Rapid annealing and quenching of aluminum alloy products to reduce roping or ludering

Abstract

A method for preparing a rolled aluminum alloy product that is resistant to roping or ludering effects during drawing or forming is described. The rolled aluminum alloy product is subjected to a rapid annealing and quenching process prior to the cold rolling process. The rapid annealing and quenching treatment described herein can replace batch annealing, which is commonly used to treat hot rolled aluminum alloy products prior to cold rolling, and can reduce processing time prior to cold rolling. The rapid annealing process can heat the rolled aluminum alloy product to a desired peak temperature very quickly, for example, within a few seconds to a few minutes, and can quench the annealed aluminum alloy product quickly, for example, within a few seconds to a few minutes.

Description

[Technical Field]

[0001] The present disclosure relates generally to metallurgy, and more particularly to aluminum alloys and reduced roping aluminum alloy products. In certain aspects, the present disclosure also provides methods of making such products. [Background technology]

[0002] Aluminum alloy products are desirable for use in several different applications, including those where strength and durability are particularly desirable. For example, aluminum alloys are commonly used in place of steel for automotive exterior panels and structural applications. Because aluminum alloys are generally approximately 2.8 times less dense than steel, the use of such materials can reduce vehicle weight and significantly improve vehicle fuel economy. Nevertheless, the use of currently available aluminum alloys in applications such as automobiles presents certain challenges.

[0003] One such challenge in skin applications relates to forming automotive parts with high elongation, improved surface quality (e.g., less roping), and excellent bendability or hemability for assembly of the automotive parts.

[0004] Roping is a strain-induced roughness or macroscopic surface roughening defect. Roping can be characterized by visible lines that can be several centimeters wide along the rolling direction. Roping can result from the material being stretched along the transverse direction. The distribution of peaks and valleys on the surface can limit the use of the material for outer panels in vehicle applications. Summary of the Invention

[0005] The term "embodiments" and similar terms are intended to broadly refer to all of the subject matter of this disclosure and the claims that follow. Statements containing these terms should be understood neither to limit the subject matter described herein nor to limit the meaning or scope of the claims that follow. The embodiments of the disclosure addressed herein are defined by the claims that follow, not by this Summary. This Summary is a broad overview of various aspects of the disclosure and introduces some of the concepts that are further described in the Detailed Description section below. This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used alone to determine the scope of the claimed subject matter. The subject matter should be understood by reference to the entire specification of this disclosure, any or all drawings, and appropriate portions of each claim.

[0006] In one aspect, provided herein are methods for preparing rolled aluminum alloy products. The rolled aluminum alloy products may be resistant to roping or Ludering effects during drawing or forming. The described methods may employ processes in which the aluminum alloy products are subjected to rapid annealing and quenching during processing to impart desired properties to the aluminum alloy product. In some cases, the desired properties may be imparted directly to the aluminum alloy product immediately after being subjected to rapid annealing and quenching. In some cases, the desired properties may be imparted to and / or carried over to the aluminum alloy product during subsequent processing, which may include, for example, a rolling process, a solution heat treatment process, and / or an aging process.

[0007] In one example, a method of this embodiment may include providing a rolled aluminum alloy product, subjecting the rolled aluminum alloy product to a rapid annealing process to produce an annealed aluminum alloy product, and subjecting the annealed aluminum alloy product to a quenching process to produce a quenched aluminum alloy product. Optionally, the rapid annealing process includes heating the rolled aluminum alloy product at a rate of up to 100°C / sec to a peak temperature of between 400°C and 575°C. Optionally, the quenching process includes cooling a portion of the annealed aluminum alloy at a rate of between -500°C / sec and -2°C / sec.

[0008] As noted above, additional processing may be performed after the rapid annealing and quenching processes. For example, some methods of this embodiment may include, or may further include, subjecting the quenched aluminum alloy product to a cold rolling process to produce a cold-rolled aluminum alloy product. As another example, some methods of this embodiment may include, or may further include, subjecting the aluminum alloy product to a solution heat treatment process. Optionally, methods of this embodiment may further include subjecting the aluminum alloy product to one or more of a cutting process, a forming process, and an aging process.

[0009] The rolled aluminum alloy product used in the method of the present embodiment can be any suitable aluminum alloy product. For example, the rolled aluminum alloy product can be a hot-rolled aluminum alloy product. Optionally, the rolled aluminum alloy product has a thickness of 1 mm to 8 mm. Optionally, the rolled aluminum alloy product can be a cold-rolled aluminum alloy product. Optionally, the rolled aluminum alloy product has a thickness of 0.5 mm to 5 mm. Optionally, the rolled aluminum alloy product is at least partially non-recrystallized or not recrystallized at all. Optionally, the annealed aluminum alloy product is at least partially recrystallized or fully recrystallized. In some examples, the rolled aluminum alloy product comprises a 6xxx series aluminum alloy or a 7xxx series aluminum alloy. In some examples, the rolled aluminum alloy product comprises a 2xxx series aluminum alloy or a 5xxx series aluminum alloy.

[0010] During or after quenching, the aluminum alloy product may include, possess, or exhibit beneficial properties. In some examples, it may be desirable to minimize or reduce the size of the Mg2Si particles in the product, such as by processing according to the methods described herein, because the presence of more or larger Mg2Si particles in the aluminum alloy product may result in lower yield strength or reduced ultimate elongation. Optionally, the quenched aluminum alloy product exhibits a yield stress of 70 MPa to 160 MPa. Optionally, the quenched aluminum alloy product exhibits a total elongation of 20% to 30%. In some examples, the quenched aluminum alloy product exhibits an average Mg2Si particle size of less than 2 μm. Optionally, the quenched aluminum alloy product exhibits an electrical conductivity of 40% IACS to 55% IACS. In some examples, electrical conductivity may be related to or correlated with the amount of dissolved solutes (e.g., alloying elements) in the aluminum alloy matrix, including Mg and Si, such that a relatively low electrical conductivity may indicate a relatively high amount of dissolved Mg and Si and a relatively low amount of MgSi particles in the aluminum alloy product. The dissolution of more Mg and Si into the aluminum matrix may also result in a reduction in the average grain size. Optionally, the quenched aluminum alloy product exhibits an average grain size of 10 μm to 35 μm.

[0011] In some examples, magnetic induction heating may be used for the rapid annealing process. Optionally, the rapid annealing process includes exposing the annealed aluminum alloy product to a quenching fluid after the heating process.

[0012] It will be understood that a rapid annealing process does not include a batch or coil annealing process, such as when an entire coil of rolled aluminum alloy is heated simultaneously, such as in a furnace. Similarly, it will be understood that a quenching process does not include a batch or coil cooling process, such as when the temperature of an entire coil of rolled aluminum alloy is reduced from a heating temperature, such as in an annealing furnace. In some examples, subjecting the rolled aluminum alloy product to a rapid annealing process includes uncoiling the rolled aluminum alloy. In some examples, the rapid annealing process is a continuous heating process in which only a portion of the rolled aluminum alloy product is heated at a time. Optionally, the quenching process is a continuous cooling process in which only a portion of the annealed aluminum alloy product is cooled at a time. In some examples, after the rapid annealing process and the quenching process, the rolled aluminum alloy is recoiled. Optionally, the rapid annealing process includes passing the rolled aluminum alloy product through a heating system at a speed of between 5 m / min and 600 m / min. Optionally, the quenching process comprises passing the annealed aluminum alloy product through a quenching system at a speed of between 5 m / min and 600 m / min.

[0013] The rapid annealing process described herein can be carried out quickly, such as within minutes or tens of minutes. In some examples, the rolled aluminum alloy product is subjected to temperatures above 100°C during the rapid annealing and quenching process for up to 5 minutes. Optionally, the method of this embodiment may further include holding the rolled aluminum alloy product within 20°C of the peak temperature for up to 1 minute prior to the quenching process.

[0014] Also provided by the present disclosure are aluminum alloy articles of manufacture prepared according to the methods described herein. In some examples, the aluminum alloy products include formed or drawn aluminum alloy sheet products comprising a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy, e.g., the formed or drawn aluminum alloy sheet product has a surface arithmetic mean height (Sa) of up to 10 μm. Optionally, the formed or drawn aluminum alloy sheet product may have a thickness of 1.00 mm to 3.5 mm. In some examples, the formed or drawn aluminum alloy sheet product comprises a 6xxx series aluminum alloy. Optionally, the formed or drawn aluminum alloy sheet product is free or substantially free of surface roping bands. In some examples, the formed or drawn aluminum alloy sheet product comprises a 5xxx series aluminum alloy. Optionally, the formed or drawn aluminum alloy sheet product is free or substantially free of surface Lueders bands.

[0015] Other objects and advantages will become apparent from the following detailed description of non-limiting examples.

[0016] This specification makes reference to the accompanying drawings, in which the use of like reference numerals in different drawings is intended to indicate like or similar components. [Brief explanation of the drawings]

[0017] [Figure 1] 1 provides a schematic diagram of an exemplary method for making a rolled aluminum alloy product. [Figure 2] 1 provides a schematic diagram of the temperature of an aluminum alloy product during preparation. [Figure 3] 1 provides a schematic diagram of rapid annealing and quenching of aluminum alloy production. [Figure 4A] 1 provides optical micrographs comparing the grain structure of samples subjected to rapid annealing and quenching with samples subjected to batch annealing. [Figure 4B] 1 provides optical micrographs comparing the grain structure of samples subjected to rapid annealing and quenching with samples subjected to batch annealing. [Figure 4C] 1 provides optical micrographs comparing the grain structure of samples subjected to rapid annealing and quenching with samples subjected to batch annealing. [Figure 4D] 1 provides optical micrographs comparing the grain structure of samples subjected to rapid annealing and quenching with samples subjected to batch annealing. [Figure 4E] 1 provides optical micrographs comparing the grain structure of samples subjected to rapid annealing and quenching with samples subjected to batch annealing. [Figure 5A] 1 provides optical micrographs comparing the precipitates of samples subjected to rapid annealing and quenching with samples subjected to batch annealing. [Figure 5B] 1 provides optical micrographs comparing the precipitates of samples subjected to rapid annealing and quenching with samples subjected to batch annealing. [Figure 5C] 1 provides optical micrographs comparing the precipitates of samples subjected to rapid annealing and quenching with samples subjected to batch annealing. [Figure 5D] 1 provides optical micrographs comparing the precipitates of samples subjected to rapid annealing and quenching with samples subjected to batch annealing. [Figure 5E] 1 provides optical micrographs comparing the precipitates of samples subjected to rapid annealing and quenching with samples subjected to batch annealing. [Figure 6] 1 provides scanning electron micrograph images comparing cross sections of samples subjected to rapid annealing and quenching using different techniques. [Figure 7] Data are provided showing the yield stress of samples subjected to rapid annealing and quenching as well as samples subjected to batch annealing. [Figure 8] Data are provided showing the total elongation for samples subjected to rapid annealing and quenching as well as for samples subjected to batch annealing. [Figure 9] 1 shows optical micrographs of cross sections of samples subjected to rapid annealing and quenching and batch annealing. [Figure 10] 50 μm wide photomicrograph images of samples subjected to rapid annealing and quenching or batch annealing are provided showing the amount and size of precipitates. [Figure 11] Data are provided showing the yield stress of annealed, cold rolled, and solution heat treated samples after room temperature aging (T4 temper condition) and artificial aging / paint bake (T81 temper condition). [Figure 12] Data is provided showing the total elongation of annealed, cold rolled, and solution heat treated samples after room temperature aging (T4 temper condition). [Figure 13] 1 provides electrical conductivity results for rolled aluminum alloy product samples subjected to rapid annealing and quenching. [Figure 14A] 10 provides micrograph images showing the grain structure through the thickness of samples annealed to different temperatures at different heating rates. [Figure 14B] 10 provides micrograph images showing the grain structure through the thickness of samples annealed to different temperatures at different heating rates. [Figure 15] A and B provide photomicrograph images of samples subjected to rapid annealing to different peak temperatures at different heating rates to show the amount and size of precipitates. [Figure 16] Electrical conductivity data is provided for samples subjected to rapid annealing to different peak temperatures. [Figure 17] Measured yield stresses of samples subjected to rapid annealing to different peak temperatures are provided. [Figure 18] Measured maximum axial strains of samples subjected to rapid annealing to different peak temperatures are provided. DETAILED DESCRIPTION OF THE INVENTION

[0018] Described herein is a method for preparing rolled aluminum alloy products that are resistant to the roping or luedering effect during drawing or forming. Roping refers to the development of a series of peaks and valleys of varying depths extending along the rolling direction when certain aluminum alloys, such as 6xxx or 7xxx series alloys, are transversely drawn. These peaks and valleys impart an undesirable surface appearance to the formed or drawn aluminum alloy product. Luedering is another undesirable surface characteristic that develops in certain aluminum alloys, such as 5xxx series alloys or other Mg-containing alloys, in which dislocations propagate in the aluminum crystal lattice during forming or drawing, resulting in luedering bands. This application provides processing techniques for rolled aluminum alloy products that limit roping or luedering by subjecting the rolled aluminum alloy product to a rapid annealing and quenching process prior to one or more cold rolling processes.

[0019] The rapid annealing and quenching processes described herein can replace batch annealing, which is commonly used to treat hot-rolled aluminum alloy products before cold rolling, and can shorten the processing time before cold rolling. For example, batch annealing can take many hours (e.g., 20 hours or more) to process and generally involves placing coils of hot-rolled aluminum alloy products in a furnace, heating them to an annealing temperature, holding for a period of time, and then allowing the coils to cool to ambient temperature. In contrast, the rapid annealing and quenching processes described herein can process coils of hot-rolled aluminum alloy products very quickly, for example, within one hour. The rapid annealing and quenching processes described herein can also, or instead, be used as an intermediate annealing process between cold rolling passes.

[0020] During rapid annealing and quenching, which can be considered a continuous annealing and quenching process, or in some cases a semi-continuous annealing and quenching process, the material is uncoiled (if coiled), passed through a rapid annealing system and a quenching system, and then optionally recoiled for subsequent processing. The rapid annealing process can heat the portion of the aluminum alloy product passing through the rapid annealing system to a desired peak temperature very quickly, such as within a few seconds to a few minutes. Following this, the quenching process can cool the portion of the annealed aluminum alloy product passing through the quenching system very quickly, such as within a few seconds to a few minutes. In contrast, a batch annealing process can take many hours to heat a coil of aluminum from ambient temperature to the annealing temperature and / or to cool the coil of aluminum to ambient temperature. Overall, the time that any portion of a rolled aluminum alloy product is subjected to annealing and quenching treatments according to the processes described herein can be as short as a few seconds or up to a few minutes (e.g., 10 minutes or less).

[0021] The rapid annealing and quenching process can modify the properties of rolled aluminum alloy products and result in various strengthening effects. For example, the rolled aluminum alloy product can be at least partially recrystallized, where deformed grains of aluminum are replaced with defect-free grains during the annealing process. In some examples, the rolled aluminum alloy product may be at least partially or not recrystallized at all before rapid annealing and quenching, and / or may be at least partially or fully recrystallized after rapid annealing and quenching. The rapid annealing and quenching process can result in the annealed and quenched aluminum alloy product having a finer grain structure (e.g., smaller average grain size) and a more uniform grain structure (e.g., narrower grain size distribution), as well as different mechanical or strength properties, compared to the aluminum alloy product before annealing and quenching. These properties can be transferred to the final product through subsequent processing such as cold rolling.

[0022] In some examples, after rapid annealing and quenching, the aluminum alloy product may exhibit an average grain size of 10 μm to 35 μm, such as 10 μm to 15 μm, 15 μm to 20 μm, 20 μm to 25 μm, 25 μm to 30 μm, or 30 μm to 35 μm. In some examples, after rapid annealing and quenching, the aluminum alloy product may exhibit a yield stress of 70 MPa to 160 MPa, such as 70 MPa to 80 MPa, 80 MPa to 90 MPa, 90 MPa to 100 MPa, 100 MPa to 110 MPa, 110 MPa to 120 MPa, 120 MPa to 130 MPa, 130 MPa to 140 MPa, 140 MPa to 150 MPa, or 150 MPa to 160 MPa. In some examples, after rapid annealing and quenching, the aluminum alloy product may exhibit a total elongation of 20% to 30%, such as 20% to 21%, 21% to 22%, 22% to 23%, 23% to 24%, 24% to 25%, 25% to 26%, 26% to 27%, 27% to 28%, 28% to 29%, or 29% to 30%.

[0023] Furthermore, rapid annealing and quenching treatments can help reduce the size of precipitates, such as Mg2Si particles, that may be present in the aluminum alloy product prior to annealing and quenching. In the case of hot-rolled aluminum alloy products, the precipitates may be very coarse-grained, but after rapid annealing and quenching treatments, a significant amount of the precipitates, or even all or nearly all of the precipitates, may dissolve into the aluminum matrix, affecting properties such as electrical conductivity (e.g., strength). Again, these properties may be propagated through subsequent treatments such as cold rolling. In some cases, the reduced precipitate size compared to hot-rolled aluminum alloy products allows the solution heat treatment process applied after cold rolling to be completed in a shorter time, allowing for increased line speeds for the solution treatment to improve throughput.

[0024] In some examples, after rapid annealing and quenching, the aluminum alloy product may exhibit an average precipitate grain size (e.g., Mg2Si grain size) of less than 2 μm, such as an equivalent circle diameter or cross-sectional length of less than 2 μm. In some examples, the average precipitate grain size can be 0.1 μm to 2 μm, such as 0.1 μm to 0.2 μm, 0.2 μm to 0.3 μm, 0.3 μm to 0.4 μm, 0.4 μm to 0.5 μm, 0.5 μm to 0.6 μm, 0.6 μm to 2 μm, 0.1 μm to 2 μm, 0.1 μm to 2 μm, 0.1 μm to 2 μm, 0.1 μm to 2 μm, 0.1 μm to 2 μm, 0.1 μm to 2 μm, 0.1 μm to 2 μm, 0.1 μm to 2 μm, 0.1 μm to 2 μm, 0.1 μm to 2 μm, 0.1 μm to 2 μm, 0.1 μm to 2 μm, 0.1 μm to 2 μm, 0.1 μm to 2 μm, 0.1 μm to 2 μm, 1.8 μm to 1.9 μm, or 1.9 μm to 2 μm. In some examples, after rapid annealing and quenching, the aluminum alloy product may exhibit an electrical conductivity of 40% IACS to 55% IACS, such as 40% IACS to 41% IACS, 41% IACS to 42% IACS, 42% IACS to 43% IACS, 43% IACS to 44% IACS, 44% IACS to 45% IACS, 45% IACS to 46% IACS, 46% IACS to 47% IACS, 47% IACS to 48% IACS, 48% IACS to 49% IACS, 49% IACS to 50% IACS, 50% IACS to 51% IACS, 51% IACS to 52% IACS, 52% IACS to 53% IACS, 53% IACS to 54% IACS, or 54% IACS to 55% IACS.

[0025] It will be understood that the rapid annealing and quenching processes described herein are distinct from, and generally do not include, batch annealing processes in which an entire coil of rolled aluminum product is subjected to annealing while still in the coil configuration. As noted above, rapid annealing and quenching processes offer numerous advantages over batch annealing, including shorter annealing and cooling times and different grain and precipitate structures. The combined rapid annealing and quenching process can help control various properties of the aluminum alloy product while limiting, reducing, or eliminating the effects of roping or ludering that may otherwise occur during forming or drawing of the processed aluminum alloy product. For example, the arithmetic mean surface height (Sa) can provide a measure to characterize the presence or absence of roping or ludering. The techniques described herein are useful for producing aluminum alloy products, such as 5xxx series, 6xxx series, or 7xxx series aluminum alloy sheet products, that, after forming or drawing, exhibit a surface arithmetic mean height (Sa) of up to 10 μm, such as up to 0.5 μm, up to 1 μm, up to 2 μm, up to 3 μm, up to 4 μm, up to 5 μm, up to 6 μm, up to 7 μm, up to 8 μm, up to 9 μm, or up to 10 μm. Definitions and Explanations

[0026] 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 to limit the subject matter described herein or to limit the meaning or scope of the claims that follow.

[0027] This description refers to alloys identified by AA numbers and other associated designations (e.g., "series" or "7xxx"). 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 Ingots" (both published by The Aluminum Association).

[0028] As used herein, a plate generally has a thickness greater than about 15 mm. For example, a plate may refer to an aluminum product having a thickness 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.

[0029] 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 have a thickness of about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm, or about 15 mm.

[0030] As used herein, sheet generally refers to an aluminum product having a thickness of less than about 4 mm. For example, the sheet can have a thickness of less than about 4 mm, less than about 3 mm, less than about 2 mm, less than about 1 mm, less than about 0.5 mm, or less than about 0.3 mm (e.g., about 0.2 mm).

[0031] Reference may be made herein to alloy tempers or alloy states. To understand the descriptions of the most commonly used alloy tempers, please refer to American National Standards (ANSI) H35 on Alloy and Temper Designation Systems. The F state or temper refers to the aluminum alloy as produced. The O state or temper refers to the aluminum alloy after annealing. The Hxx state or temper (also referred to herein as the H temper) refers to the non-heat-treated aluminum alloy after cold rolling, with or without heat treatment (e.g., annealing). Suitable H tempers include the HX1, HX2, HX3, HX4, HX5, HX6, HX7, HX8, or HX9 tempers. The T1 state or temper refers to the aluminum alloy after it has been cooled from hot working and naturally aged (e.g., at room temperature). The T2 state or temper refers to the aluminum alloy after it has been cooled from hot working, cold worked, and naturally aged. The T3 condition or temper refers to an aluminum alloy that has been solution heat treated, cold worked, and naturally aged. The T4 condition or temper refers to an aluminum alloy that has been solution heat treated and naturally aged. The T5 condition or temper refers to an aluminum alloy that has been cooled from hot working and artificially aged (at high temperature). The T6 condition or temper refers to an aluminum alloy that has been solution heat treated and artificially aged. The T7 condition or temper refers to an aluminum alloy that has been solution heat treated and artificially overaged. The T8x condition or temper refers to an aluminum alloy that has been solution heat treated, cold worked, and artificially aged. The T9 condition or temper refers to an aluminum alloy that has been solution heat treated, artificially aged, and cold worked. The W condition or temper refers to an aluminum alloy after solution heat treatment.

[0032] As used herein, the terms "cast metal product," "cast product," "cast aluminum alloy product," and the like are used interchangeably and refer to products produced by direct chill casting (including direct chill co-casting) or semi-continuous casting, continuous casting (including, for example, by use of a twin belt caster, twin roll caster, block caster, or any other continuous caster), electromagnetic casting, hot top casting, or any other casting process.

[0033] As used herein, the meaning of "room temperature" can include temperatures from about 15° C. to about 30° C., such as about 15° C., about 16° C., about 17° C., about 18° C., about 19° C., about 20° C., about 21° C., about 22° C., about 23° C., about 24° C., about 25° C., about 26° C., about 27° C., about 28° C., about 29° C., or about 30° C. As used herein, the meaning of "ambient conditions" can include temperatures about room temperature, relative humidity of about 20% to about 100%, and atmospheric pressure of about 975 millibars (mbar) to about 1050 mbar. For example, the relative humidity may be about 20%, about 21%, about 22%, about 23%, about 24%, about 25%, about 26%, about 27%, about 28%, about 29%, about 30%, about 31%, about 32%, about 33%, about 34%, about 35%, about 36%, about 37%, about 38%, about 39%, about 40%, about 41%, about 42%, about 43%, about 44%, about 45%, about 46%, about 47%, about 48%, about 49%, about 50%, about 51%, about 52%, about 53%, about 54%, about 55%, about 56%, about 57%, about 58%, about 59%, about 60%, about 61% , about 62%, about 63%, about 64%, about 65%, about 66%, about 67%, about 68%, about 69%, about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84%, about 85%, about 86%, about 87%, about 88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about 98%, about 99%, about 100%, or anywhere therebetween. For example, the air pressure can be about 975 mbar, about 980 mbar, about 985 mbar, about 990 mbar, about 995 mbar, about 1000 mbar, about 1005 mbar, about 1010 mbar, about 1015 mbar, about 1020 mbar, about 1025 mbar, about 1030 mbar, about 1035 mbar, about 1040 mbar, about 1045 mbar, about 1050 mbar, or anywhere therebetween.

[0034] All ranges disclosed herein should be understood to encompass all subranges subsumed therein. For example, a stated range of "1 to 10" should be considered to encompass all subranges between the minimum value of 1 and the maximum value of 10, 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). Unless otherwise stated, the expression "maximum," when referring to a compositional amount of an element, means that the element is optional and includes a zero percent composition of that particular element. Unless otherwise stated, all compositional percentages are weight percent (wt.%).

[0035] As used herein, the meanings of "a," "an," and "the" include singular and plural references unless the context clearly dictates otherwise.

[0036] In the following examples, aluminum alloy products and their components may be described in terms of their elemental composition in weight percent (wt.%), with the maximum wt.% of the sum of all impurities in each alloy being 0.15%, with the balance being aluminum.

[0037] Accompanying elements (e.g., grain refiners and deoxidizers), or other additives, may be present in the present invention and may themselves add other properties without deviating from or significantly altering the alloys described herein or the properties of the alloys described herein.

[0038] Inevitably, impurities (including materials or elements) may be present in small amounts in the alloy due to the inherent properties of aluminum or leaching from contact with processing equipment. As explained, some alloys may contain up to about 0.25 wt.% of any element in addition to the alloying elements, incidental elements, and inevitable impurities. Method for producing alloys and aluminum alloy products

[0039] The aluminum alloy products described herein may be prepared using any suitable method, for example, by casting, homogenizing, hot rolling, annealing, cold rolling, heat treating, forming, etc. the aluminum alloy to produce the aluminum alloy product.

[0040] FIG. 1 shows an overview of an exemplary method for producing an aluminum alloy product. The method of FIG. 1 begins at 105, where an aluminum alloy 106 is cast to form a cast aluminum alloy product 107, such as an ingot or other cast product. At 110, the cast aluminum alloy product 107 is homogenized to form a homogenized aluminum alloy product 111. At 115, the homogenized aluminum alloy product 111 is subjected to one or more hot rolling passes. The hot rolled aluminum alloy product may optionally be coiled and subjected to a batch annealing process (not shown in FIG. 1 ) or other annealing processes described herein. At 120, the homogenized aluminum alloy product 111 is subjected to one or more hot rolling passes and / or one or more cold rolling passes to form a rolled aluminum alloy product 112. The rolled aluminum alloy product 112 may correspond to an aluminum alloy article (e.g., an aluminum alloy plate, an aluminum alloy shade, or an aluminum alloy sheet, etc.) As described in further detail herein, the hot rolled aluminum alloy product may be subjected to rapid annealing and quenching processes prior to cold rolling or between multiple cold rolling steps, and such treatments are not shown in Figure 1. Optionally, the rolled aluminum alloy product 112 is subjected to additional processing steps, as described below, to form an aluminum alloy article.

[0041] Non-limiting examples of casting processes include a direct chill (DC) casting process or a continuous casting (CC) process. For example, FIG. 1 shows a schematic diagram of a DC casting process at 105, although other casting processes can be used. A continuous casting system can include a pair of movable opposing casting surfaces (e.g., movable opposing belts, rolls, or blocks), a casting cavity between the pair of movable opposing casting surfaces, and a molten metal injector. The molten metal injector can have an end opening through which molten metal can exit the molten metal injector and be injected into the casting cavity.

[0042] Cast aluminum alloy products (e.g., cast ingots, cast slabs, or other cast products) can be processed by any desired technique. Optionally, this processing step can be used to prepare rolled aluminum alloy products (e.g., aluminum alloy sheets). Examples of optional processing steps include, but are not limited to, homogenizing, hot rolling, cold rolling, annealing, solution heat treatment, and pre-aging.

[0043] In the homogenization step, the cast product may be heated to a temperature ranging from about 400°C to about 600°C. For example, the cast product may be heated to a temperature of about 400°C, about 410°C, about 420°C, about 430°C, about 440°C, about 450°C, about 460°C, about 470°C, about 480°C, about 490°C, about 500°C, about 510°C, about 520°C, about 530°C, about 540°C, about 550°C, about 560°C, about 570°C, about 580°C, about 590°C, or about 600°C. 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 for the homogenization step (including the heating and soaking stages) may be up to 24 hours. For example, the homogenization step can involve heating and soaking the product to a maximum of 500°C-600°C for a total time of up to 18 hours. Optionally, the homogenization step can involve heating and soaking the product to less than 490°C for a total time of more than 18 hours. In some cases, the homogenization step includes multiple processes. In some non-limiting examples, the homogenization step involves heating the cast product to a first temperature for a first time, followed by heating to a second temperature for a second time. For example, the cast product can be heated to about 465°C for about 3.5 hours, and then to about 480°C for about 6 hours.

[0044] Following the homogenization step, a hot rolling step can optionally be performed. Before hot rolling begins, the homogenized product can be cooled to a temperature of 300°C to 450°C. For example, the homogenized product can be cooled to a temperature of 325°C to 425°C or 350°C to 400°C. The homogenized product is then hot rolled at a temperature of 300°C to 450°C to form a hot rolled plate, hot rolled sheet, or hot rolled sheet having a gauge of 3 mm to 200 mm (e.g., 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm, or anywhere therebetween).

[0045] Optionally, the cast product may be a continuously cast product that may be cooled to a temperature of 300° C. to 450° C. For example, the continuously cast product may be cooled to a temperature of 325° C. to 425° C. or 350° C. to 400° C. The continuous cast product is then hot rolled at a temperature of 300°C to 450°C to form hot rolled plate, hot rolled shade, or hot rolled sheet having a gauge of 3 mm to 200 mm (e.g., 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm, or anywhere therebetween). During hot rolling, the temperature and other operating parameters can be controlled so that the intermediate hot rolled product exiting the hot rolling mill has a temperature of 470°C or less, 450°C or less, 440°C or less, or 430°C or less.

[0046] The cast, homogenized, or hot-rolled product can optionally be cold rolled using a cold rolling mill to produce a thinner product (e.g., cold-rolled sheet). The cold-rolled product can have a gauge of about 0.5 to 10 mm, for example, about 0.7 to 6.5 mm. Optionally, the cold-rolled product can have a gauge of 0.5 mm, 1.0 mm, 1.5 mm, 2.0 mm, 2.5 mm, 3.0 mm, 3.5 mm, 4.0 mm, 4.5 mm, 5.0 mm, 5.5 mm, 6.0 mm, 6.5 mm, 7.0 mm, 7.5 mm, 8.0 mm, 8.5 mm, 9.0 mm, 9.5 mm, or 10.0 mm. Cold rolling can be performed to produce a final gauge thickness that represents a gauge reduction of up to 85% (e.g., up to 10%, up to 20%, up to 30%, up to 40%, up to 50%, up to 60%, up to 70%, up to 80%, or up to 85%) compared to the gauge before cold rolling began. Optionally, an intermediate annealing step can be performed during the cold rolling steps. For example, a first cold rolling process can be applied, followed by an annealing process (intermediate annealing), followed by a second cold rolling process. The intermediate annealing step can be performed at a temperature between about 300°C and about 450°C (e.g., about 310°C, about 320°C, about 330°C, about 340°C, about 350°C, about 360°C, about 370°C, about 380°C, about 390°C, about 400°C, about 410°C, about 420°C, about 430°C, about 440°C, or about 450°C). In some cases, the intermediate annealing step includes multiple processes. In some non-limiting examples, the intermediate annealing step includes heating the partially cold-rolled product to a first temperature for a first time period, followed by heating to a second temperature for a second time period. For example, the partially cold-rolled product can be heated to about 410°C for about 1 hour, and then to about 330°C for about 2 hours. As described elsewhere in this application, other intermediate annealing processes, such as rapid annealing and quenching, can be applied.

[0047] The cast, homogenized, or rolled product can then optionally undergo a solution heat treatment step. The solution heat treatment step can be any suitable treatment of the product that results in solutionization of the soluble particles. The cast, homogenized, or rolled product can be heated to a peak metal temperature (PMT) of up to 590°C (e.g., 400°C to 590°C) and soaked at the PMT for a period of time to form a hot product. For example, the cast, homogenized, or rolled product can be soaked at 480°C for a soak time of up to 30 minutes (e.g., 0 seconds, 60 seconds, 75 seconds, 90 seconds, 5 minutes, 10 minutes, 20 minutes, 25 minutes, or 30 minutes). After heating and soaking, the hot product is rapidly cooled at a rate of greater than 200°C / second to a temperature of 500 to 200°C to form a heat-treated product. In one example, the hot product is cooled to a temperature of 450°C to 200°C at a quenching rate of greater than 200°C / sec. Optionally, in other cases, the cooling rate can be faster. Optionally, in other cases, the temperature can be lower. In one example, the hot product is cooled to a temperature of 450°C to 200°C at a quenching rate of greater than 200°C / sec.

[0048] After quenching, the heat-treated product can optionally be pre-aged by reheating before being wound. Pre-aging can be performed at a temperature of about 70°C to about 125°C for a period of up to 6 hours. For example, pre-aging can be performed at a temperature of about 70°C, about 75°C, about 80°C, about 85°C, about 90°C, about 95°C, about 100°C, about 105°C, about 110°C, about 115°C, about 120°C, or about 125°C. Optionally, pre-aging can be performed for about 30 minutes, about 1 hour, about 2 hours, about 3 hours, about 4 hours, about 5 hours, or about 6 hours. Pre-aging can be performed by passing the heat-treated product through a heating device, such as a device that generates radiant heat, convective heat, induction heat, infrared heat, or the like.

[0049] The cast products described herein can be used to produce products in the form of sheets, plates, or other suitable products. For example, plates comprising the products described herein can be prepared by treating an ingot in a homogenization step or by casting the product in a continuous caster, followed by a hot rolling step. In the hot rolling step, the cast product can be hot rolled to a thickness gauge of 200 mm or less (e.g., about 10 mm to about 200 mm). For example, the cast product can be hot rolled into plates having a final gauge thickness of about 10 mm to about 175 mm, about 15 mm to about 150 mm, about 20 mm to about 125 mm, about 25 mm to about 100 mm, about 30 mm to about 75 mm, or about 35 mm to about 50 mm. In some cases, the plates can be rolled into thinner metal products (e.g., sheets).

[0050] Methods of using the disclosed aluminum alloy products The aluminum alloy products described herein can be used in automotive applications and other transportation applications, including aircraft and railroad applications. For example, the disclosed aluminum alloy products can be used to prepare automotive structural components such as bumpers, side beams, roof beams, cross beams, pillar reinforcements (e.g., A-pillars, B-pillars, and C-pillars), inner panels, outer panels, side panels, inner hoods, outer hoods, or trunk lid panels. The aluminum alloy products and methods described herein can also be used in aircraft or railroad vehicle applications to prepare, for example, outer and inner panels.

[0051] The aluminum alloy products and methods described herein can also be used in electronics applications. For example, the aluminum alloy products and methods described herein can be used to prepare housings for electronic devices, including mobile phones and tablet computers. In some examples, the aluminum alloy products can be used to prepare housings for mobile phones (e.g., smartphones), tablet bottom chassis, and outer casings for other portable electronics.

[0052] Methods for treating metals and metal alloys Described herein are methods for processing metals and metal alloys, including, inter alia, aluminum, aluminum alloys, magnesium, magnesium alloys, magnesium composites, and steel, as well as the resulting processed metals and metal alloys. In some examples, the metal used in the methods described herein includes an aluminum alloy, such as a 1xxx series aluminum alloy, a 2xxx series aluminum alloy, a 3xxx series aluminum alloy, a 4xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, a 7xxx series aluminum alloy, or an 8xxx series aluminum alloy. In some examples, the material used in the methods described herein includes a non-ferrous material, such as aluminum, aluminum alloy, magnesium, magnesium-based materials, magnesium alloys, magnesium composites, titanium, titanium-based materials, titanium alloys, copper, copper-based materials, composite materials, sheets used in composite materials, or any other suitable metal, non-metal, or combination of materials. Monolithic and non-monolithic materials, such as roll-bonded materials, clad alloys, clad layers, composite materials (e.g., without limitation, carbon fiber-containing materials), or various other materials, are also useful in the methods described herein. In some examples, iron-containing aluminum alloys are useful in the methods described herein.

[0053] As a non-limiting example, exemplary 1xxx series aluminum alloys for use in the methods described herein may include AAA1100, AAA1100A, AAA1200, AA1200A, AA1300, AAA1110, AAA1120, AAA1230, AA1230A, AA1235, AA1435, AA1145, AA1345, AA1445, AAA1150, AA1350, AA1350A, AA1450, AA1370, AA1275, AAA1185, AA1285, AA1385, AAA1188, AAA1190, AA1290, AAA1193, AAA1198, or AAA1199.

[0054] Non-limiting examples of 2xxx series aluminum alloys for use in the methods described herein include AA2001, AA2002, AA2004, AA2005, AA2006, AA2007, AA2007A, AA2007B, AA2008, AA2009, AA2010, AA2011, AA2011A, AA2111, AA2111A, AA2111B, AA2012, AA2013, AA2014, AA2015, AA2016, AA2017, AA2018, AA2019, AA2020, AA2021, AA2022, AA2023, AA2024, AA2025, AA2026, AA2027, AA2028, AA2029, AA2030, AA2031, AA2032, AA2033, AA2034, AA2035, AA2036, AA2037, AA2038, AA2039, AA2040, AA2041, AA2042, AA2043, AA2044, AA2045, AA2046, AA2047, AA2048, AA2049, AA2050, AA2051, AA2052, AA2053, AA2054, AA2055, AA2056, AA2057, AA2058, AA2059, AA2060, AA2061, AA2062, AA2063, AA2064, AA 4, AA2014A, AA2214, AA2015, AA2016, AA2017, AA2017A, AA2117, AA2018, AA2218, AA2618, AA2618A, AA2219 , AA2319, AA2419, AA2519, AA2021, AA2022, AA2023, AA2024, AA2024A, AA2124, AA2224, AA2224A, AA2324, A A2424, AA2524, AA2624, AA2724, AA2824, AA2025, AA2026, AA2027, AA2028, AA2028A, AA2028B, AA2028C, AA 2029, AA2030, AA2031, AA2032, AA2034, AA2036, AA2037, AA2038, AA2039, AA2139, AA2040, AA2041, AA2044 , AA2045, AA2050, AA2055, AA2056, AA2060, AA2065, AA2070, AA2076, AA2090, AA2091, AA2094, AA2095, AA2195, AA2295, AA2196, AA2296, AA2097, AA2197, AA2297, AA2397, AA2098, AA2198, AA2099, or AA2199.

[0055] Non-limiting examples of 3xxx series aluminum alloys for use in the methods described herein include AA3002, AA3102, AA3003, AA3103, AA3103A, AA3103B, AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, AA3005A, AA3105, AA3105A, AA3105B, AA3 AA3013, AA3014, AA3015, AA3016, AA3017, AA3019, AA3020, AA3021, AA3025, AA3026, AA3030, AA3130, or AA3065.

[0056] Non-limiting exemplary 4xxx series aluminum alloys for use in the methods described herein may include AA4004, AA4104, AA4006, AA4007, AA4008, AA4009, AA4010, AA4013, AA4014, AA4015, AA4015A, AA4115, AA4016, AA4017, AA4018, AA4019, AA4020, AA4021, AA4026, AA4032, AA4043, AA4043A, AA4143, AA4343, AA4643, AA4943, AA4044, AA4045, AA4145, AA4145A, AA4046, AA4047, AA4047A, or AA4147.

[0057] Non-limiting examples of 5xxx series aluminum alloys for use in the methods described herein include AA5182, AA5183, AA5005, AA5005A, AA5205, AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110, AA5110A, AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A, AA511 9, AA5119A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5040, AA5140, AA5041, AA5042, AA5043, AA50 49, AA5149, AA5249, AA5349, AA5449, AA5449A, AA5050, AA5050A, AA5050C, AA5150, AA5051, AA5051A, AA5151, AA5251, A A5251A, AA5351, AA5451, AA5052, AA5252, AA5352, AA5154, AA5154A, AA5154B, AA5154C, AA5254, AA5354, AA5454, AA55 54, AA5654, AA5654A, AA5754, AA5854, AA5954, AA5056, AA5356, AA5356A, AA5456, AA5456A, AA5456B, AA5556, AA5556A , AA5556B, AA5556C, AA5257, AA5457, AA5557, AA5657, AA5058, AA5059, AA5070, AA5180, AA5180A, AA5082, AA5182, AA5083, AA5183, AA5183A, AA5283, AA5283A, AA5283B, AA5383, AA5483, AA5086, AA5186, AA5087, AA5187, or AA5088.

[0058] Non-limiting examples of 6xxx series aluminum alloys for use in the methods described herein include AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA6206, AA630 6, AA6008, AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, A A6016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027, AA602 8, AA6031, AA6032, AA6033, AA6040, AA6041, AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA6053, A A6055, AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560, AA6660, AA6061, AA6061A, AA62 61, AA6361, AA6162, AA6262, AA6262A, AA6063, AA6063A, AA6463, AA6463A, AA6763, AA6963, AA6064, AA6064A, AA6065, AA6066, AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A, AA6182, AA6091, or AA6092.

[0059] Non-limiting examples of 7xxx series aluminum alloys for use in the methods described herein include AA7011, AA7019, AA7020, AA7021, AA7039, AA7072, AA7075, AA7085, AA7108, AA7108A, AA7015, AA7017, AA7018, AA7019A, AA7024, AA7025, AA7 028, AA7030, AA7031, AA7033, AA7035, AA7035A, AA7046, AA7046A, AA7003, AA7004, AA7005, AA 7009, AA7010, AA7011, AA7012, AA7014, AA7016, AA7116, AA7122, AA7023, AA7026, AA7029, AA71 29, AA7229, AA7032, AA7033, AA7034, AA7036, AA7136, AA7037, AA7040, AA7140, AA7041, AA704 9, AA7049A, AA7149, AA7204, AA7249, AA7349, AA7449, AA7050, AA7050A, AA7150, AA7250, AA705 AA7076, AA7178, AA7278, AA7278A, AA7081, AA7181, AA7185, AA7090, AA7093, AA7095, or AA7099.

[0060] Non-limiting examples of 8xxx series aluminum alloys for use in the methods described herein include AA8005, AA8006, AA8007, AA8008, AA8010, AA8011, AA8011A, AA8111, AA8211, AA8112, AA8014, AA8015, AA8016, AA8017, AA8018, AA8019, AA8021 , AA8021A, AA8021B, AA8022, AA8023, AA8024, AA8025, AA8026, AA8030, AA8130, AA8040, AA8050, AA8150, AA8076, AA8076A, AA8176, AA8077, AA8177, AA8079, AA8090, AA8091, or AA8093.

[0061] 2 provides a plot showing exemplary temperatures of a cast aluminum alloy product during various stages of the manufacturing process, according to some embodiments. As part of the initial casting stage 205, in which the molten aluminum alloy is formed into an ingot, casting, or other solid or metal product, the molten aluminum alloy may be cooled and / or solidified by a process that includes quenching or cooling the metal by exposing the aluminum alloy to water or an aqueous solution, for example, in a vertical semi-continuous casting process or in a continuous casting process that includes quenching immediately after casting.

[0062] Following the casting stage 205, the aluminum alloy product may be subjected to a homogenization process 210, in which the aluminum alloy is heated to a temperature below its melting or solidus temperature. Optionally, the aluminum alloy product is heated to a temperature at which the base aluminum metal and any alloying elements form a solid solution.

[0063] Following the homogenization process 210, the aluminum alloy product may be subjected to one or more processes that may form a desired microcrystalline structure within the aluminum alloy product, for example, while elongating the aluminum alloy product. Such processes may correspond to, for example, hot rolling 215 and / or cold rolling 220, such as to form a shaft, plate, or sheet from an aluminum alloy ingot or other casting or aluminum alloy product.

[0064] In some embodiments, exposing the elevated temperature aluminum alloy product to a solution, such as water, an aqueous solution, or a vapor phase solution, in a quenching or cooling process may be used to reduce the temperature of the aluminum alloy product to a temperature that is desirable or useful for subsequent processing. For example, exposing the aluminum alloy product to water or an aqueous solution may be useful for cooling the aluminum alloy product between the hot rolling process 215 and the cold rolling process 230.

[0065] Following the hot rolling process 215 and / or the optional cold rolling process 220, the aluminum alloy product may be subjected to a rapid annealing and quenching process 225, in which the aluminum alloy product is rapidly heated, optionally held at or near a peak temperature for a short period of time, and then rapidly cooled to produce an annealed aluminum alloy product with at least partial recrystallization of the aluminum alloy grains. It will be understood that in some cases, the optional cold rolling process 220 is not used, and the aluminum alloy product undergoes the rapid annealing and quenching process 225 following the hot rolling process 215, optionally without bringing the aluminum alloy product all the way back to ambient temperature, prior to cold rolling. In some examples, the optional cold rolling process 220 is performed at ambient or room temperature, or at a temperature above ambient or room temperature. In some examples, the aluminum alloy product is at ambient or room temperature, or at a temperature above ambient or room temperature, prior to the rapid annealing and quenching process 225. For example, after hot rolling, the aluminum alloy product may not be cooled completely to ambient or room temperature, or may be heated by the cold rolling process 220, or the cold rolling process 220 may be performed at a temperature above ambient or room temperature. If the aluminum alloy product is at a temperature above ambient or room temperature, less heat may need to be added to the aluminum alloy product during the rapid annealing and quenching process 225 to achieve the target annealing temperature than if the aluminum alloy product was at ambient or room temperature.

[0066] After the rapid annealing and quenching process 225, the aluminum alloy product is subjected to a cold rolling process 230. Further details of the rapid annealing and quenching process 225 are described herein. If the optional cold rolling process 220 is used, a second rapid annealing and quenching process can optionally be used, such as before the optional cold rolling process 220. In some examples, the cold rolling process 230 is performed at ambient or room temperature or at a temperature above ambient or room temperature.

[0067] A variety of different peak temperatures can be used for the rapid annealing processes described herein. Typically, peak temperatures between 400°C and 575°C can be used. Optionally, the peak temperature can be between 400°C and 405°C, 405°C and 410°C, 410°C and 415°C, 415°C and 420°C, 420°C and 425°C, 425°C and 430°C, 430°C and 435°C, 435°C and 440°C, 440°C and 445°C, 445°C and 450°C, 450°C and 455°C, 455°C and 460°C, 460°C and 465°C, 465°C and 470°C, 470°C and 475°C, 475°C and 480°C, 480°C and 480°C. The peak temperature may be 5°C, 485°C to 490°C, 490°C to 495°C, 495°C to 500°C, 505°C to 510°C, 510°C to 515°C, 515°C to 520°C, 520°C to 525°C, 525°C to 530°C, 530°C to 535°C, 535°C to 540°C, 540°C to 545°C, 545°C to 550°C, 550°C to 555°C, 555°C to 460°C, 560°C to 465°C, 565°C to 570°C, or 570°C to 575°C. It will be appreciated that the peak temperature used may vary depending on the aluminum alloy.

[0068] The aluminum alloy product may optionally be subjected to a solution heat treatment process 235, in which the temperature of the aluminum alloy product is raised to and held above a threshold temperature, such as a temperature at which precipitated components within the aluminum alloy product dissolve into solid solution. At the end of the solution heat treatment 235, the aluminum alloy product may be subjected to a quenching process 240, in which the dissolved components are locked in place by rapidly lowering the temperature of the aluminum alloy via a quenching process. Such a quenching process 240 may include exposing the aluminum alloy product to a solution, such as water, an aqueous solution, or a quenching solution comprising a gas solution. In some examples, the rapid annealing and quenching process 225 may allow for a shorter hold time during the solution heat treatment process 235 compared to a solution heat treatment of an aluminum alloy product that is not subjected to the rapid annealing and quenching process 225.

[0069] In embodiments, the process outlined in FIG. 2 may be carried out individually or as part of one or more continuous processing lines in which the aluminum alloy product may be transported between processing stages as a coil, film, or web of material. The aluminum alloy product may be transported between stages, for example, by rolling the aluminum alloy product under tension on or between one or more rollers, or by transporting the aluminum alloy product on one or more conveyors. Additionally, other stages not explicitly identified may be included before, between, and / or after any of the stages identified in FIG. 2. Other exemplary stages include, but are not limited to, a cleaning stage, a chemical treatment stage, or a finishing stage. By way of example, a finishing stage may correspond to a surface anodizing stage, a powder coating stage, a painting stage, a printing stage, etc. Other exemplary stages include cutting, blanking, and forming processes. In some cases, the aluminum alloy product may be transported between stages by rolling the aluminum alloy product into a coil, transporting the coil to the next processing stage, and unwinding the aluminum alloy product for further processing.

[0070] 3 provides a schematic diagram of an exemplary rapid annealing and quenching system 300 for processing an aluminum alloy product 305. The aluminum alloy product 305 may include any suitable aluminum alloy product, such as a hot-rolled aluminum alloy product or a cold-rolled aluminum alloy product. The aluminum alloy product 305 may include any aluminum alloy described herein, but may particularly include a 2xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy. The aluminum alloy product 305 may have any suitable thickness, such as a thickness of 1 mm to 8 mm, or a thickness of 0.5 mm to 5 mm.In some examples, the thickness of the aluminum alloy product may be 1.0 mm to 1.1 mm, 1.1 mm to 1.2 mm, 1.2 mm to 1.3 mm, 1.3 mm to 1.4 mm, 1.4 mm to 1.5 mm, 1.5 mm to 1.6 mm, 1.6 mm to 1.7 mm, 1.7 mm to 1.8 mm, 1.8 mm to 1.9 mm, 1.9 mm to 2.0 mm, 2.0 mm to 2.1 mm, 2.1 mm to 2.2 mm, 2.2 mm to 2.3 mm, 2.3 mm to 2.4 mm, 2.4 mm to 2.5 mm, 2.5 mm to 2.6 mm, 2.6mm~2.7mm, 2.7mm~2.8mm, 2.8mm~2.9mm, 2.9mm~3.0mm, 3.0mm~3.1mm, 3.1mm~3.2mm, 3.2mm~3.3mm, 3.3mm~3.4mm, 3.4mm~3.5mm, 3 .5mm~3.6mm, 3.6mm~3.7mm, 3.7mm~3.8mm, 3.8mm~3.9mm, 3.9mm~4.0mm, 4.0mm~4.1mm, 4.1mm~4.2mm, 4.2mm~4.3mm, 4.3mm~4.4mm, 4. 4mm~4.5mm, 4.5mm~4.6mm, 4.6mm~4.7mm, 4.7mm~4.8mm, 4.8mm~4.9mm, 4.9mm~5.0mm, 5.0mm~5.1mm, 5.1mm~5.2mm, 5.2mm~5.3mm, 5.3 mm~5.4mm, 5.4mm~5.5mm, 5.5mm~5.6mm, 5.6mm~5.7mm, 5.7mm~5.8mm, 5.8mm~5.9mm, 5.9mm~6.0mm, 6.0mm~6.1mm, 6.1mm~6.2mm, 6.2m m~6.3mm, 6.3mm~6.4mm, 6.4mm~6.5mm, 6.5mm~6.6mm, 6.6mm~6.7mm, 6.7mm~6.8mm, 6.8mm~6.9mm, 6.9mm~7.0mm, 7.0mm~7.1mm, 7.1mm ~7.2mm, 7.2mm~7.3mm, 7.3mm~7.4mm, 7.4mm~7.5mm, 7.5mm~7.6mm, 7.6mm~7.7mm, 7.7mm~7.8mm, 7.8mm~7.9mm, or 7.9mm~8.0mm.

[0071] Rapid annealing and quenching system 300 can include separate annealing system 310 and quenching system 315, or can include a combined annealing system and quenching system. Rapid annealing system 310 can include any suitable annealing system capable of raising the temperature of the aluminum alloy product to a peak temperature at a rapid rate, such as up to about 100°C / sec. Examples of heating rates available for rapid annealing systems include 1°C / sec to 5°C / sec, 5°C / sec to 10°C / sec, 10°C / sec to 15°C / sec, 15°C / sec to 20°C / sec, 20°C / sec to 25°C / sec, 25°C / sec to 30°C / sec, 30°C / sec to 35°C / sec, 35°C / sec to 40°C / sec, 40°C / sec to 45°C / sec, 45°C / sec to 50°C / sec, and 50°C / sec to 55°C / sec. Examples of suitable heating rates include 50°C / s to 50°C / s, 50°C / s to 55°C / s, 55°C / s to 60°C / s, 60°C / s to 65°C / s, 65°C / s to 70°C / s, 70°C / s to 75°C / s, 75°C / s to 80°C / s, 80°C / s to 85°C / s, 85°C / s to 90°C / s, 90°C / s to 95°C / s, or 95°C / s to 100°C / s. In some cases, heating rates greater than 100°C / s may be used. In one example, the rapid annealing system 310 may include a series of permanent magnetic rotors 320 used to heat the aluminum alloy product 305 by magnetic induction heating. The permanent magnetic rotors 320 may be provided in any suitable arrangement of individual permanent magnetic rotors 320 or pairs of permanent magnetic rotors 320. Further details of an exemplary magnetic rotor-based magnetic induction heating system are described in U.S. Patent Application Publication No. 2018 / 0091263, which is incorporated herein by reference in its entirety.

[0072] The quenching system 315 may include any suitable quenching system capable of rapidly reducing the temperature of the aluminum alloy product, such as at a rate of about -500°C / s to about -2°C / s. Examples of cooling rates that may be utilized in a quenching system include -5°C / s to -10°C / s, -10°C / s to -15°C / s, -15°C / s to -20°C / s, -20°C / s to -25°C / s, -25°C / s to -30°C / s, -30°C / s to -35°C / s, -35°C / s to -40°C / s, -40°C / s to -45°C / s, - 45℃ / sec~-50℃ / sec, -50℃ / sec~-55℃ / sec, -55℃ / sec~-60℃ / sec, -60℃ / sec~-65℃ / sec, -65℃ / sec~-70℃ / sec, - 70℃ / sec~-75℃ / sec, -75℃ / sec~-80℃ / sec, -80℃ / sec~-85℃ / sec, -85℃ / sec~-90℃ / sec, -90℃ / sec~-95℃ / sec, - 95℃ / sec~-100℃ / sec, -100℃ / sec~-125℃ / sec, -125℃ / sec~-150℃ / sec, -150℃ / sec~-175℃ / sec, -175℃ / sec ~-200℃ / sec, -200℃ / sec~-225℃ / sec, -225℃ / sec~-250℃ / sec, -150℃ / sec~-275℃ / sec, -275℃ / sec~-300℃ Cooling rates below -500°C / s may be used in some cases. As used herein, a cooling rate of -5°C / s means that the temperature of the aluminum alloy product decreases by 5°C per second. In one example, the quenching system 315 may include a series of spray nozzles 325 used to apply a quenching fluid to the aluminum alloy product 305. Exemplary quenching fluids may include gas, air, water, aqueous solutions, oil, or other suitable quenching fluids.

[0073] Optionally, a holding region may be disposed between the rapid annealing system 310 and the quenching system 315. The holding region may include any suitable region that maintains the temperature of the aluminum alloy product 305 at or near the peak temperature achieved in the rapid annealing system 310, for example, within 20°C of the peak temperature. The holding region may maintain the temperature of the aluminum alloy product 305 at or near the peak temperature, for example, for up to 1 minute. Examples of holding times include 5 to 10 seconds, 10 to 15 seconds, 15 to 20 seconds, 20 to 25 seconds, 25 to 30 seconds, 30 to 35 seconds, 35 to 40 seconds, 40 to 45 seconds, 45 to 50 seconds, 50 to 55 seconds, or 55 seconds to 1 minute. In some cases, holding times of more than 1 minute may be applied.

[0074] In some examples, the rapid heating and quenching system 300 can be used to anneal and quench the aluminum alloy product 305 very quickly, such as in less than five minutes. For example, a portion of the aluminum alloy product 305 can enter the rapid annealing system 310, exit the rapid annealing system 310, enter the quenching system 315, and exit the quenching system 315 in less than five minutes. In some cases, any portion of the aluminum alloy product is exposed to temperatures greater than or about 100°C for up to five minutes during rapid annealing and quenching. In some examples, these times may be 5 seconds to 5 minutes, such as 30 seconds to 45 seconds, 45 seconds to 1 minute, 1 minute to 1.25 minutes, 1.25 minutes to 1.5 minutes, 1.5 minutes to 1.75 minutes, 1.75 minutes to 2 minutes, 2 minutes to 2.25 minutes, 2.25 minutes to 2.5 minutes, 2.5 minutes to 2.75 minutes, 2.75 minutes to 3 minutes, 3 minutes to 3.25 minutes, 3.25 minutes to 3.5 minutes, 3.5 minutes to 3.75 minutes, 3.75 minutes to 4 minutes, 4 minutes to 4.25 minutes, 4.25 minutes to 4.5 minutes, 4.5 minutes to 4.75 minutes, or 4.75 minutes to 5 minutes. The total time required to process all of the aluminum alloy product 305 may depend on the rate at which the aluminum alloy product 305 passes through the rapid annealing and quenching system 300 and the length of the aluminum alloy product.In some examples, the aluminum alloy product 305 may have a melting point of 10 m / min to 20 m / min, 20 m / min to 30 m / min, 30 m / min to 40 m / min, 40 m / min to 50 m / min, 50 m / min to 60 m / min, 60 m / min to 70 m / min, 70 m / min to 80 m / min, 80 m / min to 90 m / min, 90 m / min to 100 m / min, 100 m / min to 110 m / min, 110 m / min to 120 m / min, 120 m / min to 130 m / min, 130 m / min to 140 m / min, 140 m / min to 150 m / min, 150 m / min to 160 m / min, 160 m / min to 170 m / min, 170 m / min to 180 m / min, 180 m / min to 200 m / min, 180 m / min to 210 m / min, 180 m / min to 220 m / min, 180 m / min to 230 m / min, 180 m / min to 240 m / min, 180 m / min to 250 m / min, 180 m / min to 260 m / min, 180 m / min to 270 m / min, 180 m / min to 290 m / min, 190 m / min to 290 m / min, 200 m / min to 300 m / min, 200 m / min to 310 m / min, 210 m / min to 320 m / min, 210 m / min to 330 m / min, 210 m / min to 340 m m / min~170m / min, 170m / min~180m / min, 180m / min~190m / min, 190m / min~200m / min, 200m / min~210m / min, 210m / min~220m / min, 220m / min~230m / min, 230m / min~240m / min, 24 0m / min~250m / min, 250m / min~260m / min, 260m / min~270m / min, 270m / min~280m / min, 280m / min~290m / min, 290m / min~300m / min, 300m / min~310m / min, 310m / min~320m / min, 32 0m / min~330m / min, 330m / min~340m / min, 340m / min~350m / min, 350m / min~360m / min, 360m / min~370m / min, 370m / min~380m / min, 380m / min~390m / min, 390m / min~400m / min, 4 00m / min~410m / min, 410m / min~420m / min, 420m / min~430m / min, 430m / min~440m / min, 440m / min~450m / min, 450m / min~460m / min, 460m / min~470m / min, 470m / min~480m / min, 4 The material may be passed through the rapid annealing and / or quenching system 300 at a rate of 5 m / min to 600 m / min, such as 80 m / min to 490 m / min, 490 m / min to 500 m / min, 500 m / min to 510 m / min, 510 m / min to 520 m / min, 520 m / min to 530 m / min, 530 m / min to 540 m / min, 540 m / min to 550 m / min, 550 m / min to 560 m / min, 560 m / min to 570 m / min, 570 m / min to 580 m / min, 580 m / min to 590 m / min, or 590 m / min to 600 m / min.In some examples, the entire coil of aluminum alloy product 305, including the processes of uncoiling the aluminum alloy product 305, passing the aluminum alloy product 305 through the rapid annealing and quenching system 300, and recoiling the aluminum alloy product 305, may be annealed and quenched by the rapid annealing and quenching system 300 in less than 30 minutes, less than 1 hour, or less than 2 hours.

[0075] The rapid heating and quenching system 300 can have any suitable heating power and line capacity. In some cases, the line capacity can be a function of the heating power, the arrival temperature of the aluminum alloy product 305, and the peak temperature to which the aluminum alloy product 305 is raised. In some examples, the rapid heating and quenching system 300 can have a heating power of 1 MW to 10 MW or more. Exemplary powers include, but are not limited to, 1 MW, 1.5 MW, 2 MW, 2.5 MW, 3 MW, 3.5 MW, 4 MW, 4.5 MW, 5 MW, 5.5 MW, 6 MW, 6.5 MW, 7 MW, 7.5 MW, 8 MW, 8.5 MW, 9 MW, 9.5 MW, or 10 MW. The power can be more, less, or between these values. The temperature of the aluminum alloy product 305 prior to entering the rapid heating and quenching system 300 or upon entering the rapid heating and quenching system 300 can be any suitable temperature, such as, for example, about 25°C to about 400°C, such as, for example, about 25°C to 50°C, 50°C to 75°C, 75°C to 100°C, 100°C to 125°C, 125°C to 150°C, 150°C to 175°C, 175°C to 200°C, 200°C to 225°C, 225°C to 250°C, 250°C to 275°C, 275°C to 300°C, 300°C to 325°C, 325°C to 350°C, 350°C to 375°C, or 375°C to 400°C. The line capacity of the rapid heating and quenching system can be in the range of about 40 kTa to about 400 kTa, such as 40 kTa to 50 kTa, 50 kTa to 75 kTa, 75 kTa to 100 kTa, 100 kTa to 125 kTa, 125 kTa to 150 kTa, 150 kTa to 175 kTa, 175 kTa to 200 kTa, 200 kTa to 225 kTa, 225 kTa to 250 kTa, 250 kTa to 275 kTa, 275 kTa to 300 kTa, 300 kTa to 325 kTa, 325 kTa to 350 kTa, 350 kTa to 375 kTa, or 375 kTa to 400 kTa. Line capacities can be even higher, such as when the heating power is greater than 7.5 MW or 10 MW.

[0076] In some instances, uncoiling may not be used immediately prior to rapid annealing. For example, in some instances, the rapid annealing and quenching system 300 may be located downstream of the cold rolling process, such that the aluminum alloy product 305 is rapidly annealed and quenched immediately after the cold rolling pass, where the aluminum alloy product 305 has already been uncoiled. In some instances, recoiling may not be used immediately after quenching. For example, in some instances, the rapid annealing and quenching system 300 may be located upstream of the cold rolling process, such that the aluminum alloy product 305 is rapidly annealed and quenched immediately after the cold rolling pass, where the aluminum alloy product 305 is already uncoiled.

[0077] The aluminum alloy product subjected to rapid annealing and quenching may comprise any suitable alloy and may have any suitable dimensions. For example, the alloy product may have a thickness of 1 mm to 8 mm. In some examples, the aluminum alloy product may comprise a 6xxx series aluminum alloy, a 7xxx series aluminum alloy, a 2xxx series aluminum alloy, or a 5xxx series aluminum alloy.

[0078] The examples disclosed herein serve to further illustrate aspects of the present invention, but at the same time do not constitute any limitation thereof. On the contrary, it is clearly understood that various embodiments, modifications, and equivalents thereof may be employed, and may suggest themselves to those skilled in the art after reading the description herein, without departing from the spirit of the present invention. The examples and embodiments described herein may also utilize conventional procedures, unless otherwise indicated. Some procedures are described herein for illustrative purposes.

[0079] Example 1 A series of tests were conducted to evaluate the properties of rolled aluminum alloy products subjected to rapid annealing and quenching as described herein. Initial tests were performed using a Gleeble thermomechanical simulator to evaluate mechanical properties, extent of recrystallization, and precipitate coarsening as a function of annealing temperature and quenching rate, and to help define processing conditions for subsequent testing. 5 mm thick hot-rolled 6xxx series aluminum alloy coupons were heated to peak temperatures of 325°C to 500°C using rapid heating (approximately 10-20°C / s) and subjected to air quenching immediately upon reaching the peak, air quenching 10 seconds after reaching the peak temperature, or unquenched cooling using a temperature profile similar to coil cooling. The air quenching rate was approximately -40°C / s.

[0080] Starting at a temperature of 450° C., complete or nearly complete recrystallization was observed for all samples. Air-quenched samples did not show significant recrystallization at peak temperatures below 400° C. For samples subjected to a cooling profile similar to coil cooling, significant (approximately 80%) and complete recrystallization were observed for peak temperatures of 350° C. and 400° C., respectively.

[0081] For samples subjected to a cooling profile similar to that of coil cooling, a small amount of precipitate coarsening was observed at a peak temperature of 400°C, with more pronounced coarsening observed at peak temperatures of 450°C and 500°C. For samples subjected to immediate air quenching, no precipitate coarsening was observed at any peak temperature. For samples with a 10 second delayed air quench, no precipitate coarsening was observed at any peak temperature, except for the sample exposed to a peak temperature of 500°C, at which point some coarsening was observed.

[0082] Figures 4A, 4B, 4C, 4D, and 4E provide optical micrographs comparing the grain structures of 6xxx series aluminum alloy production samples that were rapidly heated to different peak temperatures and then immediately air-cooled, rapidly heated to different peak temperatures and then air-cooled after 10 seconds, and batch annealed in a batch annealing furnace for 2 hours and then coil-cooled. The samples subjected to rapid heating to 500°C are more fully recrystallized and exhibit smaller, more equiaxed grains than the equivalent production samples subjected to batch annealing.

[0083] Figures 5A, 5B, 5C, 5D, and 5E provide optical micrographs comparing precipitates in 6xxx series aluminum alloy product samples that were rapidly heated to different peak temperatures and then immediately air-cooled, rapidly heated to different peak temperatures and then air-cooled after 10 seconds, and batch annealed for 2 hours in a batch annealing furnace followed by coil cooling. The samples subjected to rapid heating and air quenching generally show less grain coarsening than the samples subjected to slower coil quenching with batch annealing.

[0084] Subsequent tests were conducted by passing 5 mm thick hot-rolled 6xxx series aluminum alloy sheet panel specimens through a rapid heating and quenching unit, which used magnetic induction heating to rapidly heat the specimens to peak metal temperature and then quench them by exposure to cooling water. Heating rates of up to or about 20°C / s were used, and cooling rates of about -100°C / s were used.

[0085] Figure 6 shows scanning electron micrograph images comparing cross sections of a sample processed using the Gleable thermomechanical simulator (top) and a sample processed in a rapid heating and quenching unit (bottom). Both samples were subjected to rapid heating at a rate of approximately 20°C / s to a peak temperature of 460°C, yet the microstructures were nearly indistinguishable.

[0086] Subsequent testing was performed by uncoiling two coils of 5 mm thick hot-rolled 6xxx series aluminum alloy sheet and passing them through a rapid heating and quenching unit. In this unit, the samples were rapidly heated to peak metal temperature using magnetic induction heating and then quenched by exposure to cooling water. A heating rate of up to or about 20°C / s was used, with a cooling rate of about -100°C / s. The first coil was processed using a peak temperature of 460°C, and the second coil was processed using a peak temperature of 490°C. After rapid annealing and quenching, the samples were subjected to cold rolling to reduce the thickness from 5 mm to 0.9 mm. After cold rolling, the samples were subjected to continuous annealing and solution heat treatment. Here, the samples were heated to 540°C and held for 8 seconds before air quenching. For reference, a comparative sample was subjected to batch annealing and coil cooling. At various times during the treatment, the samples were subjected to mechanical testing.

[0087] Figure 7 provides data showing the yield stress of samples subjected to rapid annealing and water quenching, as well as samples subjected to batch annealing (all before cold rolling). Figure 8 provides data showing the total elongation of samples subjected to rapid annealing and water quenching, as well as samples subjected to batch annealing (all before cold rolling). The measurements shown in these figures correspond to properties averaged across the transverse width of the samples. The samples subjected to rapid annealing and quenching exhibited higher yield strengths and lower elongations compared to the batch annealed samples.

[0088] Figure 9 shows optical micrographs of the cross sections of the samples that were subjected to rapid annealing and water quenching, and the batch annealing (all before cold rolling). The samples that were subjected to rapid annealing and quenching exhibited a more uniform and fine grain structure compared to the batch annealing sample.

[0089] Figure 10 provides 50 μm wide photomicrograph images showing the amount and size of MgSi precipitates (dark spots in the image) for samples subjected to rapid annealing at 490°C and water quenching, and for samples subjected to batch annealing (both before cold rolling). The samples subjected to rapid annealing and quenching exhibited finer precipitates, indicating higher strength and formability. Due to the fewer coarse precipitates, the samples subjected to rapid annealing and quenching do not require as much time for the subsequent solution heat treatment process to dissolve the precipitates as the batch annealed samples.

[0090] The mechanical properties of the samples were evaluated after cold rolling, solution heat treatment, and aging (rapid annealing at 460°C and water quenching, RH+Q460°C; rapid annealing at 490°C and water quenching, RH+Q490°C; and batch annealing, BA). Figure 11 compares the yield stress of the samples after room temperature aging (T4 temper condition) and artificial aging / paint bake (T81 temper condition). Figure 12 compares the total elongation of the samples after room temperature aging (T4 temper condition). The strength and elongation properties of the samples in each condition are comparable.

[0091] Subsequent testing was performed by uncoiling coils of hot-rolled 6xxx series aluminum alloy sheet and passing them through a rapid heating and quenching unit, where the metal was rapidly heated at 5°C / s, 10°C / s, 20°C / s, 40°C / s, or 100°C / s to a peak metal temperature of 460°C, 480°C, 490°C, or 530°C, and then quenched by exposure to cooling water. After rapid annealing and quenching, the samples were subjected to cold rolling. After cold rolling, the samples were subjected to continuous annealing and solution heat treatment. At various points during processing, the samples were subjected to testing.

[0092] For example, to assess the relative amount of dissolved solute (alloying elements) within the aluminum matrix, samples were subjected to conductivity testing. The results of the conductivity tests are shown in Figure 13. For samples annealed to a peak temperature of 460°C, the measured conductivity is generally consistent, but at a heating rate of 100°C / s, the conductivity decreases. For samples annealed to a peak temperature of 530°C, the lowest conductivity was observed at heating rates of 5°C / s and 10°C / s, indicating that these samples had the highest amount of dissolved solute within the aluminum matrix. Meanwhile, for samples processed at a heating rate of 100°C / s, fine particles remain undissolved.

[0093] Figure 14A shows a micrograph of the through-thickness grain structure (transverse cross section, perpendicular to the rolling direction) of a sample annealed to a peak temperature of 460°C, demonstrating that the heating rate does not significantly affect the grain size. Figure 14C shows a micrograph of the through-thickness grain structure (transverse cross section, perpendicular to the rolling direction) of a sample annealed to a peak temperature of 530°C, demonstrating that the heating rate does not significantly affect the grain size.

[0094] 15A and 15B provide photomicrograph images of samples subjected to rapid annealing to peak temperatures of 460°C and 530°C at different heating rates, showing the amount and size of Mg2Si precipitates (dark areas in the images). In general, the particle content appears similar at the different heating rates, although the particle number appears to decrease at the higher peak temperature of 530°C.

[0095] Figure 16 shows the electrical conductivity data for samples rapidly annealed to different peak temperatures, showing the conductivity values ​​measured at different locations in %IACS (International Annealing Copper Standard). These values ​​are significantly lower than those observed for the batch-annealed reference sample, which exhibited an electrical conductivity of approximately 56.8%IACS.

[0096] Figure 17 provides the measured yield stresses of samples subjected to rapid annealing to different peak temperatures. These values ​​are significantly higher than those observed for the batch-annealed reference sample, which exhibited a yield strength of approximately 51–52 MPa.

[0097] Figure 18 provides the measured maximum axial strains for samples subjected to rapid annealing to different peak temperatures. These values ​​are significantly lower than those observed for the batch-annealed reference sample, which exhibited a maximum axial strain of approximately 32–36 MPa.

[0098] Exemplary Embodiments As used hereinafter, any reference to a series of embodiments (e.g., "Embodiments 1-4") or an unrecited group of embodiments (e.g., "any preceding or subsequent embodiment") should be understood as a disjunctive reference to each of those embodiments (e.g., "Embodiments 1-4" should be understood as "Embodiments 1, 2, 3, or 4").

[0099] Embodiment 1 is a method comprising: providing a rolled aluminum alloy product; subjecting the rolled aluminum alloy product to a rapid annealing process to produce an annealed aluminum alloy product, the rapid annealing process heating the rolled aluminum alloy product at a rate of up to 100°C / sec to a peak temperature of between 400°C and 575°C; and subjecting the annealed aluminum alloy product to a quenching process to produce a quenched aluminum alloy product, the quenching process cooling a portion of the annealed aluminum alloy at a rate of between -500°C / sec and -2°C / sec.

[0100] Example 2 is the method of any preceding or subsequent example, further comprising subjecting the quenched aluminum alloy product to a cold rolling process to produce a cold rolled aluminum alloy product.

[0101] Example 3 is the method of any preceding or subsequent example, further comprising subjecting the quenched aluminum alloy product to a solution heat treatment process.

[0102] Example 4 is the method of any preceding or subsequent example, further comprising subjecting the quenched aluminum alloy product to one or more of a cutting process, a forming process, and an aging process.

[0103] Example 5 is the method of any preceding or subsequent example, wherein the rolled aluminum alloy product is a hot-rolled aluminum alloy product.

[0104] Example 6 is the method of any preceding or subsequent example, wherein the quenched aluminum alloy product exhibits an average Mg2Si grain size of less than 2 μm.

[0105] Example 7 is the method of any preceding or subsequent example, wherein the quenched aluminum alloy product exhibits an electrical conductivity of between 40% IACS and 55% IACS.

[0106] Example 8 is the method of any of the preceding or subsequent examples, wherein the quenched aluminum alloy product exhibits a yield stress of 70 MPa to 160 MPa.

[0107] Example 9 is the method of any preceding or subsequent example, wherein the quenched aluminum alloy product exhibits a total elongation of 20% to 30%.

[0108] Example 10 is the method of any of the preceding or subsequent examples, wherein the quenched aluminum alloy product exhibits an average grain size of 10 μm to 35 μm.

[0109] Example 11 is the method of any preceding or subsequent example, wherein the thickness of the rolled aluminum alloy product is between 1 mm and 8 mm.

[0110] Example 12 is the method of any preceding or subsequent example, wherein the thickness of the rolled aluminum alloy product is between 0.5 mm and 5 mm.

[0111] Example 13 is the method of any preceding or subsequent example, wherein the rolled aluminum alloy product is at least partially non-recrystallized, or not at all recrystallized.

[0112] Example 14 is the method of any of the preceding or subsequent examples, wherein the annealed aluminum alloy product is at least partially recrystallized, or fully recrystallized.

[0113] Example 15 is the method of any preceding or subsequent example, wherein the rapid annealing process comprises heating the rolled aluminum alloy product using one or more magnetic induction heating units.

[0114] Example 16 is the method of any preceding or subsequent example, wherein the rapid annealing or quenching process comprises exposing the annealed aluminum alloy product to a quenching fluid.

[0115] Example 17 is the method of any preceding or subsequent example, wherein the rolled aluminum alloy product is a cold-rolled aluminum alloy product.

[0116] Example 18 is the method of any preceding or subsequent example, wherein the rolled aluminum alloy product comprises a 6xxx series aluminum alloy or a 7xxx series aluminum alloy.

[0117] Example 19 is the method of any preceding or subsequent example, wherein the rolled aluminum alloy product comprises a 2xxx series aluminum alloy or a 5xxx series aluminum alloy.

[0118] Example 20 is the method of any preceding or subsequent example, wherein the rapid annealing process does not include a batch or coil annealing process; wherein the rapid annealing process does not include a batch or coil cooling process; wherein subjecting the rolled aluminum alloy product to the rapid annealing process includes uncoiling the rolled aluminum alloy product; or wherein the method further includes coiling the quenched aluminum alloy product prior to a subsequent cold rolling process.

[0119] Example 21 is the method of any preceding or subsequent example, wherein the rapid annealing process is a continuous heating process in which only a portion of the rolled aluminum alloy product is heated at a time, or wherein the quenching process is a continuous cooling process in which only a portion of the annealed aluminum alloy product is cooled at a time.

[0120] Example 22 is the method of any preceding or subsequent example, wherein the rapid annealing process comprises passing the rolled aluminum alloy product through a heating system at a speed of from 5 m / min to 600 m / min, or wherein the quenching process comprises passing the annealed aluminum alloy product through a quenching system at a speed of from 5 m / min to 600 m / min.

[0121] Example 23 is the method of any of the preceding or subsequent examples, wherein the rolled aluminum alloy product is subjected to temperatures greater than 100°C during a rapid annealing and quenching process for up to 5 minutes.

[0122] Example 24 is the method of any preceding or subsequent example, further comprising holding the rolled aluminum alloy product within 20° C. of the peak temperature for up to 1 minute prior to the quenching process.

[0123] Embodiment 25 is an aluminum alloy prepared using the method of any preceding or subsequent embodiment.

[0124] Embodiment 26 is an aluminum alloy product, including a formed or drawn aluminum alloy sheet product comprising a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, or a 7xxx series aluminum alloy, wherein the formed or drawn aluminum alloy sheet product has a surface arithmetic mean height (Sa) of up to 10 μm and a thickness of 1.00 mm to 3.5 mm.

[0125] Example 27 is the aluminum alloy product of any preceding or subsequent example, wherein the formed or drawn aluminum alloy sheet product comprises a 6xxx series aluminum alloy, and wherein the formed or drawn aluminum alloy sheet product is free of, or substantially free of, surface roping bands.

[0126] Example 28 is the aluminum alloy product of any preceding or subsequent example, wherein the formed or drawn aluminum alloy sheet product comprises a 5xxx series aluminum alloy, and wherein the formed or drawn aluminum alloy sheet product is free of, or substantially free of, surface Lueders bands.

[0127] Example 29 is the aluminum alloy product of any of the preceding embodiments, prepared according to the method of any of the preceding embodiments.

[0128] All patents and publications cited herein are incorporated by reference in their entirety. The foregoing description of embodiments, including exemplary embodiments, has been presented only for purposes of illustration and description and is not intended to be exhaustive or limited to the precise form disclosed. Many modifications, adaptations, and uses thereof will be apparent to those skilled in the art.

Claims

1. Providing a rolled aluminum alloy product; subjecting the rolled aluminum alloy product to a rapid annealing process to produce an annealed aluminum alloy product, the rapid annealing process heating the rolled aluminum alloy product at a rate of up to 100°C / sec to a peak temperature of between 400°C and 575°C; subjecting the annealed aluminum alloy product to a quenching process to produce a quenched aluminum alloy product, the quenching process cooling a portion of the annealed aluminum alloy product at a rate of between -500°C / sec and -2°C / sec; A method comprising:

2. 10. The method of claim 1, further comprising subjecting the quenched aluminum alloy product to a cold rolling process to produce a cold rolled aluminum alloy product.

3. 10. The method of claim 1, further comprising subjecting the quenched aluminum alloy product to a solution heat treatment process.

4. 10. The method of claim 1, further comprising subjecting the quenched aluminum alloy product to one or more of a cutting process, a forming process, and an aging process.

5. 10. The method of claim 1, wherein the rolled aluminum alloy product is a hot rolled aluminum alloy product.

6. The quenched aluminum alloy product has an average Mg content of less than 2 μm ２ The method of claim 1 , wherein the Si particle size is indicated.

7. 10. The method of claim 1, wherein the quenched aluminum alloy product exhibits an electrical conductivity of between 40% IACS and 55% IACS.

8. 10. The method of claim 1, wherein the quenched aluminum alloy product exhibits a yield stress of between 70 MPa and 160 MPa.

9. 10. The method of claim 1, wherein the quenched aluminum alloy product exhibits a total elongation of 20% to 30%.

10. 10. The method of claim 1, wherein the quenched aluminum alloy product exhibits an average grain size of 10 μm to 35 μm.

11. 2. The method of claim 1, wherein the rolled aluminum alloy product has a thickness of 1 mm to 8 mm.

12. 2. The method of claim 1, wherein the rolled aluminum alloy product has a thickness of 0.5 mm to 5 mm.

13. 10. The method of claim 1, wherein the rolled aluminum alloy product is at least partially non-recrystallized or not recrystallized at all.

14. 10. The method of claim 1, wherein the annealed aluminum alloy product is at least partially recrystallized or fully recrystallized.

15. 10. The method of claim 1, wherein the rapid annealing process comprises heating the rolled aluminum alloy product using one or more magnetic induction heating units.

16. The method of claim 1 , wherein the quenching process comprises exposing the annealed aluminum alloy product to a quenching fluid.

17. 10. The method of claim 1, wherein the rolled aluminum alloy product is a cold rolled aluminum alloy product.

18. 10. The method of claim 1, wherein the rolled aluminum alloy product comprises a 6xxx series aluminum alloy or a 7xxx series aluminum alloy.

19. 10. The method of claim 1, wherein the rolled aluminum alloy product comprises a 2xxx-series aluminum alloy or a 5xxx-series aluminum alloy.

20. 10. The method of claim 1, wherein the rapid annealing process does not include a batch or coil annealing process; the rapid annealing process does not include a batch or coil cooling process; subjecting the rolled aluminum alloy product to the rapid annealing process includes uncoiling the rolled aluminum alloy product; or further includes coiling the quenched aluminum alloy product prior to a subsequent cold rolling process.

21. 10. The method of claim 1, wherein the rapid annealing process is a continuous heating process in which only a portion of the rolled aluminum alloy product is heated at a time, or the quenching process is a continuous cooling process in which only a portion of the annealed aluminum alloy product is cooled at a time.

22. 10. The method of claim 1, wherein the rapid annealing process comprises passing the rolled aluminum alloy product through a heating system at a speed of from 5 m / min to 600 m / min, or wherein the quenching process comprises passing the annealed aluminum alloy product through a quenching system at a speed of from 5 m / min to 600 m / min.

23. 10. The method of claim 1, wherein the rolled aluminum alloy product is subjected to temperatures in excess of 100°C during the rapid annealing and quenching processes for up to 5 minutes.

24. 10. The method of claim 1, further comprising holding the rolled aluminum alloy product within 20°C of the peak temperature for up to 1 minute prior to the quenching process.

25. An aluminium alloy prepared using the method of any one of claims 1 to 24.

26. 1. Aluminum alloy products, including formed or drawn aluminum alloy sheet products comprising a 5xxx-series aluminum alloy, a 6xxx-series aluminum alloy, or a 7xxx-series aluminum alloy, The formed or drawn aluminum alloy sheet product has a surface arithmetic mean height (Sa) of up to 10 μm; The formed or drawn aluminum alloy sheet product has a thickness of 1.00 mm to 3.5 mm.

27. 27. The aluminum alloy product of claim 26, wherein the formed or drawn aluminum alloy sheet product comprises a 6xxx series aluminum alloy, and wherein the formed or drawn aluminum alloy sheet product is free or substantially free of surface roping bands.

28. 27. The aluminum alloy product of claim 26, wherein the formed or drawn aluminum alloy sheet product comprises a 5xxx series aluminum alloy, and the formed or drawn aluminum alloy sheet product is free or substantially free of surface Lueders bands.

29. An aluminium alloy product according to any one of claims 26 to 28, prepared using a method according to any one of claims 1 to 24.

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