High strength aluminum alloy for can end stock and preparation method thereof

Abstract

Described herein are novel aluminum alloys, including recycled aluminum alloy materials, that exhibit high strength and high formability. For example, the aluminum alloys described herein suitable for use as can end stocks exhibit high strength and formability despite having a lower Mg content than the conventional AA5182 aluminum alloy used to manufacture can end stocks. The present disclosure provides a cost-effective alternative to the use of AA5182 alloy for can end stocks.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of and priority to U.S. Provisional Application No. 63 / 364,163, filed May 4, 2022, the contents of which are incorporated by reference in their entirety herein for all intents and purposes.

[0002] The present disclosure relates to the fields of metallurgy, aluminum alloys, aluminum fabrication, and related fields. In particular, the present disclosure provides novel aluminum alloys having a high amount of recycled aluminum material that may be useful for producing can end stocks. The present disclosure also relates to a method of producing novel aluminum alloys from recycled aluminum alloy material that provides control of grain size of components in the microstructure of the aluminum alloy to improve the mechanical properties of the aluminum alloy. [Background technology]

[0003] Can end stocks are traditionally made from high-strength aluminum alloys with good formability. The mechanical requirements of the aluminum alloys used to manufacture can end stocks are different from the mechanical requirements of the can body stock. In general, the aluminum alloys for manufacturing can end stocks may require higher strength than the can body stock. As a result, can end stocks are often made from aluminum alloys with high magnesium (Mg) content. For example, can end stocks may be made from a highly engineered AA5182 aluminum alloy, which has a tightly controlled composition and process for manufacturing the alloy.

[0004] Many aluminum manufacturers use the same alloy for can end stock. Attempts to improve the composition of aluminum alloys for can end stock have not been successful, mainly because mechanical properties (e.g., strength and formability) are significantly affected by changes in aluminum alloy composition. For example, the composition of AA5182 aluminum alloy is strictly controlled to have a magnesium (Mg) content of 4.0 wt% to 5.0 wt%, a manganese (Mn) content of 0.20 wt% to 0.50 wt%, a maximum iron (Fe) content of 0.35 wt%, a maximum silicon (Si) content of 0.20 wt%, a maximum copper (Cu) content of 0.15 wt%, and a maximum chromium (Cr) content of 0.10 wt%. However, recycled materials such as used beverage cans (UBCs) have not been used to manufacture can end stock and can body stock because UBCs contain two separate aluminum alloys with different aluminum alloy compositions. Specifically, can end stock is typically made from AA5182 aluminum alloy, and can body stock is typically made from AA3104 aluminum alloy. Because the two aluminum alloys of UBC are different, there is little commonality in the composition to make new aluminum alloys for can body stock and can end stock. Therefore, when UBC is used to make new aluminum alloys, primary aluminum and additional alloying elements need to be added to adjust the composition to make can end stock and can body stock. This reduces the cyclicality of recycled aluminum alloy production to make new aluminum alloys, and the recycled content is reduced because the addition of primary aluminum is required. Furthermore, the additional primary aluminum increases the amount of carbon dioxide production and increases the cost, leading to environmental harm and high costs.

[0005] Furthermore, aluminum alloys produced from high content recycled aluminum materials generally contain large amounts of alloying elements, which may be difficult to disassemble and result in large components in the aluminum alloy microstructure that adversely affect the aluminum alloy's mechanical properties. For example, large amounts of Si, Fe, and / or Mn, which are common alloying elements in recycled aluminum alloy materials, can cause problems with the aluminum alloy microstructure (e.g., Al x (e.g., the large components cannot be easily broken down during rolling deformation). Thus, the large components remain in the aluminum alloy microstructure of the aluminum alloy product (e.g., sheet) after fabrication. The large components in the aluminum alloy microstructure can, for example, adversely affect the formability of the aluminum alloy. Summary of the Invention

[0006] The embodiments contained in this disclosure are defined by the claims, not this Summary. This Summary is a high-level overview of various aspects of the invention and introduces some concepts that are further described in the Detailed Description section below. This Summary is not intended to identify key features or important features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to the entire specification, any or all drawings, and appropriate portions of each claim.

[0007] Described herein are aluminum alloys that provide a more cost-effective and recyclable material alternative to the use of AA5182 for can end stock. In some embodiments, the present disclosure relates to an aluminum alloy comprising 0.10-0.35 wt% Si, 0.20-0.60 wt% Fe, 0.05-0.25 wt% Cu, 0.25-1.20 wt% Mn, 1.3-5.0 wt% Mg, max 0.20 wt% Cr, max 0.30 wt% Zn, max 0.20 wt% Ti, max 0.15 wt% impurities, and Al. In some embodiments, the present disclosure relates to an aluminum alloy comprising 0.10-0.35 wt.% Si, 0.20-0.60 wt.% Fe, 0.05-0.25 wt.% Cu, 0.25-1.20 wt.% Mn, 2.0-5.0 wt.% Mg, up to 0.20 wt.% Cr, up to 0.30 wt.% Zn, up to 0.20 wt.% Ti, up to 0.15 wt.% impurities, and Al. In some embodiments, the aluminum alloy includes 0.10-0.30 wt% Si, 0.20-0.50 wt% Fe, 0.05-0.25 wt% Cu, 0.30-1.0 wt% Mn, 2.2-5.0 wt% Mg, up to 0.15 wt% Cr, up to 0.30 wt% Zn, up to 0.15 wt% Ti, up to 0.15 wt% impurities, and Al. In some embodiments, the aluminum alloy includes 0.10-0.25 wt% Si, 0.20-0.50 wt% Fe, 0.05-0.25 wt% Cu, 0.30-0.90 wt% Mn, 2.5-5.0 wt% Mg, up to 0.10 wt% Cr, up to 0.25 wt% Zn, up to 0.10 wt% Ti, up to 0.15 wt% impurities, and Al. In some embodiments, the aluminum alloy includes 0.20-0.35 wt% Si, 0.20-0.50 wt% Fe, 0.05-0.25 wt% Cu, 0.30-0.90 wt% Mn, 2.5-5.0 wt% Mg, max 0.05 wt% Cr, max 0.25 wt% Zn, max 0.05 wt% Ti, max 0.15 wt% impurities, and Al.In some embodiments, the aluminum alloy includes 0.20-0.35 wt% Si, 0.40-0.60 wt% Fe, 0.15-0.25 wt% Cu, 0.60-1.2 wt% Mn, 2.0-4.0 wt% Mg, up to 0.03 wt% Cr, up to 0.20 wt% Zn, up to 0.03 wt% Ti, up to 0.15 wt% impurities, and Al. In some embodiments, the ratio of Mg:Cu is 10:1-80:1 and the ratio of Mn:Cu is 2:1-15:1. In some embodiments, the ratio of Mg:Cu is 15:1-70:1 and the ratio of Mn:Cu is 3:1-12:1. In some embodiments, the aluminum alloy has a combined Fe and Si content of greater than 0.40 wt%. In some embodiments, the aluminum alloy has a combined Mg, Mn, and Cu content of 3.5 wt.% to 5.0 wt.%. In some embodiments, the aluminum alloy comprises at least 40 wt.% recycled scrap. In some embodiments, the aluminum alloy comprises less than 30 wt.% primary aluminum. In some embodiments, the aluminum alloy has a thermal conductivity of at least 30.0 KJ / m as measured by ASTM B871-1(2021). 2 In some embodiments, the aluminum alloy has a yield strength of at least 340 MPa. In some embodiments, the aluminum alloy has an ultimate tensile strength of at least 380 MPa. In some embodiments, the aluminum alloy has a total elongation of at least 4%. In some embodiments, the can end stock comprises any one of the aluminum alloys aforementioned.

[0008] In some embodiments, a method for producing an aluminum alloy is provided. The method includes casting an aluminum alloy to form a cast product, the aluminum alloy comprising 0.10-0.35 wt% Si, 0.20-0.60 wt% Fe, 0.05-0.25 wt% Cu, 0.25-1.20 wt% Mn, 2.0-5.0 wt% Mg, max 0.20 wt% Cr, max 0.30 wt% Zn, max 0.20 wt% Ti, max 0.15 wt% impurities, and Al, homogenizing the cast product, hot rolling the cast product to produce a hot rolled product, cold rolling the hot rolled product to produce a final gauge rolled product, and optionally annealing the final gauge rolled product. In some aspects, the method includes lacquering and hardening the final gauge rolled product. In some embodiments, the homogenization step includes a first homogenization step and a second homogenization step. In some embodiments, the first homogenization step includes soaking the cast product at a temperature of 375°C to 450°C for 0.5 hours to 5 hours. In some embodiments, the second homogenization step includes soaking the cast product at a temperature of 450°C to 550°C for 0.01 hours to 5 hours. In some embodiments, the aluminum alloy includes 0.10 to 0.25 wt% Si, 0.20 to 0.50 wt% Fe, 0.05 to 0.25 wt% Cu, 0.30 to 0.90 wt% Mn, 2.5 to 5.0 wt% Mg, up to 0.10 wt% Cr, up to 0.25 wt% Zn, up to 0.10 wt% Ti, up to 0.15 wt% impurities, and Al. In some embodiments, the ratio of Mg:Cu is between 15:1 and 70:1 and the ratio of Mn:Cu is between 3:1 and 12:1. In some embodiments, the metal product is prepared by the methods described above. In some embodiments, the metal product is can end stock.

[0009] In some embodiments, the present disclosure provides an aluminum alloy comprising 0.01-0.60 wt.% Si, 0.01-0.80 wt.% Fe, 0.05-0.30 wt.% Cu, 0.80-1.40 wt.% Mn, 1.3-5.0 wt.% Mg, max. 0.20 wt.% Cr, max. 0.30 wt.% Zn, max. 0.05 wt.% Ti, max. 0.15 wt.% impurities, and balance Al. In some embodiments, the aluminum alloy includes 0.10-0.50 wt% Si, 0.20-0.70 wt% Fe, 0.11-0.30 wt% Cu, 0.80-1.00 wt% Mn, 1.5-5.0 wt% Mg, up to 0.20 wt% Cr, up to 0.25 wt% Zn, up to 0.05 wt% Ti, up to 0.15 wt% impurities, and the balance Al. In some embodiments, the aluminum alloy includes 0.22-0.32 wt% Si, 0.50-0.65 wt% Fe, 0.20-0.30 wt% Cu, 0.80-0.92 wt% Mn, 2.0-4.0 wt% Mg, up to 0.20 wt% Cr, up to 0.25 wt% Zn, up to 0.03 wt% Ti, up to 0.15 wt% impurities, and the balance Al. In some embodiments, the aluminum alloy includes 0.25-0.32 wt.% Si, 0.45-0.55 wt.% Fe, 0.20-0.30 wt.% Cu, 0.80-0.92 wt.% Mn, 2.0-4.0 wt.% Mg, 0.01-0.20 wt.% Cr, up to 0.25 wt.% Zn, up to 0.03 wt.% Ti, up to 0.15 wt.% impurities, and the balance Al. In some embodiments, the aluminum alloy includes 0.25-0.35 wt% Si, 0.45-0.55 wt% Fe, 0.16-0.30 wt% Cu, 0.80-0.92 wt% Mn, 3.0-4.0 wt% Mg, 0.05-0.15 wt% Cr, up to 0.25 wt% Zn, up to 0.03 wt% Ti, up to 0.15 wt% impurities, and the balance Al. In some embodiments, the aluminum alloy includes 0.05-0.20 wt% Cr. In some embodiments, the aluminum alloy has a ratio of Mg:Cr between 20:1 and 70:1. In some embodiments, the aluminum alloy has a combined Si, Cr, and Cu content greater than 0.35 wt%.In some embodiments, the aluminum alloy has a combined Fe and Si content of greater than 0.40 wt.%. In some embodiments, the aluminum alloy has a microstructure with a Fe content of less than 1.45 μm, as measured by area. 2 In some embodiments, the aluminum alloy comprises at least 40 wt.% recycled scrap. In some embodiments, the aluminum alloy comprises less than 30 wt.% primary aluminum. In some embodiments, the aluminum alloy has a yield strength of at least 340 MPa. In some embodiments, the aluminum alloy has an ultimate tensile strength of at least 380 MPa. In some embodiments, the aluminum alloy has a total elongation of at least 4%. In some embodiments, the can end stock comprises any one of the aforementioned aluminum alloys.

[0010] In some embodiments, a method for producing an aluminum alloy is provided, the method including: casting an aluminum alloy to form a cast product, the aluminum alloy comprising 0.01-0.60 wt% Si, 0.01-0.80 wt% Fe, 0.05-0.30 wt% Cu, 0.80-1.40 wt% Mn, 1.3-5.0 wt% Mg, max 0.20 wt% Cr, max 0.30 wt% Zn, max 0.05 wt% Ti, max 0.15 wt% impurities, and balance Al; homogenizing the cast product, where homogenizing the cast product produces alpha phase grains; hot rolling the cast product to produce a hot rolled product; cold rolling the hot rolled product to produce a final gauge rolled product; and optionally annealing the final gauge rolled product. In some embodiments, the aluminum alloy comprises 0.05-0.20 wt. % Cr with a ratio of Mg:Cr between 20:1 and 70:1. In some embodiments, the homogenizing step comprises heating and soaking the cast product at a temperature between 450° C. and 570° C., the homogenizing configured to convert the large grains to alpha phase grains. In some embodiments, the cast product is soaked at the homogenizing temperature for up to 10 hours. In some embodiments, the aluminum alloy comprises a grain area % of alpha phase grains of 1.5% or more as measured by volume after homogenization. In some embodiments, the aluminum alloy includes 0.22-0.32 wt.% Si, 0.50-0.65 wt.% Fe, 0.20-0.30 wt.% Cu, 0.80-0.92 wt.% Mn, 2.0-4.0 wt.% Mg, max. 0.20 wt.% Cr, max. 0.25 wt.% Zn, max. 0.03 wt.% Ti, max. 0.15 wt.% impurities, and the balance Al.

[0011] Further aspects, objects, and advantages will become apparent from consideration of the detailed description and drawings that follow. [Brief description of the drawings]

[0012] [Figure 1]1 illustrates a graph of yield stress, ultimate tensile strength, and total elongation for an exemplary aluminum alloy according to some embodiments described herein. [Diagram 2] FIG. 1 shows a graph of yield stress (MPa) of an exemplary aluminum alloy according to some embodiments described herein, as measured in the longitudinal (L), transverse (T), and diagonal (D) directions, respectively, relative to the rolling direction. [Diagram 3] 1A and 1B show graphs of grain area % and grain number density of alpha grains, Al(Fe,Mn) grains, and Mg2Si grains in the microstructure of an aluminum alloy as they relate to the concentrations of Fe and Si in an exemplary aluminum alloy. [Figure 4] FIG. 4 shows a graph of the propagation energy and yield stress of the exemplary alloys shown in FIGS. 3A and 3B as measured according to ASTM B873-1(2021). [Diagram 5] 1A and 1B show graphs of grain area % and grain number density of alpha grains, Al(Fe,Mn) grains, and Mg2Si grains in the microstructure of an aluminum alloy as they relate to the concentration of Mn in an exemplary aluminum alloy. [Figure 6] FIG. 5C shows a graph of the propagation energy and yield stress of the exemplary alloys shown in FIGS. 5A and 5B as measured according to ASTM B873-1(2021). [Figure 7] 1A and 1B show graphs of grain area % and grain number density of alpha grains, Al(Fe,Mn) grains, and Mg2Si grains in the microstructure of an aluminum alloy as it relates to the concentration of Mg in an exemplary aluminum alloy. [Figure 8] FIG. 7C shows a graph of the propagation energy and yield stress of the exemplary alloys shown in FIGS. 7A and 7B measured according to ASTM B873-1(2021). [Figure 9] 1A and 1B show graphs of particle area % and particle number density of alpha particles, Al(Fe,Mn) particles, and Mg2Si particles in the microstructure of an aluminum alloy as they relate to the concentrations of Mg and Mn in an exemplary aluminum alloy. [Figure 10]FIG. 10 shows a graph of the propagation energy and yield stress of the exemplary alloys shown in FIGS. 9A and 9B measured according to ASTM B873-1(2021). [Figure 11] 1 shows a graph of strain to failure for bulge tests of exemplary alloys measured according to ISO 16808 (2021). [Figure 12] 1 shows a graph of buckling strength of exemplary alloys. [Figure 13] 13A and 13B show scanning electron microscope (SEM) images of the microstructure of an AA5182 aluminum alloy (FIG. 13A) and an exemplary aluminum alloy made from a large amount of recycled aluminum material (FIG. 13B). [Figure 14A] FIG. 14A shows a graph depicting the grains in the microstructure of an aluminum alloy as a function of homogenization temperature for Example Alloy 9 (FIG. 14A) based on thermodynamic equilibrium calculations performed in Thermo-Carc. [Figure 14B] FIG. 14B shows a graph depicting the grains in the microstructure of aluminum alloy as a function of homogenization temperature for example alloy 10 (FIG. 14B), based on thermodynamic equilibrium calculations performed in Thermo-Carc. [Figure 14C] FIG. 14C shows a graph depicting the grains in the microstructure of aluminum alloy as a function of homogenization temperature for example alloy 11 (FIG. 14C) based on thermodynamic equilibrium calculations performed in Thermo-Carc. [Figure 14D] FIG. 14D shows a graph depicting the grains in the microstructure of aluminum alloy as a function of homogenization temperature for example alloy 12 (FIG. 14D) based on thermodynamic equilibrium calculations performed in Thermo-Carc. [Figure 15] 15A and 15B show graphs of grain area % (FIG. 15A) and average grain size (FIG. 15B), measured by area, in the aluminum alloy microstructure of example alloys 13-16. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] Described herein are novel aluminum alloys that exhibit high strength and formability. Surprisingly, the aluminum alloys described herein exhibit high strength and formability despite having a lower Mg content than the conventional conventional AA5182 aluminum alloy used to manufacture can end stocks. The aluminum alloys described herein incorporate a higher amount of recycled aluminum material and less primary aluminum compared to the conventional aluminum alloys used to manufacture can end stocks, and still maintain good mechanical properties of the can end stocks. For example, the aluminum alloys described herein may contain 40% more recycled aluminum material and 30% less primary aluminum than the conventional aluminum alloys used to manufacture can end stocks, and still exhibit properties equivalent to AA5182 aluminum alloy. The aluminum alloy compositions described throughout this specification provide a cost-effective alternative to the use of AA5182 aluminum alloy for can end stocks.

[0014] Conventional AA5182 aluminum alloys for manufacturing can end stocks require a tightly controlled composition to meet the minimum strength requirements of can end stocks while maintaining formability for manufacturing complex shapes. Generally, greater strength is required for aluminum alloys used to manufacture can end stocks compared to can body stocks, which requires such can end stocks to be made from aluminum alloys containing a large amount of Mg, such as AA5182 aluminum alloys. This limits the amount of recycled aluminum material that can be used to manufacture AA5182 aluminum alloys. For example, AA5182 aluminum alloys cannot be manufactured from a large amount of used beverage cans because AA5182 aluminum alloys contain small amounts of Fe, Si, Mn, and Cu compared to used beverage cans. Used beverage cans may contain a mixture of two different aluminum alloys in the can body stock and the can end stock. The aluminum alloy used for can end stocks is usually AA5182 aluminum alloy, and the aluminum alloy used for can body stocks is usually AA3104 aluminum alloy. The AA3104 aluminum alloy contains a smaller amount of Mg and a larger amount of Fe, Si, Mn, and Cu compared to the AA5182 aluminum alloy. Due to the mismatch in the aluminum alloy composition between the AA3104 aluminum alloy and the AA5182 aluminum alloy, used beverage cans have an aluminum alloy composition between the compositions of the AA3104 aluminum alloy and the AA5182 aluminum alloy. Therefore, in order to produce can end stocks containing a large amount of recycled material, such as used beverage cans, it is necessary to produce the AA5182 aluminum alloy using more alloying elements (e.g., Mg addition) and primary aluminum, which significantly increases the material cost. This limits the amount of recycled aluminum material that can be used to produce can end stocks.

[0015] The novel aluminum alloys described herein can utilize a higher amount of recycled aluminum material and achieve properties similar to AA5182 aluminum alloy. Specifically, the aluminum alloys described herein can tolerate a higher amount of Fe, Si, Mn, and / or Cu compared to AA5182 aluminum alloy and also achieve good strength and formability properties. Additionally, the aluminum alloys described herein can include a lower amount of Mg that can be compensated for by adding elements such as Mn and Cu to balance the strength. Due to the composition of the aluminum alloys described herein, the composition gap between the can body stock and the can end stock is reduced to reduce the amount of primary aluminum and reduce the addition of alloying elements (e.g., Mg). By reducing the composition gap between the aluminum alloys of the can body stock and the can end stock, more recycled aluminum alloys such as used beverage cans can be used to produce the aluminum alloys for the can end stock. For example, the aluminum alloys described herein can be produced from at least 40% recycled scrap by weight and less than 30% primary aluminum by weight.

[0016] Additionally, the aluminum alloy composition produces can end stock with similar properties as conventional AA5182 aluminum alloy, allowing can manufacturers to produce the aluminum alloy without changes to existing methods. In some embodiments, greater volumes of post-consumer beverage cans may be used with the aluminum alloys described herein, thereby reducing the amount of primary aluminum required, reducing overall costs, and maintaining equivalent or greater rolling productivity.

[0017] The aforementioned aluminum alloy compositions have processing advantages despite having a large amount of recycled aluminum alloys, which is a common problem for using a large amount of recycled aluminum alloys in new aluminum alloys. Specifically, the amount of Mg in the aluminum alloy composition may naturally decrease to about 1 wt.% Mg during the remelting process via fluxing, degassing, and drossing. Thus, the final molten aluminum alloy composition may be very similar to AA3104 aluminum alloy. The aluminum alloys described herein can be reused to make can body stock. Furthermore, by appropriately adjusting the Mg content, the aluminum alloys described herein can also be reused to make can end stock. Beneficially, this allows for closed-loop recycling of used beverage cans (UBCs) made from the aluminum alloy compositions described herein. In this way, UBC scrap can be continuously recycled in a closed-loop system to produce aluminum alloys without significant changes in the alloying elements. That is, aluminum alloy products (e.g., UBCs) made from the aluminum alloy compositions described herein can be used to produce new aluminum alloys for can end stock or can body stock. Furthermore, since the Fe, Si, Cu, and Mn levels in UBC scrap are similar to the aluminum alloy compositions described herein, only additional Mg needs to be added to the aluminum alloy to produce can end stock from UBC.

[0018] In some embodiments, the present disclosure relates to an aluminum alloy having a composition similar to that of AA3104 aluminum alloy (except for Mg) and exhibiting properties (e.g., buckling strength) similar to that of AA5182 aluminum alloy. For example, the aluminum alloy may include Fe, Si, Cu, and Mn contents similar to that of AA3104 aluminum alloy and may include a Mg content of greater than 2.0 wt.%. The aluminum alloy may include a large amount of recycled material and achieve properties similar to those of AA5182 aluminum alloy. In some embodiments, the aluminum alloy described herein may have a composition similar to that of AA3104 aluminum alloy and may include a Mg content of 2.0 wt.% to 4.0 wt.% and may exhibit a buckling strength of greater than 90 psi. Beneficially, the aluminum alloy includes Fe, Si, Cu, and Mn in amounts similar to that of AA3104 aluminum alloy used for UBC. Thus, UBC scrap can be used almost entirely to produce aluminum alloys, eliminating the need to dilute the aluminum alloy with primary aluminum or add alloying elements for hardening. This provides an aluminum alloy that may contain a higher amount of UBC scrap and less primary aluminum, with minimal or no additional alloying elements other than Mg. Advantageously, the aluminum alloy may contain Mg content to meet the strength requirements of can end stock. If UBC scrap is used to produce the aluminum alloy without Mg addition, the strength of the resulting aluminum alloy may be significantly lower, resulting in insufficient buckling strength (e.g., shell buckling strength and can end buckling strength). The aluminum alloy described herein may contain a higher amount of Mg compared to AA3104 aluminum alloy to meet the minimum strength requirements of can end stock. In some embodiments, the aluminum alloy described herein may have a similar composition to AA3104 aluminum alloy and may contain a Mg content of more than 1.3 wt.% (e.g., 1.3 wt.% to 2.0 wt.% Mg). This aluminum alloy may be used in applications with low strength requirements.

[0019] In order to maintain a high level of recycled content in the aluminum alloy composition described herein, the aluminum alloy composition can be similar to AA3104 aluminum alloy. For example, Mg may be the primary alloying element added to the aluminum alloy composition, and the remaining alloying elements may be similar to AA3104 aluminum alloy. Therefore, it may not be necessary to add other hardening alloying elements (e.g., Mn and Cu) to the aluminum alloy composition. This is beneficial because the hardening alloying elements (e.g., Mn and Cu) do not oxidize during the remelting process, thereby affecting the recyclability of the aluminum alloy or UBC composition of the can body. Maintaining an aluminum alloy composition similar to AA3104 aluminum alloy may simplify the remelting process and reduce the need to change aluminum alloys during fabrication. The aluminum alloy composition described herein contains a higher level of recycled content and less primary aluminum, while exhibiting mechanical properties similar to the current aluminum alloy composition of can end stock (e.g., similar to AA5182 aluminum alloy).

[0020] In some embodiments, the present disclosure provides a novel method of making an aluminum alloy produced from a large amount of recycled aluminum alloy material (e.g., compared to AA5182 aluminum alloy). Beneficially, the aluminum alloy composition described herein includes a specific combination of alloying elements to produce alpha phase particles during carefully controlled homogenization. For example, by reducing the Mg content and / or adding Cr (e.g., up to 0.20 wt%) to the aluminum alloy composition, the aluminum alloy can be homogenized at a wider range of homogenization temperatures to produce a larger volume fraction of alpha phase particles (e.g., compared to other aluminum alloys that do not include the same combination of alloying elements). By controlling the homogenization temperature and the aluminum alloy composition, the formation of alpha particles is maximized. For example, the aluminum alloy described herein includes a higher volume fraction of alpha particles compared to aluminum alloys also produced from a large amount of recycled aluminum alloy material. The alpha phase particles include phases (e.g., eutectic phases) that can be broken down into smaller particles during hot rolling, thereby resulting in an aluminum alloy with good formability and mechanical properties.

[0021] Aluminum alloys produced from large amounts of recycled aluminum alloy materials contain large components in the aluminum alloy microstructure that are difficult to disassemble and adversely affect the mechanical properties of the aluminum alloy. For example, large amounts of Si, Fe, and / or Mn, which are common alloying elements in recycled aluminum alloy materials, can cause problems in the aluminum alloy microstructure (e.g., Al x The grain size and number density of the components in the microstructure of an aluminum alloy determine, in part, the formability and performance of the aluminum alloy. Therefore, control of grain size is beneficial to produce aluminum alloys with desired mechanical properties.

[0022] The aluminum alloys described herein, having carefully controlled amounts of Si, Mg, Cu, and Cr, and produced according to the methods described herein, provide an aluminum alloy microstructure that contains a higher amount of alpha phase grains and a lower amount of large constituents compared to other aluminum alloys produced from recycled aluminum alloy materials. Specifically, the aluminum alloys have a microstructure that contains a high number density of small grains by modifying the alloying elements and homogenizing at a temperature where the alpha phase transformation occurs. The aforementioned aluminum alloys have a microstructure that contains a high number density of small grains by modifying the large grains and homogenizing at a temperature where the alpha phase transformation occurs. lx (Fe, Mn) has a wide range of homogenization temperatures that convert the large constituents to alpha phase particles. Additionally, the aluminum alloy is homogenized at a homogenization temperature that converts the large constituents to alpha phase particles. In some embodiments, the aforementioned aluminum alloy can be homogenized at a temperature range of 450°C to 570°C to provide a high volume fraction of alpha phase particles compared to other aluminum alloys produced from recycled aluminum alloy materials. The alpha phase particles generated during homogenization can be broken down into smaller particles during hot rolling, thereby significantly improving formability.

[0023] Definitions and Explanations As used herein, the terms "invention," "the invention," "this invention," and "the present invention" are intended to refer broadly to all of the subject matter of this patent application and the claims that follow. Statements containing these terms should not be understood as limiting the subject matter described herein or limiting the meaning or scope of the claims that follow.

[0024] This description refers to alloys identified by aluminum industry designations such as "series" or "5xxx." For an understanding of the numbering systems most commonly used to name and identify aluminum and its alloys, please refer 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.

[0025] As used herein, the meanings of "a," "an," or "the" include singular as well as plural references unless the context clearly dictates otherwise.

[0026] As used herein, a plate generally has a thickness of greater than about 15 mm. For example, a plate may 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.

[0027] As used herein, a shade (also called a sheet plate) generally has a thickness of about 4 mm to about 15 mm. For example, the shade may be about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm, or about 15 mm thick.

[0028] As used herein, sheet refers to an aluminum product having a thickness of less than about 4 mm (eg, less than 3 mm, less than 2 mm, less than 1 mm, less than 0.5 mm, less than 0.3 mm, or less than 0.1 mm). For example, the sheet can be about 0.1 mm, about 0.2 mm, about 0.3 mm, about 0.4 mm, about 0.5, about 0.6 mm, about 0.7 mm, about 0.8 mm, about 0.9 mm, about 1 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, about 2.4 mm, about 2.5 mm, about 2.6 mm, about 2.7 mm, about 2.8 mm, about 2.9 mm, about 3 mm, about 3.1 mm, about 3.2 mm, about 3.3 mm, about 3.4 mm, about 3.5 mm, about 3.6 mm, about 3.7 mm, about 3.8 mm, about 3.9 mm, or about 4 mm thick.

[0029] As used herein, formability refers to the ability of a material to deform into a desired shape without forming errors such as fracture, tearing, necking, earing, or wrinkling, springback, or galling. In engineering, formability can be classified by the deformation mode. Examples of deformation modes include drawing, stretching, bending, and stretch flanging.

[0030] As used herein, primary aluminum refers to an aluminum material containing at least about 99.7% by weight aluminum. Primary aluminum is produced from the primary few conversions of raw materials to aluminum (e.g., the processing of bauxite to alumina and the electrolysis of alumina to aluminum).

[0031] As used herein, yield stress (also referred to as yield strength) refers to the point at which an aluminum alloy begins to plastically deform and can no longer return to its original state.

[0032] In this application, reference may be made to alloy tempers or alloy states. For an understanding of the most commonly used alloy temper descriptions, see American National Standards (ANSI) H35 on Alloy and Temper Designation Systems. The F temper or temper refers to the aluminum alloy as produced. The O temper or temper refers to the aluminum alloy after annealing. The Hxx temper or temper, also referred to herein as the H temper, refers to an aluminum alloy that is not heat treatable 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 temper or temper refers to an aluminum alloy that has been cooled from hot working and naturally aged (e.g., at room temperature). The T2 temper or temper refers to an aluminum alloy that has been cooled from hot working, cold worked, and naturally aged. The T3 temper or temper refers to an aluminum alloy that has been solution heat treated, cold worked, and naturally aged. The T4 temper or temper refers to an aluminum alloy that has been solution heat treated and naturally aged. The T5 temper or temper refers to an aluminum alloy that has been cooled from hot working and artificially aged (at an elevated temperature). The T6 temper or temper refers to an aluminum alloy that has been solution heat treated and artificially aged. The T7 temper or temper refers to an aluminum alloy that has been solution heat treated and artificially overaged. The T8x temper or temper refers to an aluminum alloy that has been solution heat treated, cold worked, and artificially aged. The T9 temper or temper refers to an aluminum alloy that has been solution heat treated, artificially aged, and cold worked. The W temper or temper refers to an aluminum alloy after solution heat treatment.

[0033] 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.

[0034] All ranges disclosed herein should be understood to include both endpoints and any and all subranges subsumed therein. For example, a stated range of "1 to 10" should be considered to include all subranges having a minimum value of 1 to a maximum value of 10 (and inclusive). That is, all subranges begin with a minimum value of 1 or greater (e.g., 1 to 6.1) and end with a maximum value of 10 or less (e.g., 5.5 to 10).

[0035] The following aluminum alloys are described in terms of elemental composition in weight percent (wt%) based on the total weight of the alloy. In the specific example of each alloy, the balance is aluminum, and the maximum wt% of the sum of impurities is 0.15%.

[0036] Alloy composition The properties of an aluminum alloy are determined in part by the composition of the aluminum alloy, which in certain aspects may influence or even determine whether the alloy has suitable properties for a desired application.

[0037] The alloys described herein are novel aluminum alloys. The alloys exhibit high strength and high formability (e.g., excellent elongation and forming properties) while containing higher amounts of recycled aluminum alloys. The properties of the alloys are achieved, at least in part, due to the elemental composition properties of the alloys. In some cases, the novel aluminum alloys described herein can contain lower Mg content and higher levels of Si and Fe compared to conventional AA5182 aluminum alloys, as further described below.

[0038] In some examples, the aluminum alloys described herein may have the following elemental compositions as shown in Table 1: [Table 1]

[0039] In some examples, the aluminum alloys described herein may have the following elemental compositions as shown in Table 2: [Table 2]

[0040] In some examples, the aluminum alloys described herein may have the following elemental compositions as shown in Table 3: [Table 3]

[0041] In some examples, the aluminum alloy may have the following elemental composition as presented in Table 4. [Table 4]

[0042] In some examples, the aluminum alloy may have the following elemental composition as presented in Table 5. [Table 5]

[0043] In some examples, the aluminum alloy may have the following elemental composition as presented in Table 6. [Table 6]

[0044] In some examples, the aluminum alloy may have the following elemental composition as presented in Table 7. [Table 7]

[0045] In some examples, the aluminum alloy may have the following elemental composition as presented in Table 8. [Table 8]

[0046] In some examples, the aluminum alloy may have the following elemental composition as presented in Table 9. [Table 9]

[0047] In some examples, the aluminum alloy may have the following elemental composition as presented in Table 10. [Table 10]

[0048] Silicon (Si) In some examples, the aluminum alloys described herein include an amount of Si between 0.10% and 0.35% (e.g., between 0.10% and 0.30%, between 0.10% and 0.25%, or between 0.20% and 0.35%) based on the total weight of the alloy. For example, the alloy may include 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.30%, 0.31%, 0.32%, 0.33%, 0.34%, or 0.35% Si, all expressed in weight percent. In some embodiments, aluminum alloy compositions containing less than 0.10 wt.% Si may limit the amount of recycled aluminum material that can be used in the aluminum alloy composition. For example, AA3104 aluminum alloy used in can body stock typically contains 0.6 wt.% Si. In some embodiments, aluminum alloy compositions containing more than 0.35 wt.% Si may form coarse Mg2Si particles in the aluminum alloy microstructure. The coarse Mg2Si particles in the aluminum alloy microstructure may reduce the formability and strength of the aluminum alloy.

[0049] Iron (Fe) In some examples, the aluminum alloys described herein include Fe in an amount between 0.20% and 0.60% (e.g., between 0.20% and 0.50%, between 0.20% and 0.35%, or between 0.40% and 0.60%) based on the total weight of the alloy. For example, the alloy may include 0.20%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.30%, 0.31%, 0.32%, 0.33%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.40%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.60%, 0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.70%, 0.71%, 0.72%, 0.73%, 0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, 0.80%, 0.81%, 0.82%, 0.83%, 0.84%, 0.85%, 0.86%, 0.87%, 0.88%, 0. The aluminum alloy composition may contain 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, or 0.60% Fe. All expressed in weight percent. In some embodiments, an aluminum alloy composition containing less than 0.20% Fe by weight may result in processing defects. For example, the aluminum alloy may have poor runnability due to excessive die buildup. Runnability refers to whether the aluminum alloy contains defects or clogging during the process of manufacturing the aluminum alloy. Additionally, containing less than 0.20% Fe by weight in the aluminum alloy composition may limit the amount of recycled aluminum material that can be used in the aluminum alloy. In some embodiments, aluminum alloy compositions containing greater than 0.50 wt. % Si may exhibit poor formability due to the large amount of intermetallic particles containing Fe in the aluminum alloy microstructure.

[0050] Copper (Cu) In some examples, the aluminum alloys described herein include Cu in an amount between 0.05% and 0.25% (e.g., between 0.15% and 0.25%) based on the total weight of the alloy. For example, the alloys may include 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%, 0.21%, 0.22%, 0.23%, 0.24%, or 0.25% Cu, all expressed in weight percent. As described herein, the aluminum alloys may include 0.05% to 0.25% Cu by weight to compensate for the reduced Mg content and strengthen the aluminum alloy. In some embodiments, aluminum alloys containing less than 0.05 wt.% Cu may lead to insufficient strength properties, while aluminum alloys containing more than 0.25 wt.% Cu may lead to excessive strength, poor formability, and susceptibility to corrosion.

[0051] Manganese (Mn) In some examples, the aluminum alloys described herein can include 0.25% to 1.20% Mn (e.g., 0.30% to 1.0%, 0.30% to 0.90%, or 0.60% to 1.20%) based on the total weight of the alloy. For example, the alloy can include 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.30%, 0.31%, 0.32%, 0.33%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.40%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.60%, 0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.70%, 0.71%, 0.72%, 0.73%, 0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, 0.80%, 0.81%, 0.82%, 0.83%, 0.84%, 0.85%, 0.86%, 0.87%, 0.88%, 0.89%, 0.90%, 0.91%, 0.92%, 0.93%, 0.94%, 0. 8%, 0.49%, 0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.60%, 0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.70%, 0.71%, 0.72%, 0.73%, 0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, 0.80%, 0.81%, 0.82%, 0.83%, 0.84%, 0.85%, 0.86%, 0.87%, 0.88%, 0.89%, 0.90%, 0.91%, 0.92%, 0.93%, 0.94%, 0.95%, 0.96%, 0.97%, 0.98%, 0.99%, 0.99%, 0.10%, 0.106%, 0.108%, 0.109%, 0.110%, 0.120%, 0.121%, 0.122%, 0.123%, 0.124%, 0.125%, 0.126%, 0.127%, 0.128%, 0.130%, 0.131%, 0.132%, 0.133%, 0.134%, 0.135%, 0.136%, 0.137%, 0.138%, 0.139%, 0.140%, 0.141%, 0.142%, 0.143%, 3%, 0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, 0.80%, 0.81%, 0.82%, 0.83%, 0.84%, 0.85%, 0.86%, 0.87%, 0.88%, 0.89%, 0.90%, 0.91%, 0.92%, 0.93%, 0.94%, 0.95%, 0.96%, 0.97%, 0.98%, 0.99%, 100%, 101%, 102%, 103%, 104%, 105%, 106%, 107%, 108%, 109%, 110%, 111%, 112%, 113%, 114%, 115%, 116%, 117%, 118%, 119%, 120%, 121%, 122%, 123%, 124%, 125%, 126%, 127%, 128%, 129%, 130%, 131%, 132%, 133%, 134%, 135%, 136%, 137%, 138%, 139%, 140%, 141%, 142%, 143%, 144%, 145%, 146%, 147%, 148%, 149%, 150%, 151%, 152%, 153%, 154%, 155%, 156%, 157%, 158%, 159%, 160%, 161%, 162%, 163%, 164%, 165%, 166%, 167%, 168%, 169%, 1 The aluminum alloy may contain 0.8%, 0.99%, 1.00%, 1.01%, 1.02%, 1.03%, 1.04%, 1.05%, 1.06%, 1.07%, 1.08%, 1.09%, 1.10%, 1.11%, 1.12%, 1.13%, 1.14%, 1.15%, 1.16%, 1.17%, 1.18%, 1.19%, or 1.20% Mn. All expressed in weight percent. As described herein, the aluminum alloy may contain 0.30 wt.% to 1.2 wt.% Cu to compensate for the reduced Mg content and strengthen the aluminum alloy. In some embodiments, aluminum alloys containing less than 0.30 wt.% Mn may result in insufficient strength properties. In some embodiments, aluminum alloys containing more than 0.90 wt. % Mn may lead to intermetallic phases that can degrade formability and final fabrication performance.

[0052] Magnesium (Mg) In some examples, the aluminum alloys described herein may include Mg in an amount between 2.0% and 5.0% (e.g., between 2.2% and 5.0%, between 2.5% and 5.0%, or between 2.0% and 4.0%) based on the total weight of the alloy. For example, the alloy may include 2.0%, 2.1%, 2.2%, 2.3%, 2.4%, 2.5%, 2.6%, 2.7%, 2.8%, 2.9%, 3.0%, 3.1%, 3.2%, 3.3%, 3.4%, 3.5%, 3.6%, 3.7%, 3.8%, 3.9%, 4.0%, 4.1%, 4.2%, 4.3%, 4.4%, 4.5%, 4.6%, 4.7%, 4.8%, 4.9%, or 5.0% Mg, all expressed in weight percent. In some embodiments, aluminum alloys containing less than 2.0 wt.% Mg may lead to insufficient strength properties, while aluminum alloys containing more than 5.0 wt.% Mg may lead to excessive strength leading to workability issues, as well as increased stress corrosion cracking and late softening.

[0053] In some examples, the novel aluminum alloys described herein may include a lower Mg content than that of conventional AA5182 aluminum alloys and may include one or more of Cu or Mn, among other elements, in specific amounts. For example, the aluminum alloy may include at least one of Cu or Mn in the aforementioned amounts to compensate for the reduced content of Mg in the aluminum alloy. This may avoid adding additional Mg to the aluminum alloy composition, thereby reducing costs.

[0054] Zinc (Zn) In some examples, the aluminum alloys described herein include Zn in an amount up to 0.30% (e.g., 0.05%-0.25%, 0.10%-0.25%, or 0.15%-0.25%) based on the total weight of the alloy. For example, the alloy may contain 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, or 0.30% Zn. In some cases, Zn is absent (i.e., 0%) in the alloy. All expressed in weight percent.

[0055] Chromium (Cr) In some examples, the aluminum alloys described herein include an amount of Cr up to 0.20% (e.g., up to 0.15%, up to 0.10%, up to 0.05%, up to 0.03%, 0.01%-0.20%, 0.05%-0.20%, or 0.05%-0.15%) based on the total weight of the alloy. For example, the alloy may include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, or 0.20% Cr. In some cases, Cr is absent (i.e., 0%) in the alloy. All expressed in weight percent. In some embodiments, the addition of Cr to the aluminum alloy composition can promote the formation of alpha phase particles in the aluminum alloy microstructure. The addition of Cr can beneficially optimize the grain size (e.g., reduce grain size) of the aluminum alloy by promoting the conversion of larger components to alpha phase particles during homogenization. The grain size and number density of grains in the aluminum alloy microstructure are important factors that in part determine the formability and performance of the aluminum alloy. In some embodiments, Cr can be added to any of the aluminum alloys in Tables 1-10 to control grain size formation in the aluminum alloy microstructure.

[0056] Titanium (Ti) In some examples, the aluminum alloys described herein include an amount of Ti up to 0.20% (e.g., up to 0.15%, up to 0.10%, up to 0.05%, or 0.03%) based on the total weight of the alloy. For example, the alloy may include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, or 0.20% Ti. In some cases, Ti is absent (i.e., 0%) in the alloy. All expressed in weight percent.

[0057] In some examples, the aluminum alloys described herein may include a total content of Mg, Mn, and Cu in an amount of 3.5%, 3.6%, 3.7%, 3.8%, 3.9%, 4.0%, 4.1%, 4.2%, 4.3%, 4.4%, 4.5%, 4.6%, 4.7%, 4.8%, 4.9%, or 5.0%. All expressed in weight percent. In some embodiments, aluminum alloys including a total weight percent of Mg, Mn, and Cu less than 3.5% may lead to insufficient buckling strength. In some embodiments, aluminum alloys including a total weight percent of Mg, Mn, and Cu greater than 5.0% may lead to excessive strength. In some examples, the aluminum alloys described herein may include a ratio of Mg to Cu (also referred to herein as Mg:Cu ratio) of 12:1 to 80:1 (e.g., 12:1 to 70:1 to 15:1 to 70:1). For example, the Mg:Cu ratio is 12:1, 13:1, 14:1, 15:1, 16:1, 17:1, 18:1, 19:1, 20:1, 21:1, 22:1, 23:1, 24:1, 25:1, 26:1, 27:1, 28:1, 29:1, 30:1, 31:1, 32:1, 33:1, 34:1, 35:1, 36:1, 37:1, 38:1, 39:1, 40:1, 41:1, 42:1, 43:1, 44:1, 45:1, 46:1, 47:1, 48:1, 49:1, 50:1, 51:1, 52:1, 53:1, 54:1, 55:1, 56:1, 57:1, 58:1, 59:1, 60:1, 61:1, 62:1, 63:1, 64:1, 65:1, 66:1, 67:1, 68:1, 69:1, 70:1, 71:1, 72:1, 73:1, 74:1, 75:1, 76:1, 77:1, 78:1, 79:1, 80:1, 81:1, 82:1, 83:1, 84:1, 85:1, 86:1, 87:1, 88:1, 89:1, 90:1, 91:1, 92:1, 93:1, 94:1, 9 :1, 47:1, 48:1, 49:1, 50:1, 51:1, 52:1, 53:1, 54:1, 55:1, 56:1, 57:1, 58:1, 59:1, 60:1, 61:1, 62:1, 63:1, 64:1, 65:1, 66:1, 67:1, 68:1, 69:1, 70:1, 71:1, 72:1, 73:1, 74:1, 75:1, 76:1, 77:1, 78:1, 79:1, or 80:1.

[0058] In some examples, the aluminum alloys described herein can include a ratio of Mn to Cu (also referred to herein as the Mn:Cu ratio) of 2:1 to 15:1 (e.g., 2:1 to 12:1, or 3:1 to 12:1). For example, the Mn:Cu ratio can be 2:1, 3:1, 4:1, 5:1, 6:1, 7:1, 8:1, 9:1, 10:1, 11:1, 12:1, 13:1, 14:1, or 15:1.

[0059] trace elements Optionally, the aluminum alloys described herein may further include other trace elements, sometimes referred to as impurities, in amounts of 0.05% or less, 0.04% or less, 0.03% or less, 0.02% or less, or 0.01% or less. These impurities may include, but are not limited to, Sc, V, Ni, Hf, Zr, Sn, Ga, Ca, Bi, Na, Pb, or combinations thereof. Thus, Sc, V, Ni, Hf, Zr, Sn, Ga, Ca, Bi, Na, or Pb may be present in the alloy in amounts of 0.05% or less, 0.04% or less, 0.03% or less, 0.02% or less, or 0.01% or less. The sum of all impurities does not exceed 0.15% (e.g., 0.1%). All expressed in weight percent. The remaining percentage of each alloy may be aluminum.

[0060] Aluminum alloy composition based on AA3104 alloy The present disclosure also provides aluminum alloys having a similar composition to AA3104 aluminum alloy, but with a higher amount of Mg. The aluminum alloys may contain similar Fe, Si, Cu, and Mn contents as AA3104 aluminum alloy, and may contain Mg contents greater than 1.3 wt. %. This provides aluminum alloys that contain a higher amount of UBC scrap and less primary aluminum compared to AA3104 aluminum alloy, and may have minimal or no additional alloying elements other than Mg. These aluminum alloys can meet the minimum strength requirements of can end stock.

[0061] In some examples, the aluminum alloy may have the following elemental composition as presented in Table 11. [Table 11]

[0062] In some examples, the aluminum alloys described herein may have the following elemental compositions as shown in Table 12. [Table 12]

[0063] In some examples, the aluminum alloy may have the following elemental composition as presented in Table 13. [Table 13]

[0064] In some examples, the aluminum alloy may have the following elemental composition as presented in Table 14. [Table 14]

[0065] In some examples, the aluminum alloy may have the following elemental composition as presented in Table 15. [Table 15]

[0066] In some examples, the aluminum alloy may have the following elemental composition as presented in Table 16. [Table 16]

[0067] In some examples, the aluminum alloys described herein may have the following elemental compositions as shown in Table 17. [Table 17]

[0068] In some examples, the aluminum alloy may have the following elemental composition as presented in Table 18. [Table 18]

[0069] In some examples, the aluminum alloy may have the following elemental composition as presented in Table 19. [Table 19]

[0070] In some examples, the aluminum alloy may have the following elemental composition as presented in Table 20. [Table 20]

[0071] Silicon (Si) In some examples, the aluminum alloys described herein include Si in an amount between 0.01% and 0.60% (e.g., between 0.10% and 0.50%, between 0.20% and 0.40%, between 0.25% and 0.35%, between 0.22% and 0.33%, or between 0.25% and 0.32%) based on the total weight of the alloy. For example, alloys may be 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.30%, 0.31%, 0.32%, 0.33%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.40%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.60%, 0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.70%, 0.71%, 0.72%, 0.73%, 0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, 0.80%, 0.81%, 0.82%, 0.83%, 0.84%, It may contain 1%, 0.32%, 0.33%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.40%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, or 0.60% Si, all expressed as % by weight.

[0072] Iron (Fe) In some examples, the aluminum alloys described herein include 0.01%-0.80% (e.g., 0.05%-0.70%, 0.10%-0.50%, 0.40%-0.60%, 0.45%-0.55%, 0.50%-0.65%, or 0.45%-0.55%) Fe based on the total weight of the alloy. For example, the alloy may include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.30%, 0.31%, 0.32%, 0.33%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.40%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.60%, 0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.65%, 0.65%, 0.65%, 0 0%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, 0.30%, 0.31%, 0.32%, 0.33%, 0.34%, 0.35%, 0.36%, 0.37%, 0.38%, 0.39%, 0.40%, 0.4 It may contain 1%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, 0.50%, 0.51%, 0.52%, 0.53%, 0.54%, 0.55%, 0.56%, 0.57%, 0.58%, 0.59%, 0.60%, 0.61%, 0.62%, 0.63%, 0.64%, 0.65%, 0.66%, 0.67%, 0.68%, 0.69%, 0.70%, 0.71%, 0.72%, 0.73%, 0.74%, 0.75%, 0.76%, 0.77%, 0.78%, 0.79%, or 0.80% Fe. All are expressed as weight percent.

[0073] Copper (Cu) In some examples, the aluminum alloys described herein include Cu in an amount between 0.05% and 0.30% (e.g., 0.05-0.25, 0.05-0.25, 0.11-0.30, 0.20-0.30, 0.10%-0.25%, 0.15%-0.25%, or 0.16%-0.20%) based on the total weight of the alloy. For example, the alloy may contain 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, or 0.30% Cu, all expressed as weight percent.

[0074] Manganese (Mn) In some examples, the aluminum alloys described herein can include Mn in an amount between 0.80% and 1.40% (e.g., between 0.80% and 1.20%, between 0.80% and 1.10%, or between 0.80% and 0.92%) based on the total weight of the alloy. For example, alloys may have the following properties: 0.80%, 0.81%, 0.82%, 0.83%, 0.84%, 0.85%, 0.86%, 0.87%, 0.88%, 0.89%, 0.90%, 0.91%, 0.92%, 0.93%, 0.94%, 0.95%, 0.96%, 0.97%, 0.98%, 0.99%, 1.00%, 1.01%, 1.02%, 1.03%, 1.04%, 1.05%, 1.06%, 1.07%, 1.08%, 1.09%, 1.10%, 1.11%, 1.12%, 1.13%, 1.14%, 1.15%, 1.16%, 1.17%, 1.18%, 1.19%, 1.20%, 1.21%, 1.22%, 1.23%, 1.24%, 1.25%, 1.26%, 1.27%, 1.28%, 1.29%, 1.30%, 1.31%, 1.32%, 1.33%, 1.34%, 1.35%, 1.36%, 1.37%, 1.38%, 1.39%, 1.40%, 1.41%, 1.42%, 1.43%, 1.44%, 1.45%, 1.46%, 1.47%, 1.48%, 1.49%, 1.50%, 1.51%, 1.52%, 1.53%, 1.54%, 1.55%, 1.56%, 1.57%, 1.58%, 1.59%, 1.60%, 1.61%, 1.62%, 1 The material may contain 1.11%, 1.12%, 1.13%, 1.14%, 1.15%, 1.16%, 1.17%, 1.18%, 1.19%, 1.20%, 1.21%, 1.22%, 1.23%, 1.24%, 1.25%, 1.26%, 1.27%, 1.28%, 1.29%, 1.30%, 1.31%, 1.32%, 1.33%, 1.34%, 1.35%, 1.36%, 1.37%, 1.38%, 1.39%, or 1.40% Mn, all expressed as weight percent.

[0075] Magnesium (Mg) In some examples, the aluminum alloys described herein can include Mg in an amount between 1.3% and 5.0% (e.g., between 1.5% and 5.0%, between 2.0% and 5.0%, between 2.0% and 4.0%, between 3.0 and 4.0%, or between 1.3% and 2.0%) based on the total weight of the alloy. For example, the alloy may contain 1.3%, 1.4%, 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, 2.0%, 2.1%, 2.2%, 2.3%, 2.4%, 2.5%, 2.6%, 2.7%, 2.8%, 2.9%, 3.0%, 3.1%, 3.2%, 3.3%, 3.4%, 3.5%, 3.6%, 3.7%, 3.8%, 3.9%, 4.0%, 4.1%, 4.2%, 4.3%, 4.4%, 4.5%, 4.6%, 4.7%, 4.8%, 4.9%, or 5.0% Mg, all expressed in weight percent. In some embodiments, the aluminum alloys described herein may contain 1.3% to 2.0% Mg for applications requiring less strength (e.g., can bodies or can end stock for water or other low pressure applications).

[0076] Zinc (Zn) In some examples, the aluminum alloys described herein include Zn in an amount up to 0.30% (e.g., 0.05%-0.25%, 0.10%-0.25%, or 0.15%-0.25%) based on the total weight of the alloy. For example, the alloy may contain 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, 0.20%, 0.21%, 0.22%, 0.23%, 0.24%, 0.25%, 0.26%, 0.27%, 0.28%, 0.29%, or 0.30% Zn. In some cases, Zn is absent (i.e., 0%) in the alloy. All expressed in weight percent.

[0077] Chromium (Cr) In some examples, the aluminum alloys described herein include an amount of Cr up to 0.20% (e.g., up to 0.15%, up to 0.10%, up to 0.05%, up to 0.03%, 0.01%-0.20%, 0.05%-0.20%, or 0.05%-0.15%) based on the total weight of the alloy. For example, the alloy may include 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.10%, 0.11%, 0.12%, 0.13%, 0.14%, 0.15%, 0.16%, 0.17%, 0.18%, 0.19%, or 0.20% Cr. In some cases, Cr is absent (i.e., 0%) in the alloy. All expressed in weight percent. In some embodiments, the addition of Cr to the aluminum alloy composition can promote the formation of alpha phase particles in the aluminum alloy microstructure. The addition of Cr can beneficially optimize the grain size of the aluminum alloy (e.g., reduce the overall grain size) by promoting the conversion of larger components to alpha phase particles during homogenization. The grain size and number density of grains in the aluminum alloy microstructure are important factors that in part determine the formability and performance of the aluminum alloy. In some embodiments, Cr can be added to any of the aluminum alloys in Tables 11-20 to control grain size formation in the aluminum alloy microstructure.

[0078] In some embodiments, the amount of Cr and Mg is carefully controlled to promote alpha phase particles. It has been found that adding additional Cr and reducing the amount of Mg in the aforementioned aluminum alloy compositions of Tables 11-20 can beneficially promote the formation of alpha phase particles. In some embodiments, the addition of Cr and the reduction of Mg in the aluminum alloy composition may be proportional. For example, if Cr is added in an amount of 0.05 wt.%, the Mg content can be reduced by 0.50 wt.% to 1.00 wt.%. As an example, if the aluminum alloy includes 0.10 wt.% Cr, the Mg content of the aluminum alloy can be reduced by 0.50 wt.%. In some examples, the aluminum alloys described herein can include a ratio of Mg to Cr (also referred to herein as Mg:Cr ratio) of 20:1 to 70:1 (e.g., 25:1 to 65:1 or 25:1 to 35:1). For example, the Mg:Cr ratio may be 20:1, 25:1, 30:1, 35:1, 40:1, 45:1, 50:1, 55:1, 60:1, 65:1, or 70:1. In some embodiments, the inclusion of Mg and Cr in the aforementioned ratios produces an aluminum alloy that has good strength and formability of the aluminum alloy.

[0079] In some examples, the aluminum alloys described herein may include a combined Si, Cr, and Cu content in an amount greater than 0.35% (e.g., greater than 0.36%, 0.37%, 0.38%, 0.39%, 0.40%, 0.41%, 0.42%, 0.43%, 0.44%, 0.45%, 0.46%, 0.47%, 0.48%, 0.49%, or 0.50%), all expressed in weight percent.

[0080] Titanium (Ti) In some examples, the aluminum alloys described herein contain Ti in an amount of 0.05% or less, 0.04% or less, 0.03% or less, 0.02% or less, or 0.01% or less, based on the total weight of the alloy. For example, the alloy may contain 0.01%, 0.02%, 0.03%, 0.04%, or 0.05% Ti. In some cases, Ti is absent (i.e., 0%) in the alloy. All expressed in weight percent.

[0081] trace elements Optionally, the aluminum alloys described herein may further include other trace elements, sometimes referred to as impurities, in amounts of 0.05% or less, 0.04% or less, 0.03% or less, 0.02% or less, or 0.01% or less. These impurities may include, but are not limited to, Sc, V, Ni, Hf, Zr, Sn, Ga, Ca, Bi, Na, Pb, or combinations thereof. Thus, Sc, V, Ni, Hf, Zr, Sn, Ga, Ca, Bi, Na, or Pb may be present in the alloy in amounts of 0.05% or less, 0.04% or less, 0.03% or less, 0.02% or less, or 0.01% or less. The sum of all impurities does not exceed 0.15% (e.g., 0.1%). All expressed in weight percent. The remaining percentage of each alloy may be aluminum.

[0082] recycled content The aluminum alloys described herein can tolerate higher amounts of recycled aluminum alloy scrap and still exhibit desired mechanical properties. The impact of impurities and / or alloying elements on the mechanical properties of the aluminum alloy is reduced by providing an adjusted aluminum alloy composition to compensate for the impurities. This allows for higher amounts of less expensive, more impure recycled aluminum materials (e.g., used beverage cans) to produce aluminum alloys that can still exhibit desired properties. The aluminum alloys described herein can include higher amounts of recycled aluminum alloys with little or no additional primary aluminum and reduced amounts of more expensive alloying elements (e.g., Mg).

[0083] In some embodiments, the aluminum alloy compositions described herein provide compositions well suited for utilizing used beverage can (UBC) scrap or other aluminum alloy containers as recycled materials. UBC scrap is a mixture of various aluminum alloys (e.g., from different aluminum alloys used in can bodies and can ends) and can often contain foreign matter such as rainwater, beverage residues, organic matter (e.g., paints and coatings), and other materials. UBC scrap typically contains a mixture of metals from various alloys, for example, metals from can bodies (e.g., AA3104, AA3004, or other 3xxx series aluminum alloys) and can ends (e.g., AA5182 or other 5xxx series aluminum alloys). UBC scrap can be shredded, decoated, or depainted before being melted for use as liquid metal stock in the casting of new metal products.

[0084] As described herein, the aluminum alloy compositions described herein reduce the compositional gap between can body stock and can end stock. This allows for the use of more recycled aluminum alloy, specifically UBC scrap, to produce can end stock, reducing the amount of primary aluminum and additional alloying elements (e.g., Mg). In some embodiments, the aluminum alloys described herein include 25% or more of high UBC scrap, such as 30% or more, 35% or more, 40% or more, 45% or more, 50% or more, 55% or more, 60% or more, 65% or more, 70% or more, or 75% or more of high UBC scrap. In terms of ranges, the aluminum alloys described herein can include 25% to 100% UBC scrap (e.g., 25% to 95%, 30% to 90%, 35% to 85%, 40% to 80%, 50% to 70%, or 35% to 50%).

[0085] As mentioned above, in some embodiments, the UBC scrap includes a mixture of alloys including 3xxx series aluminum alloys and 5xxx series aluminum alloys. In some embodiments, the UBC scrap can include 5xxx series aluminum alloys in an amount of 0%-75% (e.g., 5%-70%, 10%-65%, 15%-60%, 20%-50%, or 25%-40%) based on the total weight of the recycled scrap. For example, the UBC scrap can include more than 0% 5xxx series aluminum alloy scrap (e.g., more than 1%, more than 5%, more than 10%, more than 15%, more than 20%, or more than 25%) based on the total weight of the UBC scrap. All expressed in weight percent.

[0086] In some embodiments, the UBC scrap can include 3xxx series aluminum alloy scrap (from mixed alloy scrap) in an amount of 0%-75% (e.g., 5%-70%, 10%-65%, 15%-60%, 20%-50%, or 25%-40%) based on the total weight of the UBC scrap. For example, the UBC scrap can include more than 0% 3xxx series aluminum alloy scrap (e.g., more than 1%, more than 5%, more than 10%, more than 15%, more than 20%, or more than 25%) based on the total weight of the UBC scrap. All expressed in weight percent.

[0087] In some embodiments, the aluminum alloys described herein contain less than 35% primary aluminum, such as, for example, less than 34%, less than 33%, less than 32%, less than 31%, less than 30%, less than 29%, less than 28%, less than 27%, less than 26%, less than 25%, less than 24%, less than 23%, less than 22%, less than 21%, or less than 20%, all expressed in weight percent.

[0088] characteristics In some examples, aluminum alloy products (e.g., aluminum alloy sheets) made from the aluminum alloys described herein can have a yield strength of about 260 MPa or greater. For example, aluminum alloy products made from the aluminum alloys described herein can have a yield strength of 270 MPa or greater, 280 MPa or greater, 290 MPa or greater, 300 MPa or greater, 310 MPa or greater, 320 MPa or greater, 325 MPa or greater, 330 MPa or greater, 335 MPa or greater, 340 MPa or greater, or 345 MPa or greater, 350 MPa or greater, 355 MPa or greater, 360 MPa or greater, 365 MPa or greater, 370 MPa or greater. In some cases, the yield strength is about 260 MPa to about 420 MPa (e.g., about 280 MPa to about 450 MPa, about 300 MPa to about 425 MPa, or about 325 MPa to about 400 MPa), or anywhere in between. The aluminum alloy products described herein may exhibit yield strengths as described herein when measured in the longitudinal (L), transverse (T), and / or diagonal (D) directions, respectively, relative to the rolling direction.

[0089] In some examples, aluminum alloy products made from the aluminum alloys described herein can have an ultimate tensile strength of about 280 MPa or greater. For example, the aluminum alloy products can have an ultimate tensile strength of 290 MPa or greater, 300 MPa or greater, 310 MPa or greater, 320 MPa or greater, 330 MPa or greater, 340 MPa or greater, 350 MPa or greater, 355 MPa or greater, 360 MPa or greater, 365 MPa or greater, 370 MPa or greater, 375 MPa or greater, 380 MPa or greater, 385 MPa or greater, 390 MPa or greater, 395 MPa or greater, or 400 MPa or greater. In some cases, the yield strength is about 280 MPa to about 550 MPa (e.g., about 300 MPa to about 500 MPa, about 350 MPa to about 475 MPa, or about 375 MPa to about 430 MPa), or anywhere in between. The aluminum alloy products described herein may exhibit ultimate tensile strengths as described herein when measured in the longitudinal (L), transverse (T), and / or diagonal (D) directions, respectively, relative to the rolling direction.

[0090] In some examples, aluminum alloy products produced from the aluminum alloys described herein can have a total elongation of about 4%-20% (e.g., 4%-18%, 5%-16%, 5.5%-14%, 6%-12%, or 6.5%-10%). For example, aluminum alloy products produced from the aluminum alloys described herein can have a total elongation of about 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, or any value therebetween. The aluminum alloy products described herein can exhibit a total elongation as described herein when measured in the longitudinal (L), transverse (T), and / or diagonal (D) directions, respectively, relative to the rolling direction.

[0091] Aluminum alloy manufacturing method casting The aluminum alloy products described herein can be cast into cast products using a direct chill (DC) process or cast using a continuous casting (CC) process. The casting process is carried out according to standards commonly used in the aluminum industry, as known to those skilled in the art. 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 examples, the casting process is carried out by a CC process to form slabs, strips, and the like. In some examples, the casting process is a DC casting process to form cast products.

[0092] The cast product, slab, or strip can then be subjected to further processing steps. Optionally, further processing steps can be used to prepare an aluminum alloy product (e.g., sheet, shade, or plate). Such processing steps include, but are not limited to, homogenization, hot rolling, cold rolling, and an optional lacquering step. The processing steps are described below with respect to the cast product. However, the processing steps can also be used for cast slabs or strips, using modifications known to those skilled in the art.

[0093] Homogenization in Practice 1 Homogenization conditions can optimize grain formation in aluminum alloys (e.g., produce more alpha phase grains that can be broken down into smaller grains), resulting in better mechanical properties. Grain size and grain number density determine the formability and performance of aluminum alloys. In some embodiments, grain size in aluminum alloy microstructures can be controlled by modifying alloying elements (e.g., ignite Cr and reduce Mg), which can promote the conversion of constituent grains from large grains (e.g., Alx(Fe,Mn)) to alpha phase grains (e.g., Al-(Fe,Mn)Si) during homogenization. Thus, the homogenization practice in combination with aluminum alloy composition can promote grain breakup and grain size reduction in aluminum alloy microstructures.

[0094] Aluminum alloys made from high content recycled aluminum alloy materials contain a large amount of Fe, Si, and / or Mn compared to aluminum alloys that do not contain high content recycled aluminum alloy materials. For example, aluminum alloys made from used beverage cans or other aluminum alloy scrap contain a large amount of Fe, Si, and / or Mn. These additional alloying elements result in large particles with a much larger number density that are difficult to break down. For example, large particles such as Alx(Fe,Mn) particles are difficult to break down, but alpha phase particles can easily break down into smaller particles during the rolling process. Therefore, for good mechanical properties of aluminum alloys, it is beneficial to convert Alx(Fe,Mn) to alpha phase particles.

[0095] FIG. 13A shows a scanning electron microscope (SEM) image of the microstructure of AA5182 aluminum alloy, and FIG. 1B shows a SEM image of the microstructure of a recycle-oriented aluminum alloy containing 0.40 wt% Fe, 0.16 wt% Si, 0.60 wt% Mn, 0.07 wt% Cu, 4.0 wt% Mg, and the remaining Al. Both alloys are used to produce aluminum alloys for can end stocks. The recycle-oriented aluminum alloy is produced from a high content of recycled aluminum alloy material, while the AA5182 aluminum alloy has a tightly controlled aluminum alloy composition and is produced from very little recycled aluminum alloy material. Due to the high recycled content of the recycle-oriented aluminum alloy, there is a large amount of alloying elements in the aluminum alloy. For example, the recycle-oriented aluminum alloy contains a higher amount of Si, Mn, and Fe than the AA5182 aluminum alloy. As shown in FIG. 13B, the presence of a large amount of alloying elements in the aluminum alloy intended for recycling leads to the formation of grains having a large size (e.g., larger than 5 microns) in the aluminum alloy microstructure. In comparison, FIG. 13A shows that the microstructure of the AA5182 aluminum alloy contains grains having a smaller size and a smaller number density of large grains. Larger components adversely affect the properties of the aluminum alloy. For example, larger components result in poor formability. Surprisingly, it has been found that the grain size in the aluminum alloy microstructure can be controlled by modifying the alloying elements in the aluminum alloy composition (e.g., adding Cr and decreasing Mg) and homogenizing the aluminum under certain conditions to promote the conversion of the constituent grains from large grains to alpha phase grains. For example, modifying the aluminum alloy composition to lower the amount of Mg and add a high level of Cr in combination with homogenization may aid in converting the larger components in the aluminum alloy microstructure to smaller alpha phase grains. For example, the method described herein may be used to reduce the amount of Al during homogenization. x The (Fe, Mn) constituents may be converted to alpha phase particles. In some embodiments, the homogenization conditions may aid in converting the large particles to alpha phase particles.

[0096] In some embodiments, the cast product may be heated to a homogenization temperature ranging from about 450°C to about 570°C. For example, the cast product may be heated to a temperature of 450°C, 460°C, 470°C, 480°C, 490°C, 500°C, 510°C, 520°C, 530°C, 540°C, 550°C, 560°C, or 570°C. In some embodiments, the cast product may be homogenized at a homogenization temperature range of 450°C to 570°C (e.g., 500°C to 560°C or 525°C to 550°C), which results in the highest concentration of stable alpha phase particles. As discussed above, the aluminum alloys described herein provide a larger homogenization temperature window for producing alpha phase particles. Specifically, homogenization of the aluminum alloys of Tables 6-10 and Tables 16-20 over a homogenization temperature window of 450° C. to 570° C. can convert large constituents to alpha phase particles in the aluminum alloy microstructure throughout the homogenization temperature range, which advantageously increases the amount of large constituents converted to alpha phase particles during homogenization.

[0097] In some embodiments, the heating rate to the homogenization temperature may be about 70° C. / hour or less, about 60° C. / hour or less, or about 50° C. / hour or less. The cast product may then be soaked (i.e., held at the indicated temperature) for a period of time at the homogenization temperature to form a homogenized product. In some examples, the total time in the homogenization step, including the heating and soaking stages, may be up to about 10 hours. For example, the cast product may be soaked for 10 minutes, 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 6 hours, 7 hours, 8 hours, 9 hours, or 10 hours.

[0098] Homogenization in Practice 2 In the homogenization step, the cast product may be heated to a homogenization temperature, such as a temperature in the range of about 400°C to about 600°C. For example, the cast product may be heated to a temperature of 400°C, 410°C, 420°C, 430°C, 440°C, 450°C, 460°C, 470°C, 480°C, 490°C, 500°C, 510°C, 520°C, 530°C, 540°C, 550°C, 560°C, 570°C, 580°C, 590°C, or 600°C. In some embodiments, the heating rate to the peak metal temperature may be about 70°C / hour or less, about 60°C / hour or less, or about 50°C / hour or less. The product may then be soaked (i.e., held at the indicated temperature) for a period of time to form a homogenized product. In some examples, the total time in the homogenization step, including the heating and soaking stages, may be up to about 10 hours.

[0099] In some embodiments, the homogenization step described herein may be a two-stage homogenization. The first stage may include heating the cast product to a first homogenization temperature of about 350°C to about 450°C (e.g., 360°C to 440°C, 370°C to 430°C, 380°C to 420°C, or 400°C to 420°C). For example, the cast product may be heated to a temperature of about 350°C, 360°C, 370°C, 380°C, 390°C, 400°C, 410°C, 420°C, 430°C, 440°C, or 450°C. In some cases, the cast product is heated to a first homogenization temperature of 400°C to 420°C. In some cases, the heating rate to the first homogenization temperature may be about 70°C / hour or less, about 60°C / hour or less, or about 50°C / hour or less. The cast product is then soaked (i.e., held at the first homogenization temperature) for a period of time. In some cases, the cast product is soaked at the first homogenization temperature for up to 5 hours (e.g., 30 minutes to 5 hours). For example, the cast product may be soaked at a first homogenization temperature of 350°C to 450°C for 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, or 5 hours. In some embodiments, the cast product may be soaked at a first homogenization temperature of 400°C to 420°C for 1 hour to 2 hours.

[0100] The second stage may include heating the cast product from the first homogenization temperature to a second homogenization temperature of about 450°C to about 550°C (e.g., 460°C to 540°C, 470°C to 530°C, 480°C to 520°C, or 480°C to 510°C). For example, the cast product may be heated to a temperature of about 450°C, 460°C, 470°C, 480°C, 490°C, 500°C, 510°C, 520°C, 530°C, 540°C, or 550°C. In some cases, the cast product is heated to the first homogenization temperature of 480°C to 510°C. The cast product is then soaked at the second homogenization temperature for a period of time. In some cases, the cast product is soaked at the second homogenization temperature for up to 5 hours (e.g., 30 minutes to 5 hours). For example, the cast product may be soaked for 30 minutes, 1 hour, 2 hours, 3 hours, 4 hours, or 5 hours at a first homogenization temperature of 450° C. to 550° C. In some embodiments, the cast product may be soaked for 0 hours to 2 hours at a second homogenization temperature of 480° C. to 510° C.

[0101] Hot rolling The homogenization step can be followed by a hot rolling step. The homogenized product can be hot rolled using a rolling mill to produce a hot rolled product. Before the start of hot rolling, the homogenized product can be cooled to a desired temperature, for example, about 200°C to about 425°C. For example, the homogenized product can be cooled to a temperature of about 200°C to about 400°C or about 250°C to about 375°C, about 300°C to about 425°C, or about 350°C to about 400°C. The homogenized product can then be hot rolled at a hot rolling temperature, for example, about 200°C to about 450°C, to produce a hot rolled product (e.g., a hot rolled plate, a hot rolled shat, or a hot rolled sheet).

[0102] Cold rolling The hot rolled product can be cold rolled using a cold rolling mill into a thinner product, such as a final gauge rolled product. The final gauge product can have a gauge between about 0.5 and about 10 mm, such as, for example, about 0.7 and about 6.5 mm. Optionally, the final gauge rolled product can have a gauge of about 0.5 mm, about 1.0 mm, about 1.5 mm, about 2.0 mm, about 2.5 mm, about 3.0 mm, about 3.5 mm, about 4.0 mm, about 4.5 mm, about 5.0 mm, about 5.5 mm, about 6.0 mm, about 6.5 mm, about 7.0 mm, about 7.5 mm, about 8.0 mm, about 8.5 mm, about 9.0 mm, about 9.5 mm, or about 10.0 mm. Cold rolling can be performed to result in a final gauge thickness that represents a gauge reduction of up to about 85% (e.g., up to about 10%, up to about 20%, up to about 30%, up to about 40%, up to about 50%, up to about 60%, up to about 70%, up to about 80%, or up to about 85% reduction) compared to the gauge before the cold rolling began. In some embodiments, the cold rolling step can include one or more cold rolling steps to achieve the desired gauge thickness reduction. Optionally, the process for producing an aluminum alloy can include a mutual annealing step (e.g., one or more cold rolling steps).

[0103] Lacquer paint Subsequently, the final gauge rolled product may optionally undergo a lacquering step. The lacquering step may apply a coating to the final gauge rolled product at a temperature of 150°C to 400°C for 1 second to 10 minutes. For example, the final gauge rolled product may be lacquered at a temperature of 150°C to 400°C, 200°C to 400°C, 250°C to 350°C, 200°C to 300°C, or 300°C to 400°C. The peak metal temperature of the final gauge rolled product during the lacquering process may range from 100°C to 300°C (e.g., 125°C to 275°C, 150°C to 250°C, or 200°C to 300°C).

[0104] Microstructure of Aluminum Alloys The aluminum alloys described herein contain small grains in the aluminum alloy microstructure. A significant amount of grains present in the aluminum alloy microstructure are less than 1.45 μm in area. 2 For example, the particle size, measured by area, is 1.40 μm 2 Below, 1.35μm 2 Below, 1.30μm 2 Below, 1.25μm 2 Below, 1.20μm 2 Below, 1.15μm 2 Less than or equal to 1.10μm 2 In some examples, the particle size is 0.80 μm or less. 2 ~1.45μm 2 (For example, 0.85 μm 2 ~1.40μm 2 or 0.90 μm 2 ~1.35μm 2 As used herein, a "substantial amount" in reference to particle number refers to at least 50% of the particles present in the aluminum alloy. For example, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 99% of the particles present in an aluminum alloy product are in the range of 1.45 μm. 2 It has the following particle size:

[0105] The aluminum alloys described herein comprise alpha phase particles. In some embodiments, the aluminum alloys described herein comprise a grain area percent of alpha phase particles, measured by volume, of 1.5% or more, 1.6% or more, 1.7% or more, 1.8% or more, 1.9% or more, or 2.0% or more. In some embodiments, the aluminum alloys described herein comprise a grain area percent of alpha phase particles, measured by volume, of 1.5% to 2.5% (e.g., 1.5% to 2.0%, 2.0% to 2.5%, or 1.7% to 2.1%).

[0106] The aluminum alloys described herein include a ratio of alpha phase particles to Alx(Fe,Mn) that beneficially provides good formability properties of the aluminum alloy. In some embodiments, the ratio of alpha phase particles to Alx(Fe,Mn) in the microstructure of the aluminum alloy is between 5:1 and 40:1 (e.g., between 6:1 and 30:1, between 8:1 and 25:1, between 8:1 and 20:1, or between 10:1 and 20:1). In some embodiments, the ratio of alpha phase particles to Alx(Fe,Mn) in the microstructure of the aluminum alloy is 5:1, 6:1, 7:1, 8:1, 9:1, 10:1, 11:1, 12:1, 13:1, 14:1, 15:1, 16:1, 17:1, 18:1, 19:1, 20:1, 21:1, 22:1, 23:1, 24:1, 25:1, 26:1, 27:1, 28:1, 29:1, 30:1, 31:1, 32:1, 33:1, 34:1, 35:1, 36:1, 37:1, 38:1, 39:1, or 40:1.

[0107] Examples of Preferred Methods and Alloy Products Example 1 is an aluminum alloy containing 0.10-0.35 wt% Si, 0.20-0.60 wt% Fe, 0.05-0.25 wt% Cu, 0.25-1.20 wt% Mn, 2.0-5.0 wt% Mg, max 0.20 wt% Cr, max 0.30 wt% Zn, max 0.20 wt% Ti, max 0.15 wt% impurities, and max Al.

[0108] Example 2 is an aluminum alloy as described in any preceding or following claim, wherein the aluminum alloy contains 0.10-0.30 wt.% Si, 0.20-0.50 wt.% Fe, 0.05-0.25 wt.% Cu, 0.30-1.0 wt.% Mn, 2.2-5.0 wt.% Mg, up to 0.15 wt.% Cr, up to 0.30 wt.% Zn, up to 0.15 wt.% Ti, up to 0.15 wt.% impurities, and Al.

[0109] Example 3 is the aluminum alloy of any preceding or following description, wherein the aluminum alloy contains 0.10-0.25 wt.% Si, 0.20-0.50 wt.% Fe, 0.05-0.25 wt.% Cu, 0.30-0.90 wt.% Mn, 2.5-5.0 wt.% Mg, up to 0.10 wt.% Cr, up to 0.25 wt.% Zn, up to 0.10 wt.% Ti, up to 0.15 wt.% impurities, and Al.

[0110] Example 4 is the aluminum alloy of any preceding or following description, wherein the aluminum alloy contains 0.20-0.35 wt.% Si, 0.20-0.50 wt.% Fe, 0.05-0.25 wt.% Cu, 0.30-0.90 wt.% Mn, 2.5-5.0 wt.% Mg, max. 0.05 wt.% Cr, max. 0.25 wt.% Zn, max. 0.05 wt.% Ti, max. 0.15 wt.% impurities, and Al.

[0111] Example 5 is the aluminum alloy of any preceding or following description, wherein the aluminum alloy contains 0.20-0.35 wt.% Si, 0.40-0.60 wt.% Fe, 0.15-0.25 wt.% Cu, 0.60-1.2 wt.% Mn, 2.0-4.0 wt.% Mg, max. 0.03 wt.% Cr, max. 0.20 wt.% Zn, max. 0.03 wt.% Ti, max. 0.15 wt.% impurities, and Al.

[0112] Example 6 is an aluminum alloy as described in any preceding or subsequent example, wherein the ratio of Mg:Cu is from 10:1 to 80:1 and the ratio of Mn:Cu is from 2:1 to 15:1.

[0113] Example 7 is an aluminum alloy as described in any preceding or subsequent example, having a Mg:Cu ratio of 15:1 to 70:1 and a Mn:Cu ratio of 3:1 to 12:1.

[0114] Example 8 is an aluminum alloy as described in any preceding or subsequent example having a combined Fe and Si content greater than 0.40 wt.%.

[0115] Example 9 is an aluminum alloy as described in any preceding or subsequent example, having a combined Mg, Mn, and Cu content of 3.5 wt.% to 5.0 wt.%.

[0116] Example 10 is the aluminum alloy of any preceding or subsequent example, wherein the aluminum alloy comprises at least 40 wt. % recycled scrap.

[0117] Example 11 is the aluminum alloy of any preceding or subsequent example, wherein the aluminum alloy contains less than 30 wt. % primary aluminum.

[0118] Example 12 is a method for producing an aluminum alloy having a compressive strength of at least 30.0 KJc / m as measured by ASTM B871-1(2021). 2 The aluminum alloy of any preceding or subsequent example has a propagation energy of

[0119] Example 13 is an aluminum alloy as described in any preceding or subsequent example, wherein the aluminum alloy has a yield strength of at least 340 MPa.

[0120] Example 14 is an aluminum alloy as described in any preceding or subsequent example, wherein the aluminum alloy has an ultimate tensile strength of at least 380 MPa.

[0121] Example 15 is an aluminum alloy as described in any preceding or subsequent example, wherein the aluminum alloy has a total elongation of at least 4%.

[0122] Example 16 is a can end stock comprising the aluminum alloy described in any preceding or subsequent example.

[0123] Example 17 is a method of producing an aluminum alloy comprising: casting an aluminum alloy to form a cast product, the aluminum alloy comprising 0.10-0.35 wt.% Si, 0.20-0.60 wt.% Fe, 0.05-0.25 wt.% Cu, 0.25-1.20 wt.% Mn, 2.0-5.0 wt.% Mg, max. 0.20 wt.% Cr, max. 0.30 wt.% Zn, max. 0.20 wt.% Ti, max. 0.15 wt.% impurities and Al; homogenizing the cast product; hot rolling the cast product to produce a hot rolled product; cold rolling the hot rolled product to produce a final gauge rolled product; and optionally annealing the final gauge rolled product.

[0124] Example 18 is the method of any preceding or subsequent example, wherein the method further comprises lacquering and curing the final gauge rolled product.

[0125] Example 19 is the method of any preceding or subsequent example, wherein the homogenization step includes a first homogenization step and a second homogenization step.

[0126] Example 20 is the method of any preceding or subsequent example, wherein the first homogenization step includes soaking the cast product at a temperature between 375° C. and 450° C. for 0.5 hours to 5 hours.

[0127] Example 21 is the method of any preceding or subsequent example, wherein the second homogenization step includes soaking the cast product at a temperature between 450° C. and 550° C. for 0.01 hours to 5 hours.

[0128] Example 22 is the method of any preceding or subsequent method, wherein the aluminum alloy comprises 0.10-0.25 wt.% Si, 0.20-0.50 wt.% Fe, 0.05-0.25 wt.% Cu, 0.30-0.90 wt.% Mn, 2.5-5.0 wt.% Mg, max. 0.15 wt.% Cr, max. 0.25 wt.% Zn, max. 0.15 wt.% Ti, max. 0.15 wt.% impurities, and Al.

[0129] Example 23 is the method of any preceding or subsequent example, wherein the ratio of Mg:Cu is from 15:1 to 70:1 and the ratio of Mn:Cu is from 3:1 to 12:1.

[0130] Example 24 is a metal product prepared from the method described in any preceding or subsequent example.

[0131] Example 25 is a metal product prepared from the method described in any preceding or subsequent example, wherein said metal product is can end stock.

[0132] Example 26 is an aluminum alloy containing 0.01-0.60 wt.% Si, 0.01-0.80 wt.% Fe, 0.05-0.30 wt.% Cu, 0.80-1.40 wt.% Mn, 1.3-5.0 wt.% Mg, max. 0.20 wt.% Cr, max. 0.30 wt.% Zn, max. 0.05 wt.% Ti, max. 0.15 wt.% impurities, and the balance Al.

[0133] Example 27 is the aluminum alloy of any preceding or following description, wherein the aluminum alloy contains 0.10-0.50 wt.% Si, 0.20-0.70 wt.% Fe, 0.11-0.30 wt.% Cu, 0.80-1.00 wt.% Mn, 1.5-5.0 wt.% Mg, max. 0.20 wt.% Cr, max. 0.25 wt.% Zn, max. 0.05 wt.% Ti, max. 0.15 wt.% impurities, and balance Al.

[0134] Example 28 is the aluminum alloy of any preceding or following description, wherein the aluminum alloy contains 0.22-0.32 wt.% Si, 0.50-0.65 wt.% Fe, 0.20-0.30 wt.% Cu, 0.80-0.92 wt.% Mn, 2.0-4.0 wt.% Mg, max. 0.20 wt.% Cr, max. 0.25 wt.% Zn, max. 0.03 wt.% Ti, max. 0.15 wt.% impurities, and balance Al.

[0135] Example 29 is the aluminum alloy of any preceding or following description, wherein the aluminum alloy contains 0.25-0.32 wt.% Si, 0.45-0.55 wt.% Fe, 0.20-0.30 wt.% Cu, 0.80-0.92 wt.% Mn, 2.0-4.0 wt.% Mg, 0.01-0.20 wt.% Cr, max. 0.25 wt.% Zn, max. 0.03 wt.% Ti, max. 0.15 wt.% impurities, and balance Al.

[0136] Example 30 is the aluminum alloy of any preceding or following description, wherein the aluminum alloy contains 0.25-0.35 wt.% Si, 0.45-0.55 wt.% Fe, 0.16-0.30 wt.% Cu, 0.80-0.92 wt.% Mn, 3.0-4.0 wt.% Mg, 0.05-0.15 wt.% Cr, max. 0.25 wt.% Zn, max. 0.03 wt.% Ti, max. 0.15 wt.% impurities, and balance Al.

[0137] Example 31 is an aluminum alloy as described in any preceding or subsequent example, wherein the aluminum alloy includes 0.05-0.20 wt. % Cr.

[0138] Example 32 is the aluminum alloy of any preceding or subsequent example, wherein the aluminum alloy has a ratio of Mg:Cr from 20:1 to 70:1.

[0139] Example 33 is the aluminum alloy of any preceding or subsequent example, wherein the aluminum alloy has a combined Si, Cr, and Cu content greater than 0.35 wt.%.

[0140] Example 34 is the aluminum alloy of any preceding or subsequent example, wherein the aluminum alloy comprises a combined Fe and Si content of greater than 0.40 wt.%.

[0141] Example 35 shows that the grains in the microstructure of the aluminum alloy are 1.45 μm in diameter, as measured by area. 2 An aluminum alloy as described in any preceding or subsequent example having a grain size as follows:

[0142] Example 36 is the aluminum alloy of any preceding or subsequent example, wherein the aluminum alloy comprises at least 40 wt. % recycled scrap.

[0143] Example 37 is the aluminum alloy of any preceding or subsequent example, wherein the aluminum alloy comprises less than 30 wt.% primary aluminum. In some embodiments, the aluminum alloy has a yield strength of at least 340 MPa.

[0144] Example 38 is the aluminum alloy of any preceding or subsequent example, wherein the aluminum alloy comprises an ultimate tensile strength of at least 380 MPa.

[0145] Example 39 is the aluminum alloy of any preceding or subsequent example, wherein the aluminum alloy comprises a total elongation of at least 4%.

[0146] Example 40 is a can end stock comprising the aluminum alloy described in any preceding or subsequent example.

[0147] Example 41 is a method for producing an aluminum alloy, comprising: casting an aluminum alloy to form a cast product, the aluminum alloy comprising 0.01-0.60 wt.% Si, 0.01-0.80 wt.% Fe, 0.05-0.30 wt.% Cu, 0.80-1.40 wt.% Mn, 1.3-5.0 wt.% Mg, max. 0.20 wt.% Cr, max. 0.30 wt.% Zn, max. 0.05 wt.% Ti, max. 0.15 wt.% impurities, and balance Al; homogenizing the cast product, wherein homogenizing the cast product produces alpha phase grains; hot rolling the cast product to produce a hot rolled product; cold rolling the hot rolled product to produce a final gauge rolled product; and optionally annealing the final gauge rolled product.

[0148] Example 42 is the method of any preceding or subsequent example, wherein the aluminum alloy comprises 0.05-0.20 wt. % Cr and a ratio of Mg:Cr between 20:1 and 70:1.

[0149] Example 43 is the method of any preceding or subsequent example, wherein the homogenizing step includes heating and soaking the cast product at a temperature between 450°C and 570°C, and the homogenizing is configured to convert large grains into alpha phase grains.

[0150] Example 44 is the method of any preceding or subsequent example, wherein the cast product is soaked at the homogenization temperature for up to 10 hours.

[0151] Example 45 is the method of any preceding or subsequent example, wherein the aluminum alloy comprises a grain area percentage of alpha phase grains, measured by volume after homogenization, of greater than 1.5%.

[0152] Example 46 is the method of any preceding or subsequent method, wherein the aluminum alloy comprises 0.22-0.32 wt.% Si, 0.50-0.65 wt.% Fe, 0.20-0.30 wt.% Cu, 0.80-0.92 wt.% Mn, 2.0-4.0 wt.% Mg, max. 0.20 wt.% Cr, max. 0.25 wt.% Zn, max. 0.03 wt.% Ti, max. 0.15 wt.% impurities, and balance Al.

[0153] The following examples serve to further illustrate the invention, but without, however, limiting it in any way. On the contrary, it is clearly understood that recourse can be had to various embodiments, modifications and equivalents, which may suggest themselves to those skilled in the art after reading the description herein, without departing from the spirit of the invention.

[0154] During the testing described in the following examples, conventional procedures were followed unless otherwise noted, some of which are described below for illustrative purposes.

[0155] Working Example Example 1 The aluminum alloy samples were tested to determine the properties of the aluminum alloys described herein. Comparative Example 1 and Examples 1-5 were prepared according to the methods described herein. Comparative Example 1 was prepared from a conventional AA5182 aluminum alloy currently used as can end stock. Examples 1-5 were prepared from the aluminum alloys described herein. Table 21 shows the aluminum alloy compositions of Comparative Example 1 and Examples 1-5, respectively. [Table 21]

[0156] As shown in Table 21, Comparative Example 1 contains lower amounts of Si and Fe compared to Examples 1-5. Although Comparative Example 1 and Example 1 have similar compositions, the difference between Fe and Si is small for aluminum alloys used to manufacture can end stocks and can cause significant differences in performance. Comparative Example 1 contains 35 wt.% primary aluminum. Examples 1-4 contain 25%-30 wt.% primary aluminum, and Example 5 contains 20 wt.% primary aluminum. The aluminum alloys described herein contain up to 15 wt.% less primary aluminum than AA5182 aluminum alloy, which can result in significant cost savings. Additionally, Examples 1-5 can incorporate a higher amount of UBC scrap in place of primary aluminum because the aluminum alloys can tolerate higher amounts of Si and Fe.

[0157] FIG. 1 shows a graph of yield strength, ultimate tensile strength, and total elongation for Comparative Example 1 and Examples 1-5. Examples 1-5 exhibited similar yield strength, ultimate tensile strength, and total elongation properties to Comparative Example 1, despite having less primary aluminum and a higher amount of UBC scrap. In fact, Examples 1-3 exhibited the same or greater yield strength and ultimate tensile strength properties as Comparative Example 1. Examples 1 and 2 also exhibited the same or greater total elongation properties compared to Comparative Example 1. Examples 4 and 5 contained significantly less Mg than Comparative Example 1 and achieved similar yield strength and ultimate tensile strength to Comparative Example 1. The additional Mn in Examples 4 and 5 may have contributed additional strengthening to compensate for the reduced amount of Mg.

[0158] FIG. 2 shows a graph of yield strength (MPa) when measured in the longitudinal (L), transverse (T), and diagonal (D) directions relative to the rolling direction for Comparative Example 1 and Examples 1-5, respectively. Comparative Example 1 showed a yield stress of about 350 MPa in each of the L, T, and D directions. Examples 2 and 3 showed higher yield strength in the L, T, and D directions compared to Comparative Example 1, despite having higher contents of Si and Fe. Example 3, with a Mn content of 0.60 wt.%, showed the highest yield stress in the L, T, and D directions. Examples 3 and 4, each with 4.1 wt.% Mg, showed similar yield stress values ​​to Comparative Example 1, despite having less Mg. Example 4 demonstrates that decreasing the Mg content of the alloy composition while increasing the Mn content can achieve similar yield stress in the L, T, and D directions compared to Comparative Example 1. Additionally, Example 5 demonstrates that increasing the recycled content of the alloy composition by increasing Fe and Si led to a yield stress that was similar to Comparative Example 1. These results indicate that by increasing the recycled content and substituting higher levels of Mn for Mg, the resulting properties are consistent with current commercially available aluminum alloys for can end stocks.

[0159] Comparative Example 1, and Examples 1, 4, and 5 were evaluated to determine the effect of Fe and Si on the particle number density and particle area % of alpha particles, Al(Fe,Mn) particles, and Mg2Si particles in the microstructure of the aluminum alloy. The particle number density and particle area % results for Comparative Example 1, and Examples 1, 4, and 5 are shown in Figures 3A and 3B. Example 1, which contained more Si and Fe than Comparative Example 1, had a total particle area percentage of over 1.50% that was greater than Comparative Example 1. Example 1 showed a smaller particle size than Comparative Example 1 despite having a higher number density of alpha particles, Al(Fe,Mn) particles, and Mg2Si particles. Examples 4 and 5, both of which had lower Mg content and higher Mn content than Comparative Example 1, showed a larger particle size alpha % than Comparative Example 1. As described herein, increasing the Si and Fe content in the aluminum alloy composition allows for a higher regenerative content. For example, aluminum alloy compositions with increased Si and Fe (e.g., Example 5) maintained similar grain sizes to Example 4, but the grain area of ​​Al(Fe,Mn) increased. Furthermore, increasing the Fe, Si, and Mn contents while simultaneously decreasing the Mg content (Examples 4 and 5) resulted in a comparable overall grain size to Comparative Example 1, but significantly increased the alpha particle number density and decreased the grain number density of Al(Fe,Mn) and Mg2Si.

[0160] Samples of Comparative Example 1, and Examples 1, 4, and 5 were formed into 1 mm thick rectangular specimens for crack propagation testing by the Cahn Tear Test (ASTM B871-10(2021)). Using a specimen with a pre-existing crack, the specimens were tested for fracture toughness by crack propagation energy while a cyclic load was applied to each side of the crack and allowed the crack to grow. FIG. 4 shows the results of the Cahn Tear Test for Comparative Example 1, and Examples 1, 4, and 5. Example 1 had a lower propagation energy and a higher yield stress compared to Comparative Example 1. Additionally, Example 4, which had a lower Mg content and a higher Si and Fe content than Comparative Example 1, exhibited a lower propagation energy while maintaining a relatively similar yield stress when compared to Comparative Example 1. The results show that the aluminum alloys described herein, which include a lower amount of Mg and a higher amount of Si and Fe, exhibit similar propagation energy and yield stress when compared to Comparative Example 1. Furthermore, increased amounts of Si, Fe, and Mn combined with lower levels of Mg further increase the recycled content of the aluminium alloy while providing properties comparable to the current AA5182 aluminium alloy.

[0161] Examples 1 and 2 were evaluated to determine the effect of Mn on the particle number density and particle area % of alpha particles, Al(Fe,Mn) particles, and Mg2Si particles in the microstructure of the aluminum alloy. Figures 5A and 5B show graphs of particle area % and particle number density of alpha particles, Al(Fe,Mn) particles, and Mg2Si particles in the microstructure of Examples 1 and 2. Example 1 contained 0.16 wt% Si, 0.40 wt% Fe, and 0.33 wt% Mn, and Example 2 contained the same amounts of Si and Fe, and a higher content of Mn at 0.60 wt%. Example 2 showed larger grain size and particle area of ​​alpha particles and Al(Fe,Mn) particles than Example 1. The higher amount of Mn in Example 2 also increased the particle number density compared to Example 1.

[0162] FIG. 6 shows the results of the Cahn tear test (ASTM B871-10(2021)) for Examples 1 and 2. Example 1 had a tear strength of 38.8 KJ / m2 and a yield stress of about 360 MPa, and Example 2 has a propagation energy of 34.4 KJ / m 2 and a yield stress of about 375 MPa. Example 2, which had a higher Mn content than Example 1, showed a lower propagation energy and a higher yield stress than Example 1.

[0163] Examples 2 and 3 were evaluated to determine the effect of Mg on the particle number density and particle area % of alpha particles, Al(Fe,Mn) particles, and Mg2Si particles in the microstructure of the aluminum alloy. Figures 7A and 7B show graphs of particle area % and particle number density of alpha particles, Al(Fe,Mn) particles, and Mg2Si particles in the microstructures of Examples 2 and 3. Example 3 contained a lower Mg content (4.1 wt%) compared to Example 2 (4.9 wt%). Example 3 had a grain size of about 2.4 μm 2 and about 2% of the particle area, which was consistent with Comparative Example 1. Example 3 had a smaller particle size and a smaller area ratio of Al(Fe,Mn) compared to Example 2. By changing the Mg content from 4.9 wt% (Example 2) to 4.1 wt% (Example 3), the particle number density of alpha particles increased, and the particle number densities of both Al(Fe,Mn) and Mg2Si decreased.

[0164] FIG. 8 shows the results of the Cahn Tear Test (ASTM B871-10(2021)) for Examples 2 and 3. Alloy Example 2 had a tear strength of 34.4 KJ / m 2 and a yield stress of about 375 MPa. Example 3, which had a lower Mg content than Example 2, had a propagation energy of 36.1 KJ / m 2 and a yield stress of about 360 MPa.

[0165] Examples 1, 3, and 4 were evaluated to determine the effect of Mg and Mn on the particle number density and particle area % of alpha particles, Al(Fe,Mn) particles, and Mg2Si particles in the microstructure of the aluminum alloy. Figures 9A and 9B show graphs of particle area % and particle number density of alpha particles, Al(Fe,Mn) particles, and Mg2Si particles in the microstructures of Examples 1, 3, and 4. Example 3, which had a lower Mg content than Example 1, had a higher area fraction of alpha particles and a lower area fraction of Al(Fe,Mn) and Mg2Si particles than Example 1. Furthermore, as the Mg content decreased, the grain size of Examples 3 and 4 became larger compared to Example 1. Furthermore, it was found that by replacing Mg with Mn, the total grain area was almost consistent for each of Examples 1, 3, and 4, but Examples 3 and 4 showed an increase in alpha area % and a lower Mg2Si area % compared to Example 1. The particle number density of Examples 3 and 4 was lower than that of Example 1, but the particle size of Examples 3 and 4 was larger.

[0166] FIG. 10 shows the results of the Cahn tear test (ASTM B871-10(2021)) for Examples 1, 3, and 4. Example 1 had a tear strength of 38.8 KJ / m 2 and a yield stress of about 360 MPa. Examples 3 and 4, which had less Mg and more Mn than Example 1, showed similar properties for propagation energy and yield stress. Specifically, Example 3 had a propagation energy of 36.1 KJ / m 2 and a yield stress of about 355 MPa. Example 4 had a propagation energy of 32.2 KJ / m 2 and a yield stress of about 340 MPa. The results indicate that the aluminum alloys described herein containing lower amounts of Mg and higher amounts of Mn exhibit similar propagation energies. Furthermore, the results suggest that the alloy composition maintains comparable physical properties as the AA5182 aluminum alloy, while compensating for the lower Mg content with increased Mn, Si, and Fe to increase the regenerative content.

[0167] Comparative Example 1 and Examples 1-5 were formed into 1 mm thick disks to test formability using the mini-bulge test according to ISO16808 (2022). FIG. 11 shows the results of the mini-bulge test for Comparative Example 1 and Examples 1-5. For example, Comparative Example 1 had an average strain to failure of 0.170, while Example 1, which had a higher content of Fe and Si, had a relatively comparable average strain to failure of 0.168. Furthermore, Example 2, which had a higher content of Mn than Comparative Example 1, showed no change in average strain to failure when compared to Example 1. Furthermore, by reducing the Mg content to 4.1 wt%, as shown in Example 3, the value of the average strain to failure increased to 0.176. Further reducing the Mg content while increasing the Mn content as shown in Example 4 reduced the average strain to failure to 0.137. Furthermore, by maintaining the same levels of Mn and Mg as in Example 4 and increasing the Fe and Si content, Example 5 exhibited an average strain to failure of 0.161 similar to Comparative Example 1. The results presented here show that by modifying the alloy composition to contain less Mg and increasing the Fe, Si, and Mn content, it is possible to significantly increase its regenerative content while maintaining the same physical properties as Comparative Example 1.

[0168] Example 2 Aluminum alloy samples were tested to determine the properties of the aluminum alloys described herein. Comparative Examples 2 and 3, and Examples 7 and 8 were prepared according to the methods described herein. Comparative Example 1 was prepared from a conventional AA3104 aluminum alloy currently used as a can body stock, and Comparative Example 2 has a similar composition to AA3104 aluminum alloy, but with a lower Mg content. Examples 7 and 8 are alloys with Fe, Si, Cu, and Mn contents similar to the AA3104 aluminum alloy with a higher amount of Mg. Table 22 shows the aluminum alloy compositions of Comparative Examples 2 and 3, and Examples 7 and 8, respectively. [Table 22]

[0169] As shown in FIG. 12, Examples 7 and 8 achieve buckling strengths of 600 kPa or more. Buckling strengths were measured using an end buckling test station (Model 9009H4, manufactured by Altek Company). Examples 7 and 8 have similar compositions to Comparative Examples 7 and 8, but with higher Mg content. Because Examples 7 and 8 have similar compositions to Comparative Example 7 (which is an AA3104 aluminum alloy), these aluminum alloys can be produced from larger amounts of recycled UBC scrap containing similar amounts of Fe, Si, Cu, and Mn. This eliminates the need to dilute the aluminum alloys of Examples 7 and 8 with primary aluminum or add additional hardening elements. In one example, to produce an aluminum alloy composition from recycled UBC, at least 2 wt. % Mg can be added to cast an alloy composition with similar levels of Fe, Si, Cu, and Mn in the UBC found in Examples 7 and 8 of Table 21. Furthermore, by maintaining the aluminum alloy composition, which may be similar to AA3104 aluminum alloy, the remelt process may be simplified to reduce process changes during fabrication. The aluminum alloy composition of Examples 7 and 8 has Fe, Si, Cu, and Mn similar to conventional aluminum alloys for can body stock and can end stock, which allows the remelt process to be much simpler, making the remelt process a complete loop with no alloy changes. Furthermore, the regeneration content is significantly higher, as there is much less need for primary aluminum or hardening elements. In contrast, conventional AA5182 aluminum alloy would require dilution with Fe, Si, Cu, Mn, and the addition of large amounts of Mg for casting from UBC.

[0170] Example 3 To determine the microstructure of the aluminum alloys described herein, sample aluminum alloys were investigated when prepared according to specific homogenization conditions. Examples 9-12 are alloys described herein containing various amounts of Mg and Cr. Table 23 shows the composition of each of the aluminum alloys of Examples 9-12. [Table 23]

[0171] Standard thermodynamic calculations were performed for Examples 9-12 using Thermo-Calc Software (trademark, supplied by Thermo-Calc Software AB) to screen the effect of modifying the aluminum alloy composition on the alpha phase transformation during homogenization. Figures 14A-14D show equilibrium phase fraction diagrams for Examples 9-12. The x-axis represents the homogenization temperature (°C) and the y-axis represents the volume fraction (mol) of different particles in the aluminum alloy. The green line represents the alpha phase particles (Al6Mn) and the yellow line represents Mg2Si. The dark blue line represents the liquidus temperature of the aluminum alloy (e.g., the temperature at which the aluminum alloy begins to melt). The grey shaded area indicates the homogenization temperature window where the alpha phase article is stable in the aluminum alloy. Figures 14A-14D show the effect of aluminum alloy composition on the homogenization temperature window for producing alpha phase particles. FIG. 14A shows that Example 9 has a very narrow homogenization temperature window for producing stable alpha phase particles, ranging from about 550°C to about 600°C. However, a large portion of the homogenization temperature window overlaps with the liquidus temperature at which the aluminum alloy melts, which is undesirable. This effectively limits the homogenization temperature range for producing alpha phase particles. FIG. 14A shows that an aluminum alloy produced from a large amount of recycled aluminum alloy material has a narrow homogenization temperature window for producing alpha phase particles, thereby limiting the amount of alpha phase in the aluminum alloy.

[0172] 14B-14D show that the stability of the alpha phase can be enhanced by modifying the alloying elements shown in Examples 9-12. Specifically, FIG. 14B shows the effect of Mg reduction on the homogenization temperature window compared to Example 9, FIG. 14C shows the Cr coinage on the homogenization temperature window compared to Example 9, and FIG. 14B shows the combined effect of Mg reduction and Cr addition on the homogenization temperature window compared to Example 9. Each of Examples 10-12 has a much larger homogenization temperature window for producing alpha phase particles. This provides more mass for phase transformation of the larger constituent elements to the alpha phase. When homogenization is performed at a temperature within the alpha stability region, phase transformation of Alx(Fe,Mn) to the alpha phase can occur. As shown in FIG. 14A-14D, it has surprisingly been found that the grain size of aluminum alloys produced from a large amount of recycled aluminum material can be controlled by modifying the alloying elements and homogenizing at a temperature that promotes the conversion of the larger constituents to alpha phase particles.

[0173] Further, FIG. 14B shows that by decreasing Mg, the homogenization temperature range is wider to produce stable alpha phase particles. Similarly, FIG. 14C shows that the homogenization temperature range of the aluminum alloy with Cr is even larger to produce stable alpha phase particles. FIG. 14D shows that the homogenization temperature range of the aluminum alloy with Cr and less Mg had the largest homogenization window to produce stable alpha phase particles. As described herein, it is beneficial because the alpha phase particles can be broken down into smaller particles because they contain eutectic formations that break down during hot rolling. Even though the volume fraction of the particles increases, the grain size is substantially smaller. In contrast, Al(Fe,Mn) is a very bulky and hard particle that is difficult to break down. In some embodiments, a homogenization temperature range of 450°C to 570°C (e.g., 500°C to 560°C, or 525°C to 550°C) produces the highest concentration of stable alpha phase particles.

[0174] Example 4 Sample aluminum alloys were tested to investigate the amount and size of grains in the microstructure of the aluminum alloys described herein when prepared according to the methods described herein. Examples 13-16 are alloys containing various amounts of Si, Cu, Mg, and Cr. Table 24 shows the aluminum alloy composition of each of Examples 13-16. [Table 24]

[0175] Figures 15A and 15B show the effect of aluminum alloy composition on the grain area (%) and average grain size in the microstructure of Examples 13-16. As shown in Figure 15A, Example 13 had the most Alx(Fe,Mn) grains, which are large components that are difficult to break down in the rolling process, and the least amount of alpha phase grains. Figure 15B also shows that Example 13 had the largest average grain size of about 1.50 square microns. Example 14, which contains more Si than Example 13, had 50% less Alx(Fe,Mn) grains compared to Example 13. In addition, Example 13 had an average grain size of about 1.45 square microns. The data show that the addition of Si to the aluminum alloy composition can cause more alpha phase transformation in the microstructure of the aluminum alloy, resulting in a smaller average grain size.

[0176] Furthermore, Example 15 shows the coins with Cu addition, and Example 16 shows the effect of Mg reduction and Cr addition on the grain area (%) and average grain size in the microstructure of the aluminum alloy. The grain area (%) of alpha phase grains is more than 1.8 wt% in each of Examples 15 and 16. Both Examples 15 and 16 have few or no Alx(Fe,Mn) grains. The ratio of alpha phase grains to Alx(Fe,Mn) grains in Examples 15 and 16 is higher than Examples 13 and 14, and Example 16 has few Alx(Fe,Mn) grains in the microstructure of the aluminum alloy. Examples 15 and 16 also had grains that were less than 1.30 square microns. The examples show that the addition of Si, Cu, Cr, and reduction of Mg can beneficially convert large components into alpha phase grains during homogenization. Specifically, Example 16, which had less Mg and additional Cr, produced a higher grain area % of alpha phase grains and had the smallest average grain size.

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

Claims

1. % Cr, max. 0.30 wt. % Zn, max. 0.20 wt. % Ti, max. 0.15 wt. % impurities, and max. 0.25 wt. % Al.

2. 2. The aluminum alloy of claim 1 comprising 0.10-0.30 wt.% Si, 0.20-0.50 wt.% Fe, 0.05-0.25 wt.% Cu, 0.30-1.0 wt.% Mn, 2.2-5.0 wt.% Mg, max. 0.15 wt.% Cr, max. 0.30 wt.% Zn, max. 0.15 wt.% Ti, max. 0.15 wt.% impurities, and Al.

3. 2. The aluminum alloy of claim 1 comprising 0.10-0.25 wt.% Si, 0.20-0.50 wt.% Fe, 0.05-0.25 wt.% Cu, 0.30-0.90 wt.% Mn, 2.5-5.0 wt.% Mg, max. 0.10 wt.% Cr, max. 0.25 wt.% Zn, max. 0.10 wt.% Ti, max. 0.15 wt.% impurities, and Al.

4. 2. The aluminum alloy of claim 1 comprising 0.20-0.35 wt.% Si, 0.20-0.50 wt.% Fe, 0.05-0.25 wt.% Cu, 0.30-0.90 wt.% Mn, 2.5-5.0 wt.% Mg, max. 0.05 wt.% Cr, max. 0.25 wt.% Zn, max. 0.05 wt.% Ti, max. 0.15 wt.% impurities, and Al.

5. 2. The aluminum alloy of claim 1, comprising 0.20-0.35 wt.% Si, 0.40-0.60 wt.% Fe, 0.15-0.25 wt.% Cu, 0.60-1.2 wt.% Mn, 2.0-4.0 wt.% Mg, max. 0.03 wt.% Cr, max. 0.20 wt.% Zn, max. 0.03 wt.% Ti, max. 0.15 wt.% impurities, and Al.

6. An aluminium alloy according to any one of claims 1 to 5, wherein the ratio of Mg:Cu is from 10:1 to 80:1 and the ratio of Mn:Cu is from 2:1 to 15:

1.

7. An aluminium alloy according to any one of claims 1 to 6, wherein the ratio of Mg:Cu is from 15:1 to 70:1 and the ratio of Mn:Cu is from 3:1 to 12:

1.

8. The aluminum alloy according to any one of claims 1 to 7, wherein the total content of Fe and Si is more than 0.40 wt%.

9. The aluminum alloy according to any one of claims 1 to 8, wherein the total content of Mg, Mn, and Cu is 3.5% by weight to 5.0% by weight.

10. An aluminium alloy according to any one of the preceding claims, wherein the aluminium alloy comprises at least 40% by weight of recycled scrap.

11. An aluminium alloy according to any preceding claim, wherein the aluminium alloy contains less than 30% by weight of primary aluminium.

12. The aluminum alloy has a thermal expansion coefficient of at least 30.0 KJ / m as measured by ASTM B871-1(2021). ２ The aluminum alloy according to any one of claims 1 to 11, having a propagation energy of

13. An aluminium alloy according to any preceding claim, wherein the aluminium alloy has a yield strength of at least 340 MPa.

14. An aluminium alloy according to any preceding claim, wherein the aluminium alloy has an ultimate tensile strength of at least 380 MPa.

15. An aluminium alloy according to any preceding claim, wherein the aluminium alloy has a total elongation of at least 4%.

16. A can end stock comprising the aluminium alloy of any one of claims 1 to 15.

17. 1. A method for producing an aluminum alloy, comprising the steps of: casting an aluminum alloy to form a cast product, the aluminum alloy comprising 0.10-0.35 wt.% Si, 0.20-0.60 wt.% Fe, 0.05-0.25 wt.% Cu, 0.25-1.20 wt.% Mn, 2.0-5.0 wt.% Mg, max. 0.20 wt.% Cr, max. 0.30 wt.% Zn, max. 0.20 wt.% Ti, max. 0.15 wt.% impurities, and Al; homogenizing the cast product; hot rolling the cast product to produce a hot rolled product; cold rolling the hot rolled product to produce a final gauge rolled product; Optionally annealing the final gauge rolled product; The method comprising:

18. 20. The method of claim 17, further comprising lacquering and curing the final gauge rolled product.

19. 19. The method of claim 17 or 18, wherein the homogenization step comprises a first homogenization step and a second homogenization step.

20. 20. The method of claim 19, wherein the first homogenization step comprises soaking the cast product at a temperature between 375°C and 450°C for a period between 0.5 hours and 5 hours.

21. 20. The method of claim 19, wherein the second homogenization step comprises soaking the cast product at a temperature between 450°C and 550°C for a period between 0.01 hours and 5 hours.

22. 22. The method according to any of claims 17 to 21, wherein the aluminium alloy comprises 0.10-0.25 wt% Si, 0.20-0.50 wt% Fe, 0.05-0.25 wt% Cu, 0.30-0.90 wt% Mn, 2.5-5.0 wt% Mg, max 0.10 wt% Cr, max 0.25 wt% Zn, max 0.10 wt% Ti, max 0.15 wt% impurities and Al.

23. 23. The method of any of claims 17 to 22, wherein the ratio of Mg:Cu is from 15:1 to 70:1 and the ratio of Mn:Cu is from 3:1 to 12:

1.

24. A metal product prepared by the method according to any one of claims 17 to 23.

25. 25. The metal article of claim 24, wherein the metal article is a can end stock.

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