic material are independently selected from Cu, Zn, and Mg. In various non-limiting embodiments, the first cathodic material, the second cathodic material, and the third cathodic material are a mixture of at least two elements independently selected from Cu, Zn, Mg, Mn, Si, Fe, Cr, Ti, Zr, V, and Li.

[0029] In certain non-limiting embodiments, the first cathodic material, the second cathodic material, and the third cathodic material are Cu. Cu can make the corrosion potential of the corresponding layer more electronegative and provide solid solution strengthening for the corresponding layer. In various non-limiting embodiments, the copper concentration can be limited to 1 wt% or less to inhibit precipitation, which can adversely affect the self-corrosion resistance of the corresponding layer.

[0030] In various non-limiting embodiments, the first concentration can be at least 0.1 wt% greater than the second concentration, such as, for example, at least 0.15 wt% greater, at least 0.2 wt% greater, or at least 0.25 wt% greater. In various non-limiting embodiments, the second concentration can be at least 0.05 wt% greater than the third concentration, such as, for example, at least 0.1 wt% greater, at least 0.15 wt% greater, or at least 0.2 wt% greater. In various non-limiting embodiments, the core layer 102 comprises at least 0.5 wt% of a first anodic material. In various non-limiting embodiments in which the first anodic material, the second anodic material, and the third anodic material are Cu, the first concentration can be in the range of 0.5 wt% to 1 wt% Cu, the second concentration can be in the range of 0.25 wt% to 0.5 wt% Cu, and the third concentration can be in the range of 0.3 wt% to 0.7 wt% Cu. In various non-limiting embodiments, starting from the core layer 102 and advancing towards the first layer 104 through the thickness of the cladding composite 100, the concentration of the anodic material increases with each subsequent layer.

[0031] Referring again to Figures 1-3 , the core layer 102 of the cladding composites 100, 200 comprises a first aluminum alloy, which can be, for example, a 1XXX series aluminum alloy, a 3XXX series aluminum alloy, a 5XXX series aluminum alloy, or a 6XXX series aluminum alloy. In various non-limiting embodiments, the first aluminum alloy comprises: 0.05 wt% to 1.5 wt% of Si; 0 wt% to 0.8 wt% of Fe; 0.5 wt% to 1.0 wt% of Cu; 0.5 wt% to 1.8 wt% of Mn; 0 wt% to 0.2 wt% of Mg; 0 wt% to 0.25 wt% of Zn; 0 wt% to 0.25 wt% of Cr; 0 wt% to 0.15 wt% of Zr; aluminum; optionally, incidental elements; and impurities. In some non-limiting embodiments, the first aluminum alloy comprises: 0.05 wt% to 0.95 wt% of Si; 0 wt% to 0.8 wt% of Fe; 0.7 wt% to 1.0 wt% of Cu; 1.25 wt% to 1.8 wt% of Mn; 0 wt% to 0.15 wt% of Mg; 0 wt% to 0.15 wt% of Zn; 0 wt% to 0.15 wt% of Cr; 0 wt% to 0.1 wt% of Zr; aluminum; optionally, incidental elements; and impurities.

[0032] Still referring again to Figures 1-3, the first layer 104 of the cladding composites 100, 200 comprises a second aluminum alloy, which can be, for example, a 1XXX series aluminum alloy or a 3XXX series aluminum alloy. In various non-limiting embodiments, the second aluminum alloy comprises: 0.05 wt% to 1.0 wt% of Si; 0.25 wt% to 0.5 wt% of Cu; 0 wt% to 0.5 wt% of Zr; 0 wt% to 0.8 wt% of Fe; 0.1 wt% to 1.5 wt% of Mn; 0 wt% to 0.25 wt% of Zn; 0 wt% to 0.2 wt% of Mg; 0 wt% to 0.2 wt% of Ti; 0 wt% to 1 wt% of Cr; 0 wt% to 0.5 wt% of Bi; aluminum; optionally, incidental elements; and impurities. In various non-limiting embodiments, the second aluminum alloy comprises: 0.05 wt% to 1.0 wt% of Si; 0.25 wt% to 0.5 wt% of Cu; 0 wt% to 0.5 wt% of Zr; 0 wt% to 0.8 wt% of Fe; 0.1 wt% to 1.5 wt% of Mn; 0 wt% to 0.1 wt% of Zn; 0 wt% to 0.1 wt% of Mg; 0 wt% to 0.2 wt% of Ti; 0 wt% to 1 wt% of Cr; 0 wt% to 0.5 wt% of Bi; aluminum; optionally, incidental elements; and impurities. In various non-limiting embodiments, the second aluminum alloy comprises 0 wt% to 0.5 wt% of Zn, such as, for example, 0 wt% to 0.25 wt% of Zn, 0 wt% to 0.1 wt% of Zn or 0 wt% to 0.5 wt% of Zn.

[0033] Reference Figure 2 , the second layer 106 of the cladding composite 200 comprises a third aluminum alloy, such as, for example, an aluminum alloy comprising: 0.05 wt% to 1.0 wt% of Si; 0.25 wt% to 0.5 wt% of Cu; 0 wt% to 0.5 wt% of Zr; 0 wt% to 0.8 wt% of Fe; 0.1 wt% to 1.5 wt% of Mn; 0 wt% to 0.25 wt% of Zn; 0 wt% to 0.2 wt% of Mg; 0 wt% to 0.2 wt% of Ti; 0 wt% to 1 wt% of Cr; 0 wt% to 0.5 wt% of Bi; aluminum; optionally, incidental elements; and impurities.

[0034] Reference Figures 1-2 , the thickness of each layer in the cladding composite 100 can be configured based on the desired structural properties of the article to be produced from or combined with the cladding composite 100. For example, in various non-limiting embodiments, the core layer 102 can have a first thickness t1, which can be within the total thickness of the cladding composite 100 (i.e., t 总) within the range of 60% to 90% of. In various non-limiting embodiments, the first layer 104 may have a second thickness t2, and the second thickness is within the total thickness (t of the cladding composite material 100 总 ) within the range of 3% to 20%. Refer to Figure 2 , in various non-limiting embodiments, if present, the second layer 106 may have a third thickness t3, and the third thickness is within the total thickness (t of the cladding composite material 100 总 ) within the range of 3% to 20%. In various non-limiting embodiments, the first thickness t1 is greater than the second thickness t2 and also greater than the third thickness t3. In certain non-limiting embodiments, refer to Figures 1-2 , the total thickness (t of the cladding composite materials 100, 200 总 ) is within the range of 100 μm to 5 mm, such as, for example, within the range of 200 μm to 1 mm.

[0035] Figure 4 is a block diagram of a non-limiting embodiment of a method for forming a cladding composite material according to the present disclosure and an article comprising the cladding composite material, such as, for example, a heat exchanger. In certain non-limiting embodiments, the method includes forming a cladding composite material, such as cladding composite materials 100, 200 ( Figure 4 , step 402). For example, a non-limiting embodiment of the method may include: casting the core layer 102, the first layer 104, and optionally the second layer 106 using a multi-layer casting method, and hot working (e.g., hot rolling) an assembly including a sheet of the core layer 102, a sheet of the first layer 104, and optionally a sheet of the second layer 106 to fix the layers together and form the cladding composite materials 100, 200, or a combination of multi-layer casting and hot working.

[0036] Referring again to Figure 4 , the method further includes, after forming the cladding composite material (e.g., cladding composite materials 100, 200), bringing a first portion containing a first material into contact with a second portion containing all or a part of a non-limiting embodiment of the cladding composite material ( Figure 4 , step 404). For example, a non-limiting embodiment of the method according to the present disclosure may include bringing a first portion containing a first material into contact with a second portion containing all or a part of the cladding composite materials 100, 200. In various non-limiting embodiments, the first portion may be joined to the second portion ( Figure 4 , step 406). For example, the first portion may be joined to the second portion by an adhesive, welding, soldering, brazing, a mechanical joint, or a combination thereof. In various non-limiting embodiments, the first material includes aluminum or an aluminum alloy, such as, for example, a 1XXX series aluminum alloy or a 3XXX series aluminum alloy.

[0037] In various non - limiting embodiments according to the present disclosure, the cladding composite material (e.g., cladding composite materials 100, 200) can have a composition and thickness suitable for forming into a tube. For example, referring to Figure 5 , the cladding composite material 100 or the cladding composite material 200 can be formed into a tube 500. For example, the bendable cladding composite material 100 is such that the first end 508 of the cladding composite material 100 contacts the second end 510 of the cladding composite material 100, thereby forming a tube. The first end 508 and the second end 510 can be bonded together by, for example, an adhesive, welding, soldering, brazing, or a combination thereof. The outer diameter d1 of the tube can be in the range of 3 millimeters (mm) to 30 mm, such as, for example, 3 mm to 8 mm or 5 mm to 7 mm.

[0038] In various non - limiting embodiments, an article such as, for example, a heat exchanger can include a structural element that includes all or a portion of the cladding composite materials 100, 200, such as, for example, all or a portion of the tube 500. The heat exchanger can have suitable galvanic corrosion resistance. The heat exchanger can be, for example, a part of a heating, ventilation, and air - conditioning (HVAC) system.

[0039] For example, referring to Figure 6 , the tube 500 can be a part of a heat exchanger 600. As shown, the heat exchanger 600 includes tubes 500a - 500d and fins 620a - 620d. The fins 620a - 620d can be arranged in a stack, with gaps 622a - 622b between each pair of adjacent fins 620a - 620d. The widths of the gaps 622a - 622b can be the same or different. In various non - limiting embodiments, the gaps 622a - 622b can be absent, and adjacent fins can be in direct contact with each other. The fins 620a - 620d can have holes 624a - 624d extending therethrough, and the holes 624a - 624d can receive the tubes 500a - 500d. The tubes 500a - 500d can be coupled to the fins 620a - 620c by, for example, an adhesive, welding, soldering, brazing, a mechanical joint (e.g., expanded to a friction fit with the fins 620a - 620c), or a combination thereof. The number of tubes 500a - 500d, fins 620a - 620d, and holes 624a - 624d can vary based on the desired application.

[0040] Embodiment

[0041] The present disclosure will be more fully understood by reference to the following examples, which provide non - limiting aspects of various embodiments according to the present disclosure.

[0042] A number of aluminum alloy compositions were selected according to the present disclosure, as listed in Table 1 below. An internally created computer model was used to estimate the corrosion potential of each of the listed aluminum alloy compositions.

[0043] Table 1: Aluminum Alloy Composition Examples and Estimated Corrosion Potentials

[0044]

[0045] Using the aluminum alloy compositions A - G listed in Table 1, a number of clad composite materials were modeled. A number of double - clad composite materials of Examples 1 - 10 were modeled to include a first layer 100 μm thick and a core layer 600 μm thick. The triple - clad composite material of Example 11 was modeled to include a first layer 25 μm thick, a second layer 75 μm thick, and a core layer 600 μm thick, where the second layer was disposed between the first layer and the core layer. After the selected layers were virtually assembled, a brazing diffusion computer model was applied to the assembly to virtually bond the layers together and form a virtual clad composite material, and the corrosion potential across the thickness of the clad composite material was modeled. The calculated corrosion potential across the thickness of the clad composite material was used to evaluate the expected corrosion performance of the composite material. The results are shown in Table 2 below:

[0046] Table 2: Clad Composite Material Examples

[0047]

[0048]

[0049] As shown in Table 2, when the corrosion potential difference between the first layer and the core layer is at least 8 mV, based on the evaluation using the computer model, the expected corrosion performance of the clad composite material is good. It is believed that other embodiments of the clad composite material according to the present disclosure will also exhibit good corrosion performance.

[0050] The following numbered clauses are directed to various non - limiting embodiments and aspects according to the present disclosure.

[0051] Clause 1. A clad composite material, the clad composite material comprising:

[0052] a core layer comprising a first aluminum alloy having a first corrosion potential; and

[0053] a first layer comprising a second aluminum alloy having a second corrosion potential;

[0054] wherein the second corrosion potential is in the range of - 600 mV to - 800 mV, and the first corrosion potential is at least 8 mV less electronegative and not more than 100 mV less electronegative than the second corrosion potential.

[0055] Clause 2. The clad composite material of Clause 1, wherein the first corrosion potential is not more than 50 mV less electronegative than the second corrosion potential.

[0056] Clause 3. The clad composite material of any one of Clauses 1-2, wherein the first corrosion potential is not more than 30 mV less electronegative than the second corrosion potential.

[0057] Clause 4. The clad composite material of any one of Clauses 1-3, wherein the second corrosion potential is in the range of -700 mV to -730 mV and the first corrosion potential is in the range of -650 mV to -720 mV.

[0058] Clause 5. The clad composite material of any one of Clauses 1-4, wherein the second corrosion potential is in the range of -715 mV to -730 mV and the first corrosion potential is in the range of -690 mV to -720 mV.

[0059] Clause 6. The clad composite material of any one of Clauses 1-5, wherein the first layer is disposed on the core layer.

[0060] Clause 7. The clad composite material of any one of Clauses 1-6, the clad composite material further comprising:

[0061] A second layer intermediate the core layer and the first layer, the second layer comprising an aluminum alloy having a third corrosion potential; and

[0062] wherein the third corrosion potential is less than the first corrosion potential and greater than the second corrosion potential.

[0063] Clause 8. The clad composite material of any one of Clauses 1-7, wherein:

[0064] The core layer comprises a first concentration of a first cathodic material; and

[0065] The first layer comprises a second concentration of a second cathodic material, wherein the first concentration is greater than the second concentration.

[0066] Clause 9. The clad composite material of Clause 8, wherein the first cathodic material and the second cathodic material comprise materials independently selected from the group consisting of Cu, Zn, Mg, Mn, Si, Fe, Cr, Ti, Zr, V, Li, and combinations of two or more thereof.

[0067] Clause 10. The clad composite material of Clause 9, wherein the first cathodic material and the second cathodic material are Cu.

[0068] Clause 11. The clad composite material of Clause 10, wherein the first concentration is at least 0.1 wt% greater than the second concentration.

[0069] Clause 12. A clad composite according to any one of Clauses 8 - 10, wherein the core layer comprises at least 0.5% by weight of the first cathodic material.

[0070] Clause 13. A clad composite according to any one of Clauses 1 - 12, wherein:

[0071] the core layer comprises 0.5% to 1.0% by weight of Cu; and

[0072] the first layer comprises 0.25% to 0.5% by weight of Cu.

[0073] Clause 14. A clad composite according to any one of Clauses 1 - 13, wherein the core layer and the first layer are bonded together.

[0074] Clause 15. A clad composite according to any one of Clauses 1 - 14, wherein the second aluminum alloy comprises: 0.05% to 1.0% by weight of Si; 0.25% to 0.5% by weight of Cu; 0% to 0.5% by weight of Zr; 0% to 0.8% by weight of Fe; 0.1% to 1.5% by weight of Mn; 0% to 0.25% by weight of Zn; 0% to 0.2% by weight of Mg; 0% to 0.2% by weight of Ti; 0% to 1% by weight of Cr; 0% to 0.5% by weight of Bi; aluminum; optionally, one or more incidental elements; and impurities.

[0075] Clause 16. A clad composite according to any one of Clauses 1 - 15, wherein the first aluminum alloy comprises: 0.05% to 1.5% by weight of Si; 0% to 0.8% by weight of Fe; 0.5% to 1.0% by weight of Cu; 0.5% to 1.8% by weight of Mn; 0% to 0.2% by weight of Mg; 0% to 0.25% by weight of Zn; 0% to 0.25% by weight of Cr; 0% to 0.15% by weight of Zr; aluminum; optionally, one or more incidental elements; and impurities.

[0076] Clause 17. An article comprising:

[0077] a clad composite according to any one of Clauses 1 - 16; and

[0078] fins coupled to the first layer of the clad composite, wherein the fins comprise a 1XXX series aluminum alloy or a 3XXX series aluminum alloy.

[0079] Clause 18. The article of Clause 17, wherein the corrosion potential of the fins is in the range of -740 mV to -900 mV.

[0080] Article 19. An article according to any one of Articles 17 - 18, wherein the cladding composite material is in the shape of a tube.

[0081] Article 20. An article according to any one of Articles 17 - 19, wherein the fins contain no more than 0.25 wt% Zn.

[0082] Article 21. A heat exchanger comprising a structural element that comprises all or a part of an article according to any one of Articles 17 - 20.

[0083] Article 22. The heat exchanger of Article 21, wherein the heat exchanger is part of a heating, ventilation, and air conditioning system.

[0084] Article 23. A method for forming an article, the method comprising:

[0085] contacting a first portion comprising a first material with a second portion comprising all or a part of a cladding composite material according to any one of Articles 1 - 22; and

[0086] coupling the first portion to the second portion.

[0087] Article 24. The method of Article 23, wherein the first material comprises a 1XXX series aluminum alloy or a 3XXX series aluminum alloy.

[0088] Article 25. The method according to any one of Articles 23 - 24, wherein the article is a heat exchanger.

[0089] Article 26. The method of Article 25, wherein the heat exchanger is part of a heating, ventilation, and air conditioning system.

[0090] In this specification, unless otherwise indicated, all numerical parameters should be understood to be prefaced and qualified in all instances by the term "about", wherein the numerical parameters have the characteristic of inherent variability of the underlying measurement technique used to determine the value of the parameter. At the very least, and without attempting to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter set forth herein should at least be construed in accordance with the number of reported significant digits and by application of ordinary rounding techniques.

[0091] In addition, any numerical range recited herein includes all sub-ranges subsumed within the recited range. For example, the range "1 to 10" includes all sub-ranges between the recited minimum value 1 and the recited maximum value 10 (and including the end values), i.e., the minimum value is equal to or greater than 1, and the maximum value is equal to or less than 10. Moreover, all ranges recited herein include the endpoints of the recited range. For example, the range "1 to 10" includes the endpoints 1 and 10. Any maximum numerical limitation recited in this specification is intended to include all lower numerical limitations subsumed therein, and any minimum numerical limitation recited in this specification is intended to include all higher numerical limitations subsumed therein. Accordingly, the applicant reserves the right to modify this specification (including the claims) to expressly recite any sub-range subsumed within the ranges expressly recited herein. All such ranges are inherently described in this specification.

[0092] Unless otherwise indicated, the grammatical articles "a", "an", and "the" as used herein are intended to include "at least one" or "one or more", even if in some instances "at least one" or "one or more" is expressly used. Thus, the foregoing grammatical articles are used herein to refer to one or more than one (i.e., "at least one") of a particular identified element. In addition, the use of a singular noun includes the plural, and the use of a plural noun includes the singular, unless the context of use otherwise requires.

[0093] Those skilled in the art will recognize that, for clarity of concepts, the articles and methods described herein and their accompanying discussions are used as examples, and various configuration modifications are contemplated. Accordingly, as used herein, the specific embodiments / implementations set forth and the accompanying discussions are intended to represent their more general classes. Generally, the use of any particular example is intended to represent its class, and the absence of a particular component, device, operation / action, and object should not be regarded as restrictive. Although this disclosure provides descriptions of various specific aspects for purposes of illustrating aspects of the disclosure and / or its potential applications, it should be understood that those skilled in the art will envision variations and modifications. Accordingly, one or more inventions described herein should be understood to be at least as broad as the claims, and not more narrowly defined than the specific illustrative aspects provided herein.

Claims

1. A cladding composite material, the cladding composite material comprising: A core layer, the core layer comprising a first aluminum alloy having a first corrosion potential; and A first layer, the first layer comprising a second aluminum alloy having a second corrosion potential, wherein the second aluminum alloy comprises 0 wt% to 0.5 wt% of Zn; Wherein the second corrosion potential is in the range of -600 mV to -800 mV, and the first corrosion potential is at least 8 mV and not more than 100 mV more electronegative than the second corrosion potential.

2. The cladding composite material according to claim 1, wherein the first corrosion potential is not more than 50 mV more electronegative than the second corrosion potential.

3. The cladding composite material according to claim 1, wherein the first corrosion potential is not more than 30 mV more electronegative than the second corrosion potential.

4. The cladding composite material according to claim 1, wherein the second corrosion potential is in the range of -700 mV to -730 mV and the first corrosion potential is in the range of -650 mV to -720 mV.

5. The cladding composite material according to claim 1, wherein the second corrosion potential is in the range of -715 mV to -730 mV and the first corrosion potential is in the range of -690 mV to -720 mV.

6. The cladding composite material according to claim 1, wherein the first layer is disposed on the core layer.

7. The cladding composite material according to claim 1, the cladding composite material further comprising: A second layer intermediate the core layer and the first layer, the second layer comprising an aluminum alloy having a third corrosion potential; and Wherein the third corrosion potential is less than the first corrosion potential and greater than the second corrosion potential.

8. The cladding composite material according to claim 1, wherein The core layer comprises a first concentration of a first cathodic material; and The first layer comprises a second concentration of a second cathodic material; Wherein the first concentration is greater than the second concentration.

9. The cladding composite material according to claim 8, wherein the first cathodic material and the second cathodic material comprise materials independently selected from Cu, Zn, Mg, Mn, Si, Fe, Cr, Ti, Zr, V, Li, and combinations of two or more thereof.

10. The cladding composite material according to claim 9, wherein the first cathodic material and the second cathodic material are Cu.

11. The cladding composite material according to claim 10, wherein the first concentration is at least 0.1 wt% greater than the second concentration.

12. The cladding composite material according to claim 8, wherein the core layer comprises at least 0.5 wt% of the first cathodic material.

13. The cladding composite material according to claim 1, wherein: The core layer comprises 0.5 wt% to 1.0 wt% of Cu; and The first layer comprises 0.25 wt% to 0.5 wt% of Cu.

14. The cladding composite material according to claim 1, wherein the core layer and the first layer are bonded together.

15. The cladding composite material according to claim 1, wherein the second aluminum alloy comprises: 0.05 wt% to 1.0 wt% of Si; 0.25 wt% to 0.5 wt% of Cu; 0 wt% to 0.5 wt% of Zr; 0 wt% to 0.8 wt% of Fe; 0.1 wt% to 1.5 wt% of Mn; 0 wt% to 0.25 wt% of Zn; 0 wt% to 0.2 wt% of Mg; 0 wt% to 0.2 wt% of Ti; 0 wt% to 1 wt% of Cr; 0 wt% to 0.5 wt% of Bi; aluminum; optionally, one or more incidental elements; and impurities.

16. The cladding composite material according to claim 1, wherein the first aluminum alloy comprises: 0.05 wt% to 1.5 wt% of Si; 0 wt% to 0.8 wt% of Fe; 0.5 wt% to 1.0 wt% of Cu; 0.5 wt% to 1.8 wt% of Mn; 0 wt% to 0.2 wt% of Mg; 0 wt% to 0.25 wt% of Zn; 0 wt% to 0.25 wt% of Cr; 0 wt% to 0.15 wt% of Zr; aluminum; optionally, one or more incidental elements; and impurities.

17. An article, the article comprising: the cladding composite material according to claim 1; and fins coupled to the first layer of the cladding composite material, wherein the fins comprise a 1XXX series aluminum alloy or a 3XXX series aluminum alloy.

18. The article according to claim 17, wherein the corrosion potential of the fins is in the range of -740 mV to -900 mV.

19. The article according to claim 17, wherein the cladding composite material is in a tube shape.

20. The article according to claim 17, wherein the fins comprise no more than 0.25 wt% of Zn.

21. A heat exchanger, the heat exchanger comprising a structural element, the structural element comprising all or a part of the article according to claim 17.

22. The heat exchanger according to claim 21, wherein the heat exchanger is part of a heating, ventilation, and air conditioning system.

23. A method for forming an article, the method comprising: bringing a first portion comprising a first material into contact with a second portion comprising all or a part of the cladding composite material according to claim 1; and coupling the first portion to the second portion.

24. The method according to claim 23, wherein the first material comprises a 1XXX series aluminum alloy or a 3XXX series aluminum alloy.

25. The method according to claim 23, wherein the article is a heat exchanger.

26. The method according to claim 25, wherein the heat exchanger is part of a heating, ventilation, and air conditioning system.

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