Functionally gradient aluminum alloy products and methods of making

Abstract

To produce flat rolled aluminum alloy products and to attempt to manufacture such products to exhibit multiple properties.SOLUTION: The present disclosure generally provides aluminum alloy products having a functional gradient across at least one dimension of the aluminum alloy product. The disclosure also provides articles of manufacture made from such products, and methods of making such products, such as through casting and rolling. The disclosure also provides various end uses of such products, such as in automotive, aerospace, marine, defense, transportation, electronics, and industrial applications.SELECTED DRAWING: None

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of and priority to U.S. Provisional Application No. 63 / 198,018, filed September 24, 2020, which is hereby incorporated by reference in its entirety.

[0002] The present disclosure generally provides aluminum alloy products having functional grading in at least one dimension of the product. The present disclosure also provides methods of making aluminum alloy products having functional grading in at least one dimension, for example by direct chill casting and rolling. The present disclosure also provides various end uses of such products, for example, automotive, aerospace, marine, transportation, electronics, defense and industrial applications. [Background technology]

[0003] Aluminum alloy products are desirable for use in a number of different applications, particularly those where light weight, strength, and durability are desirable. For example, aluminum alloys are increasingly replacing steel as structural components in automobiles and other transportation devices. Because aluminum alloys are generally about 2.8 times less dense than steel, the use of such materials can reduce the weight of devices and significantly improve their energy efficiency. Even so, the use of aluminum alloy products can pose certain challenges.

[0004] One particular challenge relates to flat rolled aluminum alloy products and attempts to manufacture such products to exhibit multiple properties. Such properties may include mechanical properties such as Young's modulus, Poisson's ratio, shear modulus, density, conductivity, and thermal expansion coefficient. Such properties may also include corrosion resistance, bond durability, and anodizability. Attempts to control these properties may rely on combining multiple materials, for example, by melt casting or roll bonding. However, products made from multiple materials lack reusability and may still not provide the desired properties. Summary of the Invention

[0005] The embodiments encompassed by this disclosure are defined by the claims, and not by this Summary. This Summary provides a broad overview of various aspects of the invention and introduces some concepts that are further described in the Detailed Description section. This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used alone to define the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification, any or all of the drawings, and the claims.

[0006] In one aspect, described is a method of preparing a functionally graded aluminum alloy product. The method of this aspect may include casting an ingot into a mold or casting a melt into a casting cavity to form a casting. The casting may include an aluminum alloy. The casting may include at least one peritectic forming element and at least one eutectic forming element. Casting may include a) forming primary grains enriched in at least one peritectic forming element and depleted in at least one eutectic element, and b) controlling migration and accumulation of the primary grains. The method may include homogenizing the casting, during which the primary grains precipitate. The method may include rolling the homogenized casting to form the functionally graded aluminum alloy product.

[0007] In an embodiment, the method may involve an aluminum alloy including a 2xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy.

[0008] In an embodiment, the method may include at least one peritectic forming element present in an amount of 0.2 wt.% or less.

[0009] In an embodiment, the method may include at least one eutectic forming element being present in an amount greater than 0.2 wt.%.

[0010] In an embodiment, the method may include casting the ingot into a mold using a direct chill casting process.

[0011] In an embodiment, the method may include casting the molten liquid into a casting cavity using a continuous casting process.

[0012] In an embodiment, the method may include a continuous casting process including casting with at least one of a twin belt caster, a twin roll caster, a block caster, or any other continuous casting machine.

[0013] In an embodiment, the rolling may include hot rolling.

[0014] In an embodiment, the method may include precipitating primary grains inhibiting recrystallization during rolling.

[0015] In an embodiment, the method may include an aluminum alloy product that is functionally graded across the thickness of the product.

[0016] In an embodiment, the method may include an aluminum alloy product that is functionally graded across the width of the product.

[0017] In an embodiment, the method may include the primary grains having a maximum dimension of between 25 and 250 microns.

[0018] In an embodiment, the method may include an aluminum alloy that includes at least one peritectic forming element and at least one eutectic forming element.

[0019] In an embodiment, the method may include at least one peritectic forming element, at least one eutectic forming element, or a combination thereof, being added to the ingot or liquid metal during casting.

[0020] In an embodiment, the method may include forming primary grains, which further includes forming at least one of a solute element, an intermetallic grain, a solute-rich grain, a strengthening grain, or a combination thereof.

[0021] In another aspect, described is an aluminum product having a functional gradient across at least one dimension, the functional gradient including a non-recrystallized center and a recrystallized surface, and / or a change in the proportion of reinforcing particles from the center to the surface.

[0022] In an embodiment, the product may include at least one peritectic forming element in the non-recrystallized center.

[0023] In an embodiment, the product may include at least one peritectic forming element including at least one of Ti, Zr, V, Hf, Nb, Ta, Cr or combinations thereof.

[0024] In an embodiment, the product may include at least one peritectic element present in an amount of 0.2% by weight or less.

[0025] In an embodiment, the product may include at least one eutectic forming element in the recrystallized plane.

[0026] In an embodiment, the product may include eutectic forming elements including at least one of Si, Cu, Fe, Zn, Mg, Sc, Ni, Mn, Ce, and Y, and combinations thereof.

[0027] In an embodiment, the product may include eutectic formers present in an amount greater than 0.2% by weight.

[0028] In an embodiment, the product may include at least one reinforcing particle.

[0029] In an embodiment, the reinforcing particles may include at least one of TiB2, TiC, NbB2, Al2O3, SiC, ZrB2, AlB2, Al3Ti, Al7Cr, Al3Zr, Al3Nb, Al3Ta, Al3V, AlN, Al3Ni, Al3Hf, Al3HfO, and combinations thereof.

[0030] In an embodiment, the reinforcing particles are added to the melt or formed in situ during casting.

[0031] In an embodiment, the reinforcing particles are present in an amount greater than 0.1 wt.%.

[0032] In another aspect, described is an aluminum alloy article comprising any of the aluminum alloy products described above.

[0033] The present disclosure also provides aluminum alloy products made by the processes disclosed herein.

[0034] Further disclosed are products comprising the aluminum alloy products of the present disclosure. In some embodiments, the products comprise rolled aluminum alloy products. Examples of such products include, but are not limited to, automobile, truck, trailer, train, rail vehicle, aircraft parts, such as body panels or other parts for any of the above, bridges, pipelines, pipes, piping, boats, ships, storage vessels, storage tanks, furniture, windows, doors, rail tracks, functional or decorative building components, pipe railings, electronic components, conduits, beverage containers, food containers, or foils. In some embodiments, the products are automobile or transportation body parts, such as automotive body parts (e.g., bumpers, side beams, roof beams, cross beams, pillar reinforcements, inner panels, outer panels, side panels, hood inners, hood outers, and trunk lid panels). These products may also include aerospace products and electronic device housings.

[0035] Further aspects and embodiments are set forth in the detailed description, claims, non-limiting examples, and figures, all of which are included herein. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0036] The present disclosure provides flat rolled aluminum alloy products with functional grading across at least one dimension of the product. These products may exhibit functional grading formed during at least one manufacturing process while maintaining reusability and other desirable mechanical properties. The functionally graded aluminum alloy products of the present disclosure have final properties, including hardness, tensile strength and elongation, that vary along the dimension of the functional gradient. Typically, composite materials, i.e. products made by joining different materials, have distinct interfaces that result in changes in properties. These interfaces can be disrupted by delamination of materials. By intentionally forming functional gradients, the distinct interfaces are replaced by gradual interfaces. The gradual interfaces allow for a smooth transition of properties from one material or region of materials to another. As a result, delamination does not occur.

[0037] Creating functional gradients in aluminum alloy products is particularly useful for flat rolled products formed by melt casting or roll bonding to improve formability or corrosion resistance, however such products suffer from the drawback of being non-recyclable since the material can no longer be recycled back into its individual parts.

[0038] The functionally graded materials described herein exploit the segregation behavior that occurs during direct chill casting, rather than trying to avoid or correct it. Typically, in a given region, certain peritectic forming particles may be concentrated in the ingot center, and eutectic forming particles may be depleted in the ingot center. Such segregation is considered problematic and is typically considered a defect. For this reason, conventional methods aim to characterize and eliminate segregation, rather than intentionally promoting and controlling it. The functionally graded materials described herein may also exploit the segregation behavior that occurs during continuous casting, such as twin roll casting or twin belt casting. In continuous casting, a central segregation is formed along the thickness of the cast piece. Unlike in the case of direct chill casting, twin belt or twin roll casters produce a positive segregation in the center, which can be used to produce a functional gradient in the alloy product.

[0039] The functional grading of the aluminum alloy products described herein can be understood by starting with the primary grains formed during the casting process. These grains, which have a maximum dimension between 25 microns and 250 microns, contain both peritectic and eutectic elements. "Peritectic formers" refers to elements that form a single solid phase by reaction with a liquid with a different solid phase, such as titanium (Ti), zirconium (Zr), vanadium (V), niobium (Nb), hafnium (Hf), tantalum (Ta) and chromium (Cr). "Eutectic formers" refers to elements that form two different solid phases by decomposition of a single-phase liquid, such as silicon (Si), copper (Cu), magnesium (Mg), scandium (Sr), iron (Fe), cerium (Ce) and zinc (Zn).

[0040] As the eutectic forming element(s) is increased beyond its maximum solid solubility (according to a simple binary eutectic phase diagram), the fraction of eutectic around the primary aluminum grain increases. When the local chemistry exceeds the eutectic chemistry, a eutectic phase ("D-phase") will form. The central eutectic phase can be manipulated by adjusting the casting parameters or by changing the alloy chemistry.

[0041] Below the maximum solid solubility of primary aluminum (according to a simple binary peritectic phase diagram), the peritectic fraction and peritectic phase ("A" phase) increase as the peritectic formers increase. When casting alloy chemistries with peritectic formers above the maximum solid solution, the liquid delivered to the mold will already have fine peritectic phases, and therefore, for example, during continuous casting, these peritectic element-rich primary aluminum grains, or "primary grains," will migrate toward the center of the strand during casting resulting in a gradient structure strand. Whether direct or continuous casting is used, segregation of phases other than the primary grains, such as solute elements, intermetallic particles, solute-rich grains, and strengthening particles, can also occur. An example of a peritectic phase found primarily in the center of the strand compared to the surface of 6xxx alloys is the intermetallic Al3Ti grain. Another example is reinforcing particles, such as at least one of TiB2, TiC, NbB2, Al2O3, SiC, ZrB2, AlB2, Al3Ti, Al7Cr, Al3Zr, Al3Nb, Al3Ta, Al3V, AlN, Al3Ni, Al3Hf, Al3HfO, and combinations thereof.

[0042] Peritectic forming elements are commonly used to control the recrystallization behavior in aluminum alloy products, but their segregation behavior is typically ignored because they are present in small amounts, e.g., less than 0.2 wt.%. By preferentially segregating peritectic forming elements, e.g., elements that form dispersoids, the recrystallization behavior of rolled aluminum alloy products can be controlled through the thickness of the product.

[0043] As described herein, segregation can be controlled at various times in the manufacturing process and by various methods. In some embodiments, segregation is controlled during the casting process. Examples include controlling the deposition and accumulation of primary grains in various ways. For example, flow patterns may be controlled within the ingot during casting, such as direct chill casting, to spatially distribute the primary grains. In some embodiments, at least one of primary grains, solute elements, intermetallic particles, solute-rich grains, strengthening particles, or combinations thereof may be formed in the system. In some embodiments, the casting speed may be adjusted. In some embodiments, convection may be applied during casting, such as by magnetic means or physical stirring. Furthermore, segregation may be controlled during the homogenization process. Primary grains may precipitate during this process, allowing for the presence of recrystallization where the grains precipitated. Such a process allows for a gradient microstructure through the thickness of the resulting flat rolled product. In some embodiments, grain growth may be manipulated even after recrystallization, such as by selectively heating the ingot being rolled through its thickness. This may allow further gradients in grain morphology to be controlled. For example, the temperature profile may be varied during rolling, for example by magnetic, microwave or induction heating methods.

[0044] Definitions and Explanations: As used herein, the terms "invention," "the invention," "this invention," and "the present invention" are intended to broadly refer to all of the subject matter of this patent application and the claims that follow. It is to be understood that phrases containing these terms are not intended to limit the subject matter described herein or to limit the meaning or scope of the claims that follow.

[0045] In this description, reference is made to alloys identified by AA numbers and other related designations, such as "series" or "7xxx." For an understanding of the number designation systems commonly used in naming and identifying aluminum and its alloys, reference is made to "International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys" or "Registration Record of Aluminum Association Alloy Designations and Chemical Composition Limits for Aluminum Alloys in the Form of Castings and Ingot," both published by The Aluminum Association.

[0046] As used herein, a flat plate typically has a thickness of greater than about 15 mm. For example, a flat plate can refer to an aluminum product having a thickness of greater than about 15 mm, greater than about 20 mm, greater than about 25 mm, greater than about 30 mm, greater than about 35 mm, greater than about 40 mm, greater than about 45 mm, greater than about 50 mm, or greater than about 100 mm.

[0047] As used herein, a shade (also referred to as sheet metal) typically has a thickness of about 4 mm to about 15 mm. For example, the shade may have a thickness of about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm, or about 15 mm.

[0048] As used herein, thin sheet typically refers to an aluminum product having a thickness of less than about 4 mm. For example, the thin sheet may have a thickness of less than about 4 mm, less than about 3 mm, less than about 2 mm, less than about 1 mm, less than about 0.5 mm, or less than about 0.3 mm (e.g., about 0.2 mm).

[0049] In this application, alloy tempers or conditions may be referred to. For an understanding of the most commonly used alloy temper designations, please refer to "American National Standards (ANSI) H35 on Alloy and Temper Designation Systems". The F condition or temper refers to the aluminum alloy as produced. The O condition or temper refers to the aluminum alloy after annealing. The Hxx condition or temper, also referred to herein as temper H, refers to non-heat treatable aluminum alloys after cold rolling with or without heat treatment (e.g., annealing). Suitable H tempers include HX1, HX2, HX3 HX4, HX5, HX6, HX7, HX8, or HX9 tempers. The T1 condition or temper refers to the aluminum alloy that has been cooled from hot working and naturally aged (e.g., at room temperature). The T2 condition or temper refers to the aluminum alloy that has been cooled from hot working, cold worked, and naturally aged. The T3 condition or temper refers to the aluminum alloy that has been solution heat treated, cold worked, and naturally aged. The T4 condition or temper refers to the aluminum alloy that has been solution heat treated, and naturally aged. The T5 condition or temper refers to the aluminum alloy that has been cooled from hot working and artificially aged (at an elevated temperature). The T6 condition or temper refers to the aluminum alloy that has been solution heat treated, and artificially aged. The T7 condition or temper refers to the aluminum alloy that has been solution heat treated, and artificially overaged. The T8x condition or temper refers to the aluminum alloy that has been solution heat treated, cold worked, and artificially aged. The T9 condition or temper refers to the aluminum alloy that has been solution heat treated, artificially aged, and cold worked. The W condition or temper refers to the aluminum alloy after solution heat treatment.

[0050] As used herein, the terms "cast metal product," "casting," "cast aluminum alloy product," and the like are used interchangeably and refer to products produced by direct chill casting (including direct chill co-casting) or semi-continuous casting, continuous casting (including, for example, by use of a twin belt caster, twin roll caster, block caster, or any other continuous casting machine), electromagnetic casting, hot top casting, or any other casting method.

[0051] As used herein, the meaning of "room temperature" can include a temperature of about 15° C. to about 30° C., such as about 15° C., about 16° C., about 17° C., about 18° C., about 19° C., about 20° C., about 21° C., about 22° C., about 23° C., about 24° C., about 25° C., about 26° C., about 27° C., about 28° C., about 29° C., or about 30° C. As used herein, the meaning of "ambient conditions" can include a temperature of about room temperature, a relative humidity of about 20% to about 100%, and an atmospheric pressure of about 975 millibar (mbar) to about 1050 mbar. For example, the relative humidity may be about 20%, about 21%, about 22%, about 23%, about 24%, about 25%, about 26%, about 27%, about 28%, about 29%, about 30%, about 31%, about 32%, about 33%, about 34%, about 35%, about 36%, about 37%, about 38%, about 39%, about 40%, about 41%, about 42%, about 43%, about 44%, about 45%, about 46%, about 47%, about 48%, about 49%, about 50%, about 51%, about 52%, about 53%, about 54%, about 55%, about 56%, about 57%, about 58%, about 59%, about 60%, about The concentration may be 61%, about 62%, about 63%, about 64%, about 65%, about 66%, about 67%, about 68%, about 69%, about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84%, about 85%, about 86%, about 87%, about 88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about 98%, about 99%, about 100%, or any value in between. For example, atmospheric pressure can be about 975 mbar, about 980 mbar, about 985 mbar, about 990 mbar, about 995 mbar, about 1000 mbar, about 1005 mbar, about 1010 mbar, about 1015 mbar, about 1020 mbar, about 1025 mbar, about 1030 mbar, about 1035 mbar, about 1040 mbar, about 1045 mbar, about 1050 mbar, or any value in between.

[0052] All ranges disclosed herein should be understood to encompass any and all subranges contained therein. For example, a range stated as "1-10" should be considered to include any and all subranges between a minimum value of 1 and a maximum value of 10 (and including the endpoints), i.e., starting from a minimum value of 1 or more, e.g., 1-6.1, to a maximum value of 10 or less, e.g., 5.5-10. Unless otherwise indicated, the phrase "less than" means, when referring to a compositional amount of an element, that the element is optional and includes a zero percent composition of that particular element. Unless otherwise indicated, all compositional percentages are expressed as weight percent (wt.%).

[0053] As used herein, the meanings of "a," "an," and "the" are inclusive of the singular and plural meanings, unless the context clearly indicates otherwise.

[0054] In the following examples, the aluminum alloy products and their components may be described by their elemental composition in weight percent (wt.%). In each alloy, the maximum wt.% of the sum of all impurities is 0.15%, the balance being aluminum.

[0055] Incidental elements, such as grain refiners and deoxidizers, or other additives, may be present in the present invention and may themselves impart other characteristics to the alloys described herein without departing from or significantly altering the characteristics of the alloys described herein.

[0056] Due to the inherent properties of aluminum or leaching from contact with processing equipment, small amounts of unavoidable impurities, including materials or elements, may be present in the alloy. Some impurities typically found in aluminum include iron and silicon. The alloys described may contain up to about 0.25 wt.% of any element in addition to the alloying elements, incidental elements, and unavoidable impurities.

[0057] Aluminum alloy products In at least one embodiment, the present disclosure provides an aluminum alloy product comprising an aluminum alloy material having a functional gradient in at least one dimension. In some non-limiting embodiments, the functional gradient can be across the thickness of the aluminum alloy product. In other embodiments, the functional gradient can be across the width of the aluminum alloy product.

[0058] The aluminum alloy product may include any suitable aluminum alloy material ranging from 1xxx series aluminum alloys to 8xxx series aluminum alloys. In some embodiments, the aluminum alloy material is a 2xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy. In some embodiments, the aluminum alloy material is a 5xxx series aluminum alloy including, among other elements, 0.2 wt.% or less of a peritectic former (e.g., Ti, Zr, or Cr) and more than 0.2 wt.% of a eutectic former (e.g., Si, Cu, or Mg). In some aspects, the total content of the peritectic formers is 0.2 wt.% or less. In other aspects, each peritectic former is present in an amount of 0.2 wt.% or less. In some aspects, the total content of the eutectic formers is greater than 0.2 wt.%. In other aspects, each eutectic former is present in an amount greater than 0.2 wt.%. In some embodiments, the aluminum alloy includes a predetermined amount of the peritectic and / or eutectic formers. In other embodiments, some or all of the eutectic forming elements and / or some or all of the peritectic forming elements desired in the aluminum alloy product are added to the ingot during casting.

[0059] By way of non-limiting example, exemplary 1xxx series aluminum alloys for use in the methods described herein may include AA1100, AA1100A, AA1200, AA1200A, AA1300, AA1110, AA1120, AA1230, AA1230A, AA1235, AA1435, AA1145, AA1345, AA1445, AA1150, AA1350, AA1350A, AA1450, AA1370, AA1275, AA1185, AA1285, AA1385, AA1188, AA1190, AA1290, AA1193, AA1198, or AA1199.

[0060] Non-limiting exemplary 2xxx series aluminum alloys for use in the methods described herein include AA2001, A2002, AA2004, AA2005, AA2006, AA2007, AA2007A, AA2007B, AA2008, AA2009, AA2010, AA2011, AA2011A, AA2111, AA2111A, AA2111B, AA2012, AA2013, AA2014, AA2015, AA2016, AA2017, AA2018, AA2019, AA2020, AA2021, AA2022, AA2023, AA2024, AA2025, AA2026, AA2027, AA2028, AA2029, AA2030, AA2031, AA2032, AA2033, AA2034, AA2035, AA2036, AA2037, AA2038, AA2039, AA2040, AA2041, AA2042, AA2043, AA2044, AA2045, AA2046, AA2047, AA2048, AA2049, AA2050, AA2051, AA2052, AA2053, AA2054, AA2055, AA2056, AA2057, AA2058, AA2059, AA2060, AA2061, AA2062, AA2063, AA2064, AA20 014, AA2014A, AA2214, AA2015, AA2016, AA2017, AA2017A, AA2117, AA2018, AA2218, AA2618, AA2618A, AA22 19, AA2319, AA2419, AA2519, AA2021, AA2022, AA2023, AA2024, AA2024A, AA2124, AA2224, AA2224A, AA2324, AA2424, AA2524, AA2624, AA2724, AA2824, AA2025, AA2026, AA2027, AA2028, AA2028A, AA2028B, AA2028C, A A2029, AA2030, AA2031, AA2032, AA2034, AA2036, AA2037, AA2038, AA2039, AA2139, AA2040, AA2041, AA2044 , AA2045, AA2050, AA2055, AA2056, AA2060, AA2065, AA2070, AA2076, AA2090, AA2091, AA2094, AA2095, AA2195, AA2295, AA2196, AA2296, AA2097, AA2197, AA2297, AA2397, AA2098, AA2198, AA2099 or AA2199.

[0061] Non-limiting exemplary 3xxx series aluminum alloys for use in the methods described herein include AA3002, AA3102, AA3003, AA3103, AA3103A, AA3103B, AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, AA3005A, AA3105, AA3105A, AA3105B, AA may include A3007, AA3107, AA3207, AA3207A, AA3307, AA3009, AA3010, AA3110, AA3011, AA3012, AA3012A, AA3013, AA3014, AA3015, AA3016, AA3017, AA3019, AA3020, AA3021, AA3025, AA3026, AA3030, AA3130, or AA3065.

[0062] Non-limiting exemplary 4xxx series aluminum alloys for use in the methods described herein may include AA4004, AA4104, AA4006, AA4007, AA4008, AA4009, AA4010, AA4013, AA4014, AA4015, AA4015A, AA4115, AA4016, AA4017, AA4018, AA4019, AA4020, AA4021, AA4026, AA4032, AA4043, AA4043A, AA4143, AA4343, AA4643, AA4943, AA4044, AA4045, AA4145, AA4145A, AA4046, AA4047, AA4047A, or AA4147.

[0063] Non-limiting exemplary 5xxx series aluminum alloys for use in the methods and products described herein include AA5182, AA5183, AA5005, AA5005A, AA5205, AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110, AA5110A, AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A, AA5119, AA5119A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5040, AA5140, AA5041, AA5042, AA5043, AA5049, AA5149, AA5249, AA5349, AA5449, AA5449A, AA5050, AA5050A, AA5050C, AA5150, AA5051, AA5051A, AA5151, AA52 51, AA5251A, AA5351, AA5451, AA5052, AA5252, AA5352, AA5154, AA5154A, AA5154B, AA5154C, AA5254, AA5354, AA5454, A A5554, AA5654, AA5654A, AA5754, AA5854, AA5954, AA5056, AA5356, AA5356A, AA5456, AA5456A, AA5456B, AA5556, AA555 AA5183, AA5283A, AA5283, AA5283A, AA5283B, AA5383, AA5483, AA5086, AA5186, AA5087, AA5187, or AA5088.

[0064] Non-limiting exemplary 6xxx series aluminum alloys for use in the methods described herein include AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA6206, AA6 306, AA6008, AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015 , AA6016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027, AA6 028, AA6031, AA6032, AA6033, AA6040, AA6041, AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA6053, AA6055, AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560, AA6660, AA6061, AA6061A, AA6 261, AA6361, AA6162, AA6262, AA6262A, AA6063, AA6063A, AA6463, AA6463A, AA6763, A6963, AA6064, AA6064A, AA6065, AA6066, AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A, AA6182, AA6091 or AA6092.

[0065] Non-limiting exemplary 7xxx series aluminum alloys for use in the methods described herein include AA7011, AA7019, AA7020, AA7021, AA7039, AA7072, AA7075, AA7085, AA7108, AA7108A, AA7015, AA7017, AA7018, AA7019A, AA7024, AA7025, AA7028, AA7030, AA7031, AA7033, AA7035, AA7035A, AA7046, AA7046A, AA7003, AA7004, AA7005, AA7009, AA7010, AA7011, AA7012, AA7014, AA7016, AA7116, AA7122, AA7023, AA7026, AA7029, AA 7129, AA7229, AA7032, AA7033, AA7034, AA7036, AA7136, AA7037, AA7040, AA7140, AA7041, AA7 049, AA7049A, AA7149, 7204, AA7249, AA7349, AA7449, AA7050, AA7050A, AA7150, AA7250, AA705 5, AA7155, AA7255, AA7056, AA7060, AA7064, AA7065, AA7068, AA7168, AA7175, AA7475, AA7076, AA7178, AA7278, AA7278A, AA7081, AA7181, AA7185, AA7090, AA7093, AA7095 or AA7099.

[0066] Non-limiting exemplary 8xxx series aluminum alloys for use in the methods described herein include AA8005, AA8006, AA8007, AA8008, AA8010, AA8011, AA8011A, AA8111, AA8211, AA8112, AA8014, AA8015, AA8016, AA8017, AA8018, AA8019, AA80 21, AA8021A, AA8021B, AA8022, AA8023, AA8024, AA8025, AA8026, AA8030, AA8130, AA8040, AA8050, AA8150, AA8076, AA8076A, AA8176, AA8077, AA8177, AA8079, AA8090, AA8091 or AA8093.

[0067] As described herein, the peritectic formers may be present in an amount of 0.2 wt.% or less. In some embodiments, each peritectic former is present in an amount of 0.2 wt.% or less. In other embodiments, the sum of all peritectic formers is 0.2 wt.% or less. Peritectic formers include Ti, Zr, V, Nb, Hf, Ta, and Cr.

[0068] In certain embodiments, the aluminum alloy includes titanium (Ti) in an amount of about 0.2% or less (e.g., 0.01% to 0.2%) based on the total weight of the alloy. For example, the alloy may include about 0.001%, about 0.002%, about 0.003%, about 0.004%, about 0.005%, about 0.006%, about 0.007%, about 0.008%, about 0.009%, about 0.01%, about 0.011%, about 0.012%, about 0.013%, about 0.014%, about 0.015%, about 0.016%, about 0.017%, about 0.018%, about 0.019%, about 0.020%, about 0.021%, about 0.022%, about 0.023%, about 0.024%, about 0.025%, about 0.026%, about 0.027%, about 0.028%, about 0.029%, about 0.030%, about 0.031%, about 0.032%, about 0.033%, about 0.034%, about 0.035%, about 0.036%, about 0.037%, about 0.038%, about 0.039%, about 0.040%, about 0.041%, about 0.042%, about 0.043%, about 0.044%, about 0.045%, about 0.046%, about 0.047%, about 0.048%, about 0.049%, about 0.050 ... .016%, approx. 0.017%, approx. 0.018%, approx. 0.019%, approx. 0.02%, approx. 0.021%, approx. 0.022%, approx. 0.023%, approx. 0.024%, approx. 0.025%, approx. 0.026%, approx. 0.027%, approx. 0.028%, approx. 0.029%, approx. 0.03%, approx. 0.031%, approx. 0.032 %, approximately 0.033%, approximately 0.034%, approximately 0.035%, approximately 0.036%, approximately 0.037%, approximately 0.038%, approximately 0.039%, approximately 0.04%, approximately 0.05%, approximately 0.051%, approximately 0.052%, approximately 0.053%, approximately 0.054%, approximately 0.055%, approximately 0.056%, approximately 0.057%, and It may contain about 0.058%, about 0.059%, about 0.06%, about 0.07%, about 0.08%, about 0.09%, about 0.1%, about 0.11%, about 0.12%, about 0.13%, about 0.14%, about 0.15%, about 0.16%, about 0.17%, about 0.18%, about 0.19% or about 0.2% Ti, all expressed as wt.%.

[0069] In some embodiments, the aluminum alloy includes zirconium (Zr) in an amount between 0% and about 0.2% (e.g., 0.01% to 0.2%) based on the total weight of the alloy. For example, the alloy may include 0%, about 0.001%, about 0.002%, about 0.003%, about 0.004%, about 0.005%, about 0.006%, about 0.007%, about 0.008%, about 0.009%, about 0.01%, about 0.02%, about 0.03%, about 0. The alloy may contain about 0.04%, about 0.05%, about 0.06%, about 0.07%, about 0.08%, about 0.09%, about 0.1%, about 0.11%, about 0.12%, about 0.13%, about 0.14%, about 0.15%, about 0.16%, about 0.17%, about 0.18%, about 0.19%, or about 0.20% Zr. In certain embodiments, no Zr is present in the alloy (i.e., 0%). All are expressed in wt.%.

[0070] In some embodiments, the aluminum alloy includes vanadium (V) in an amount between 0% and about 0.2% (e.g., 0.01% to 0.2%) based on the total weight of the alloy. For example, the alloy may include 0%, about 0.001%, about 0.002%, about 0.003%, about 0.004%, about 0.005%, about 0.006%, about 0.007%, about 0.008%, about 0.009%, about 0.01%, about 0.02%, about 0.03%, about 0. The alloy may contain about 0.04%, about 0.05%, about 0.06%, about 0.07%, about 0.08%, about 0.09%, about 0.1%, about 0.11%, about 0.12%, about 0.13%, about 0.14%, about 0.15%, about 0.16%, about 0.17%, about 0.18%, about 0.19%, or about 0.20% V. In certain embodiments, no V is present in the alloy (i.e., 0%). All are expressed in wt.%.

[0071] In some embodiments, the aluminum alloy includes niobium (Nb) in an amount between 0% and about 0.2% (e.g., between 0.01% and 0.2%) based on the total weight of the alloy. For example, the alloy may include 0%, about 0.001%, about 0.002%, about 0.003%, about 0.004%, about 0.005%, about 0.006%, about 0.007%, about 0.008%, about 0.009%, about 0.01%, about 0.02%, about 0.03%, about 0.04%, about 0.05%, about 0.06%, about 0. ...8%, about 0.009%, about 0.01%, about 0.02%, about 0.03%, about 0.04%, about 0.05%, about 0.06%, about 0.07%, about 0.08%, about 0.08%, about 0.09%, about 0.01%, about 0.02%, about 0.03%, about 0.04%, about 0.05%, about 0.06%, about 0.07%, about 0.07%, about 0.07%, about 0.07%, about 0.07%, about 0.07%, about 0.07%, about 0.07%, about 0.07%, about 0.07%, about 0.07%, about 0.07%, about 0.07%, about 0.07%, about 0.07%, about 0.07%, about 0.07%, about 0.07%, about 0. %, about 0.05%, about 0.06%, about 0.07%, about 0.08%, about 0.09%, about 0.1%, about 0.11%, about 0.12%, about 0.13%, about 0.14%, about 0.15%, about 0.16%, about 0.17%, about 0.18%, about 0.19%, or about 0.20% Nb. In certain embodiments, no Nb is present in the alloy (i.e., 0%). All are expressed in wt.%.

[0072] In some embodiments, the aluminum alloy includes hafnium (Hf) in an amount between 0% and about 0.2% (e.g., 0.01% to 0.2%) based on the total weight of the alloy. For example, the alloy may include 0%, about 0.001%, about 0.002%, about 0.003%, about 0.004%, about 0.005%, about 0.006%, about 0.007%, about 0.008%, about 0.009%, about 0.01%, about 0.02%, about 0.03%, about 0.0 The alloy may contain about 4%, about 0.05%, about 0.06%, about 0.07%, about 0.08%, about 0.09%, about 0.1%, about 0.11%, about 0.12%, about 0.13%, about 0.14%, about 0.15%, about 0.16%, about 0.17%, about 0.18%, about 0.19%, or about 0.20% Hf. In certain embodiments, no Hf is present in the alloy (i.e., 0%). All are expressed in wt.%.

[0073] In some embodiments, the aluminum alloy includes tantalum (Ta) in an amount between 0% and about 0.2% (e.g., 0.01% to 0.2%) based on the total weight of the alloy. For example, the alloy may include 0%, about 0.001%, about 0.002%, about 0.003%, about 0.004%, about 0.005%, about 0.006%, about 0.007%, about 0.008%, about 0.009%, about 0.01%, about 0.02%, about 0.03%, about 0.0 The alloy may contain about 4%, about 0.05%, about 0.06%, about 0.07%, about 0.08%, about 0.09%, about 0.1%, about 0.11%, about 0.12%, about 0.13%, about 0.14%, about 0.15%, about 0.16%, about 0.17%, about 0.18%, about 0.19%, or about 0.20% Ta. In certain embodiments, Ta is not present in the alloy (i.e., 0%). All are expressed in wt.%.

[0074] In some embodiments, the aluminum alloy includes chromium (Cr) in an amount between 0% and approximately 0.2% (eg, between 0.01% and 0.2%) based on the total weight of the alloy. For example, the alloy may include 0%, about 0.001%, about 0.002%, about 0.003%, about 0.004%, about 0.005%, about 0.006%, about 0.007%, about 0.008%, about 0.009%, about 0.01%, about 0.02%, about 0.03%, about 0.04%, about 0.05%, about 0.06%, about 0.07%, about 0.08%, about 0.09%, about 0.1%, about 0.11%, about 0.12%, about 0.13%, about 0.14%, about 0.15%, about 0.16%, about 0.17%, about 0.18%, about 0.19%, or about 0.20% Cr. In certain embodiments, no Cr is present in the alloy (i.e., 0%). All are expressed as wt.%.

[0075] As described herein, the eutectic formers may be present in an amount greater than 0.2 wt.%. In some embodiments, each eutectic former is present in an amount greater than 0.2 wt.%. In other embodiments, the sum of all eutectic formers is greater than 0.2 wt.%. Eutectic formers include Si, Cu, Mg, Sc, Fe, Ce, Zn, and Ni, Sr, Ca, and Y.

[0076] In some embodiments, the aluminum alloy includes silicon (Si) in an amount between 0% and about 2% (e.g., between 0.01% and 2%, between 0.05% and 1.75%, between 0.1% and 1.5%, or between 0.15% and 1%) based on the total weight of the alloy. For example, the alloy may include 0%, about 0.05%, about 0.1%, about 0.15%, about 0.2%, about 0.25%, about 0.3%, about 0.35%, about 0.4%, about 0.45%, about 0.5%, about 0.55%, about 0.6%, about 0.65%, about 0.7%, about 0.75%, about 0.8%, about 0.85%, about 0.9%, about 0.95%, about 1%. , about 1.05%, about 1.1%, about 1.15%, about 1.2%, about 1.25%, about 1.3%, about 1.35%, about 1.4%, about 1.45%, about 1.5%, about 1.55%, about 1.6%, about 1.65%, about 1.7%, about 1.75%, about 1.8%, about 1.85%, about 1.9%, about 1.95%, or about 2% Si. In certain embodiments, no Si is present in the alloy (i.e., 0%). All are expressed in wt.%.

[0077] In some embodiments, the aluminum alloy includes copper (Cu) in an amount between 0% and about 7% (e.g., between 0.2% and 6.8%, between 0.25% and 6.75%, between 0.3% and 6.5%, or between 0.4% and 5%) based on the total weight of the alloy. For example, the alloy may include 0%, about 0.01%, about 0.02%, about 0.03%, about 0.04%, about 0.05%, about 0.06%, about 0.07%, about 0.08%, about 0.09%, about 0.1%, about 0.15%, about 0.2%, about 0.25%, about 0.3%, about 0.35%, about 0.4%, about 0.45%, about 0.5%, about 0.55%, about 0.6%, about 0.65%, about 0.70%, about 0.75%, about 0.8%, about 0.85%, approximately 0.9%, approximately 0.95%, approximately 1%, approximately 1.05%, approximately 1.1%, approximately 1.15%, approximately 1.2%, approximately 1.25%, approximately 1.3%, approximately 1.35%, approximately 1.4%, approximately 1.45%, approximately 1.5%, approximately 1.55%, approximately 1.6%, approximately 1.65%, approximately 1.7%, approximately 1.75%, approximately 1.8%, approximately 1.85%, approximately 1.9%, approximately 1.95%, approximately 2%, approximately 2.05%, approximately 2.1, approximately 2.15%, and 2.2%, approximately 2.25%, approximately 2.3%, approximately 2.35%, approximately 2.4%, approximately 2.45%, approximately 2.5%; approximately 2.6%, approximately 2.65%, approximately 2.7%, approximately 2.75%, approximately 2.8%, approximately 2.85%, approximately 2.9%, approximately 2.95%, approximately 3%, approximately 3.05%, approximately 3.1%, approximately 3.15%, approximately 3.2%, approximately 3.25%, approximately 3.3%, approximately 3.35%, approximately 3.4%, approximately 3.45%, approximately 3.5%, approximately 3.55%, Approximately 3.6%, approximately 3.65%, approximately 3.7%, approximately 3.75%, approximately 3.8%, approximately 3.85%, approximately 3.9%, approximately 3.95%; approximately 4%, approximately 4.05%, approximately 4.1%, approximately 4.15%, approximately 4.2%, approximately 4.25%, approximately 4.3%, approximately 4.35%, approximately 4.4%, approximately 4.45%, approximately 4.5%, approximately 4.55%, approximately 4.6%, approximately 4.65%, approximately 4.7%, approximately 4.75%, approximately 4.8%, approximately 4.85%, approximately 4.9%, approximately 4.95%; approximately 5%, approximately 5.05%, approximately 5.1%, approximately 5.15%, approximately 5.2%, approximately 5.25%, approximately 5.3%, approximately 5.35%, approximately 5.4%, approximately 5.45%, approximately 5.5%, approximately 5.55%, approximately 5.6%, approximately 5.65%, approximately 5.7%, approximately 5.75%, approximately 5.8%, approximately 5.85%, approximately 5.9%, approximately 5.95%; and It may contain about 6%, about 6.05%, about 6.1%, about 6.15%, about 6.2%, about 6.25%, about 6.3%, about 6.35%, about 6.4%, about 6.45%, about 6.5%, about 6.55%, about 6.6%, about 6.65%, about 6.7%, about 6.75%, about 6.8%, about 6.85%, about 6.9%, about 6.95%, or about 7% Cu. In certain embodiments, no Cu is present in the alloy (i.e., 0%). All are expressed as wt.%.

[0078] In some embodiments, the aluminum alloy includes magnesium (Mg) in an amount between 0% and about 7% (e.g., between 0.2% and 7%, between 0.25% and 7%, between 0.3% and 6.5%, or between 0.4% and 5%) based on the total weight of the alloy. For example, the alloy may include 0%, about 0.01%, about 0.02%, about 0.03%, about 0.04%, about 0.05%, about 0.06%, about 0.07%, about 0.08%, about 0.09%, about 0.1%, about 0.15%, about 0.2%, about 0.25%, about 0.3%, about 0.35%, about 0.4%, about 0.45%, about 0.5%, about 0.55%, about 0.6%, about 0.65%, about 0.70%, about 0.75%, about 0.8%, about 0.85%, approximately 0.9%, approximately 0.95%, approximately 1%, approximately 1.05%, approximately 1.1%, approximately 1.15%, approximately 1.2%, approximately 1.25%, approximately 1.3%, approximately 1.35%, approximately 1.4%, approximately 1.45%, approximately 1.5%, approximately 1.55%, approximately 1.6%, approximately 1.65%, approximately 1.7%, approximately 1.75%, approximately 1.8%, approximately 1.85%, approximately 1.9%, approximately 1.95%, approximately 2%, approximately 2.05%, approximately 2.1, approximately 2.15%, and 2.2%, approximately 2.25%, approximately 2.3%, approximately 2.35%, approximately 2.4%, approximately 2.45%, approximately 2.5%; approximately 2.6%, approximately 2.65%, approximately 2.7%, approximately 2.75%, approximately 2.8%, approximately 2.85%, approximately 2.9%, approximately 2.95%, approximately 3%, approximately 3.05%, approximately 3.1%, approximately 3.15%, approximately 3.2%, approximately 3.25%, approximately 3.3%, approximately 3.35%, approximately 3.4%, approximately 3.45%, approximately 3.5%, approximately 3.55%, Approximately 3.6%, approximately 3.65%, approximately 3.7%, approximately 3.75%, approximately 3.8%, approximately 3.85%, approximately 3.9%, approximately 3.95%; approximately 4%, approximately 4.05%, approximately 4.1%, approximately 4.15%, approximately 4.2%, approximately 4.25%, approximately 4.3%, approximately 4.35%, approximately 4.4%, approximately 4.45%, approximately 4.5%, approximately 4.55%, approximately 4.6%, approximately 4.65%, approximately 4.7%, approximately 4.75%, approximately 4.8%, approximately 4.85%, approximately 4.9%, approximately 4.95%; approximately 5%, approximately 5.05%, approximately 5.1%, approximately 5.15%, approximately 5.2%, approximately 5.25%, approximately 5.3%, approximately 5.35%, approximately 5.4%, approximately 5.45%, approximately 5.5%, approximately 5.55%, approximately 5.6%, approximately 5.65%, approximately 5.7%, approximately 5.75%, approximately 5.8%, approximately 5.85%, approximately 5.9%, approximately 5.95%; and It may contain about 6%, about 6.05%, about 6.1%, about 6.15%, about 6.2%, about 6.25%, about 6.3%, about 6.35%, about 6.4%, about 6.45%, about 6.5%, about 6.55%, about 6.6%, about 6.65%, about 6.7%, about 6.75%, about 6.8%, about 6.85%, about 6.9%, about 6.95%, or about 7% Mg. In certain embodiments, no Mg is present in the alloy (i.e., 0%). All are expressed in wt.%.

[0079] In some embodiments, the aluminum alloy includes scandium (Sc) in an amount between 0% and about 2% (e.g., between 0.01% and 2%, between 0.05% and 1.75%, between 0.1% and 1.5%, or between 0.15% and 1%) based on the total weight of the alloy. For example, the alloy may include 0%, about 0.05%, about 0.1%, about 0.15%, about 0.2%, about 0.25%, about 0.3%, about 0.35%, about 0.4%, about 0.45%, about 0.5%, about 0.55%, about 0.6%, about 0.65%, about 0.7%, about 0.75%, about 0.8%, about 0.85%, about 0.9%, about 0.95%, about 1%. , about 1.05%, about 1.1%, about 1.15%, about 1.2%, about 1.25%, about 1.3%, about 1.35%, about 1.4%, about 1.45%, about 1.5%, about 1.55%, about 1.6%, about 1.65%, about 1.7%, about 1.75%, about 1.8%, about 1.85%, about 1.9%, about 1.95%, or about 2% Sc. In certain embodiments, no Sc is present in the alloy (i.e., 0%). All are expressed in wt.%.

[0080] In some embodiments, the aluminum alloy includes iron (Fe) in an amount between 0% and about 2% (e.g., between 0.01% and 2%, between 0.05% and 1.75%, between 0.1% and 1.5%, or between 0.15% and 1%) based on the total weight of the alloy. For example, the alloy may include 0%, about 0.05%, about 0.1%, about 0.15%, about 0.2%, about 0.25%, about 0.3%, about 0.35%, about 0.4%, about 0.45%, about 0.5%, about 0.55%, about 0.6%, about 0.65%, about 0.7%, about 0.75%, about 0.8%, about 0.85%, about 0.9%, about 0.95%, about 1%. , about 1.05%, about 1.1%, about 1.15%, about 1.2%, about 1.25%, about 1.3%, about 1.35%, about 1.4%, about 1.45%, about 1.5%, about 1.55%, about 1.6%, about 1.65%, about 1.7%, about 1.75%, about 1.8%, about 1.85%, about 1.9%, about 1.95%, or about 2% Fe. In certain embodiments, no Fe is present in the alloy (i.e., 0%). All are expressed in wt.%.

[0081] In some embodiments, the aluminum alloy includes cerium (Ce) in an amount between 0% and about 2% (e.g., between 0.01% and 2%, between 0.05% and 1.75%, between 0.1% and 1.5%, or between 0.15% and 1%) based on the total weight of the alloy. For example, the alloy may include 0%, about 0.05%, about 0.1%, about 0.15%, about 0.2%, about 0.25%, about 0.3%, about 0.35%, about 0.4%, about 0.45%, about 0.5%, about 0.55%, about 0.6%, about 0.65%, about 0.7%, about 0.75%, about 0.8%, about 0.85%, about 0.9%, about 0.95%, about 1%. , about 1.05%, about 1.1%, about 1.15%, about 1.2%, about 1.25%, about 1.3%, about 1.35%, about 1.4%, about 1.45%, about 1.5%, about 1.55%, about 1.6%, about 1.65%, about 1.7%, about 1.75%, about 1.8%, about 1.85%, about 1.9%, about 1.95%, or about 2% Ce. In certain embodiments, no Ce is present in the alloy (i.e., 0%). All are expressed in wt.%.

[0082] In some embodiments, the aluminum alloy comprises zinc (Zn) in an amount between 0% and approximately 10% (e.g., between 0.01% and 10%, between 0.05% and 9%, between 0.1% and 9%, or between 0.15% and 9%) based on the total weight of the alloy.For example, the alloy may be 0%, approximately 0.01%, approximately 0.02%, approximately 0.03%, approximately 0.04%, approximately 0.05%, approximately 0.06%, approximately 0.07%, approximately 0.08%, approximately 0.09%, approximately 0.1%, approximately 0.15%, approximately 0.2%, approximately 0.25%, approximately 0.3%, approximately 0.35%, approximately 0.4%, approximately 0.45%, approximately 0.5%, approximately 0.55%, approximately 0.6%, approximately 0.65%, approximately 0.70%, approximately 0.75%, approximately 0.8%, approximately 0.85%, approximately 0. ...15%, approximately 0.2%, approximately 0.25%, approximately 0.3%, approximately 0.35%, approximately 0.4%, approximately 0.45%, approximately 0.5%, approximately 0.55%, approximately 0.6%, approximately 0.65%, approximately 0.70%, approximately 0.75%, approximately 0.8%, .95%, approximately 1%, approximately 1.1%, approximately 1.2%, approximately 1.3%, approximately 1.4%, approximately 1.5%, approximately 1.6%, approximately 1.7%, approximately 1.8%, approximately 1.9%, approximately 2%, approximately 2.1%, approximately 2.2%, approximately 2.3%, approximately 2.4%, approximately 2.5%, approximately 2.6%, approximately 2.7%, approximately 2.8%, approximately 2.9%, approximately 3%, approximately 3.1%, approximately 3.2%, approximately 3.3%, approximately 3.4%, approximately 3.5%, approximately 3.6%, approximately 3.7%, approximately 3.8%, approximately 3.9%, and 4%, approximately 4.1%, approximately 4.2%, approximately 4.3%, approximately 4.4%, approximately 4.5%, approximately 4.6%, approximately 4.7%, approximately 4.8%, approximately 4.9%, approximately 5%, approximately 5.1%, approximately 5.2%, approximately 5.3%, approximately 5.4%, approximately 5.5%, approximately 5.6%, approximately 5.7%, approximately 5.8%, approximately 5.9%, approximately 6%, approximately 6.1%, approximately 6.2%, approximately 6.3%, approximately 6.4%, approximately 6.5%, approximately 6.6%, approximately 6.7%, approximately 6.8%, approximately 6.9%, approximately 7%, approximately The alloy may contain about 7.1%, about 7.2%, about 7.3%, about 7.4%, about 7.5%, about 7.6%, about 7.7%, about 7.8%, about 7.9%, about 8%, about 8.1%, about 8.2%, about 8.3%, about 8.4%, about 8.5%, about 8.6%, about 8.7%, about 8.8%, about 8.9%, about 9%, about 9.1%, about 9.2%, about 9.3%, about 9.4%, about 9.5%, about 9.6%, about 9.7%, about 9.8%, about 9.9%, or about 10% Zn. In certain embodiments, no Zn is present in the alloy (i.e., 0%).All are expressed as wt.%.

[0083] In some embodiments, the aluminum alloy includes nickel (Ni) in an amount of about 2% (e.g., 0.01%-2%, 0.05%-1.75%, 0.1%-1.5%, or 0.15%-1%) based on the total weight of the alloy. For example, the alloy may include 0%, about 0.05%, about 0.1%, about 0.15%, about 0.2%, about 0.25%, about 0.3%, about 0.35%, about 0.4%, about 0.45%, about 0.5%, about 0.55%, about 0.6%, about 0.65%, about 0.7%, about 0.75%, about 0.8%, about 0.85%, about 0.9%, about 0.95%, about 1%. , about 1.05%, about 1.1%, about 1.15%, about 1.2%, about 1.25%, about 1.3%, about 1.35%, about 1.4%, about 1.45%, about 1.5%, about 1.55%, about 1.6%, about 1.65%, about 1.7%, about 1.75%, about 1.8%, about 1.85%, about 1.9%, about 1.95%, or about 2% Ni. In certain embodiments, no Ni is present in the alloy (i.e., 0%). All are expressed in wt.%.

[0084] In some embodiments, the aluminum alloy includes strontium (Sr) in an amount between 0% and about 2% (e.g., between 0.01% and 2%, between 0.05% and 1.75%, between 0.1% and 1.5%, or between 0.15% and 1%) based on the total weight of the alloy. For example, the alloy may include 0%, about 0.05%, about 0.1%, about 0.15%, about 0.2%, about 0.25%, about 0.3%, about 0.35%, about 0.4%, about 0.45%, about 0.5%, about 0.55%, about 0.6%, about 0.65%, about 0.7%, about 0.75%, about 0.8%, about 0.85%, about 0.9%, about 0.95%, about 1%. , about 1.05%, about 1.1%, about 1.15%, about 1.2%, about 1.25%, about 1.3%, about 1.35%, about 1.4%, about 1.45%, about 1.5%, about 1.55%, about 1.6%, about 1.65%, about 1.7%, about 1.75%, about 1.8%, about 1.85%, about 1.9%, about 1.95% or about 2% Sr. In certain embodiments, no Sr is present in the alloy (i.e., 0%). All are expressed in wt.%.

[0085] In some embodiments, the aluminum alloy includes calcium (Ca) in an amount between 0% and about 2% (e.g., between 0.01% and 2%, between 0.05% and 1.75%, between 0.1% and 1.5%, or between 0.15% and 1%) based on the total weight of the alloy. For example, the alloy may include 0%, about 0.05%, about 0.1%, about 0.15%, about 0.2%, about 0.25%, about 0.3%, about 0.35%, about 0.4%, about 0.45%, about 0.5%, about 0.55%, about 0.6%, about 0.65%, about 0.7%, about 0.75%, about 0.8%, about 0.85%, about 0.9%, about 0.95%, about 1%. , about 1.05%, about 1.1%, about 1.15%, about 1.2%, about 1.25%, about 1.3%, about 1.35%, about 1.4%, about 1.45%, about 1.5%, about 1.55%, about 1.6%, about 1.65%, about 1.7%, about 1.75%, about 1.8%, about 1.85%, about 1.9%, about 1.95%, or about 2% Ca. In certain embodiments, no Ca is present in the alloy (i.e., 0%). All are expressed in wt.%.

[0086] In some embodiments, the aluminum alloy includes yttrium (Y) in an amount between 0% and about 2% (e.g., between 0.01% and 2%, between 0.05% and 1.75%, between 0.1% and 1.5%, or between 0.15% and 1%) based on the total weight of the alloy. For example, the alloy may include 0%, about 0.05%, about 0.1%, about 0.15%, about 0.2%, about 0.25%, about 0.3%, about 0.35%, about 0.4%, about 0.45%, about 0.5%, about 0.55%, about 0.6%, about 0.65%, about 0.7%, about 0.75%, about 0.8%, about 0.85%, about 0.9%, about 0.95%, about 1%. , about 1.05%, about 1.1%, about 1.15%, about 1.2%, about 1.25%, about 1.3%, about 1.35%, about 1.4%, about 1.45%, about 1.5%, about 1.55%, about 1.6%, about 1.65%, about 1.7%, about 1.75%, about 1.8%, about 1.85%, about 1.9%, about 1.95%, or about 2% Y. In certain embodiments, Y is not present in the alloy (i.e., 0%). All are expressed in wt.%.

[0087] Aluminum alloys may also contain immiscible elements that do not undergo peritectic or eutectic reactions, such as Pb, Bi, In, and Sn.

[0088] In some embodiments, the aluminum alloy includes manganese (Mn) in an amount between 0% and about 2% (e.g., between 0.01% and 2%, between 0.05% and 1.75%, between 0.1% and 1.5%, or between 0.25% and 1%) based on the total weight of the alloy. For example, the alloy may include 0%, about 0.05%, about 0.1%, about 0.15%, about 0.2%, about 0.25%, about 0.3%, about 0.35%, about 0.4%, about 0.45%, about 0.5%, about 0.55%, about 0.6%, about 0.65%, about 0.7%, about 0.75%, about 0.8%, about 0.85%, about 0.9%, about 0.95%, about 1%. , about 1.05%, about 1.1%, about 1.15%, about 1.2%, about 1.25%, about 1.3%, about 1.35%, about 1.4%, about 1.45%, about 1.5%, about 1.55%, about 1.6%, about 1.65%, about 1.7%, about 1.75%, about 1.8%, about 1.85%, about 1.9%, about 1.95% or about 2% Mn. In certain embodiments, no Mn is present in the alloy (i.e., 0%). All are expressed in wt.%.

[0089] Optionally, the aluminum alloy composition may further include trace elements, sometimes referred to as impurities, in an amount of about 0.05% or less, about 0.04% or less, about 0.03% or less, about 0.02% or less, or about 0.01% or less, respectively. These impurities may include, but are not limited to, Ga, B, C, Be, or combinations thereof. Thus, Ga, B, B, C, or Be may be present in the alloy in an amount of about 0.05% or less, about 0.04% or less, about 0.03% or less, about 0.02% or less, or about 0.01% or less. In certain embodiments, the sum of all impurities does not exceed about 0.15% (e.g., about 0.1%). All are expressed in wt.%. In certain embodiments, the remaining percentage of the alloy is aluminum.

[0090] The alloy compositions disclosed herein, including the aluminum alloy materials of any of the above embodiments, have aluminum (Al) as the major component, e.g., in an amount of at least 80.0% of the alloy. Optionally, the alloy composition has at least 85.0% Al, or at least 86.0% Al, or at least 86.5% Al, or at least 87.0% Al, or at least 87.5% Al, or at least 88.0% Al, or at least 88.5% Al, or at least 89.0% Al, or at least 89.5% Al, or at least 90.0% Al, or at least 90.5% Al, or at least 91.0% Al, or at least 91.5% Al, or at least 92.0% Al, all expressed in wt.%.

[0091] In some embodiments, reinforcing materials may be added to the alloy to form a metal matrix composite (MMC). MMCs are described in WO2012 / 164581, entitled "A Process for Producing Reinforced Aluminum-Metal Matrix Composites," filed May 30, 2012, and incorporated herein by reference in its entirety. Such reinforcing materials may include SiC, TiB2, Al2O3, B4C, TiC, CNTs (carbon nanotubes), and the like. MMCs are known for their high strength and light weight and may be used in the automotive industry. In some embodiments, the reinforcing materials may be present in an amount of 20% or less by weight of the metal matrix composite. Without wishing to be bound by theory, it is believed that the functional grading described herein may be applicable to MMCs, since having a non-recrystallized region in the center of the MMC product may allow for reduced delamination between the substrate and the reinforcing material.

[0092] In some embodiments, the reinforcing materials may be formed "in situ" inside the ingot pool, or may be formed in the metal delivery system, or inside the melting / holding furnace. Such "in situ" reinforcing materials have a better tendency to bond with the substrate compared to reinforcing materials added "ex situ". Such "in situ" reinforcing materials may include TiB2, TiC, NbB2, Al2O3, SiC, ZrB2, AlB2, Al3Ti, Al7Cr, Al3Zr, Al3Nb, Al3Ta, Al3V, AlN, Al3Hf, Al3HfO, and the like.

[0093] The aluminum alloy article disclosed herein may be any suitable aluminum alloy article. As described above, the article is formed from an aluminum alloy product having a functional gradient across at least one dimension. In some embodiments, the functional gradient is across the thickness of the product. For example, the product may have a non-recrystallized region in the center that may exhibit high strength, but the outer surface of the product may be recrystallized, which may help maintain formability. Recrystallization may be quantified based on grain aspect ratio using optical microscopy, or by structure using electron backscatter diffraction or x-ray diffraction, as described below.

[0094] The aluminum alloy product may have any suitable physical structure. Optionally, the aluminum alloy product is a rolled aluminum alloy plate, sheet, or sheet. In some embodiments, the aluminum alloy product is a rolled aluminum alloy sheet. In some embodiments, the aluminum alloy product is a rolled aluminum alloy sheet.

[0095] The degree of recrystallization, or recrystallization index, may be determined by any suitable method known in the art. For example, in a micrograph, such as a scanning electron micrograph (SEM) or optical micrograph (OM), a higher degree of recrystallization or recrystallization index may be observed by a grain structure with a higher degree of uniformity. In some other examples, electron backscatter diffraction (EBSD) may also be used to evaluate the degree of recrystallization. Optionally, the degree of recrystallization is indicated by a "recrystallization index," which as used herein refers to the formula: 1-LAGB / (MAGB+HAGB). In some embodiments, the recrystallization index refers to or represents the percentage, amount, or volume of material that is recrystallized compared to the total amount or volume of the material. LAGB refers to the amount of grain boundaries in a given volume where the misorientation between adjacent grains is between 2° and 15° (i.e., the amount of low angle grain boundaries). MAGB refers to the amount of grain boundaries in a given volume where the misorientation between adjacent grains is greater than 15° but less than or equal to 30° (i.e., amount of medium angle grain boundaries). HAGB refers to the amount of grain boundaries in a given volume where the misorientation between adjacent grains is greater than 30° (i.e., amount of high angle grain boundaries). The amount or value of LAGB, MAGB, and HAGB can be determined by measuring the angle of misorientation between adjacent grains as recorded by EBSD. Recovery or recrystallization of a material can reduce the energy stored in the material when a highly deformed material is annealed at high temperatures. Recovery competes with recrystallization because both are driven by stored energy during annealing. Recovery can be defined as the annealing process occurring in a deformed material that occurs without the movement of high angle grain boundaries. The deformed structure is often a cellular structure with dislocation angles. As recovery proceeds, these cell walls undergo a transition to a pure subgrain structure. This occurs by the gradual elimination of non-essential dislocations and the rearrangement of remaining dislocations into low-angle grain boundaries. On the other hand, recrystallization is the formation of new grain structures in the deformed material by the formation and migration of high-angle grain boundaries driven by the stored energy of deformation. Hence, LAGBs are eliminated during the recrystallization process.

[0096] The functional gradient formed as described herein can span at least one dimension of the aluminum alloy product, such as thickness and / or width. Optionally, at least two outer regions of the aluminum alloy product, such as at least two parallel surfaces of the product, have a higher recrystallization index than the recrystallization index toward the center of the aluminum alloy product. Optionally, the at least two outer regions have a recrystallization index that is at least 0.01 higher (e.g., 0.01-1.0), or at least 0.03 higher, or at least 0.05 higher, or at least 0.07 higher, or at least 0.10 higher, or at least 0.15 higher, or at least 0.20 higher, or at least 0.25 higher, or at least 0.30 higher, or at least 0.35 higher, or at least 0.40 higher, or at least 0.45 higher, or at least 0.50 higher than the recrystallization index of the center of the aluminum alloy product.

[0097] Functional grading may also be understood by reviewing the composition of the aluminum alloy product across the dimension of the functional gradient. For example, a functional gradient may have a higher peritectic forming element content along the centerline of the ingot, while there may be a higher eutectic forming element content along the outer regions.

[0098] The aluminum alloy products described herein may independently exhibit a tensile strength of from 200 MPa to 700 MPa, or even greater than 700 MPa, such as up to 750 MPa, up to 800 MPa, or up to 850 MPa. For example, the tensile strength is 200MPa~650MPa, 200MPa~600MPa, 200MPa~550MPa, 200MPa~500MPa, 250MPa~650MPa, 250MPa~600MPa, 250MPa~550MPa, 250MPa~500MPa, 300MPa~650MPa, 300MPa~600MPa, 300MPa~550MPa, 300MPa~500MPa, 350MPa~650MPa, 350MPa~600MPa, 350MPa~550MPa, 350MPa~500MPa, 400MPa~650MPa, 400MPa~600MPa, 400MPa~550MPa, 400MPa~500MPa , 200MPa to 225MPa, 225MPa to 250MPa, 250MPa to 275MPa, 275MPa to 300MPa, 300MPa to 325MPa, 325MPa to 350MPa, 350MPa to 375MPa, 375MPa to 400MPa, 400MPa to 425MPa, 425MPa to 450MPa, 450MPa to 475MPa, 475MPa to 500MPa, 500MPa to 525MPa, 525MPa to 550MPa, 550MPa to 575MPa, 575MPa to 600MPa, 600MPa to 625MPa, 625MPa to 650MPa, 650MPa to 675MPa, or 675MPa to 700MPa.

[0099] The aluminum alloy products described herein may independently exhibit a yield strength of 200 MPa to 600 MPa, or even greater than 600 MPa, e.g., 650 MPa, 700 MPa, or 750 MPa. For example, the yield strength may be 200 MPa to 550 MPa, 200 MPa to 500 MPa, 250 MPa to 600 MPa, 250 MPa to 550 MPa, 250 MPa to 500 MPa, 300 MPa to 600 MPa, 300 MPa to 550 MPa, 300 MPa to 500 MPa, 350 MPa to 600 MPa, 350 MPa to 550 MPa, 350 MPa to 500 MPa, 400 MPa to 600 MPa, 400 MPa to 550 MPa, 400 MPa to 500 MPa, 200 MPa to 225 MPa , 225MPa to 250MPa, 250MPa to 275MPa, 275MPa to 300MPa, 300MPa to 325MPa, 325MPa to 350MPa, 350MPa to 375MPa, 375MPa to 400MPa, 400MPa to 425MPa, 425MPa to 450MPa, 450MPa to 475MPa, 475MPa to 500MPa, 500MPa to 525MPa, 525MPa to 550MPa, 550MPa to 575MPa, or 575MPa to 600MPa.

[0100] Method for preparing an aluminum alloy product In certain aspects, the disclosed aluminum alloy products are products of the disclosed methods. Without intending to limit the scope of the inventions set forth herein, the properties of the aluminum alloy products set forth herein are determined in part by the formation of certain microstructures during their preparation.

[0101] In at least one embodiment, the present disclosure provides a method of making an aluminum alloy product, the method including providing an aluminum alloy in a molten state as molten aluminum alloy; casting the molten aluminum alloy to form an aluminum alloy casting; homogenizing the aluminum alloy casting to form a homogenized aluminum alloy casting; and rolling the homogenized aluminum alloy casting to form a rolled aluminum alloy product. In some embodiments, the molten aluminum alloy is cast to cast an ingot by a direct chill (DC) casting process. In some embodiments, the molten aluminum alloy is cast into a casting cavity by using a twin belt caster, twin roll caster, block caster, or any other continuous caster in a continuous (CC) casting process.

[0102] casting The methods disclosed herein may include adding different alloying elements to the melt pool in the form of master alloys (binary or ternary or quaternary elements) or pure metals. This may involve stirring the furnace using magnets or manual stirring. Optionally, strengthening particles may be added. This may involve removing slag.

[0103] The methods disclosed herein may include using an induction or gas fired furnace or an electric resistance furnace to prepare the melt.

[0104] The methods disclosed herein may include pouring a molten aluminum alloy to form an aluminum alloy casting. In some embodiments, the molten alloy may be treated prior to pouring. The treatment may include one or more of melting in a furnace, degassing in line, melting in line, and filtering. The aluminum alloy casting may be formed using any casting process conducted in accordance with standards commonly used in the aluminum industry known to those skilled in the art, including the direct casting and continuous casting processes described herein.

[0105] In certain embodiments, the melt includes dispersion strengthening particles that can be added just prior to delivering the melt to a mold using a direct casting process. Additionally or alternatively, the melt includes dispersion strengthening particles that are added as a secondary melt deep inside the pool while the primary melt is still flowing. In certain embodiments, the secondary melt is rich in dispersoid-forming elements and is injected directly deep inside the pool.

[0106] To name a few non-limiting examples, the casting process may include a direct chill (DC) casting process or a continuous casting (CC) process. A continuous casting system may include a pair of movable opposing casting surfaces (e.g., movable opposing belts, rolls, or blocks), a casting cavity between the pair of movable opposing casting surfaces, and a molten metal injector. The molten metal injector may have an open end through which molten metal may flow out of the injector and into the casting cavity. In some embodiments, the CC process may include, but is not limited to, the use of a twin belt caster, a twin roll caster, or a block caster. In some embodiments, the casting process is carried out by a CC process to form a casting in the form of a billet, slab, shake, cast piece, etc. In some aspects, DC casting is used.

[0107] Castings, such as ingots, billets, slabs, cast pieces, and the like, may be processed by any means known to those skilled in the art. Optionally, a processing step may be used to produce a sheet. Such processing steps may include, but are not limited to, homogenization, hot rolling, cold rolling, solution heat treatment, and optional pre-aging steps, as known to those skilled in the art. Processing steps may be suitably applied to any casting, including, but not limited to, ingots, billets, slabs, cast pieces, flat plates, cast pieces, and the like, with modifications and techniques as known to those skilled in the art. As described below, specific processing steps may be used to prepare aluminum alloy articles with specific recrystallization index distributions.

[0108] In some cases, the casting process may affect the recrystallization and modifications that may occur during subsequent processing steps. For example, the distribution of dispersoid-forming elements in a casting, such as an ingot, may affect the ability of the casting to undergo recrystallization. By selectively forming primary grains that are enriched in at least one peritectic forming element and depleted in at least one eutectic element, and segregating the peritectic (dispersoid) forming elements during the casting process, different regions of the casting, as well as processed products and articles, may be more or less susceptible to recrystallization. Peritectic forming elements may precipitate from a supersaturated solution in the form of nanoscale dispersoids, which may be, for example, 10 nm to 100 nm in diameter. These dispersoids may have a size that does not promote recrystallization nucleation as larger particles do. Rather, these particles may inhibit the movement of dislocations and grain boundaries such that recrystallization is inhibited. The volume or mass fraction of these dispersoids may dictate or affect the inherent recrystallization behavior in the casting.

[0109] In addition to the primary grain size influencing the macrosegregation of peritectic elements in the center, the increase in solid solubility of peritectic elements in the primary aluminum grains can also determine the amount of macrosegregation in, for example, a cast ingot. The increase in solid solubility of peritectic elements is determined by the solidification path of the primary grains. Once the peritectic elements are in solid solution in the primary grains and thus the primary grains are settled in the ingot center, the peritectic elements can also precipitate downstream during the deformation stage regardless of the primary grain size. Recrystallization occurs during hot rolling, since dispersoids mostly form during the homogenization process. Therefore, the cast primary grain size (or dendrite size) may not be related to the peritectic (dispersoid) forming elements and the recrystallization mechanism. In some cases, there may be so-called "grain-free zones" in which no dispersoids are present in the primary grains after homogenization. This is believed to occur when the distribution of peritectic (dispersoid) forming elements across the primary grains varies, with the peritectic elements being abundant in the center of the primary grains and depleted towards the grain (or dendrite) boundaries where they can affect recrystallization.

[0110] In large scale casting, depletion or accumulation of alloying elements can occur. This is known as macrosegregation, which can be caused by the relative movement of solid-liquid phases with disparate compositions. The center of the ingot is particularly susceptible to macrosegregation, for example during casting. For example, this region of the ingot can exhibit depletion of eutectic forming elements, with the relative depletion being proportional to the casting speed. This property is further elucidated by Yu and Granger in “Macrosegregation in Aluminum Alloy Ingot Cast by the Semicontinuous Direct Chill (DC) Method, International Conference on Aluminum alloys-Their physical and mechanical properties,” Charlottesville, Virginia. Warley (UK): EMAS; 1986, p. 17-29. As described herein, this behavior has previously been considered to be a hindrance, but the present invention rather purposefully creates macrosegregation, but in a unique way, to create a functional gradient. This functional gradient resulted in an aluminum rolling product with desirable properties and that is reusable. Advantageously, more primary grains accumulate in the center resulting in an aluminum alloy product that has a functional gradient across at least one dimension of the product.

[0111] Similarly, peritectic or dispersoid forming elements may be selectively enriched in the centerline of the ingot, with enhanced enrichment achieved by increasing the casting speed. Thus, by varying the casting speed, the distribution of dispersoid forming elements may be optimized in the center of the ingot, which may affect the rate at which recrystallization occurs. For example, by increasing the casting speed in an ingot containing dispersoid forming elements, the concentration of dispersoid forming elements in the center of the ingot may be increased compared to a slower casting speed. The enhanced dispersoid content in the corresponding solidified ingot may then be used to affect the recrystallization rate in the center of the processed object during subsequent processing steps (e.g., rolling, annealing, etc.). Thus, casting may affect the amount and rate of recrystallization in the center relative to the surface during subsequent, e.g., rolling and annealing steps. Thus, the methods disclosed herein may optionally utilize high speed casting processes, such as about 1.5 inches per minute (IPM) or greater, for example, 1.5-10 IPM, 2.5-10 IPM, 3.5-10 IPM, or 4.5-10 IPM.

[0112] Various parameters can be adjusted in the casting process to affect the formation of dispersoids in desired locations, e.g., toward the center of the ingot or toward the outer surface. For example, the flow rate of the molten metal in the ingot can be controlled to enrich the peritectic (dispersoid) elements. To adjust the flow rate, a high-velocity jet melting technique using a custom nozzle moves the flow toward the short faces and the rolling surface at an angle that makes the pool profile steeper, which encourages more grains to settle in the center. The high-velocity jet melting technique can be performed without the use of magnets. Alternatively, large magnets placed on each rolling surface and rotating in opposite directions can be used to create a flow moving from the rolling surface toward the ingot center. Another alternative for adjusting the flow can include using a large combo bag with an angled slot to create a flow moving toward the end faces, which encourages more primary grains to settle in the center at the bottom of the pool. Yet another alternative for adjusting the flow may include using magnetic high-velocity liquid jet technology, which allows creating a deeper liquid pool and thus enhancing segregation. This also creates more positive segregation of the eutectic elements in the center of the ingot. In addition to or instead of adjusting the flow, convection may be applied by magnetic means or by physical stirring. These methods may be used to change how the grains settle during casting. In a further embodiment, the casting speed may be increased, which may help to increase the depth of the molten pool. Furthermore, increasing the angle of the solidification interface may lead to enhanced migration of the grains to the bottom of the molten pool in the mold, e.g., toward the center of the ingot. The process may be adjusted depending on how the functional gradient is desired to flow, e.g., whether to concentrate the dispersoids at the center of the ingot or toward the surface / edge.

[0113] Other distinguishing aspects of the casting process resulting in the desired ingot may include any of the following aspects. For example, in-situ techniques may be used to increase the puddle depth to create more macrosegregation. Additionally or alternatively, commercially available wiper techniques may be used to increase the puddle depth. Additionally or alternatively, a second liquid jet rich in peritectic and / or eutectic elements (e.g., may be a binary alloy liquid) may be directly injected deeper into the puddle below the primary liquid jet to significantly increase the segregation factor, which may also help increase the solid solubility of elements in the aluminum primary grains during DC casting, and notably, a similar approach may be applied to CC. Additionally or alternatively, a binary rod may be injected or fed directly into the center of the puddle to realize an increase in the concentration of those rod elements at the center when the rod melts. Additionally or alternatively, a vapor of the slurry (or a liquid containing reinforcing particles) may be injected or pumped into the center of the pool so that the cast ingot maintains a finer grain size without coarsening or agglomeration at the center of the ingot. Additionally or alternatively, a combination of the above techniques may be used to effect macrosegregation enhancement, such as a combination of high velocity liquid jet techniques used in conjunction with a commercial wiper and / or by varying the casting speed.

[0114] Homogenization The homogenization step may include heating an aluminum alloy casting prepared from an alloy composition described herein to achieve a peak metal temperature (PMT) of at least 400°C (e.g., at least 400°C, at least 410°C, at least 420°C, at least 430°C, at least 440°C, at least 450°C, at least 460°C, at least 470°C, at least 480°C, at least 490°C, at least 500°C, at least 510°C, at least 520°C, or at least 530°C). For example, the aluminum alloy product may be heated to a temperature of 400°C to 580°C, 420°C to 575°C, 440°C to 570°C, 460°C to 565°C, 485°C to 560°C, 500°C to 560°C, or 520°C to 580°C. Optionally, the heating rate to the PMT is 100° C. / hr or less, 75° C. / hr or less, 50° C. / hr or less, 40° C. / hr or less, 30° C. / hr or less, 25° C. / hr or less, 20° C. / hr or less, or 15° C. / hr or less. Optionally, the heating rate to the PMT is 10° C. / min to 100° C. / min (e.g., 10° C. / min to 90° C. / min, 10° C. / min to 70° C. / min, 10° C. / min to 60° C. / min, 20° C. / min to 90° C. / min, 30° C. / min to 80° C. / min, 40° C. / min to 70° C. / min, or 50° C. / min to 60° C. / min).

[0115] In some cases, the aluminum alloy casting is then soaked (i.e., held at a particular temperature, such as the PMT) for a period of time. In some embodiments, the aluminum alloy casting is soaked for 24 hours or less (e.g., 30 minutes to 6 hours, inclusive). For example, in some embodiments, the aluminum alloy product is soaked at a temperature of at least 400° C. for 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 6 hours, 7 hours, 8 hours, 9 hours, 10 hours, 11 hours, 12 hours, 13 hours, 14 hours, 15 hours, 16 hours, 17 hours, 18 hours, 19 hours, 20 hours, 21 hours, 22 hours, 23 hours, 24 hours, or any period in between.

[0116] In some embodiments, the homogenization described herein may be performed in a two-stage homogenization process. In some embodiments, the homogenization process may include the heating and soaking steps described above, which may be referred to as a first stage, and may further include a second stage. In the second stage of the homogenization process, the temperature of the aluminum alloy casting is increased to a temperature higher than that used for the first stage of the homogenization process. The aluminum alloy casting temperature may be increased, for example, to a temperature at least 5° C. higher than the aluminum alloy casting temperature during the first stage of the homogenization process. For example, the aluminum alloy casting temperature may be increased to a temperature of at least 405° C. (e.g., at least 410° C., at least 415° C., or at least 420° C.). The heating rate to the second stage homogenization temperature may be 5° C. / hour or less, 3° C. / hour or less, or 2.5° C. / hour or less. The aluminum alloy casting is then soaked for a period of time during the second stage. In some embodiments, the aluminum alloy casting is soaked for 10 hours or less (e.g., 30 minutes to 10 hours, including end points). For example, the aluminum alloy casting may be soaked at a temperature of at least 405° C. for 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 6 hours, 7 hours, 8 hours, 9 hours, or 10 hours. In some embodiments, after homogenization, the aluminum alloy casting is allowed to cool to room temperature in air.

[0117] The homogenization process may allow for the precipitation of peritectic or dispersoid phases formed during casting. As described herein, the ingot may have a higher amount of peritectic forming elements in the center of the ingot, but this may be reversed to have a higher amount of dispersoids at the surface, if desired.

[0118] Temperature gradients inside the homogenization furnace can be used to create changes in the microstructure across the ingot cross section, for example, temperature differences between the surface and center of the ingot will result in changes in dispersoid formation.

[0119] After homogenization, the surface of the ingot may be sprayed with quench water for several seconds so that the exterior surface cools faster and the interior surface is maintained at a higher temperature, which may also promote gradients in the microstructure across the cross section. The gradients in the microstructure may include at least one of gradients in chemical composition, primary grain distribution, insoluble intermetallic particles (type, size, shape, distribution), texture, or distribution of recrystallized grains, strengthening precipitates, and / or strengthening particles.

[0120] Hot rolling The homogenization step may be followed by one or more hot rolling passes, which is the step where a gradient microstructure is considered to be formed, since the dispersoid phase acts to inhibit recrystallization. As described above, the dispersoid phase may be present in greater amounts in the ingot center or at the ingot surface, depending on the desired end use and desired properties.

[0121] In some cases, the aluminum alloy product is hot rolled at a temperature ranging from 250°C to 550°C (e.g., 300°C to 500°C, or 350°C to 450°C, or 300°C to 520°C). In some embodiments, the aluminum alloy product is selectively heated during rolling, for example, using different temperature profiles providing gradient heating, to manipulate the grain growth process after recrystallization. Gradient heating may use magnetic, microwave, or induction heating methods. For example, gradient heating may include heating a sheet or ironed gauge plate such that an outer portion has a temperature higher than the recrystallization temperature and an inner portion has a temperature lower than the recrystallization temperature. Alternatively, or in addition, water sprays may be applied immediately after heating, such that the outer portion quickly drops to a temperature lower than the recrystallization temperature while the inner portion maintains a temperature higher than the recrystallization temperature.

[0122] In certain embodiments, the aluminum alloy product is hot rolled to a thickness gauge between 4 mm and 15 mm (e.g., between 5 mm and 12 mm), which is referred to as a sheet. For example, the aluminum alloy product may be hot rolled to a thickness gauge of 15 mm, 14 mm, 13 mm, 12 mm, 11 mm, 10 mm, 9 mm, 8 mm, 7 mm, 6 mm, or 5 mm, or any value in between.

[0123] In certain other embodiments, the aluminum alloy product may be hot rolled to a gauge greater than 15 mm thick (e.g., plate). For example, the aluminum alloy product may be hot rolled to a gauge of 25 mm thick, 24 mm thick, 23 mm thick, 22 mm thick, 21 mm thick, 20 mm thick, 19 mm thick, 18 mm thick, 17 mm thick, or 16 mm thick, or any suitable gauge in between, or greater than 25 mm thick.

[0124] In certain other embodiments, the aluminum alloy product may be cross-rolled laterally.

[0125] In other examples, the aluminum alloy product may be hot rolled to a gauge of less than 4 mm (e.g., sheet). For example, the aluminum alloy product may be hot rolled to a thickness gauge of 3.5 mm, a thickness gauge of 3 mm, a thickness gauge of 2 mm, or a thickness gauge of 1 mm, or any value in between.

[0126] Cold rolling and annealing, and further rolling Following hot rolling, one or more cold rolling passes may be performed. In certain embodiments, the rolled product (e.g., plate, shat, or sheet) from the hot rolling step may be cold rolled into a thin gauge shat or sheet. In some embodiments, the thin gauge shat or sheet may be cold rolled to have a thickness (i.e., a first thickness) in the range of 0.9 mm to 12.0 mm, or 2.0 mm to 8.0 mm, or 3.0 mm to 6.0 mm, or 4.0 mm to 5.0 mm. In some embodiments, the thin gauge sheet or plate has a thickness of 12.0 mm, 11.9 mm, 11.8 mm, 11.7 mm, 11.6 mm, 11.5 mm, 11.4 mm, 11.3 mm, 11.2 mm, 11.1 mm, 11.0 mm, 10.9 mm, 10.8 mm, 10.7 mm, 10.6 mm, 10.5 mm, 10.4 mm, 10.3 mm, 10.2 mm, 10.1 mm, 10.0 mm, 9.9 mm, 9.8 ... mm, 9.7mm, 9.6mm, 9.5mm, 9.4mm, 9.3mm, 9.2mm, 9.1mm, 9.0mm, 8.9mm, 8.8mm, 8.7mm, 8.6mm, 8.5mm, 8.4mm, 8.3mm, 8 .2mm, 8.1mm, 8.0mm, 7.9mm, 7.8mm, 7.7mm, 7.6mm, 7.5mm, 7.4mm, 7.3mm, 7.2mm, 7.1mm, 7.0mm, 6.9mm, 6.8mm, 6.7mm , 6.6mm, 6.5mm, 6.4mm, 6.3mm, 6.2mm, 6.1mm, 6.0mm, 5.9mm, 5.8mm, 5.7mm, 5.6mm, 5.5mm, 5.4mm, 5.3mm, 5.2mm, 5.1 mm, 5.0mm, 4.9mm, 4.8mm, 4.7mm, 4.6mm, 4.5mm, 4.4mm, 4.3mm, 4.2mm, 4.1mm, 4.0mm, 3.9mm, 3.8mm, 3.7mm, 3.6mm, 3 Cold rolled to a thickness of 0.5mm, 3.4mm, 3.3mm, 3.2mm, 3.1mm, 3.0mm, 2.9mm, 2.8mm, 2.7mm, 2.6mm, 2.5mm, 2.4mm, 2.3mm, 2.2mm, 2.1mm, 2.0mm, 1.9mm, 1.8mm, 1.7mm, 1.6mm, 1.5mm, 1.4mm, 1.3mm, 1.2mm, 1.1mm, 1.0mm or 0.9mm, or any value in between.

[0127] In some embodiments, the one or more cold rolling passes reduce the thickness of the rolled aluminum product by at least 30%, or at least 35%, or at least 40%, or at least 45%, or at least 50%, or at least 55%, or at least 60%, or at least 65%, or at least 70%. In some embodiments, the one or more cold rolling passes reduce the casting to a thickness (i.e., a first thickness) of 10 mm or less, or 9 mm or less, or 8 mm or less, or 7 mm or less, or 6 mm or less, or 5 mm or less.

[0128] Following one or more cold rolling passes, an anneal may be performed, which is sometimes referred to as an intermediate or intermediate anneal since it is performed midway through the rolling process, e.g., in some embodiments, the anneal is followed by one or more further rolling passes.

[0129] The annealing step may include heating the rolled aluminum product from room temperature to a temperature of 380°C to 500°C (e.g., 385°C to 495°C, 390°C to 490°C, 395°C to 485°C, 400°C to 480°C, 405°C to 475°C, 410°C to 470°C, 415°C to 465°C, 420°C to 460°C, 425°C to 455°C, 430°C to 460°C, 380°C to 450°C, 405°C to 475°C, or 430°C to 500°C).

[0130] This intermediate annealing step may, for example, result in certain beneficial texture features in the resulting product. In particular, intermediate annealing aids in the formation of recrystallized microstructures on the surface of the product, and in the center of the product, recovery and / or non-recrystallized structures. In some instances, the texture on the surface of the product will be dominated by recrystallized components, including cube, cube ND, and cube RD, rather than deformation-type components such as Bs, S, and Cu. Therefore, the bending performance of the product is improved without reducing strength.

[0131] The plate, sheet, or sheet may be soaked at the intermediate annealing temperature for a period of time. In one non-limiting example, the plate, sheet, or sheet is soaked for approximately 2 hours or less (e.g., about 15 to about 120 minutes, including end points). For example, the plate, sheet, or sheet may be soaked at a temperature of about 400° C. to about 500° C. for 15 minutes, 20 minutes, 25 minutes, 30 minutes, 35 minutes, 40 minutes, 45 minutes, 50 minutes, 55 minutes, 60 minutes, 65 minutes, 70 minutes, 75 minutes, 80 minutes, 85 minutes, 90 minutes, 95 minutes, 100 minutes, 105 minutes, 110 minutes, 115 minutes, or 120 minutes, or any value in between.

[0132] In some embodiments, the intermediate annealing of the rolled aluminum alloy product is conducted at a temperature that is 45° C. or less, or 40° C. or less, or 35° C. or less, or 30° C. or less, or 25° C. or less, or 20° C. or less, or 15° C. or less, or 10° C. or less above the minimum recrystallization temperature of the aluminum alloy. In some embodiments, the intermediate annealing of the rolled aluminum alloy product is conducted at a temperature above the minimum recrystallization temperature of the aluminum alloy for 3.0 hours or less, or 2.5 hours or less, or 2.0 hours or less, or 1.5 hours or less, or 1.0 hour or less.

[0133] Optionally, the intermediate annealing may include multiple annealing sub-steps. For example, in some embodiments, the annealing is performed at a first temperature above the minimum recrystallization temperature for a first period of time and at a second temperature above the minimum recrystallization temperature for a second period of time. For example, the first temperature above the minimum recrystallization temperature may exceed the second temperature above the minimum recrystallization temperature. The annealing may, for example, subject the surface portion to higher temperature annealing conditions earlier than the intermediate portion. By using a two (or more) step intermediate annealing process, where the temperature is lowered in the second step compared to the first step, the surface portion of the rolled aluminum alloy product may be subjected to recrystallization conditions for a longer period of time than the intermediate portion. This may also occur in a single step intermediate annealing process where a single annealing temperature is used, but the effect may be more pronounced in a multiple step annealing process.

[0134] Optionally, the intermediate anneal is followed by further rolling, such as cold rolling. In some embodiments, one or more additional cold rolling passes are performed. The additional rolling brings the aluminum alloy product to a final gauge (i.e., a second gauge). In some embodiments, the final gauge is in the range of 0.1 mm to 4.0 mm. In some embodiments, the final thickness is 4.0 mm, 3.9 mm, 3.8 mm, 3.7 mm, 3.6 mm, 3.5 mm, 3.4 mm, 3.3 mm, 3.2 mm, 3.1 mm, 3.0 mm, 2.9 mm, 2.8 mm, 2.7 mm, 2.6 mm, 2.5 mm, 2.4 mm, 2.3 mm, 2.2 mm, 2.1 mm, 2.0 mm, 1.9 mm, 1.8 mm, 1.7 mm, 1.6 mm, 1.5 mm, 1.4 mm, 1.3 mm, 1.2 mm, 1.1 mm, 1.0 mm, 0.9 mm, 0.8 mm, 0.7 mm, 0.6 mm, 0.5 mm, 0.4 mm, 0.3 mm, 0.2 mm, or 0.1 mm. In some further such embodiments, the final thickness is 4.0 mm or less, or 3.5 mm or less, or 3.0 mm or less, or 2.5 mm or less, or 2.0 mm or less, or 1.5 mm or less, or 1.0 mm or less, or 0.5 mm or less, or 0.3 mm or less, or 0.1 mm or less.

[0135] Finishing process Optionally, the intermediate anneal and / or additional rolling may be followed by additional finishing steps including, but not limited to, one or more of solutionizing, quenching, aging and coiling.

[0136] In some embodiments, a solution heat treatment step may be performed. The solution heat treatment step may include heating the aluminum alloy product from room temperature to a temperature of 430° C. to 580° C. For example, the solution heat treatment step may include heating the aluminum alloy product from room temperature to a temperature of 440° C. to 580° C., 460° C. to 500° C., or 480° C. to 490° C. In some examples, the heating rate of the solution heat treatment step can be from 250° C. / hr to 350° C. / hr (e.g., 250° C. / hr, 255° C. / hr, 260° C. / hr, 265° C. / hr, 270° C. / hr, 275° C. / hr, 280° C. / hr, 285° C. / hr, 290° C. / hr, 295° C. / hr, 300° C. / hr, 305° C. / hr, 310° C. / hr, 315° C. / hr, 320° C. / hr, 325° C. / hr, 330° C. / hr, 335° C. / hr, 340° C. / hr, 345° C. / hr, or 350° C. / hr).

[0137] In some embodiments, the aluminum alloy product may then be cooled to a temperature of about 25° C. in a quenching step based on the gauge selected, with the quenching rate varying from about 50° C. / s to about 400° C. / s. For example, the quenching rate may be from about 50° C. / s to about 375° C. / s, from about 60° C. / s to about 375° C. / s, from about 70° C. / s to about 350° C. / s, from about 80° C. / s to about 325° C. / s, from about 90° C. / s to about 300° C. / s, from about 100° C. / s to about 275° C. / s, from about 125° C. / s to about 250° C. / s, from about 150° C. / s to about 225° C. / s, or from about 175° C. / s to about 200° C. / s.

[0138] In the quenching process, the aluminum alloy product is rapidly quenched by a liquid (e.g., water) and / or gas, or another selected quenching medium. In certain aspects, the aluminum alloy product may be rapidly quenched by water. In certain embodiments, the aluminum alloy product is quenched by air.

[0139] In some embodiments, the aluminum alloy product may be artificially aged for a period of time to produce a T6 or T7 temper. In certain embodiments, the aluminum alloy product may be artificially aged (AA) for a period of time at about 100°C to 225°C (e.g., 100°C, 105°C, 110°C, 115°C, 120°C, 125°C, 130°C, 135°C, 140°C, 145°C, 150°C, 155°C, 160°C, 165°C, 170°C, 175°C, 180°C, 185°C, 190°C, 195°C, 200°C, 205°C, 210°C, 215°C, 220°C, or 225°C). Optionally, the aluminum alloy product may be cold worked and artificially aged for a period of about 15 minutes to about 48 hours (e.g., 15 minutes, 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 6 hours, 7 hours, 8 hours, 9 hours, 10 hours, 11 hours, 12 hours, 13 hours, 14 hours, 15 hours, 16 hours, 17 hours, 18 hours, 19 hours, 20 hours, 21 hours, 22 hours, 23 hours, 24 hours, 25 hours, 26 hours, 27 hours, 28 hours, 29 hours, 30 hours, 31 hours, 32 hours, 33 hours, 34 hours, 35 hours, 36 hours, 37 hours, 38 hours, 39 hours, 40 hours, 41 hours, 42 hours, 43 hours, 44 hours, 45 hours, 46 hours, 47 hours, or 48 hours, or any value in between).

[0140] In some embodiments, for improved manufacturability or formability, an in-production or post-production annealing step may also be applied to produce an aluminum alloy product in a wound form. For example, an alloy in wound form may be supplied in temper O using a hot or cold rolling step and an annealing step following the hot or cold rolling step. Forming may occur in temper O, followed by a solution heat treatment, quenching and artificial aging / paint baking.

[0141] In certain embodiments, an annealing step may be applied to the roll to produce an aluminum alloy product in roll form that has enhanced formability compared to Temper F. While not intended to be limiting of the invention, the objectives of the anneal and annealing parameters may include: (1) to remove work hardening in the material to achieve formability; (2) to recrystallize or restore the material without causing significant grain growth; (3) to manipulate or transform the structure to make it suitable for forming and to reduce anisotropy while still being formable; and (4) to avoid coarsening of existing precipitates.

[0142] In one or more aspects, the present disclosure provides an aluminum alloy product formed by the process set forth above, or any embodiment thereof.

[0143] product The present disclosure provides an article of manufacture comprising the aluminum alloy product disclosed herein. In some embodiments, the article of manufacture comprises a rolled aluminum alloy product. Examples of such articles include, but are not limited to, automobiles, trucks, trailers, trains, rail vehicles, aircraft, armored vehicles, ships, boats, body panels or parts for any of the above, bridges, pipelines, pipes, piping, boats, ships, storage vessels, storage tanks, furniture, windows, doors, railroad tracks, functional or decorative building components, pipe railings, electronic components, conduits, beverage containers, food containers, or foils.

[0144] In some other embodiments, the aluminum alloy articles disclosed herein may be used in automotive and / or transportation applications, including motor vehicle, aircraft, and rail applications, or any other desired application. In some examples, the aluminum alloy products disclosed herein may be used to make automotive body part products, such as bumpers, side beams, roof beams, cross beams, pillar reinforcements (e.g., A-pillars, B-pillars, and C-pillars), inner panels, outer panels, side panels, inner hoods, outer hoods, or trunk lid panels. The aluminum alloys and methods described herein may also be used in aircraft or rail applications, such as to make exterior and interior panels.

[0145] In some other embodiments, the aluminum alloy articles disclosed herein may be used in electronics applications. For example, the aluminum alloy products disclosed herein may also be used to make housings for electronic devices, including mobile phones and tablet computers. In some examples, the alloys may be used to make housings for mobile phones (e.g., smartphones) and tablet bottom chassis casings.

[0146] In some other embodiments, the aluminum alloy products disclosed herein may be used in industrial applications, for example, the aluminum alloy products disclosed herein may be used to make products for the general market.

[0147] In some other embodiments, the aluminum alloy articles disclosed herein may be used as aerospace body parts. For example, the aluminum alloy articles disclosed herein may be used to make structural aerospace body parts, such as wings, fuselages, ailerons, rudders, elevators, cowlings, or supports. In some other embodiments, the aluminum alloy articles disclosed herein may be used to make non-structural aerospace body parts, such as seat rails, seat frames, panels, or hinges.

[0148] The following examples serve to further illustrate certain specific embodiments of the present disclosure, but do not, however, constitute any limitation thereon. Rather, it should be clearly understood that reliance can be placed on various embodiments, modifications thereof, and equivalents that may spontaneously suggest themselves to a person skilled in the art after reading the description herein, without departing from the spirit of the present disclosure.

[0149] Exemplary Aspects

[0150] As used hereinafter, any reference to a series of embodiments (e.g., "Embodiments 1-4") or to an unrecited group of embodiments (e.g., "any preceding or subsequent embodiment") should be understood to refer to each of those embodiments separately (e.g., "Embodiments 1-4" should be understood as "Embodiments 1, 2, 3 or 4"). Aspect 1 is a method of preparing a functionally graded aluminum alloy product, comprising: casting an ingot into a mold or pouring a melt into a casting cavity to form a casting, the casting comprising an aluminum alloy, the casting comprising at least one peritectic forming element and at least one eutectic forming element, the casting comprising: a) forming primary grains enriched in the at least one peritectic forming element and depleted in the at least one eutectic element, and b) controlling migration and accumulation of the primary grains; homogenizing the casting, wherein the primary grains precipitate during the homogenization; and rolling the homogenized casting to form the functionally graded aluminum alloy product.

[0151] Example 2 is the method of any preceding or following example, wherein the aluminum alloy is a 2xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy.

[0152] Example 3 is the method of any preceding or following example, wherein the at least one peritectic forming element is present in an amount of 0.2 wt.% or less.

[0153] Example 4 is the method of any preceding or following example, wherein the at least one eutectic former element is present in an amount greater than 0.2 wt.%.

[0154] Example 5 is the method of any of the preceding or following examples, wherein casting an ingot into the mold comprises a direct chill casting process.

[0155] Example 6 is the method according to any of the preceding or following examples, wherein pouring the molten liquid into the casting cavity and casting comprises a continuous casting process.

[0156] Example 7 is the method of any preceding or following example, wherein the continuous casting process includes casting with at least one of a twin belt caster, a twin roll caster, a block caster, or any other continuous caster.

[0157] Example 8 is the method of any of the preceding or following examples, wherein the rolling comprises hot rolling.

[0158] Example 9 is the method of any preceding or following example, wherein the precipitated primary grains inhibit recrystallization during the rolling.

[0159] Example 10 is the method of any preceding or following example, wherein the aluminum alloy product is functionally graded across a thickness of the product.

[0160] Example 11 is the method of any preceding or following example, wherein the aluminum alloy product is functionally graded across the width of the product.

[0161] Example 12 is the method of any preceding or following example, wherein the primary grains have a maximum dimension between 25 and 250 microns.

[0162] Example 13 is the method of any preceding or following example, wherein the aluminum alloy comprises the at least one peritectic former element and the at least one eutectic former element.

[0163] Example 14 is the method of any of the preceding or following examples, wherein the at least one peritectic forming element, the at least one eutectic forming element, or a combination thereof is added to the ingot or liquid metal during the casting.

[0164] Example 15 is the method of any preceding or following example, where forming the primary grains further includes forming at least one of solute elements, intermetallic compound particles, solute-rich grains, strengthening particles, or a combination thereof.

[0165] Example 16 is an aluminum alloy product comprising a functional gradient across at least one dimension, the functional gradient comprising a non-recrystallized center and a recrystallized surface, and / or a change in strengthening particle fraction from the center to the surface.

[0166] Example 17 is the aluminum alloy product of any preceding or following example, wherein the product includes at least one peritectic forming element in the non-recrystallized centers.

[0167] Example 18 is the aluminum alloy product of any preceding or following example, wherein the at least one peritectic forming element includes at least one of Ti, Zr, V, Hf, Nb, Ta, Cr, or a combination thereof.

[0168] Example 19 is the aluminum alloy product of any preceding or following example, wherein the at least one peritectic element is present in an amount of 0.2 wt.% or less.

[0169] Example 20 is the aluminum alloy product of any preceding or following example, wherein the product includes at least one eutectic forming element in the recrystallized plane.

[0170] Example 21 is the aluminum alloy product of any preceding or following example, wherein the eutectic former elements include at least one of Si, Cu, Fe, Zn, Mg, Sc, Ni, Mn, Ce, and Y, and combinations thereof.

[0171] Example 22 is the aluminum alloy product of any preceding or following example, wherein the eutectic former is present in an amount greater than 0.2 wt.%.

[0172] Example 23 is the aluminum alloy product of any preceding or following example, wherein the product can include at least one reinforcing particle.

[0173] Example 24 is the aluminum alloy product of any preceding or following example, wherein the reinforcing particles include at least one of TiB2, TiC, NbB2, Al2O3, SiC, ZrB2, AlB2, Al3Ti, Al7Cr, Al3Zr, Al3Nb, Al3Ta, Al3V, AlN, Al3Ni, Al3Hf, Al3HfO, and combinations thereof.

[0174] Example 25 is the aluminum alloy product of any preceding or following example, wherein the reinforcing particles are added to a molten metal or formed in situ during casting.

[0175] Example 26 is the aluminum alloy product of any preceding or following example, wherein the reinforcing particles are present in an amount greater than 0.1 wt.%.

[0176] Example 27 is an aluminum alloy article comprising the aluminum alloy product of any of the preceding embodiments.

[0177] All patents, patent applications, publications and abstracts cited above are incorporated herein by reference in their entirety. Various embodiments of the present invention have been described to accomplish various objectives of the present invention. It should be recognized that these embodiments are merely illustrative of the principles of the present invention. Numerous modifications and adaptations thereof will be readily apparent to those skilled in the art without departing from the spirit and scope of the present invention as defined in the following claims.

Claims

1. 1. A method for preparing a functionally graded aluminum alloy product, comprising:

2. Casting an ingot into a mold or pouring a melt into a casting cavity to form a casting, said casting comprising an aluminum alloy, said casting comprising at least one peritectic former and at least one eutectic former, said casting comprising: a) forming primary grains enriched in said at least one peritectic forming element and depleted in said at least one eutectic element; and b) controlling the movement and accumulation of the primary grains; said forming comprising: homogenizing the casting, during which the primary grains precipitate; rolling the homogenized casting to form the functionally graded aluminum alloy product; The method comprising:

2. 2. The method of claim 1, wherein the aluminum alloy is a 2xxx, 5xxx, 6xxx, or 7xxx series aluminum alloy.

3. 3. The method of claim 1 or claim 2, wherein the at least one peritectic forming element is present in an amount of 0.2 wt.% or less.

4. The method according to any one of claims 1 to 3, wherein said at least one eutectic former element is present in an amount greater than 0.2 wt.%.

5. The method of any of claims 1 to 4, wherein casting an ingot into the mold comprises a direct chill casting process.

6. The method of any one of claims 1 to 5, wherein pouring the melt into the casting cavity and casting comprises a continuous casting process.

7. The continuous casting process comprises: Twin belt caster, twin roll caster, block caster or any other continuous caster The method of claim 6, further comprising casting by at least one of the following:

8. The method of any of claims 1 to 7, wherein said rolling comprises hot rolling.

9. The method according to any one of claims 1 to 8, wherein the precipitated primary crystal grains inhibit recrystallization during the rolling.

10. A method according to any preceding claim, wherein the aluminium alloy product is functionally graded across the thickness of the product.

11. A method according to any preceding claim, wherein the aluminium alloy product is functionally graded across the width of the product.

12. The method of any one of claims 1 to 11, wherein the primary grains have a maximum dimension of from 25 to 250 microns.

13. The method according to any one of claims 1 to 12, wherein the aluminium alloy comprises the at least one peritectic former and the at least one eutectic former.

14. The method according to any of the preceding claims, wherein said at least one peritectic forming element, said at least one eutectic forming element, or a combination thereof is added to said ingot or liquid metal during said casting.

15. forming the primary crystal grains, solute elements, intermetallic particles, solute-rich grains, reinforcing particles, or combinations thereof The method of any of claims 1 to 14, further comprising forming at least one of:

16. 1. An aluminum alloy product comprising a functional gradient across at least one dimension, said functional gradient comprising: Non-recrystallized centers and recrystallized surfaces, and / or Change in reinforcing particle ratio from the center to the surface The aluminum alloy product comprising:

17. 17. The aluminum alloy product of claim 16, wherein said product includes at least one peritectic forming element in said non-recrystallized centers.

18. The at least one peritectic forming element is Ti, Zr, V, Hf, Nb, Ta, Cr or a combination thereof 20. The aluminum alloy product of claim 17, comprising at least one of:

19. 19. An aluminium alloy product according to claim 17 or claim 18, wherein the at least one peritectic element is present in an amount of not more than 0.2 wt.%.

20. 20. An aluminium alloy product according to any one of claims 16 to 19, wherein the product comprises at least one eutectic forming element in the recrystallised plane.

21. The eutectic forming element is Si, Cu, Fe, Zn, Mg, Sc, Ni, Mn, Ce and Y, and combinations thereof 21. The aluminum alloy product of claim 20, comprising at least one of:

22. 22. An aluminium alloy product according to claim 20 or claim 21, wherein the eutectic former elements are present in an amount greater than 0.2 wt.%.

23. The aluminium alloy product according to claims 16 to 19, wherein the product may include at least one reinforcing particle.

24. The reinforcing particles are TiB ２ 、TiC、NbB ２ 、Al ２ O ３ 、SiC、ZrB ２ 、AlB ２ 、Al ３ Ti、Al ７ Cr、Al ３ Zr、Al ３ Nb、Al ３ Ta、Al ３ V、AlN、Al ３ Ni、Al ３ Hf、Al ３ HfO, and combinations thereof 24. The aluminum alloy product of claim 23, comprising at least one of:

25. The reinforcing particles are Added to the melt or formed in situ during said casting, 25. An aluminium alloy product according to claim 23 or claim 24.

26. An aluminium alloy product according to any one of claims 23 to 25, wherein the reinforcing particles are present in an amount greater than 0.1 wt%.

27. An aluminium alloy article comprising the aluminium alloy product according to any one of claims 16 to 26.