New scrap-based aluminum alloy products

Abstract

A novel aluminum alloy is disclosed. The novel aluminum alloy may include 1.05 to 1.55 wt% Si, 0.85 to 2.10 wt% Mg, 0.15 to 0.75 wt% Cu, 0.20 to 0.90 wt% Fe, 0.5 to 1.5 wt% Mn, 0.01 to 0.15 wt% Ti, up to 0.4 wt% Zn, any one of up to 0.25 wt% Cr, Zr, and V, and up to 0.05 wt% Ni, with the balance being aluminum, incidental elements, and impurities. The novel aluminum alloy may be at least partially derived from scrap materials such as UBC or brazing scrap. The novel aluminum alloy may be processed into H-temper sheet products. The novel aluminum alloy can achieve an improved combination of at least two of strength, elongation, and corrosion resistance.

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application claims priority to U.S. Provisional Patent Application No. 63 / 344,968, filed on May 23, 2022, entitled "NEW SCRAP - BASED ALUMINUM ALLOY PRODUCTS", which is hereby incorporated by reference in its entirety.

Background Art

[0002] As described in U.S. Patent Application Publication No. 2021 / 0087664, aluminum can contribute to a portion of carbon dioxide emissions. An effective way to reduce carbon dioxide emissions and aluminum mining is by increasing the use of recycled aluminum, particularly post - consumer recycled (PCR) aluminum. One of the main sources of PCR aluminum is used beverage can (UBC) scrap. Increased recycling can have a significant impact on reducing carbon dioxide emissions and primary aluminum consumption.

Summary of the Invention

[0003] Broadly, this patent application relates to a novel aluminum alloy. The novel aluminum alloy may be derived from scrap, thereby reducing its manufacturing cost. Despite being derived from scrap, the novel aluminum alloy may exhibit excellent mechanical properties and corrosion resistance. In one embodiment, the novel aluminum alloy comprises 1.05 - 1.55 wt% Si, 0.85 - 2.10 wt% Mg, 0.15 - 0.75 wt% Cu, 0.20 - 0.90 wt% Fe, 0.5 - 1.5 wt% Mn, 0.01 - 0.15 wt% Ti, up to 0.4 wt% Zn, any of up to 0.25 wt% Cr, Zr, and V, and up to 0.05 wt% Ni, with the balance being aluminum, incidental elements, and impurities. In one approach, the novel aluminum alloy is in the form of a sheet product having a thickness of 0.4 - 4 mm. In one embodiment, the aluminum alloy sheet product exhibits at least one of the following microstructural characteristics: (i) recrystallized grains of 50% volume or less, (ii) an Mg2Si area percentage of at least 0.5%, (iii) an average Mg2Si particle area of at least 0.5 particles per square micrometer, (iv) a component area percentage of at least 0.5%, and (v) an average component particle area of at least 0.5 particles per square micrometer. The method for determining these microstructural characteristics is described in the "Microstructural Evaluation Procedure" described below.

[0004] i. Composition As described above, the novel aluminum alloy generally contains 1.05 - 1.55 wt% Si. Such silicon levels can promote, for example, improved scrap utilization and / or improved mechanical properties. In one embodiment, the novel aluminum alloy contains at least 1.10 wt% Si. In another embodiment, the novel aluminum alloy contains at least 1.15 wt% Si. In one embodiment, the novel aluminum alloy contains 1.45 wt% or less Si. In another embodiment, the novel aluminum alloy contains 1.40 wt% or less Si.

[0005] As described above, the novel aluminum alloy generally contains 0.85 to 2.10 wt% of Mg. Such magnesium levels can facilitate, for example, improved mechanical properties (e.g., strain hardening). In one embodiment, the novel aluminum alloy contains at least 0.90 wt% of Mg. In another embodiment, the novel aluminum alloy contains at least 0.95 wt% of Mg. In one embodiment, the novel aluminum alloy contains 2.05 wt% or less of Mg. In another embodiment, the novel aluminum alloy contains 2.00 wt% or less of Mg. In yet another embodiment, the novel aluminum alloy contains 1.95 wt% or less of Mg. In another embodiment, the novel aluminum alloy contains 1.90 wt% or less of Mg.

[0006] As described above, the novel aluminum alloy generally contains 0.15 to 0.75 wt% of Cu. Such levels of copper can promote improved mechanical properties, for example, without unduly degrading corrosion resistance. In one embodiment, the novel aluminum alloy contains at least 0.20 wt% of Cu. In another embodiment, the novel aluminum alloy contains at least 0.25 wt% of Cu. In yet another embodiment, the novel aluminum alloy contains at least 0.30 wt% of Cu. In one embodiment, the novel aluminum alloy contains 0.70 wt% or less of Cu. In another embodiment, the novel aluminum alloy contains 0.65 wt% or less of Cu. In yet another embodiment, the novel aluminum alloy contains 0.60 wt% or less of Cu.

[0007] As described above, the novel aluminum alloy generally contains 0.20 to 0.90 wt% of Fe. Such levels of iron can promote, for example, high scrap resistance and / or dispersion formation. In one embodiment, the novel aluminum alloy contains at least 0.25 wt% of Fe. In another embodiment, the novel aluminum alloy contains at least 0.30 wt% of Fe. In one embodiment, the novel aluminum alloy contains 0.85 wt% or less of Fe. In another embodiment, the novel aluminum alloy contains 0.80 wt% or less of Fe. In yet another embodiment, the novel aluminum alloy contains 0.75 wt% or less of Fe.

[0008] As described above, the novel aluminum alloy generally contains 0.5 to 1.5 wt% of Mn. Such levels of manganese can promote, for example, high scrap resistance and / or dispersion formation. In one embodiment, the novel aluminum alloy contains at least 0.55 wt% of Mn. In another embodiment, the novel aluminum alloy contains at least 0.60 wt% of Mn. In yet another embodiment, the novel aluminum alloy contains at least 0.65 wt% of Mn. In another embodiment, the novel aluminum alloy contains at least 0.70 wt% of Mn. In yet another embodiment, the novel aluminum alloy contains at least 0.75 wt% of Mn. In another embodiment, the novel aluminum alloy contains at least 0.80 wt% of Mn. In yet another embodiment, the novel aluminum alloy contains at least 0.85 wt% of Mn. In another embodiment, the novel aluminum alloy contains at least 0.90 wt% of Mn. In yet another embodiment, the novel aluminum alloy contains at least 0.95 wt% of Mn. In another embodiment, the novel aluminum alloy contains at least 1.0 wt% of Mn. In one embodiment, the novel aluminum alloy contains 1.45 wt% or less of Mn. In another embodiment, the novel aluminum alloy contains 1.40 wt% or less of Mn. In yet another embodiment, the novel aluminum alloy contains 1.35 wt% or less of Mn. In another embodiment, the novel aluminum alloy contains 1.30 wt% or less of Mn. In yet another embodiment, the novel aluminum alloy contains 1.25 wt% or less of Mn. In another embodiment, the novel aluminum alloy contains 1.20 wt% or less of Mn.

[0009] As described above, the novel aluminum alloy generally contains 0.01 to 0.15% by weight of Ti. Titanium can, for example, promote grain refinement. In one embodiment, the novel aluminum alloy contains at least 0.02% by weight of Ti. In another embodiment, the novel aluminum alloy contains at least 0.03% by weight of Ti. In yet another embodiment, the novel aluminum alloy contains at least 0.04% by weight of Ti. In yet another embodiment, the novel aluminum alloy contains at least 0.05% by weight of Ti. In one embodiment, the novel aluminum alloy contains 0.12% by weight or less of Ti. In another embodiment, the novel aluminum alloy contains 0.10% by weight or less of Ti. In yet another embodiment, the novel aluminum alloy contains 0.08% by weight or less of Ti. In yet another embodiment, the novel aluminum alloy contains 0.05% by weight or less of Ti.

[0010] As described above, the novel aluminum alloy may contain up to 0.40% by weight of Zn, which can promote high scrap resistance. In one embodiment, the novel aluminum alloy contains 0.35% by weight or less of Zn. In another embodiment, the novel aluminum alloy contains 0.30% by weight or less of Zn. In yet another embodiment, the novel aluminum alloy contains 0.25% by weight or less of Zn. In another embodiment, the novel aluminum alloy contains 0.20% by weight or less of Zn. In one embodiment, the novel aluminum alloy contains at least 0.01% by weight of Zn. In another embodiment, the novel aluminum alloy contains at least 0.05% by weight of Zn.

[0011] As described above, the novel aluminum alloy may contain any of Cr, Zr, and V up to 0.25 wt% that may be useful for controlling recrystallization. In one approach, the novel aluminum alloy contains Zr of 0.20 wt% or less. In another approach, the novel aluminum alloy contains Zr of 0.15 wt% or less. In one embodiment, the novel aluminum alloy contains Zr of 0.10 wt% or less. In another embodiment, the novel aluminum alloy contains Zr of 0.08 wt% or less. In yet another embodiment, the novel aluminum alloy contains Zr of 0.05 wt% or less. In another embodiment, the novel aluminum alloy contains Zr of 0.04 wt% or less. In yet another embodiment, the novel aluminum alloy contains Zr of 0.03 wt% or less. In one embodiment, the novel aluminum alloy contains at least 0.01 wt% of Zr.

[0012] In one approach, the novel aluminum alloy contains Cr of 0.20 wt% or less. In one embodiment, the novel aluminum alloy contains Cr of 0.15 wt% or less. In another embodiment, the novel aluminum alloy contains Cr of 0.10 wt% or less. In another embodiment, the novel aluminum alloy contains Cr of 0.08 wt% or less. In yet another embodiment, the novel aluminum alloy contains Cr of 0.05 wt% or less. In another embodiment, the novel aluminum alloy contains Cr of 0.04 wt% or less. In yet another embodiment, the novel aluminum alloy contains Cr of 0.03 wt% or less. In one embodiment, the novel aluminum alloy contains at least 0.01 wt% of Cr.

[0013] In one approach, the novel aluminum alloy contains V of 0.20 wt% or less. In one embodiment, the novel aluminum alloy contains V of 0.15 wt% or less. In another embodiment, the novel aluminum alloy contains V of 0.10 wt% or less. In another embodiment, the novel aluminum alloy contains V of 0.08 wt% or less. In yet another embodiment, the novel aluminum alloy contains V of 0.05 wt% or less. In another embodiment, the novel aluminum alloy contains V of 0.04 wt% or less. In yet another embodiment, the novel aluminum alloy contains V of 0.03 wt% or less. In one embodiment, the novel aluminum alloy contains at least 0.01 wt% of V.

[0014] The novel aluminum alloy generally contains the specified alloying components, with the remainder being aluminum, optionally accompanying elements, and impurities. As used herein, "accompanying element" means an element or material other than those listed above that can be optionally added to the alloy to assist in the production of the alloy. Examples of accompanying elements include casting aids such as deoxidizers. Optional accompanying elements can be included in the alloy in a cumulative amount of up to 1.0 wt%. As one non-limiting example, one or more accompanying elements can be added to the alloy during casting to reduce or limit (or optionally eliminate) cracking of the ingot due to oxide wrinkles, pits, and oxide patches. These types of accompanying elements are generally referred to herein as deoxidizers. Examples of some deoxidizers include Ca, Sr, and Be. When calcium (Ca) is included in the alloy, calcium (Ca) generally exists in an amount of up to about 0.05 wt% or up to about 0.03 wt%. In some embodiments, Ca is included in the alloy in an amount of about 0.001 to 0.03 wt% or about 0.05 wt%, such as 0.001 to 0.008 wt% (or 10 to 80 ppm). Strontium (Sr) can be included in the alloy (either wholly or partially) as a substitute for Ca and thus can be included in the alloy in the same or a similar amount as Ca. Conventionally, the addition of beryllium (Be) has helped reduce the tendency of ingots to crack, but for environmental, health, and safety reasons, some embodiments of the alloy are substantially Be-free. When Be is included in the alloy, it generally exists in an amount of up to about 20 ppm. Accompanying elements can be present in minor amounts or in significant amounts, and as long as the alloy retains the desirable properties described herein, the accompanying elements themselves can be desirable or add other properties without departing from the alloys described herein. However, it should be understood that the scope of the present disclosure should not be avoided / cannot be avoided by simply adding an amount of an element that will not otherwise affect the desired combination of properties obtained herein.

[0015] The novel aluminum alloy may contain a small amount of impurities. In one embodiment, the novel aluminum alloy contains a total of 0.15 wt% or less of impurities, and the aluminum alloy contains each impurity at 0.05 wt% or less. In another embodiment, the novel aluminum alloy contains a total of 0.10 wt% or less of impurities, and the aluminum alloy contains each impurity at 0.03 wt% or less.

[0016] The novel aluminum alloy is generally substantially free of nickel. That is, nickel is included only as an impurity and generally contains less than 0.04 wt% of Ni, or less than 0.01 wt% of Ni. The novel aluminum alloy is generally substantially free of lithium. That is, lithium is included only as an impurity and generally contains less than 0.04 wt% of Li, or less than 0.01 wt% of Li. The novel aluminum alloy is generally substantially free of silver. That is, silver is included only as an impurity and generally contains less than 0.04 wt% of Ag, or less than 0.01 wt% of Ag. The novel aluminum alloy is generally substantially free of lead. That is, lead is included only as an impurity and generally contains less than 0.04 wt% of Pb, or less than 0.01 wt% of Pb. The novel aluminum alloy is generally substantially free of cadmium. That is, cadmium is included only as an impurity and generally contains less than 0.04 wt% of Cd, or less than 0.01 wt% of Cd. The novel aluminum alloy is generally substantially free of thallium. That is, thallium is included only as an impurity and generally contains less than 0.04 wt% of Tl, or less than 0.01 wt% of Tl. The novel aluminum alloy is generally substantially free of scandium. That is, scandium is included only as an impurity and generally contains less than 0.04 wt% of Sc, or less than 0.01 wt% of Sc.

[0017] ii. Manufacturing method The novel aluminum alloy may be prepared in a wrought form and in a suitable temper. In one embodiment, the novel aluminum alloy, after being cast into an ingot or strip (e.g., direct chill casting or continuous casting), may be manufactured by performing appropriate processes to achieve various tempers, such as the H temper according to ANSI H35.1(2009), e.g., the H1 temper, the H2 temper, or the H3 temper. In one embodiment, the novel aluminum alloy is processed to the "H1 temper". In another embodiment, the novel aluminum alloy is processed to the "H2 temper". In yet another embodiment, the novel aluminum alloy is processed to the "H3 temper".

[0018] In one embodiment, the novel aluminum alloy is a direct chill (DC) cast into an ingot form. After conventional scalping, turning, or peeling (if necessary) and homogenization (if necessary) of the ingot (this homogenization may be completed before or after scalping), the ingot can be further processed by hot working the product. The product may then optionally be cold worked and / or optionally annealed. In one embodiment, processing to an H temper sheet product includes cold rolling to the final gauge and then partially annealing to achieve the H2 temper.

[0019] When the novel aluminum alloys are processed to the H temper, their manufacturing methods generally do not include solution heat treatment or artificial aging (if they do not exist). These processes add unnecessary costs, and the H temper can achieve the required properties without such processes.

[0020] In other embodiments, the novel aluminum alloy may be processed to the T temper, which includes solution heat treatment followed by natural and / or artificial aging. The high silicon magnesium (Mg2Si) content of the new alloy can promote the improvement of strength, particularly in the T4 (naturally aged) or T6 (artificially aged) tempers among other T tempers.

[0021] The novel aluminum alloy product may have any suitable final gauge thickness. In one embodiment, the novel aluminum alloy is in the form of a sheet having a thickness of 0.4 mm to 4 mm. Other wrought product forms (e.g., plates, extrusions, forgings) may be utilized.

[0022] As described above, the ingot used to produce the novel aluminum alloy described herein may be at least partially derived from aluminum alloy scrap. For example, the method may include (a) generating an aluminum alloy ingot from aluminum-based scrap, and (b) processing the aluminum alloy ingot into the form and temper of a suitable wrought product, such as an H-temper sheet product having a thickness of 0.4 to 4.0 mm.

[0023] In connection with step (a) above (i.e., generating the aluminum alloy ingot), this step (a) may include (i) mixing a first aluminum scrap material with another aluminum material to achieve a target ingot composition, (ii) heating the first aluminum scrap material and the other aluminum material, either before or after the mixing step, to produce a molten aluminum alloy, and (iii) casting the molten aluminum alloy into the aluminum alloy ingot, wherein the aluminum alloy ingot achieves the target ingot composition. The other aluminum material may be at least one of (A) a second aluminum scrap material, (B) primary aluminum, and (C) a mixture thereof. The target ingot composition may be any of the compositions disclosed herein, including the "Composition" section and the "Examples" section.

[0024] In one embodiment, at least one of the first aluminum scrap material and the second aluminum scrap material is 3xxx aluminum alloy scrap, 4xxx aluminum alloy scrap, 5xxx aluminum alloy scrap, or 6xxx aluminum alloy scrap. In one embodiment, at least one of the first aluminum scrap material and the second aluminum scrap material is 3004 and / or 3104 aluminum alloy scrap. In another embodiment, at least one of the first aluminum scrap material and the second aluminum scrap material is 4343 aluminum alloy scrap. In yet another embodiment, at least one of the first aluminum scrap material and the second aluminum scrap material is 5052 and / or 5182 aluminum alloy scrap. In another embodiment, at least one of the first aluminum scrap material and the second aluminum scrap material is 6061, 6063, 6022, 6111, and / or 6013 aluminum alloy scrap.

[0025] In one embodiment, at least one of the first aluminum scrap material and the second aluminum scrap material is brazing scrap. Suitable brazing scrap materials may include composite alloys having a core and a liner. The composite alloy may have, for example, among other things, a 3xxx aluminum alloy core and a 4xxx aluminum alloy liner, or a 3xxx core and a 7xxx aluminum alloy liner. The brazing scrap may be derived from, for example, tube stock, headers, or other heat exchanger materials.

[0026] In one embodiment, at least one of the first aluminum scrap material and the second aluminum scrap material is UBC (used beverage can) scrap. Suitable UBC scrap materials include those made from 3104 and / or 5182 aluminum alloys. In one embodiment, the UBC scrap material includes at least 3104 scrap. In another embodiment, the UBC scrap material includes at least 5182 scrap.

[0027] In one embodiment, at least one of the first and second aluminum scrap materials is automotive or industrial scrap (e.g., scrap of aluminum alloys 6061, 6063, 6022, 6111, and / or 6013).

[0028] In one embodiment, the first aluminum scrap material is at least one of brazing scrap, used beverage can (UBC) scrap, and mixtures thereof, and the other aluminum material is a second aluminum scrap material such as 3xxx, 4xxx, 5xxx, or 6xxx aluminum alloy scrap. In another embodiment, the first aluminum scrap material is at least one of brazing scrap, used beverage can (UBC) scrap, and mixtures thereof, and the other aluminum material is primary aluminum. In one embodiment, the first aluminum scrap material is brazing scrap and the second aluminum scrap material is UBC scrap.

[0029] By using scrap, the aluminum alloy ingot can contain a significant amount of scrap material. In one embodiment, at least 30% of the ingot is derived from a first aluminum scrap material (i.e., at least 30% of the ingot contains the first aluminum scrap material), and the remainder of the ingot is primary aluminum and / or other scrap materials. In another embodiment, at least 35% of the ingot is derived from the first aluminum scrap material. In yet another embodiment, at least 40% of the ingot is derived from the first aluminum scrap material. In another embodiment, at least 45% of the ingot is derived from the first aluminum scrap material. In yet another embodiment, at least 50% of the ingot is derived from the first aluminum scrap material. In another embodiment, at least 55% of the ingot is derived from the first aluminum scrap material. In yet another embodiment, at least 60% of the ingot is derived from the first aluminum scrap material. In another embodiment, at least 65% of the ingot is derived from the first aluminum scrap material.

[0030] In one embodiment, the aluminum alloy ingot comprises at least two aluminum scrap materials (a first and a second scrap material). In one embodiment, at least 50% of the ingot is derived from the first and second aluminum scrap materials (i.e., at least 50% of the ingot comprises the first and second aluminum scrap materials). In another embodiment, at least 55% of the ingot is derived from the first and second aluminum scrap materials. In yet another embodiment, at least 60% of the ingot is derived from the first and second aluminum scrap materials. In another embodiment, at least 65% of the ingot is derived from the first and second aluminum scrap materials. In yet another embodiment, at least 70% of the ingot is derived from the first and second aluminum scrap materials. In another embodiment, at least 75% of the ingot is derived from the first and second aluminum scrap materials. In yet another embodiment, at least 80% of the ingot is derived from the first and second aluminum scrap materials. In another embodiment, at least 85% of the ingot is derived from the first and second aluminum scrap materials. In yet another embodiment, at least 90% of the ingot is derived from the first and second aluminum scrap materials. In another embodiment, at least 94% of the ingot is derived from the first and second aluminum scrap materials. Additional scrap materials (third, fourth, fifth, etc.) may be used to produce any of the aluminum alloy ingots described in this paragraph.

[0031] Primary aluminum may be used with scrap of any mixture to produce aluminum alloy ingots. In one embodiment, the aluminum alloy ingot contains at least 1% primary aluminum. In another embodiment, the aluminum alloy ingot contains at least 2% primary aluminum. In yet another embodiment, the aluminum alloy ingot contains at least 3% primary aluminum. In another embodiment, the aluminum alloy ingot contains at least 4% primary aluminum. In yet another embodiment, the aluminum alloy ingot contains at least 5% primary aluminum. In another embodiment, the aluminum alloy ingot contains at least 6% primary aluminum. In one embodiment, the aluminum alloy ingot contains 60% or less primary aluminum. In another embodiment, the aluminum alloy ingot contains 55% or less primary aluminum. In yet another embodiment, the aluminum alloy ingot contains 50% or less primary aluminum. In another embodiment, the aluminum alloy ingot contains 45% or less primary aluminum. In yet another embodiment, the aluminum alloy ingot contains 40% or less primary aluminum. In another embodiment, the aluminum alloy ingot contains 30% or less primary aluminum. In yet another embodiment, the aluminum alloy ingot contains 35% or less primary aluminum. In another embodiment, the aluminum alloy ingot contains 30% or less primary aluminum. In yet another embodiment, the aluminum alloy ingot contains 25% or less primary aluminum.

[0032] iii. Microstructure As described above, the novel aluminum alloy can achieve a unique microstructure. For example, the novel aluminum alloy may contain recrystallized grains of 50% by volume or less, determined using the "recrystallization determination procedure" described below. In one embodiment, the novel aluminum alloy contains recrystallized grains of 45% by volume or less. In another embodiment, the novel aluminum alloy contains recrystallized grains of 40% by volume or less. In yet another embodiment, the novel aluminum alloy contains recrystallized grains of 35% by volume or less. In another embodiment, the novel aluminum alloy product contains recrystallized grains of 30% by volume or less. In yet another embodiment, the novel aluminum alloy contains recrystallized grains of 25% by volume or less. In another embodiment, the novel aluminum alloy product contains recrystallized grains of 20% by volume or less. In yet another embodiment, the novel aluminum alloy contains recrystallized grains of 15% by volume or less. In another embodiment, the novel aluminum alloy product contains recrystallized grains of 10% by volume or less. In one embodiment, the novel aluminum alloy contains at least 1% by volume of recrystallized grains. In another embodiment, the novel aluminum alloy product contains at least 3% by volume of recrystallized grains. In yet another embodiment, the novel aluminum alloy product contains at least 5% by volume of recrystallized grains.

[0033] As described above, the novel aluminum alloy may achieve at least 0.5% Mg2Si area percentage. In one embodiment, the novel aluminum alloy achieves at least 0.6% Mg2Si area percentage. In another embodiment, the novel aluminum alloy achieves at least 0.7% Mg2Si area percentage. In yet another embodiment, the novel aluminum alloy achieves at least 0.8% Mg2Si area percentage. In another embodiment, the novel aluminum alloy achieves at least 0.9% Mg2Si area percentage. In yet another embodiment, the novel aluminum alloy achieves at least 1.0% Mg2Si area percentage. In another embodiment, the novel aluminum alloy achieves at least 1.1% Mg2Si area percentage. In yet another embodiment, the novel aluminum alloy achieves at least 1.2% Mg2Si area percentage.

[0034] As described above, the novel aluminum alloy may achieve an average Mg2Si particle area of at least 0.5 particles per square micrometer. In one embodiment, the novel aluminum alloy achieves an average Mg2Si particle area of at least 0.75 particles per square micrometer. In another embodiment, the novel aluminum alloy achieves an average Mg2Si particle area of at least 1.0 particles per square micrometer. In yet another embodiment, the novel aluminum alloy achieves an average Mg2Si particle area of at least 1.25 particles per square micrometer. In another embodiment, the novel aluminum alloy achieves an average Mg2Si particle area of at least 1.5 particles per square micrometer. In yet another embodiment, the novel aluminum alloy achieves an average Mg2Si particle area of at least 1.75 particles per square micrometer. In another embodiment, the novel aluminum alloy achieves an average Mg2Si particle area of at least 2.0 particles per square micrometer. In yet another embodiment, the novel aluminum alloy achieves an average Mg2Si particle area of at least 2.25 particles per square micrometer. In another embodiment, the novel aluminum alloy achieves an average Mg2Si particle area of at least 2.5 particles per square micrometer. In yet another embodiment, the novel aluminum alloy achieves an average Mg2Si particle area of at least 2.75 particles per square micrometer. In another embodiment, the novel aluminum alloy achieves an average Mg2Si particle area of at least 3.0 particles per square micrometer. In yet another embodiment, the novel aluminum alloy achieves an average Mg2Si particle area of at least 3.25 particles per square micrometer. In another embodiment, the novel aluminum alloy achieves an average Mg2Si particle area of at least 3.5 particles per square micrometer.

[0035] As described above, the novel aluminum alloy may achieve a component area percentage of at least 0.5%. In one embodiment, the novel aluminum alloy achieves a component area percentage of at least 0.75%. In another embodiment, the novel aluminum alloy achieves a component area percentage of at least 1.0%. In yet another embodiment, the novel aluminum alloy achieves a component area percentage of at least 1.25%. In another embodiment, the novel aluminum alloy achieves a component area percentage of at least 1.5%. In yet another embodiment, the novel aluminum alloy achieves a component area percentage of at least 1.75%. In another embodiment, the novel aluminum alloy achieves a component area percentage of at least 2.0%. In yet another embodiment, the novel aluminum alloy achieves a component area percentage of at least 2.25%. In another embodiment, the novel aluminum alloy achieves a component area percentage of at least 2.5%. In yet another embodiment, the novel aluminum alloy achieves a component area percentage of at least 2.75%.

[0036] As described above, the novel aluminum alloy may achieve an average component particle area of at least 0.5 particles per square micrometer. In one embodiment, the novel aluminum alloy achieves an average component particle area of at least 0.75 particles per square micrometer. In another embodiment, the novel aluminum alloy achieves an average component particle area of at least 1.0 particles per square micrometer. In yet another embodiment, the novel aluminum alloy achieves an average component particle area of at least 1.25 particles per square micrometer. In another embodiment, the novel aluminum alloy achieves an average component particle area of at least 1.5 particles per square micrometer. In yet another embodiment, the novel aluminum alloy achieves an average component particle area of at least 1.75 particles per square micrometer. In another embodiment, the novel aluminum alloy achieves an average component particle area of at least 2.0 particles per square micrometer. In yet another embodiment, the novel aluminum alloy achieves an average component particle area of at least 2.25 particles per square micrometer. In another embodiment, the novel aluminum alloy achieves an average component particle area of at least 2.5 particles per square micrometer. In yet another embodiment, the novel aluminum alloy achieves an average component particle area of at least 2.75 particles per square micrometer. In another embodiment, the novel aluminum alloy achieves an average component particle area of at least 3.0 particles per square micrometer. In yet another embodiment, the novel aluminum alloy achieves an average component particle area of at least 3.25 particles per square micrometer. In another embodiment, the novel aluminum alloy achieves an average component particle area of at least 3.5 particles per square micrometer. In yet another embodiment, the novel aluminum alloy achieves an average component particle area of at least 3.75 particles per square micrometer.

[0037] As described above, the novel aluminum alloy may achieve at least one of the following fine structure characteristics: (i) recrystallized grains of 50% by volume or less, (ii) an Mg2Si area percentage of at least 0.5%, (iii) an average Mg2Si particle area of at least 0.5 particles per square micrometer, (iv) a component area percentage of at least 0.5%, and (v) an average component particle area of at least 0.5 particles per square micrometer. In one embodiment, the novel aluminum alloy achieves at least two of the fine structure characteristics (i)-(v). In another embodiment, the novel aluminum alloy achieves at least three of the fine structure characteristics (i)-(v). In another embodiment, the novel aluminum alloy achieves at least four of the fine structure characteristics (i)-(v). In another embodiment, the novel aluminum alloy achieves all of the fine structure characteristics (i)-(v).

[0038] iv. Fine Structure Evaluation Procedure The following procedures and definitions apply to the measurement of the characteristics of the fine structure (e.g., recrystallization rate, composition, and Mg2Si content) of products fabricated in accordance with this patent application.

[0039] a. Measurement of Mg2Si and Component Particles The "component area ratio" (cf) and the "Mg2Si area ratio" are the ratios of the areas covered by the component particles or Mg2Si, respectively, divided by the total area of the two-dimensional cross-section fabricated by standard metallographic sample preparation methods.

[0040] The "component area percentage" and the "Mg2Si area percentage" are determined by multiplying the respective area ratios by 100%.

[0041] The "component particle area" and the "Mg2Si particle area" are the areas of the component particles and Mg2Si particles measured in the sample, respectively.

[0042] The "average component particle area" and the "average Mg2Si particle area" are the average areas of the respective component particles or Mg2Si particles.

[0043] To measure the components, Mg2Si area ratio, and particle area, it is necessary to take backscattered electron images at 500x magnification using an Apreo S Field Emission Gun (Thermo Fisher Scientific, Waltham, MA, U.S.A) scanning electron microscope or equivalent to image the components and Mg2Si particles. The images should be taken using an acceleration voltage of 10 kV. The beam current must be 3.2 nanoamperes. The working distance should be 10 mm, the dwell time should be 5 microseconds, and the line average should be 3. Thirty images are collected at t / 2 from metallographically polished samples of each alloy. Image analysis is used to quantify the images. The pixel size for quantifying the components and MgSi particles is 0.083 microns. For the components, only particles containing at least 50 pixels are counted, the threshold is 99, and the minimum intensity average is 115. For each component particle, the number of pixels is converted to particle area and particle effective diameter. For Mg2Si particles, only particles containing at least 15 pixels are counted, the threshold is 73, and the average intensity of all pixels in the particle is not less than 65. For each Mg2Si particle, the number of pixels is converted to particle area and particle effective diameter. For calculations based on average particles, only particles completely contained within the image area are included in the calculation.

[0044] b. Recrystallization determination procedure "Recrystallization rate" etc. means the volume ratio of a wrought aluminum alloy product having recrystallized grains. The amount of recrystallized grains is determined by EBSD (electron backscatter diffraction) analysis of a suitable number of SEM micrographs of the wrought aluminum alloy product according to this "recrystallization determination procedure". Usually, it is necessary to analyze at least five micrographs.

[0045] "Recrystallized grains" means particles of a crystal microstructure that meet the "criteria for type I grains" defined below and are measured using the OIM (orientation imaging microscopy) sample preparation procedure described below.

[0046] The OIM analysis needs to be completed through the entire thickness of the sheet sample on the L-ST plane using the following OIM sample procedure. The size of the sample to be analyzed will generally vary depending on the gauge. Before measurement, the OIM sample is prepared by standard metallographic sample preparation methods. For example, after being metallographically prepared, the OIM sample is polished vibrationally (e.g., using 0.05 micron colloidal silica).

[0047] The "OIM sample procedure" is as follows. · The software used is APEX EBSD Collection Software version 2 (EDAX Inc., New Jersey, U.S.A.) or equivalent, and is connected to a Velocity EBSD camera (EDAX Inc., New Jersey, U.S.A.) or equivalent. The SEM is an APREO S field emission electron gun (Thermo Fisher Scientific, Waltham, MA, U.S.A.), or equivalent. · The operating conditions for OIM are an inclination of 68°, a working distance of 18 mm, an acceleration voltage of 15 kV, dynamic focusing, and a device-specific beam current of 51 nA (nanoampere). The collection mode is a hexagonal grid. Orientations are selected to be collected in the analysis (i.e., Hough peak information is not collected). The area size per scan (i.e., the frame) is 2.0 mm × 1 mm for a 2 mm gauge sample with a step of 0.25 micron at 80×. Depending on the gauge, various frame sizes can be used. The collected data is output to a *.osc file. As described below, the volume fraction of the first type of grains can be calculated using this data. ·Calculation of the volume fraction of the first type of grains: The volume fraction of the first type of grains is calculated using the data of the *.osc file and OIM analysis software (EDAX Inc., New Jersey, U.S.A.) version 8.1.0, or equivalent. Before the calculation, two-step data cleaning can be performed. First, for any point with a confidence index less than the threshold of 0.08, cleaning of the adjacent direction correlation is performed. Next, for any grain smaller than 3 data points, grain expansion cleaning is performed. Then, the amount of the first type of grains is calculated by the software using the criteria of the first type of grains (as follows). ·Criteria for the first type of grains: The grain average misorientation (GAM) is calculated. It is necessary to have all of "apply partitioning before calculation", "include edge grains", and "ignore the definition of twin grain boundaries". Any grain with GAM ≤ 1° is a first type of grain.

[0048] "First grain volume" (FGV) means the volume fraction of the first type of grains in the crystalline material.

[0049] "Percent Recrystallized" is determined by the following formula. FGV * 100%.

[0050] The term "grain" has the meaning defined in ASTM E112 §3.2.2. That is, "the area within the range of the original (primary) boundaries observed on the two-dimensional plane of polishing, or the volume thereof surrounded by the original (primary) boundaries of the three-dimensional object".

[0051] "Grain size" is calculated by the following formula:

Number

[0052] The "area weighted average particle size" is calculated by the following formula.

Number

[0053] v. Characteristics As described above, despite the possibility of being scrap-based, the novel aluminum alloy products described in this specification can achieve relatively high mechanical properties and / or good corrosion resistance.

[0054] In one embodiment, the novel aluminum alloy sheet product achieves a tensile yield strength (longitudinal axis direction) of at least 35 ksi. In another embodiment, the novel aluminum alloy sheet product achieves a tensile yield strength (longitudinal axis direction) of at least 36 ksi. In yet another embodiment, the novel aluminum alloy sheet product achieves a tensile yield strength (longitudinal axis direction) of at least 37 ksi. In another embodiment, the novel aluminum alloy sheet product achieves a tensile yield strength (longitudinal axis direction) of at least 38 ksi. In yet another embodiment, the novel aluminum alloy sheet product achieves a tensile yield strength (longitudinal axis direction) of at least 39 ksi. In another embodiment, the novel aluminum alloy sheet product achieves a tensile yield strength (longitudinal axis direction) of at least 40 ksi.

[0055] In one embodiment, the novel aluminum alloy sheet product achieves at least 3.0% elongation in the longitudinal direction (L). In another embodiment, the novel aluminum alloy sheet product achieves at least 3.5% elongation in the longitudinal direction (L). In yet another embodiment, the novel aluminum alloy sheet product achieves at least 4.0% elongation in the longitudinal direction (L). In another embodiment, the novel aluminum alloy sheet product achieves at least 4.5% elongation in the longitudinal direction (L). In yet another embodiment, the novel aluminum alloy sheet product achieves at least 5.0% elongation in the longitudinal direction (L).

[0056] In one embodiment, the novel aluminum alloy sheet product achieves at least equivalent ASTM G85 corrosion resistance compared to a conventional AA3004 sheet product of the same gauge.

[0057] vi. Product applications The novel aluminum alloy described herein can be used in various product applications, such as automotive or industrial sheet products. In one embodiment, the novel aluminum alloy is a sheet product used in the structure of a bantal trailer (e.g., a dry box or a refrigerated bantal trailer used in commercial transportation).

[0058] vii. Definitions "Worked aluminum alloy product" means an aluminum alloy product that is hot worked after casting, and includes rolled products (sheets or plates), forged products, and extruded products.

[0059] "Hot working", for example by hot rolling, means processing an aluminum alloy product at a high temperature, generally at least 121.1 °C (250 °F). Strain hardening is limited / avoided during hot working and generally distinguishes hot working from cold working.

[0060] "Cold working", for example by cold rolling, means processing an aluminum alloy product at a temperature not considered a hot working temperature, generally less than about 121.1 °C (250 °F) (e.g., at ambient temperature).

[0061] The definition of temper is according to ANSI H35.1 (2009) entitled "American National Standard Alloy and Temper Designation Systems for Aluminum" published by the Aluminum Association.

[0062] Strength and elongation are measured in accordance with ASTM E8 / E8M-21 and B557-15.

[0063] viii. Various matters These aspects and other aspects, advantages, and novel features of this new technology are described in part in the following description and will become apparent to those skilled in the art by consideration of the description herein, or may be learned by practicing one or more embodiments of the technology provided by this disclosure.

[0064] Among the advantages and improvements disclosed, other objects and advantages of the present invention will become apparent from the description herein. Specific embodiments of the present invention are disclosed herein, but it should be understood that the disclosed embodiments merely illustrate the present invention which may be embodied in various forms. Further, each of the examples provided in connection with the various embodiments of the present invention is intended to be illustrative and not limiting.

[0065] Throughout the specification and claims, the following words take the meanings specifically associated with this specification, unless the context clearly dictates otherwise. As used herein, the phrases "in one embodiment" and "in some embodiments" do not necessarily refer to the same embodiment, although they may. Further, the phrases "in another embodiment" and "in some other embodiments" as used herein do not necessarily refer to different embodiments, although they may. Thus, the various embodiments of the present invention may be readily combined without departing from the scope or spirit of the present invention.

[0066] In addition, as used herein, the term "or" is a comprehensive "or" functional word and is equivalent to the term "and / or" unless otherwise clearly indicated in the context. The term "based on" is not exclusive and can be based on additional elements not described unless otherwise clearly indicated in the context. Further, throughout this specification, the articles "a", "an", and "the" include plural meanings unless otherwise clearly indicated in the context. "In" includes the meanings of "in" and "on" unless otherwise clearly indicated in the context.

[0067] Although some embodiments of the present invention have been described, it should be understood that these embodiments are merely exemplary and not limiting, and that many variations may be apparent to those skilled in the art. Further, unless otherwise clearly required in the context, the various steps may be performed in any desired order, and any applicable steps may be added and / or removed.

Mode for Carrying Out the Invention

[0068] <Example 1> Several laboratory-scale aluminum alloy ingots were produced, and their compositions are shown in Table 1 below. Alloy XA39-XA46 is an experimental alloy. Aluminum alloy 3004 (AA3004) is a conventional alloy. Alloy 0437 is a conventional alloy sold under the same name by Arconic Corp.

Table 1

[0069] After casting, the alloy was conventionally scalped / peeled and homogenized. The alloy was then hot-rolled to an intermediate gauge and then cold-rolled to a final gauge of about 1 mm and then partially annealed to achieve the H291 temper.

[0070] As described in ANSI H35.1 (2009), the H temper is defined as "strain hardening type (for wrought products only)". According to ANSI H35.1, the H temper designation is applied to products whose strength has been increased by strain hardening, with or without supplementary heat treatment, resulting in some reduction in strength. After H, there are always two or more digits following. In other words, H-temper aluminum alloy products do not undergo precipitation hardening (e.g., solution heat treatment, followed by quenching, followed by natural or artificial aging), which is a heat treatment that increases strength.

[0071] The "H2 temper" is defined as "strain hardening and partial annealing". According to ANSI H35.1, the "H2 temper" designation is applied to products that have been strain hardened more than the desired final amount and then the strength has been reduced to the desired level by partial annealing. The number following this designation indicates the degree of strain hardening remaining after the product has been partially annealed. The H291 temper is a common H2 temper and is used to achieve specific minimum strength and elongation values for conventional alloys such as AA3004 and AA5052. See U.S. Patent Application Publication No. 2009 / 0159160.

[0072] The mechanical properties of the alloys in the H291 temper were tested. The results are shown in Table 2 below.

Table 2

[0073] Samples of the alloy were also tested for paint corrosion resistance. Specifically, the alloy was cleaned and then painted according to conventional aluminum alloy painting procedures. The painted alloy was then subjected to the MASTMAASIS test for 28 days in accordance with ASTM G85, Appendix A2, "Cyclic Acidified Salt For (Spray) Testing". Overall, the new alloy achieved similar or better corrosion characteristics compared to conventional AA3004. These results were unexpected considering the copper content of the new alloy, which exceeded generally 0.30 wt% Cu.

[0074] Also, a scrap friendliness evaluation was performed by comparing aluminum alloy scrap that is likely to be used to produce the alloy with the target alloy composition of each of alloys XA41-XA46. The most scrap-friendly alloys were XA42-43, each of which could likely be produced using 48 - 85% (XA42) or 48 - 96% (by weight) of common scrap such as brazing scrap and / or common 6xxx aluminum alloy scrap (e.g., AA6061 and / or AA6063 scrap).

[0075] Analysis of free silicon (free Si) and its effect on the properties was also performed. The amount of free silicon (free Si) was determined by estimating the amount of silicon occupied by iron (Fe), manganese (Mn), and chromium (Cr) in the alloy using the following formula. · Free Si (wt%) = Total Si (wt%) - ([Fe + Mn + Cr)] / 4) The results are shown in Table 3 below.

Table 3

[0076] As shown, alloys with an Mg:free Si ratio exceeding 1:1 and an Mg:free Si weight ratio close to 1.73:1 can achieve performance improvements. Alloys with lower silicon (e.g., about 0.77 wt% Si) and / or lower free Si can achieve lower mechanical properties. Additional copper can promote an increase in mechanical properties.

[0077] <Example 2> Based on the results of Example 1, alloy XA42-43 was down selected for plant-scale testing. The plant-scale XA42-43 alloy was processed to the H291 temper in generally the same manner as described in Example 1, but using industrial-scale ingots and rolling equipment. The composition and mechanical properties of the alloy are provided in Tables 4-5 below. The results of a conventional AA3004 sample are also shown below.

Table 4

Table 5

[0078] Repeatedly, despite having a composition useful for using scrap, the XA42-43 alloy achieves mechanical properties generally similar to those of conventional AA3004. The alloys produced in the plant (XA42-XA43) are also expected to achieve similar or better corrosion properties compared to conventional AA3004, considering the copper content of the new alloy. Thus, when made from scrap, the new alloy can achieve a greater cost advantage over conventional alloys while still achieving commercially valuable properties.

[0079] Microscopic analysis was also completed on the alloys of Example 2 in accordance with the "Microstructure Evaluation Procedure" described herein. The results are shown in Table 6 below.

Table 6

[0080] Although various embodiments of the present disclosure have been described in detail, it is clear that variations and modifications of those embodiments will occur to those skilled in the art. However, it should be clearly understood that such variations and modifications are within the spirit and scope of the present disclosure.

Claims

1. Aluminum alloy sheet products, 1.05 to 1.55% by weight of Si, 0.85 to 2.10% by weight of Mg, 0.15 to 0.75% by weight of Cu, 0.20 to 0.90 wt% Fe and 0.5 to 1.5% by weight of Mn, 0.01 to 0.15% by weight of Ti, A maximum of 0.4% by weight of Zn, With a maximum of 0.25% by weight of any of Cr, Zr, and V, It contains up to 0.05% by weight of Ni, The remainder consists of aluminum, accompanying elements, and impurities. The aforementioned aluminum alloy sheet product has a thickness of 0.4 to 4 mm. The aforementioned aluminum alloy sheet product is as follows: (i) Recrystallized grains of 50% by volume or less, (ii) at least 0.5% Mg ２ Si area percentage and, (iii) At least 0.5 particles per square micrometer with an average Mg ２ Si particle area and (iv) at least 0.5% of the component area percentage, (v) an aluminum alloy sheet product that achieves at least one of the following: an average component particle area of ​​at least 0.5 particles per square micrometer.

2. The aluminum alloy sheet product according to claim 1, wherein the aluminum alloy sheet product contains 1.15 to 1.40% by weight of Si.

3. The aluminum alloy sheet product according to claim 2, wherein the aluminum alloy sheet product contains 0.90 to 1.90% by weight of Mg.

4. The aluminum alloy sheet product according to claim 1, wherein the aluminum alloy sheet product contains 0.25 to 0.60% by weight of Cu.

5. The aluminum alloy sheet product according to claim 1, wherein the aluminum alloy sheet product contains 0.30 to 0.75% by weight of Fe.

6. The aluminum alloy sheet product according to claim 1, wherein the aluminum alloy sheet product contains 0.65 to 1.35% by weight of Mn.

7. The aluminum alloy sheet product according to any one of claims 1 to 6, wherein the aluminum alloy sheet product achieves 45 volume% or less of recrystallized grains, or 40 volume% or less of recrystallized grains, or 35 volume% or less of recrystallized grains, or 30 volume% or less of recrystallized grains, or 25 volume% or less of recrystallized grains, or 20 volume% or less of recrystallized grains, or 15 volume% or less of recrystallized grains.

8. The aluminum alloy sheet product contains at least 0.6%, or at least 0.7%, or at least 0.8%, or at least 0.9%, or at least 1.0%, or at least 1.1%, or at least 1.2% Mg ２ The aluminum alloy sheet product according to claim 7, which achieves a Si area percentage.

9. The aluminum alloy sheet product contains an average Mg of at least 0.75 particles per square micrometer, or at least 1.0 particles per square micrometer, or at least 1.25 particles per square micrometer, or at least 1.5 particles per square micrometer, or at least 1.75 particles per square micrometer, or at least 2.0 particles per square micrometer, or at least 2.25 particles per square micrometer, or at least 2.5 particles per square micrometer, or at least 2.75 particles per square micrometer, or at least 3.0 particles per square micrometer, or at least 3.25 particles per square micrometer, or at least 3.5 particles per square micrometer. ２ The aluminum alloy sheet product according to claim 7, which achieves a Si particle area.

10. The aluminum alloy sheet product according to claim 7, wherein the aluminum alloy sheet product achieves a component area percentage of at least 0.75%, or at least 1.0%, or at least 1.25%, or at least 1.5%, or at least 1.75%, or at least 2.0%, or at least 2.25%, or at least 2.50%, or at least 2.75%.

11. The aluminum alloy sheet product according to claim 7, wherein the aluminum alloy sheet product achieves an average component particle area of ​​at least 0.75 particles per square micrometer, or at least 1.0 particles per square micrometer, or at least 1.25 particles per square micrometer, or at least 1.5 particles per square micrometer, or at least 1.75 particles per square micrometer, or at least 2.0 particles per square micrometer, or at least 2.25 particles per square micrometer, or at least 2.5 particles per square micrometer, or at least 2.75 particles per square micrometer, or at least 3.0 particles per square micrometer, or at least 3.25 particles per square micrometer, or at least 3.5 particles per square micrometer, or at least 3.75 particles per square micrometer.

12. The aluminum alloy sheet product according to claim 7, wherein the aluminum alloy sheet product achieves a longitudinal axial (L) tensile yield strength of at least 35 ksi, or at least 36 ksi, or at least 37 ksi, or at least 38 ksi, or at least 39 ksi, or at least 40 ksi.

13. The aluminum alloy sheet product according to claim 7, wherein the aluminum alloy sheet product achieves an elongation in the longitudinal direction (L) of at least 3.0%, or at least 3.5%, or at least 4.0%, or at least 4.5%, or at least 5.0%.

14. The aluminum alloy sheet product according to claim 7, wherein the aluminum alloy sheet product achieves at least equivalent ASTM G85 corrosion resistance compared to a conventional AA3004 sheet product of equivalent gauge.

15. A method for creating aluminum alloy sheet products, (a) Producing aluminum alloy ingots from aluminum-based scrap, wherein the production is (i) to achieve a target ingot composition by mixing a first aluminum scrap material with another aluminum material, wherein the other aluminum material is at least one of (A) a second aluminum scrap material and (B) primary aluminum. (ii) Before or after the mixing step, the first aluminum scrap material and the other aluminum material are heated to produce a molten aluminum alloy, (iii) Casting the molten aluminum alloy into the aluminum alloy ingot, wherein the aluminum alloy ingot achieves the target ingot composition, and the target ingot composition is 1.05 to 1.55% by weight of Si, 0.85 to 2.10% by weight of Mg, 0.15 to 0.75% by weight of Cu, 0.20 to 0.90 wt% Fe and 0.5 to 1.5% by weight of Mn, 0.01 to 0.15% by weight of Ti, A maximum of 0.4% by weight of Zn, With a maximum of 0.25% by weight of any of Cr, Zr, and V, With a maximum of 0.05 wt% Ni, The remainder is aluminum, accompanying elements, and impurities, including casting and producing. (b) A method comprising processing the aluminum alloy ingot into an H-tempered sheet product having a thickness of 0.4 to 4.0 mm.

16. The method according to claim 15, wherein the treatment of the aluminum alloy ingot to an H-tempered sheet product comprises cold rolling to a final gauge and then partially annealing to achieve an H2 temper.

17. The aforementioned first aluminum scrap material is brazed scrap, used beverage cans The method according to claim 15 or 16, selected from the group consisting of (UBC) scrap and mixtures thereof.

18. The method according to claim 17, wherein at least 30% of the ingot contains the first aluminum scrap material, or at least 35% of the ingot contains the first aluminum scrap material, or at least 40% of the ingot contains the first aluminum scrap material, or at least 45% of the ingot contains the first aluminum scrap material, or at least 50% of the ingot contains the first aluminum scrap material, or at least 55% of the ingot contains the first aluminum scrap material, or at least 60% of the ingot contains the first aluminum scrap material, or at least 65% of the ingot contains the first aluminum scrap material.