High recycled content aluminum alloys and methods of making and using them

Abstract

Disclosed are aluminum alloys, metal products made using the aluminum alloys, and methods for processing the aluminum alloys. The disclosed alloys can be prepared using high amounts of recycled aluminum alloy content, for example, up to 100% or more recycled content. The disclosed aluminum alloys contain amounts of iron, manganese, chromium, and / or silicon that exceed comparable aluminum alloys typically made by alloying base aluminum. Additionally, the disclosed alloys contain a total manganese and chromium to iron ratio of greater than or equal to 0.60 or 0.70, or about 0.60 or 0.70, which may contribute, at least in part, to desirable bending, forming, or surface properties and characteristics of metal products made using the aluminum alloys. Because the disclosed alloys can be used to prepare automotive and structural panels, these products are produced using high amounts of recycled aluminum alloy content.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of and priority to U.S. Provisional Application No. 63 / 375,093, filed September 9, 2022, which is incorporated herein by reference in its entirety.

[0002] The present disclosure relates generally to metallurgy, and more particularly to aluminum alloys having high regenerative content. [Background technology]

[0003] Highly formable aluminum alloys are used in many different applications, particularly those requiring strength and durability. For example, 6000 series aluminum alloys are widely used in automotive applications due to their excellent combination of properties, including strength-to-weight ratio, formability, weldability, and general corrosion resistance. 6000 series aluminum alloys are typically used in place of steel for automotive structural and closure panel applications. Because aluminum alloys are generally about 2.8 times less dense than steel, the use of such materials can reduce vehicle weight and significantly improve vehicle fuel efficiency. Even so, using currently available aluminum alloys in automotive applications presents certain challenges. Summary of the Invention

[0004] The terms "embodiments" and similar terms are intended to broadly refer to the subject matter of this disclosure and all of 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 high-level 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 of the drawings, and appropriate portions of each claim.

[0005] Described herein are aluminum alloys and metal products produced using those aluminum alloys. In certain embodiments, methods for preparing the metal products are also described. In some examples, the aluminum alloy includes Al, about 1 wt.% to 1.5 wt.% Si, up to about 0.35 wt.% Fe, up to about 0.25 wt.% Cu, about 0.05 wt.% to 0.25 wt.% Mn, about 0.2 wt.% to 0.60 wt.% Mg, up to about 0.10 wt.% Cr, up to about 0.10 wt.% Ni, up to about 0.20 wt.% Zn, up to about 0.15 wt.% Ti, and up to about 0.20 wt.% V. Aluminum may be present as the balance in the aluminum alloy (e.g., the amount of aluminum alloy in addition to optional alloying elements and impurities). In some examples, the aluminum alloy contains up to 0.05 wt.% of each of any individual impurities and up to 0.25 wt.% of all impurities. Optionally, certain elements in the aluminum alloys described herein are included in specific concentrations relative to other elements in the aluminum alloy. In some examples, the ratio of the total amount of Mn and Cr to the amount of Fe in the aluminum alloy is greater than about 0.6 or greater than about 0.7, such as 0.6-0.65, 0.65-0.7, 0.7-0.75, 0.75-0.8, 0.8-0.9, 0.9-1.0, 1.0-1.1, 1.1-1.2, 1.2-1.3, 1.3-1.4, 1.4-1.5, 1.5-1.6, 1.6-1.7, 1.7-1.8, 1.8-1.9, 1.9-2.0, 2.0-2.1, 2.1-2.2, 2.2-2.3, 2.3-2.4, 2.4-2.5, or more, such as 0.6-2.5. In some examples, the aluminum alloy comprises a 6xxx series aluminum alloy. Optionally, at least a portion of the aluminum alloy comprises recycled aluminum alloy inclusions.

[0006] These concentrations, and the relationships between concentrations, may provide the ability to include relatively large amounts of recycled aluminum alloy content in the disclosed aluminum alloys while retaining useful and / or beneficial physical and mechanical properties in manufactured products produced using the aluminum alloy. In some examples, the aluminum alloys include up to 100% recycled aluminum alloy content (e.g., by weight). In some examples, the aluminum alloys include greater than 20% recycled aluminum alloy content (e.g., by weight). Without limitation, the described aluminum alloys may include a recycled aluminum alloy content (e.g., by weight) of 20% to 100%, such as, for example, 20% to 25%, 25% to 30%, 30% to 35%, 35% to 40%, 40% to 45%, 45% to 50%, 50% to 55%, 55% to 60%, 60% to 65%, 65% to 70%, 70% to 75%, 75% to 80%, 80% to 85%, 85% to 90%, 90% to 95%, or 95% to 100%.

[0007] In some examples, the aluminum alloy may contain Si in an amount of about 1 wt.% to 1.5 wt.%. For example, Si is 1.00wt.%~1.01wt.%, 1.01wt.%~1.02wt.%, 1.02wt.%~1.03wt.%, 1.03wt.%~1.04wt.%, 1.04wt.%~1.05wt.%, 1.05wt.%~1.06wt.%, 1.06wt.%~1.07wt.%, 1.07wt.%~1.08wt.%, 1.08wt.%~1.09wt.%, 1.09wt.%~1.10wt.%, 1.10wt.%~1.11wt.%, 1.11wt.%~1.12wt.%, 1.1 2wt.%~1.13wt.%, 1.13wt.%~1.14wt.%, 1.14wt.%~1.15wt.%, 1.15wt.%~1.16wt.%, 1.16wt.%~1.17wt.%, 1.17wt.%~1.18wt.%, 1.18wt.%~ 1.19wt.%, 1.19wt.%~1.20wt.%, 1.20wt.%~1.21wt.%, 1.21wt.%~1.22wt.%, 1.22wt.%~1.23wt.%, 1.23wt.%~1.24wt.%, 1.24wt.%~1.25wt .%, 1.25wt.%~1.26wt.%, 1.26wt.%~1.27wt.%, 1.27wt.%~1.28wt.%, 1.28wt.%~1.29wt.%, 1.29wt.%~1.30wt.%, 1.30wt.%~1.31wt.%, 1.3 1wt.%~1.32wt.%, 1.32wt.%~1.33wt.%, 1.33wt.%~1.34wt.%, 1.34wt.%~1.35wt.%, 1.36wt.%~1.37wt.%, 1.37wt.%~1.38wt.%, 1.38wt.%~ It may be present in the aluminum alloy in an amount of 1.39 wt.%, 1.39 wt.% to 1.40 wt.%, 1.40 wt.% to 1.41 wt.%, 1.41 wt.% to 1.42 wt.%, 1.42 wt.% to 1.43 wt.%, 1.43 wt.% to 1.44 wt.%, 1.44 wt.% to 1.45 wt.%, 1.45 wt.% to 1.46 wt.%, 1.46 wt.% to 1.47 wt.%, 1.47 wt.% to 1.48 wt.%, 1.48 wt.% to 1.49 wt.%, or 1.49 wt.% to 1.50 wt.%.

[0008] In some examples, the aluminum alloy may contain Fe in an amount up to about 0.35 wt.% Fe. For example, Fe may be present in amounts between 0 wt.% and 0.01 wt.%, between 0.01 wt.% and 0.02 wt.%, between 0.02 wt.% and 0.03 wt.%, between 0.03 wt.% and 0.04 wt.%, between 0.04 wt.% and 0.05 wt.%, between 0.05 wt.% and 0.06 wt.%, between 0.06 wt.% and 0.07 wt.%, between 0.07 wt.% and 0.08 wt.%, between 0.08 wt.% and 0.09 wt.%. .%, 0.09wt.%~0.10wt.%, 0.10wt.%~0.11wt.%, 0.11wt.%~0.12wt.%, 0.12wt.%~0.13wt.%, 0.13wt. %~0.14wt.%, 0.14wt.%~0.15wt.%, 0.15wt.%~0.16wt.%, 0.16wt.%~0.17wt.%, 0.17wt.%~0.18wt.% , 0.18wt.%~0.19wt.%, 0.19wt.%~0.20wt.%, 0.20wt.%~0.21wt.%, 0.21wt.%~0.22wt.%, 0.22wt.%~ 0.23wt.%, 0.23wt.%~0.24wt.%, 0.24wt.%~0.25wt.%, 0.25wt.%~0.26wt.%, 0.26wt.%~0.27wt.%, 0 It may be present in the aluminum alloy in an amount of 0.27 wt.% to 0.28 wt.%, 0.28 wt.% to 0.29 wt.%, 0.29 wt.% to 0.30 wt.%, 0.30 wt.% to 0.31 wt.%, 0.31 wt.% to 0.32 wt.%, 0.32 wt.% to 0.33 wt.%, 0.33 wt.% to 0.34 wt.%, or 0.34 wt.% to 0.35 wt.%.

[0009] In some examples, the aluminum alloy may contain Cu in an amount up to about 0.25 wt.%. For example, Cu is 0wt.% to 0.01wt.%, 0.01wt.% to 0.02wt.%, 0.02wt.% to 0.03wt.%, 0.03wt.% to 0.04wt.%, 0.04wt.% to 0.05wt.%, 0.05wt.% to 0.06wt.%, 0.06wt.% to 0.07wt.%, 0.07wt.% to 0.08wt.%, 0.08wt.% to 0.09wt.%, 0.09wt.% to 0.10wt.%, 0.10wt.% to 0.11wt.%, 0.11wt.% to 0.12wt.%, 0.12wt.% to 0.13wt.% , 0.13 wt.% to 0.14 wt.%, 0.14 wt.% to 0.15 wt.%, 0.15 wt.% to 0.16 wt.%, 0.16 wt.% to 0.17 wt.%, 0.17 wt.% to 0.18 wt.%, 0.18 wt.% to 0.19 wt.%, 0.19 wt.% to 0.20 wt.%, 0.20 wt.% to 0.21 wt.%, 0.21 wt.% to 0.22 wt.%, 0.22 wt.% to 0.23 wt.%, 0.23 wt.% to 0.24 wt.%, or 0.24 wt.% to 0.25 wt.%. Cu may be optional.

[0010] In some examples, the aluminum alloy may contain Mn in an amount between about 0.05 wt.% and 0.25 wt.%, for example, Mn may be between 0.05 wt.% and 0.06 wt.%, between 0.06 wt.% and 0.07 wt.%, between 0.07 wt.% and 0.08 wt.%, between 0.08 wt.% and 0.09 wt.%, between 0.09 wt.% and 0.10 wt.%, between 0.10 wt.% and 0.11 wt.%, between 0.11 wt.% and 0.12 wt.%, between 0.12 wt.% and 0.13 wt.%. It may be present in the aluminum alloy in an amount of 0.13wt.% to 0.14wt.%, 0.14wt.% to 0.15wt.%, 0.15wt.% to 0.16wt.%, 0.16wt.% to 0.17wt.%, 0.17wt.% to 0.18wt.%, 0.18wt.% to 0.19wt.%, 0.19wt.% to 0.20wt.%.

[0011] In some examples, the aluminum alloy may contain Mg in an amount between about 0.2 wt.% and 0.60 wt.%, for example, 0.20 wt.% and 0.21 wt.%, 0.21 wt.% and 0.22 wt.%, 0.22 wt.% and 0.23 wt.%, 0.23 wt.% and 0.24 wt.%, 0.24 wt.% and 0.25 wt.%, 0.25 wt.% and 0.26 wt.%, 0.26 wt.% and 0.27 wt.%, 0.27 wt.% and 0.28 wt.%, 0.28 wt.% and 0.29 wt.%, or 0.29 wt.% and 0.30 wt.%. , 0.30wt.%~0.31wt.%, 0.31wt.%~0.32wt.%, 0.32wt.%~0.33wt.%, 0.33wt.%~0.34wt.%, 0.34wt.%~0.35wt.%, 0. 35wt.%~0.36wt.%, 0.36wt.%~0.37wt.%, 0.37wt.%~0.38wt.%, 0.38wt.%~0.39wt.%, 0.39wt.%~0.40wt.%, 0.40wt .%~0.41wt.%, 0.41wt.%~0.42wt.%, 0.42wt.%~0.43wt.%, 0.43wt.%~0.44wt.%, 0.44wt.%~0.45wt.%, 0.45wt.%~ 0.46wt.%, 0.46wt.%~0.47wt.%, 0.47wt.%~0.48wt.%, 0.48wt.%~0.49wt.%, 0.49wt.%~0.50wt.%, 0.50wt.%~0.51 It may be present in the aluminum alloy in an amount of 0.51 wt.% to 0.52 wt.%, 0.52 wt.% to 0.53 wt.%, 0.53 wt.% to 0.54 wt.%, 0.54 wt.% to 0.55 wt.%, 0.55 wt.% to 0.56 wt.%, 0.56 wt.% to 0.57 wt.%, 0.57 wt.% to 0.58 wt.%, 0.58 wt.% to 0.59 wt.%, or 0.59 wt.% to 0.60 wt.%.

[0012] In some examples, the aluminum alloy may contain Cr in an amount up to about 0.10 wt.%. For example, Cr may be present in the aluminum alloy in an amount of 0 wt.% to 0.01 wt.%, 0.01 wt.% to 0.02 wt.%, 0.02 wt.% to 0.03 wt.%, 0.03 wt.% to 0.04 wt.%, 0.04 wt.% to 0.05 wt.%, 0.05 wt.% to 0.06 wt.%, 0.06 wt.% to 0.07 wt.%, 0.07 wt.% to 0.08 wt.%, 0.08 wt.% to 0.09 wt.%, or 0.09 wt.% to 0.10 wt.%. Cr may be optional.

[0013] In some examples, the aluminum alloy may contain Ni in an amount of up to about 0.10 wt.% Ni. For example, Ni may be present in the aluminum alloy in an amount of 0 wt.% to 0.01 wt.%, 0.01 wt.% to 0.02 wt.%, 0.02 wt.% to 0.03 wt.%, 0.03 wt.% to 0.04 wt.%, 0.04 wt.% to 0.05 wt.%, 0.05 wt.% to 0.06 wt.%, 0.06 wt.% to 0.07 wt.%, 0.07 wt.% to 0.08 wt.%, 0.08 wt.% to 0.09 wt.%, or 0.09 wt.% to 0.10 wt.%. Ni may be optional.

[0014] In some examples, the aluminum alloy may contain Zn in an amount up to about 0.20 wt.% Zn. For example, Zn may be present in amounts of 0 wt.% to 0.01 wt.%, 0.01 wt.% to 0.02 wt.%, 0.02 wt.% to 0.03 wt.%, 0.03 wt.% to 0.04 wt.%, 0.04 wt.% to 0.05 wt.%, 0.05 wt.% to 0.06 wt.%, 0.06 wt.% to 0.07 wt.%, 0.07 wt.% to 0.08 wt.%, 0.08 wt.% to 0.09 wt.%, 0.09 wt.% to 0.10 wt.%, 0.10 wt.% Zn may be present in the aluminum alloy in an amount of 0.11 wt.%, 0.11 wt.% to 0.12 wt.%, 0.12 wt.% to 0.13 wt.%, 0.13 wt.% to 0.14 wt.%, 0.14 wt.% to 0.15 wt.%, 0.15 wt.% to 0.16 wt.%, 0.16 wt.% to 0.17 wt.%, 0.17 wt.% to 0.18 wt.%, 0.18 wt.% to 0.19 wt.%, or 0.19 wt.% to 0.20 wt.%. Zn may be optional.

[0015] In some examples, the aluminum alloy may contain Ti in an amount up to about 0.15 wt.% Ti, e.g., Ti between 0 wt.% and 0.01 wt.%, between 0.01 wt.% and 0.02 wt.%, between 0.02 wt.% and 0.03 wt.%, between 0.03 wt.% and 0.04 wt.%, between 0.04 wt.% and 0.05 wt.%, between 0.05 wt.% and 0.06 wt.%, between 0.06 wt.% and 0.07 wt.%, between 0.07 wt.% and 0.08 wt.% , 0.08 wt.% to 0.09 wt.%, 0.09 wt.% to 0.10 wt.%, 0.10 wt.% to 0.11 wt.%, 0.11 wt.% to 0.12 wt.%, 0.12 wt.% to 0.13 wt.%, 0.13 wt.% to 0.14 wt.%, or 0.14 wt.% to 0.15 wt.%. Ti may be optional.

[0016] In some examples, the aluminum alloy may contain V in an amount of up to about 0.20 wt.% V. V may be present in the aluminum alloy in an amount of 0 wt.% to 0.01 wt.%, 0.01 wt.% to 0.02 wt.%, 0.02 wt.% to 0.03 wt.%, 0.03 wt.% to 0.04 wt.%, 0.04 wt.% to 0.05 wt.%, 0.05 wt.% to 0.06 wt.%, 0.06 wt.% to 0.07 wt.%, 0.07 wt.% to 0.08 wt.%, 0.08 wt.% to 0.09 wt.%, or 0.09 wt.% to 0.10 wt.%. V may be optional.

[0017] In some instances, Fe present in an aluminum alloy can combine with other elements to form Fe-containing intermetallic particles. For example, Fe can combine with other elements to form alpha-phase Fe-containing intermetallic particles and / or beta-phase Fe-containing intermetallic particles. In some cases, it may be desirable to control the amount of different Fe-containing intermetallic particles, or the ratio of the amount of different Fe-containing intermetallic particles, in an aluminum alloy or a metal product containing an aluminum alloy. For example, in some cases, an aluminum alloy, whether made from an aluminum alloy or a metal product containing an aluminum alloy, contains more alpha-phase Fe-containing intermetallic particles than beta-phase Fe-containing intermetallic particles.

[0018] Also described herein are metal products, such as metal products comprising aluminum alloys, such as the aluminum alloys described herein. The disclosed metal products can be processed into any desired shape or form. In certain examples, the metal products include auto body products. The disclosed metal products can be made using any suitable process in which an aluminum alloy is processed using various processing steps to produce the metal product. In some cases, the metal product is a rolled metal product. Optionally, the metal product is a double recrystallized metal product. The metal product can exhibit suitable properties, such as mechanical or physical characteristics or features, that can be advantageous for various end uses or embodiments.

[0019] In some examples, the metal product exhibits isotropic strain properties. For example, the metal product may exhibit a Lankford ratio of about 0.6 or greater, e.g., 0.6-1.0, 0.60-0.65, 0.65-0.70, 0.70-0.75, 0.75-0.80, 0.80-0.85, 0.85-0.90, 0.90-0.95, or 0.95-1.0, at about 10% strain along the machine, transverse, and diagonal directions. In some examples, the metal product exhibits a f15% flexural modulus of about 0.3-1.0, e.g., 0.3-0.4, 0.4-0.5, 0.5-0.6, 0.6-0.7, 0.7-0.8, 0.8-0.9, or 0.9-1.0, along the transverse direction. The flexural modulus (f) can be measured according to ASTM E290, where, for a given prestrain, f = r / t, where r is the minimum radius of bend without visible surface cracks, and t is the thickness of the sheet after strain. For example, f15% is the flexural modulus after a 15% transverse prestrain. In some examples, metal products exhibit an internal bend angle of about 10° to 60°, e.g., 10° to 15°, 15° to 20°, 20° to 25°, 25° to 30°, 30° to 35°, 35° to 40°, 40° to 45°, 45° to 50°, 50° to 55°, or 55° to 60°, after a 10% prestrain. In some examples, the metal product exhibits a surface arithmetic mean height (Sa) of at most 0.60 μm, e.g., less than or about 0.10 μm, less than or about 0.15 μm, less than or about 0.20 μm, less than or about 0.25 μm, less than or about 0.25 μm, less than or about 0.25 μm, less than or about 0.30 μm, less than or about 0.35 μm, less than or about 0.40 μm, less than or about 0.45 μm, less than or about 0.50 μm, less than or about 0.55 μm, or less than or about 0.60.In some examples, the metal product exhibits a yield strength of about 90 MPa to about 130 MPa in the T4 temper, e.g., 90 MPa to 95 MPa, 95 MPa to 100 MPa, 100 MPa to 105 MPa, 105 MPa to 110 MPa, 110 MPa to 115 MPa, 115 MPa to 120 MPa, 120 MPa to 125 MPa, or 125 MPa to 130 MPa. In some examples, the metal product exhibits a yield strength of about 200 MPa to about 235 MPa in the T6 temper, e.g., 200 MPa to 205 MPa, 205 MPa to 210 MPa, 210 MPa to 215 MPa, 215 MPa to 220 MPa, 220 MPa to 225 MPa, 225 MPa to 230 MPa, or 230 MPa to 235 MPa. In some examples, the metal product, when in the T4 temper, exhibits an ultimate tensile strength of about 195 MPa to about 270 MPa, e.g., 195 MPa to 200 MPa, 200 MPa to 205 MPa, 205 MPa to 210 MPa, 210 MPa to 215 MPa, 215 MPa to 220 MPa, 220 MPa to 225 MPa, 225 MPa to 230 MPa, 230 MPa to 235 MPa, 235 MPa to 240 MPa, 240 MPa to 245 MPa, 245 MPa to 250 MPa, 250 MPa to 255 MPa, 255 MPa to 260 MPa, 260 MPa to 265 MPa, or 265 MPa to 270 MPa. In some examples, the metal product, when in the T6 temper, exhibits an ultimate tensile strength of about 240 MPa to about 300 MPa, e.g., 240 MPa to 245 MPa, 245 MPa to 250 MPa, 250 MPa to 255 MPa, 255 MPa to 260 MPa, 260 MPa to 265 MPa, 265 MPa to 270 MPa, 270 MPa to 275 MPa, 275 MPa to 280 MPa, 280 MPa to 285 MPa, 285 MPa to 290 MPa, 290 MPa to 295 MPa, or 295 MPa to 300 MPa. In some examples, the metal fabrication exhibits a uniform elongation of 20% to 30% when in the T4 temper, such as, for example, 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%.In some examples, the metal fabrication exhibits a uniform elongation of 10% to 20%, for example, 10% to 11%, 11% to 12%, 12% to 13%, 13% to 14%, 14% to 15%, 15% to 16%, 16% to 17%, 17% to 18%, 18% to 19%, or 19% to 20%, for the T6 temper.

[0020] In one aspect, methods are also described herein, such as methods for processing aluminum alloys and methods for producing metal products. In some examples, the methods of this aspect include casting an aluminum alloy to produce a cast product, such as an aluminum alloy described herein, homogenizing the cast product to produce a homogenized product, hot rolling the homogenized product to produce a rolled product, and subjecting the rolled product to a final cold rolling process to produce the metal product. Optionally, the hot rolling has an exit temperature of 400°C or less. Optionally, the hot rolling achieves a thickness reduction of 90% or more between the homogenized product and the rolled product.

[0021] Optionally, the method of this aspect further includes, following hot rolling, subjecting the rolled product to a recrystallization process to produce a recrystallized product; e.g., a final cold rolling process includes cold rolling the recrystallized product to produce a metal product. Optionally, in some exemplary methods, the recrystallization process occurs between the hot rolling and the final cold rolling processes. Optionally, the method of this aspect includes subjecting the rolled product to a preliminary cold rolling process after hot rolling and before the recrystallization process; e.g., the recrystallization process occurs between the preliminary cold rolling process and the final cold rolling process.

[0022] In some examples, the recrystallization process includes annealing the rolled product at a peak metal temperature of 325°C to 425°C for up to 1 minute to produce a recrystallized product, and quenching the recrystallized product. Further details of recrystallization processes and related methods useful with the aluminum alloys described herein are described in U.S. Provisional Patent Application No. 63 / 261,042, filed September 9, 2021, which is incorporated herein by reference in its entirety.

[0023] Optionally, the method of this aspect further comprises subjecting the metal product to a solution treatment process to produce a solution treated metal product. Optionally, the method of this aspect further comprises subjecting the metal product to an aging or artificial aging process to produce an aged metal product. Further processing steps may optionally be used to process the disclosed aluminum alloys to produce metal products.

[0024] Other objects and advantages will become apparent from the following detailed description, given by way of non-limiting example.

[0025] This specification refers to the following accompanying drawings, in which the use of like reference numbers in different drawings is intended to indicate like or similar components. [Brief explanation of the drawings]

[0026] [Figure 1] 1 shows a schematic overview of an exemplary method for producing a rolled aluminum alloy product. [Figure 2] 1 provides a schematic overview of a process for preparing an aluminum alloy article. [Figure 3] 1 shows the measured grain size characteristics of various aluminum alloy samples. [Figure 4] 1 shows the measured texture characteristics of various aluminum alloy samples. [Figure 5] 1 shows the measured yield strength of various aluminum alloy samples. [Figure 6]1 shows the measured ultimate tensile strength of various aluminum alloy samples. [Figure 7] 1 shows the measured uniform elongation of various aluminum alloy samples. [Figure 8] 1 shows the measured total elongation of various aluminum alloy samples. [Figure 9] Measured strain hardening exponents at 5% strain are shown for various aluminum alloy samples. [Figure 10] The measured strain hardening exponents for various aluminum alloy specimens between 10 and 20% strain are shown. DETAILED DESCRIPTION OF THE INVENTION

[0027] Described herein are aluminum alloys, metal products made using the aluminum alloys, and methods of processing the aluminum alloys. The disclosed alloys can be prepared using high amounts of recycled aluminum alloy content, for example, up to 100% recycled content. The disclosed aluminum alloys contain amounts of iron, manganese, chromium, and / or silicon that exceed comparable aluminum alloys typically made by alloying base aluminum. Additionally, the disclosed alloys contain a total manganese and chromium to iron ratio of greater than or about 0.70, which may contribute, at least in part, to desirable bending, forming, or surface properties and characteristics of metal products made using the aluminum alloys. Because the disclosed alloys can be used to prepare automotive and structural panels, these products are produced using high amounts of recycled aluminum alloy content.

[0028] Aluminum alloys used for reclamation may be mixtures of various aluminum alloys or may contain unknown amounts of aluminum alloys. In some cases, contaminants may also be present in the aluminum alloys used for reclamation. For example, aluminum alloys used for reclamation may correspond to scrap source aluminum, such as end-of-life automotive aluminum, or industrial scrap sources, such as remelted scrap ingots (RSI), extrusion profiles, aluminum plate, brazing scrap, and cast alloy scrap.

[0029] By increasing the amount of recycled aluminum content that can be included in the aluminum alloys described herein while retaining desirable physical and mechanical properties, such that the aluminum alloys may be useful as metal products for certain applications (e.g., as body or structural panels), the energy requirements and carbon footprint for preparing the metal products can be significantly reduced. By way of example, the alloys and processing techniques described herein are useful for producing aluminum alloy sheet metal or other metal products having desirable bending properties, strength properties, forming properties (e.g., isotropic forming properties), etc.

[0030] The alloy known as AA6016 is commonly used in automotive or structural applications. However, AA6016 is generally not prepared using large amounts of recycled aluminum. For example, the elemental limits for AA6016 are typically lower for certain elements (e.g., Fe) than are typically found in recycled aluminum alloy materials. Stated differently, adding recycled aluminum content to an aluminum alloy destined to become AA6016 may require the use of large amounts of primary aluminum to ensure that certain elements (e.g., Fe) are not included in excess of their limits established by the AA6016 designation. Therefore, when a large amount of recycled aluminum content is included in an aluminum alloy, the designation may differ from AA6016. When such an alloy is processed according to techniques commonly used to prepare products using AA6016, the resulting products may have different mechanical and physical properties than those made using AA6016.

[0031] However, the alloys described herein overcome these challenges by including certain elements (e.g., iron, manganese, chromium, and / or silicon) in specific amounts and / or ratios to still retain beneficial properties. Furthermore, by carefully controlling the ratios of certain elements (e.g., the ratio of the total amount of manganese and chromium to iron), desired properties (e.g., mechanical or physical properties) in the aluminum alloy product can be achieved. Furthermore, certain processing schemes, such as those utilizing rapid, low-temperature annealing processes prior to or between cold rolling steps, can be used to impart desired properties (e.g., bending, forming, strength, and / or surface properties) to the resulting aluminum alloy product.

[0032] Definitions and Explanations As used herein, the terms "invention," "the invention," "this invention," and "the present invention" are intended to refer broadly to all of the subject matter of this patent application and the claims that follow. Statements containing these terms should not be understood to limit the subject matter described herein or to limit the meaning or scope of the claims that follow.

[0033] 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).

[0034] 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.

[0035] 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.

[0036] 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).

[0037] 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 an aluminum alloy that has been cooled from hot working and naturally aged (e.g., at room temperature). The T2 temper or temper refers to an aluminum alloy that has been cooled from hot working, cold worked, and naturally aged. The T3 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.

[0038] 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.

[0039] 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.

[0040] 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.%).

[0041] As used in this disclosure, the meanings of "a," "an," and "the" include singular and plural references unless the context clearly dictates otherwise.

[0042] In this disclosure, aluminum alloy products and their constituents 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% or 0.25%, with the balance being aluminum.

[0043] Accessory elements (e.g., grain refiners and deoxidizers), or other additives, may be present in the disclosed alloys and may themselves add other properties without deviating from or significantly altering the alloys described herein or the properties of the alloys described herein.

[0044] Inevitably, impurities (including materials or elements) may be present in small amounts in the alloy due to the inherent properties of aluminum or due to leaching from contact with processing equipment. As explained, some alloys may contain up to about 0.15 wt.% or 0.25 wt.% of any element in addition to the alloying elements, incidental elements, and unavoidable impurities.

[0045] Methods for producing and preparing alloys and aluminum alloy products The aluminum alloy products described herein can be prepared using any suitable method, for example, the aluminum alloy may be cast, homogenized, hot rolled using a breakdown mill followed by a tandem mill or using only a breakdown mill, cold rolled, heat treated, formed, etc. to produce the aluminum alloy product.

[0046] FIG. 1 shows an overview of an exemplary method for making 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 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). Optionally, the rolled aluminum alloy product 112 is subjected to additional processing steps, as described below, to form the aluminum alloy article.

[0047] The alloys described herein can be cast using any suitable casting method known to those skilled in the art. As some non-limiting examples, the casting process may include a direct chill (DC) casting process, a fusion 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 may be used. A continuous casting system may include a pair of movable opposing casting surfaces (e.g., movable opposing belts, rolls, or blocks), a casting cavity between the pair of movable opposing casting surfaces, and a molten metal injector. The molten metal injector may have an end opening through which molten metal can exit the molten metal injector and be injected into the casting cavity.

[0048] Cast aluminum alloy products (e.g., cast ingots, cast slabs, or other cast products) can be processed by any suitable technique described herein. Optionally, processing steps can be used to prepare rolled aluminum alloy products (e.g., aluminum alloy sheets). Exemplary optional processing steps include, but are not limited to, homogenizing, hot rolling, cold rolling, annealing, solution heat treating, and pre-aging.

[0049] In the homogenization step, the cast aluminum alloy product is homogenized to form a homogenized aluminum alloy product. During homogenization, the cast product may be heated at a temperature ranging from about 400°C to about 565°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, or about 540°C, up to about 565°C. The product may then be soaked (i.e., held at the indicated temperature) for a period of time to form the homogenized product. In some embodiments, the total time for the homogenization step, including the heating and soaking steps, may be up to 72 hours. For example, the product can be heated and soaked to a maximum of 500°C-565°C for a total time of up to 18 hours for the homogenization step. Optionally, the product can be heated and soaked to less than 490°C for a total time of 18 hours or more for the homogenization step. In some cases, the homogenization step includes multiple processes. In some non-limiting examples, the homogenization step includes heating the cast 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 cast product can be heated to about 465°C for about 3.5 hours, and then heated to about 480°C for about 6 hours. In some examples, the homogenization and casting processes are combined as casting with in-situ homogenization.

[0050] The homogenized aluminum alloy product is subjected to one or more roll-bonding passes and / or one or more hot rolling passes to form a rolled aluminum alloy product, which may correspond to an aluminum alloy article such as an aluminum alloy plate, aluminum alloy shade, or aluminum alloy sheet. The roll-bonding process can be performed in different ways. For example, the roll-bonding process may include both hot rolling and cold rolling. Furthermore, the roll-bonding process may be a one-step process or a multi-step process in which the material is gauge-reduced during successive rolling steps. The separate rolling steps may optionally be separated by other processing steps, including, for example, annealing steps, cleaning steps, heating steps, cooling steps, etc.

[0051] Before starting the hot rolling, the homogenized product can be allowed to cool to a temperature of between 380°C and 450°C. For example, the homogenized product can be cooled to a temperature between 400°C and 425°C. The homogenized product can then be hot rolled at a temperature of 250°C to 450°C to form a hot rolled plate, hot rolled sheet, or hot rolled sheet having a gauge between 2mm and 200mm (e.g., 2mm, 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, 9mm, 10mm, 15mm, 20mm, 25mm, 30mm, 35mm, 40mm, 45mm, 50mm, 55mm, 60mm, 65mm, 70mm, 75mm, 80mm, 85mm, 90mm, 95mm, 100mm, 110mm, 120mm, 130mm, 140mm, 150mm, 160mm, 170mm, 180mm, 190mm, 200mm, or any value in between).

[0052] Optionally, the cast product may be a continuously cast product that can be allowed to cool to a temperature of 300° C. to 535° C. For example, the continuously cast product can be allowed to cool to a temperature of 325° C. to 510° C., 350° C. to 485° C., 375° C. to 460° C., or 400° C. to 435° C. The continuously cast product can then be hot rolled at a temperature of between 300° C. and 450° C. to form, for example, a hot rolled plate, hot rolled sheath, or hot rolled sheet having a gauge of between 3 mm and 25 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, or anything in between). During hot rolling, the temperature and other operating parameters can be controlled so that the temperature of the hot rolled intermediate product exiting the hot rolling mill is 470°C or less, 450°C or less, 440°C or less, or 430°C or less.

[0053] The cast product, homogenized product, or hot-rolled product may optionally be subjected to a cracking process or a cracking tandem process. Optionally, a cold rolling process may be used after the hot rolling process, the cracking process, and / or the cracking tandem process. The cold rolling process may use a cold rolling mill to cold-roll the aluminum product into a thinner product, such as a cold-rolled sheet. The cold-rolled product may have a gauge of, for example, between about 0.1 and 7 mm, such as between about 0.7 and 6.5 mm. Optionally, the cold-rolled product may 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, or 7.0 mm. Cold rolling can be performed to result in a final gauge thickness that represents a gauge reduction of up to about 95% (e.g., up to 10%, up to 20%, up to 30%, up to 40%, up to 50%, up to 55%, up to 60%, up to 70%, up to 75%, up to 80%, or up to 85%, or up to 90%, up to 95%, or up to 99% reduction) compared to the gauge before cold rolling began.

[0054] Following the cold rolling process, an intermediate annealing process can optionally be used. In some cases, the product after the hot rolling process, the decomposition process, and / or the decomposition / tandem process is subjected to an intermediate annealing process. The intermediate annealing process can be any suitable treatment that results in a recrystallized aluminum product. The intermediate annealing process can include subjecting a non-recrystallized aluminum product (e.g., a hot-rolled product or a cold-rolled product) to a heat treatment at a predetermined temperature of 495°C or less for a time period of 25 minutes or less to produce a recrystallized aluminum product. For example, a cast product, a homogenized product, a hot-rolled product, or a cold-rolled product can be heated to a temperature of up to 495°C for a time period of up to 25 minutes as part of the intermediate annealing process. In some examples, the temperature may be, for example, 300°C to 305°C, 305°C to 310°C, 310°C to 315°C, 315°C to 320°C, 320°C to 325°C, 325°C to 330°C, 330°C to 335°C, 335°C to 340°C, 340°C to 345°C, 345°C to 350°C, 350°C to 355°C, 355°C to 360°C, 360°C to 365°C, 365°C to 370°C, 370°C to 380°C, 380°C to 390°C, 390°C to 400°C, 400°C to 410°C, 410°C to 420°C, 420°C to 430°C, 430°C to 440°C, 440°C to 450°C, 450°C to 460°C, 450°C to 460°C, 460°C to 470°C, 470°C to 480°C, 480°C to 490°C, 490°C to 500°C, 500°C to 510°C, 510°C to 520°C, 520°C to 530°C, 530°C to 540°C, 540°C to 550°C, 550°C to 560°C, 550°C to 560°C, 550°C to 5 75℃, 375℃~380℃, 380℃~385℃, 385℃~390℃, 390℃~395℃, 395℃~400℃, 400℃~405℃, 405℃~410℃, 410℃~415℃, 415℃~420℃, 420℃~425℃, 425℃~430℃, 430℃~435℃, 435℃~440℃, 440℃~445℃, 445℃~450℃, 450℃~455℃ The temperature may be from about 300°C to about 495°C, such as 455°C to 460°C, 460°C to 465°C, 465°C to 470°C, 470°C to 475°C, 475°C to 480°C, 480°C to 485°C, 485°C to 490°C, 490°C to 495°C, or 490°C to 495°C. In some examples, the temperature may be from 320°C to 495°C, 340°C to 485°C, 350°C to 475°C, or 370°C to 475°C. Any suitable temperature ramp rate may be used to heat to or cool from the specified temperature.In some examples, the product is heated to the temperature for a length of time from about 0.1 seconds to about 25 minutes, such as 0.1 seconds to 0.5 seconds, 0.5 seconds to 1 second, 1 second to 2 seconds, 2 seconds to 3 seconds, 3 seconds to 4 seconds, 4 seconds to 5 seconds, 5 seconds to 10 seconds, 10 seconds to 15 seconds, 15 seconds to 30 seconds, 30 seconds to 45 seconds, 45 seconds to 60 seconds, 60 seconds to 75 seconds, 75 seconds to 90 seconds, 90 seconds to 105 seconds, 105 seconds to 2 minutes, 2 minutes to 3 minutes, 3 minutes to 4 minutes, 4 minutes to 5 minutes, 5 minutes to 10 minutes, 10 minutes to 15 minutes, 15 minutes to 20 minutes, or 20 minutes to 25 minutes. In some cases, this may indicate that the temperature is held at or near the specified temperature, or within 5° C. or within 10° C. of the specified temperature, for that length of time. In some examples, a temperature or temperature range may be combined with a specific time length or time range. For example, the temperature may be 340°C to 485°C for a time length of 10 minutes or less, the temperature may be 350°C to 475°C for a time length of less than 1 minute, or the temperature may be 370°C to 475°C for a time length of 2 to 35 seconds. Any variation or combination of the above temperatures and time lengths may be used, and specific alloys or final product configurations may benefit from specific temperature and time length combinations or ranges.

[0055] The intermediate annealing process may be performed on cast, homogenized, or rolled products at a rate of, for example, 10 m / min to 15 m / min, 15 m / min to 20 m / min, 20 m / min to 25 m / min, 25 m / min to 30 m / min, 30 m / min to 40 m / min, 40 m / min to 45 m / min, 45 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, 10 ...20 m / min, 120 m / min to 140 m / min, 140 m / min to 150 m / min, 150 m / min to 20 m / min, 20 m / min to 25 m / min, 25 m / min to 30 m / min, 30 m / min to 40 m / min, 40 m / min to 45 m / min, 45 m / min to 50 m / min, 50 m / min to 60 The intermediate annealing process can include passing the product through a furnace at a speed of about 10 m / min to about 150 m / min, such as 100 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, or 140 m / min to 150 m / min. In some examples, the intermediate annealing process can include heating the cast, homogenized, or rolled product by passing the product through a gas-fired furnace. In some cases, the intermediate annealing process can include or use a magnetic heating unit with a heating rate of 10°C / sec to 150°C / sec. Optionally, the intermediate annealing process can include or use a quenching process (e.g., water quenching or air quenching) with a cooling rate of 5°C / sec to 150°C / sec or more to return the product to ambient or room temperature. Cold rolling the product after the intermediate annealing process may result in a non-recrystallized aluminum product with deformed grains. Cold rolling can be performed to produce a final gauge thickness representing a 25% to 99% gauge reduction (e.g., 25% to 30%, 30% to 35%, 35% to 40%, 40% to 45%, 45% to 50%, 50% to 55%, 55% to 60%, 60% to 65%, 65% to 70%, 70% to 75%, 75% to 80%, 80% to 85%, 85% to 90%, 90% to 95%, or 95% to 99% reduction) compared to the gauge before cold rolling. In some specific examples, the cold rolling process may achieve a 55% to 75%, 25% to 90%, 45% to 95%, or 60% to 99% cold reduction.

[0056] Subsequently, the product can optionally undergo one or more solution heat treatment steps. The solution heat treatment step can be any suitable treatment for metal products that results in solutionization of soluble particles. By way of example, the product can be heated to a peak metal temperature (PMT) of up to 590°C (e.g., 400°C-590°C) and soaked for a period of time at the PMT to form a high-temperature product. For example, the product can be soaked at 480°C for a soaking 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 high-temperature product is rapidly cooled between 500°C and room temperature at a rate of 90°C / second or greater to form a heat-treated product.

[0057] After quenching, the heat-treated product may optionally be pre-aged by reheating before being coiled. Pre-aging may be performed at temperatures between about 50°C and about 125°C for a period of up to 6 hours. For example, pre-aging may be performed at temperatures of about 50°C, about 55°C, about 60°C, about 65°C, 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 may 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 may be performed by passing the heat-treated product through a heating device, such as a device that emits radiant heat, convective heat, induction heat, infrared heat, or the like.

[0058] 2 provides a plot showing exemplary temperatures of a cast metal product during various stages of a manufacturing process according to various embodiments of the present disclosure. As part of the initial casting stage 205, in which the molten metal is formed into an ingot, casting, or other solid or metal product, the molten metal may be cooled and / or solidified by a process that includes quenching or cooling the metal by exposing it 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.

[0059] Following the casting step 205, the metal product may be subjected to a homogenization process 210 in which the metal is heated to a temperature below the melting or solidus temperature of the metal. Optionally, the metal product is heated to a temperature at which the base metal and any alloying elements form a solid solution.

[0060] Following the homogenization process 210, the metal product may be subjected to one or more processes that may form a desired microcrystalline structure within the metal product, for example, while elongating the metal 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 a metal ingot or other casting or metal fabrication.

[0061] In some embodiments, exposing the heated metal product to a solution, such as water, an aqueous solution, a gas, a gas mixture, or a gas-phase solution, in a quenching or cooling process may be used to reduce the temperature of the metal product to a temperature desirable or useful for subsequent processing. For example, exposing the metal product to water or an aqueous solution may be useful for cooling the metal product between the hot processing 215 and subsequent processing. Tandem and / or disassembly processing is not shown in FIG. 2 but may be performed at any suitable temperature for such processes.

[0062] Following the hot rolling process 215 and / or the cold rolling process 220 (the cold rolling process 220 may be optional), the metal product may be subjected to an intermediate annealing heat treatment process 225, in which the metal product is heated to a predetermined temperature and held for a period of time of one hour or less to produce at least partial recrystallization of the metal product. The metal product may optionally be subjected to an additional cold process 230 after the intermediate annealing heat treatment process 225. As shown in Figure 2, a variety of different peak temperatures may be used for the intermediate annealing heat treatment process 225, which may depend, for example, on the particular alloy of the metal product and / or the particular mechanical or physical properties desired in the final product.

[0063] The metal product may then be subjected to a solution heat treatment process 235, in which the temperature of the metal product is raised to above a threshold temperature, such as a temperature at which precipitated constituents within the metal product dissolve into solid solution or a temperature at which a recrystallization process occurs, and held at or above the threshold temperature for a period of time. At the end of the solution heat treatment 235, the metal product may be subjected to a quenching process 240, in which the dissolved constituents are set in place by rapidly reducing the temperature of the metal via a quenching process. Such a quenching process 240 may include exposing the metal product to a solution, such as water, an aqueous solution, or a quenching solution containing a gas or gas mixture.

[0064] 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 metal products may be transported between processing stages as coils, films, or webs of material. The metal products may be transported between stages, for example, by rolling the metal products under tension on or between one or more rollers, or by transporting the metal products 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, tandem and / or disassembly stages, cleaning stages, chemical treatment stages, or finishing stages. By way of example, finishing stages may correspond to surface anodizing stages, powder coating stages, painting stages, printing stages, etc.

[0065] 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, for example, to prepare outer and inner panels.

[0066] 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.

[0067] Methods for treating metals and metal alloys Described herein are methods for processing and using metals and metal alloys (including, among others, aluminum, aluminum alloys, magnesium, magnesium alloys, magnesium composites, and steel), as well as the resulting processed metals and metal alloys. In some examples, the metals used in the methods described herein include aluminum alloys, such as 1xxx series aluminum alloys, 2xxx series aluminum alloys, 3xxx series aluminum alloys, 4xxx series aluminum alloys, 5xxx series aluminum alloys, 6xxx series aluminum alloys, 7xxx series aluminum alloys, or 8xxx series aluminum alloys. In some examples, materials including 1xxx series aluminum alloys, 2xxx series aluminum alloys, 3xxx series aluminum alloys, 4xxx series aluminum alloys, 5xxx series aluminum alloys, 6xxx series aluminum alloys, 7xxx series aluminum alloys, or 8xxx series aluminum alloys are useful as reclaimed source content materials for the aluminum alloy and metal products described herein. In some examples, materials for use in the methods described herein include non-ferrous materials, such as aluminum, aluminum alloys, magnesium, magnesium-based materials, magnesium alloys, magnesium composites, titanium, titanium-based materials, titanium alloys, copper, copper-based materials, composites, sheets used in composites, 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, composites (e.g., without limitation, carbon fiber-containing materials), or various other materials, are also useful in the methods described herein. In some examples, aluminum alloys containing iron are useful in the methods described herein.

[0068] 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.

[0069] 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.

[0070] 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.

[0071] 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.

[0072] 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.

[0073] Non-limiting exemplary 6xxx series aluminum alloys for use in the methods described herein include AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA6206, AA6306 , AA6008, AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, AA 6016, AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027, AA6028 , AA6031, AA6032, AA6033, AA6040, AA6041, AA6042, AA6043, AA6151, AA6351, AA6351A, AA6451, AA6951, AA6053, AA6 055, AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560, AA6660, AA6061, AA6061A, AA6261 , 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.

[0074] Non-limiting exemplary 7xxx series aluminum alloys for use in the methods described herein include AA7011, AA7019, AA7020, AA7021, AA7039, AA7072, AA7075, AA7085, AA7108, AA7108A, AA7015, AA7017, AA7018, AA7019A, AA7024, AA7025, AA7 028, AA7030, AA7031, AA7033, AA7035, AA7035A, AA7046, AA7046A, AA7003, AA7004, AA7005, AA7 009, AA7010, AA7011, AA7012, AA7014, AA7016, AA7116, AA7122, A7023, AA7026, AA7029, AA7129 , AA7229, AA7032, AA7033, AA7034, AA7036, AA7136, AA7037, AA7040, AA7140, AA7041, AA7049, A A7049A, AA7149, AA7204, AA7249, AA7349, AA7449, AA7050, AA7050A, AA7150, AA7250, AA7055, A May contain A7155, AA7255, AA7056, AA7060, AA7064, AA7065, AA7068, AA7168, AA7175, AA7475, AA7076, AA7178, AA7278, AA7278A, AA7081, AA7181, AA7185, AA7090, AA7093, AA7095, or AA7099.

[0075] Non-limiting exemplary 8xxx series aluminum alloys for use in the methods described herein include AA8005, AA8006, AA8007, AA8008, AA8010, AA8011, AA8011A, AA8111, AA8211, AA8112, AA8014, AA8015, AA8016, AA8017, AA8018, AA8019, AA8021, May include AA8021A, AA8021B, AA8022, AA8023, AA8024, AA8025, AA8026, AA8030, AA8130, AA8040, AA8050, AA8150, AA8076, AA8076A, AA8176, AA8077, AA8177, AA8079, AA8090, AA8091, or AA8093.

[0076] The examples disclosed herein serve to further illustrate aspects of the present invention, but at the same time do not constitute any limitation thereof. To the contrary, it should be clearly understood that reliance may be placed on various embodiments, modifications thereof, and equivalents, which may suggest themselves to those skilled in the art after reading the description herein without departing from the spirit of the invention. The examples and embodiments described herein may also utilize conventional procedures, unless otherwise indicated. Some procedures are described herein for illustrative purposes.

[0077] Example 1 Aluminum alloy sheet metal specimens were prepared by casting, homogenizing, hot rolling, cold rolling, solution treatment, and aging the aluminum alloy. Conventional DC casting techniques were used to prepare ingots containing AA6016. The aluminum alloy contained approximately 55% recycled aluminum content. The aluminum alloy contained approximately 0.23-0.30 wt.% Fe, 0.15-0.20 wt.% Mn, and 0.009-0.025 wt.% Cr, resulting in a Mn+Cn to Fe ratio of approximately 0.67-0.73.

[0078] The ingots were homogenized at approximately 540°C for approximately 14 hours. Following conventional hot rolling, cold rolling, and solution heat treatment techniques, the homogenized product was subjected to hot rolling, followed by cold rolling, followed by solution treatment. The exit temperature after hot rolling was 405°C. The thickness reduction achieved by hot rolling was approximately 98%, while the thickness reduction achieved by cold rolling, prior to an intermediate anneal at 355°C, was 63%. Further cold rolling was then used to produce a final gauge of 1.02 mm for the cold-rolled product. The cold-rolled product was subjected to a brief (<1 min) solution treatment at a peak metal temperature between 560°C and 570°C. Samples of the solution-treated product were subjected to natural aging to achieve a T4 temper. These samples were then subjected to testing for property evaluation. Additionally, some aged samples were subjected to artificial aging to achieve a T6 temper. These samples were also subjected to tests to evaluate the properties, the results of which are shown in Tables 1 and 2. The roping properties (Sa and VDA 239-400RK 10%) were also evaluated, the results of which are shown in Table 3. [Table 1] [Table 2] [Table 3]

[0079] Example 2 Aluminum alloy sheet metal samples were prepared by casting, homogenizing, hot rolling, cold rolling, and inter-annealing recrystallization of the aluminum alloy. Conventional DC casting techniques were used to prepare ingots containing AA6016. The aluminum alloy contained approximately 55% recycled aluminum content. The aluminum alloy contained approximately 0.23-0.30 wt.% Fe, 0.15-0.20 wt.% Mn, and 0.009-0.025 wt.% Cr, resulting in a Mn+Cn to Fe ratio of approximately 0.67-0.73.

[0080] The ingots were homogenized at approximately 540°C for approximately 13-14 hours. The homogenized product was hot rolled and then cold rolled to a gauge of approximately 3.5 mm, followed by inter-annealing recrystallization, and then cold rolled to a final gauge of approximately 1.0 mm. Conventional hot and cold rolling techniques were used. The exit temperature after hot rolling was approximately 350°C, which produced fine precipitates in the samples. Several different inter-annealing techniques were applied to the hot-rolled and cold-rolled product samples. Some of the samples were subjected to a final cold rolling to a T4 temper followed by a solution heat treatment and natural aging process, and their properties (e.g., grain characteristics, mechanical properties, crystal texture, surface properties, etc.) were evaluated. Comparison samples of a different alloy (AA6016) without regenerating inclusions (C1) and the same alloy (C2) were also evaluated for comparison. Here, the same hot and cold rolling processes were used, but without the inter-annealing recrystallization treatment.

[0081] The first and second inter-annealing recrystallization techniques (RX1 and RX2) involved heating the sample to 350°C for 5 seconds followed by air quenching. The third inter-annealing recrystallization technique (RX3) involved using a magnetic induction heating system to heat the sample to 365°C for 5 seconds followed by water quenching. The fourth inter-annealing recrystallization technique (RX3) involved using a magnetic induction heating system to heat the sample to 415°C for 5 seconds followed by water quenching.

[0082] Complete recrystallization of the samples was observed for all inter-annealing recrystallization techniques tested. The grain growth observed for the first and second inter-annealing recrystallization techniques was different from that observed for the third and fourth inter-annealing recrystallization techniques, but no significant grain coarsening was observed for any of the inter-annealing recrystallization techniques.

[0083] Figure 3 shows the grain size characteristics of various aluminum alloy samples. Figure 4 shows the texture characteristics of various aluminum alloy samples. Figure 5 shows the yield strength of various aluminum alloy samples. Figure 6 shows the ultimate tensile strength of various aluminum alloy samples. Figure 7 shows the uniform elongation of various aluminum alloy samples. Figure 8 shows the total elongation of various aluminum alloy samples. Figure 9 shows the strain hardening exponent at 5% strain for various aluminum alloy samples. Figure 10 shows the strain hardening exponent at 10-20% strain for various aluminum alloy samples.

[0084] The fine grain size and highly random texture resulted in better bending and roping properties and improved forming properties compared to processing without the inter-annealing recrystallization process. Additionally, a clean microstructure with a low percentage of undissolved precipitates and microvoids contributed to the good bending properties.

[0085] Exemplary Embodiments As used hereinafter, any reference to a series of embodiments (e.g., "Embodiments 1-4") or an unrecited group of embodiments 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").

[0086] Aspect 1 is an aluminum alloy comprising Al, about 1 wt.% to 1.5 wt.% Si, up to about 0.35 wt.% Fe, up to about 0.25 wt.% Cu, about 0.05 wt.% to 0.25 wt.% Mn, about 0.2 wt.% to 0.60 wt.% Mg, up to about 0.10 wt.% Cr, up to about 0.10 wt.% Ni, up to about 0.20 wt.% Zn, up to about 0.15 wt.% Ti, and up to about 0.10 wt.% V, wherein the ratio of the total amount of Mn and Cr to the amount of Fe is greater than 0.6, and at least a portion of the aluminum alloy comprises recycled aluminum alloy inclusions.

[0087] Embodiment 2 is the aluminum alloy of any preceding or subsequent embodiment, comprising up to 100% recycled aluminum alloy content, or comprising greater than 20% recycled aluminum alloy content.

[0088] Example 3 is the aluminum alloy of any preceding or subsequent example, including a 6xxx series aluminum alloy.

[0089] Example 4 is the aluminum alloy of any preceding or subsequent example, comprising about 1.2 wt.% to 1.5 wt.% Si, about 0.10 wt.% to 0.35 wt.% Fe, about 0.05 wt.% to 0.25 wt.% Cu, about 0.10 wt.% to 0.25 wt.% Mn, about 0.25 wt.% to 0.60 wt.% Mg, about 0.005 wt.% to 0.10 wt.% Cr, about 0.03 wt.% to 0.10 wt.% Ni, about 0.02 wt.% to 0.20 wt.% Zn, about 0.01 wt.% to 0.15 wt.% Ti, and about 0.01 wt.% to 0.10 wt.% V.

[0090]

[0023] Example 5 is the aluminum alloy of any preceding or subsequent example, comprising about 1.35 wt.% to 1.5 wt.% Si, about 0.20 wt.% to 0.35 wt.% Fe, about 0.10 wt.% to 0.25 wt.% Cu, about 0.10 wt.% to 0.20 wt.% Mn, about 0.25 wt.% to 0.60 wt.% Mg, about 0.009 wt.% to 0.10 wt.% Cr, about 0.05 wt.% to 0.10 wt.% Ni, about 0.02 wt.% to 0.15 wt.% Zn, about 0.01 wt.% to 0.15 wt.% Ti, and about 0.02 wt.% to 0.10 wt.% V.

[0091] Example 6 is the aluminum alloy of any preceding or subsequent example, comprising a maximum of 0.05 wt.% each of any individual impurity, and a maximum of 0.25 wt.% of all impurities.

[0092] Example 7 is the aluminum alloy of any preceding or subsequent example, comprising more alpha-phase Fe-containing intermetallic particles than beta-phase Fe-containing intermetallic particles.

[0093]

[0013] Embodiment 8 is a metal product comprising an aluminum alloy, the aluminum alloy comprising Al, about 1 wt.% to 1.5 wt.% Si, up to about 0.35 wt.% Fe, up to about 0.25 wt.% Cu, about 0.05 wt.% to 0.25 wt.% Mn, about 0.2 wt.% to 0.60 wt.% Mg, up to about 0.10 wt.% Cr, up to about 0.10 wt.% Ni, up to about 0.20 wt.% Zn, up to about 0.15 wt.% Ti, and up to about 0.10 wt.% V, wherein the ratio of the total amount of Mn and Cr to the amount of Fe is greater than 0.6, and at least a portion of the aluminum alloy comprises recycled aluminum alloy content.

[0094]

[0023] Aspect 9 is the metal product of any preceding or subsequent aspect, wherein the aluminum alloy is the aluminum alloy of any preceding or subsequent aspect.

[0095] Example 10 is the metal product of any preceding or subsequent example, wherein the metal product is a rolled metal product.

[0096] Example 11 is the metal product of any preceding or subsequent example, wherein the metal product is a dual-recrystallized metal product.

[0097] Example 12 is the metal article of any preceding or subsequent example, wherein the metal article exhibits isotropic strain properties.

[0098] Example 13 is the metal article of any preceding or subsequent example, wherein the metal article exhibits a Lankford ratio of about 0.6 or greater at about 10% strain along the machine, transverse, and diagonal directions.

[0099] Example 14 is the metal article of any preceding or subsequent example, wherein the metal article exhibits a f15% flexural modulus along the transverse direction of about 0.3 to 1.0.

[0100] Example 15 is the metal article of any preceding or subsequent example, wherein the metal article exhibits an internal bend angle of about 10° to 60° after applying a pre-strain of about 10%.

[0101] Example 16 is the metal product of any preceding or subsequent example, wherein the metal product exhibits a surface arithmetic mean height (Sa) of up to 0.60 μm.

[0102] Example 17 is the metal product of any preceding or subsequent example, wherein the metal product exhibits a yield strength of 90 MPa to 130 MPa for the T4 temper, or 200 MPa to 235 MPa for the T6 temper.

[0103] Example 18 is the metal product of any preceding or subsequent example, wherein the metal product exhibits an ultimate tensile strength of 195 MPa to 270 MPa for the T4 temper, or 240 MPa to 300 MPa for the T6 temper.

[0104] Example 19 is the metal article of any preceding or subsequent example, wherein the metal article exhibits a uniform elongation of 20% to 30% for the T4 temper, or a uniform elongation of 10% to 20% for the T6 temper.

[0105] Embodiment 19A is the metal product of any preceding or subsequent embodiment, prepared using the method of any subsequent embodiment.

[0106]

[0031] Embodiment 19B is the metal product of any preceding embodiment prepared using the aluminum alloy of any subsequent embodiment.

[0107]

[0023] Embodiment 20 is a method of making a metal product, comprising casting an aluminum alloy to produce a cast product, the aluminum alloy comprising: Al; about 1 wt.% to 1.5 wt.% Si; up to about 0.35 wt.% Fe; up to about 0.25 wt.% Cu; about 0.05 wt.% to 0.25 wt.% Mn; about 0.2 wt.% to 0.60 wt.% Mg; up to about 0.10 wt.% Cr; up to about 0.10 wt.% Ni; up to about 0.20 wt.% Zn; and up to about 0.10 wt.% Cr. 0.15 wt.% Ti and up to about 0.10 wt.% V, wherein the ratio of the total amount of Mn and Cr to the amount of Fe is greater than 0.7, and at least a portion of the aluminum alloy comprises recycled aluminum alloy inclusions; homogenizing the cast product to produce a homogenized product; hot rolling the homogenized product to produce a rolled product; and subjecting the rolled product to a final cold rolling process product to produce the metal product.

[0108] Example 21 is the method of any preceding or subsequent example, further comprising, following the hot rolling, subjecting the rolled product to a recrystallization process to produce a recrystallized product, and wherein the final cold rolling process comprises cold rolling the recrystallized product to produce the metal product.

[0109] Example 22 is the method of any preceding or subsequent example, wherein the recrystallization process occurs between the hot rolling and the final cold rolling process.

[0110] Example 23 is the method of any preceding or subsequent example, further comprising, after the hot rolling and prior to the recrystallization process, subjecting the rolled product to a preliminary cold rolling process, wherein the recrystallization process occurs between the preliminary cold rolling process and the final cold rolling process.

[0111] Example 24 is the method of any preceding or subsequent example, wherein the recrystallization process includes annealing the rolled product at a peak metal temperature of 325°C to 425°C for up to 1 minute to produce a recrystallized product; and quenching the recrystallized product.

[0112] Example 25 is the method of any preceding or subsequent example, wherein the hot rolling exit temperature is 400° C. or less.

[0113] Example 26 is the method of any preceding or subsequent example, wherein the hot rolling achieves a thickness reduction of 90% or greater between the homogenized product and the rolled product.

[0114] Example 27 is the method of any preceding or subsequent example, further comprising subjecting the metal product to a solutionization process to produce a solutionized metal product.

[0115] Example 28 is the method of any preceding or subsequent example, further comprising subjecting the metal product to an aging or artificial aging process to produce an aged metal product.

[0116] Example 29 is the method of any preceding or subsequent example, wherein the aluminum alloy comprises up to 100% recycled aluminum alloy content, or greater than 20% recycled aluminum alloy content.

[0117] Example 30 is the method of any preceding or subsequent example, wherein the aluminum alloy comprises a 6xxx series aluminum alloy.

[0118] In a thirty-first embodiment, the aluminum alloy comprises about 1.2 wt.% to 1.5 wt.% Si, about 0.10 wt.% to 0.35 wt.% Fe, about 0.05 wt.% to 0.25 wt.% Cu, about 0.10 wt.% to 0.25 wt.% Mn, about 0.25 wt.% to 0.60 wt.% Mg, and about 0.005 wt.% Cu. % to 0.10 wt.% Cr, about 0.03 wt.% to 0.10 wt.% Ni, about 0.02 wt.% to 0.20 wt.% Zn, about 0.01 wt.% to 0.15 wt.% Ti, and about 0.01 wt.% to 0.10 wt.% V.

[0119] In a thirty-second embodiment, the aluminum alloy comprises about 1.35 wt.% to 1.5 wt.% Si, about 0.20 wt.% to 0.35 wt.% Fe, about 0.10 wt.% to 0.25 wt.% Cu, about 0.10 wt.% to 0.20 wt.% Mn, about 0.25 wt.% to 0.60 wt.% Mg, and about 0.009 wt.% Si. % to 0.10 wt.% Cr, about 0.05 wt.% to 0.10 wt.% Ni, about 0.02 wt.% to 0.15 wt.% Zn, about 0.01 wt.% to 0.15 wt.% Ti, and about 0.02 wt.% to 0.10 wt.% V.

[0120] Example 33 is the method of any preceding or subsequent example, wherein the aluminum alloy contains up to 0.05 wt.% each of any individual impurity and up to 0.25 wt.% of all impurities.

[0121] Example 34 is the method of any preceding or subsequent example, wherein the metal product exhibits isotropic strain properties.

[0122] Example 35 is the method of any preceding or subsequent example, wherein the metal product exhibits a Lankford ratio of about 0.6 or greater at about 10% strain along the machine, transverse, and diagonal directions.

[0123] Example 36 is the method of any preceding or subsequent example, wherein the metal product exhibits a f15% flexural modulus along the transverse direction of about 0.3 to 1.0.

[0124] Example 37 is the method of any preceding or subsequent example, wherein the metal article exhibits an internal bend angle of about 10° to 60° after applying a pre-strain of about 10%.

[0125] Example 38 is the method of any preceding or subsequent example, wherein the metal product exhibits a surface arithmetic mean height (Sa) of up to 0.60 μm.

[0126] Example 39 is the method of any preceding or subsequent example, wherein the metal product exhibits a yield strength of 90 MPa to 130 MPa for the T4 temper, or 200 MPa to 235 MPa for the T6 temper.

[0127] Example 40 is the method of any preceding or subsequent example, wherein the metal product exhibits an ultimate tensile strength of 195 MPa to 270 MPa for the T4 temper, or 240 MPa to 300 MPa for the T6 temper.

[0128] Example 41 is the method of any preceding or subsequent example, wherein the metal product exhibits a uniform elongation of 20% to 30% for the T4 temper, or a uniform elongation of 10% to 20% for the T6 temper.

[0129] Example 42 is the method of any preceding example, wherein the aluminum alloy is the aluminum alloy of any preceding example.

[0130] 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. An aluminum alloy comprising Al and about 1 wt. % to 1.5 wt. % Si; up to about 0.35 wt. % Fe; up to about 0.25 wt. % Cu; about 0.05 wt. % to 0.25 wt. % Mn; Approximately 0.2 wt. % to 0.60 wt. % Mg; % Cr; and up to about 0.10 wt. % Ni; Zn up to about 0.20 wt. %; up to about 0.15 wt. % Ti; up to about 0.10 wt. % V; Including, The ratio of the total amount of Mn and Cr to the amount of Fe is greater than 0.6, and at least a portion of the aluminum alloy contains recycled aluminum alloy inclusions. The aluminum alloy.

2. 10. The aluminum alloy of claim 1, comprising up to 100% recycled aluminum alloy content, or comprising more than 20% recycled aluminum alloy content.

3. 10. The aluminum alloy of claim 1, comprising a 6xxx series aluminum alloy.

4. about 1.2 wt. % to 1.5 wt. % Si; about 0.10 wt. % to 0.35 wt. % Fe; about 0.05 wt. % to 0.25 wt. % Cu; about 0.10 wt. % to 0.25 wt. % Mn; Approximately 0.25 wt. % to 0.60 wt. % Mg; about 0.005 wt. % to 0.10 wt. % Cr; about 0.03 wt. % to 0.10 wt. % Ni; about 0.02 wt. % to 0.20 wt. % Zn; about 0.01 wt. % to 0.15 wt. % Ti; About 0.01 wt. % to 0.10 wt. % V; 2. The aluminum alloy of claim 1, comprising:

5. about 1.35 wt. % to 1.5 wt. % Si; about 0.20 wt. % to 0.35 wt. % Fe; about 0.10 wt. % to 0.25 wt. % Cu; about 0.10 wt. % to 0.20 wt. % Mn; Approximately 0.25 wt. % to 0.60 wt. % Mg; about 0.009 wt. % to 0.10 wt. % Cr; about 0.05 wt. % to 0.10 wt. % Ni; about 0.02 wt. % to 0.15 wt. % Zn; about 0.01 wt. % to 0.15 wt. % Ti; About 0.02 wt. % to 0.10 wt. % V; 2. The aluminum alloy of claim 1, comprising:

6. 10. The aluminum alloy of claim 1, containing up to 0.05 wt.% of any individual impurity and up to 0.25 wt.% of all impurities.

7. 10. The aluminum alloy of claim 1 comprising more alpha phase Fe-containing intermetallic particles than beta phase Fe-containing intermetallic particles.

8. A metal product comprising an aluminum alloy, comprising: Al; about 1 wt. % to 1.5 wt. % Si; up to about 0.35 wt. % Fe; up to about 0.25 wt. % Cu; about 0.05 wt. % to 0.25 wt. % Mn; Approximately 0.2 wt. % to 0.60 wt. % Mg; % Cr; and up to about 0.10 wt. % Ni; Zn up to about 0.20 wt. %; up to about 0.15 wt. % Ti; up to about 0.10 wt. % V; Including, The ratio of the total amount of Mn and Cr to the amount of Fe is greater than 0.6, and at least a portion of the aluminum alloy contains recycled aluminum alloy inclusions. The metal product.

9. The metal product according to claim 8, wherein the aluminum alloy is the aluminum alloy according to any one of claims 1 to 7.

10. 9. The metal product of claim 8, wherein the metal product is a rolled metal product.

11. 9. The metal product of claim 8, wherein the metal product is a doubly recrystallized metal product.

12. The metal article of claim 8 , wherein the metal article exhibits isotropic strain properties.

13. 10. The metal product of claim 8, wherein the metal product exhibits a Lankford ratio of greater than or equal to about 0.6 at about 10% strain along the machine, transverse, and diagonal directions.

14. 9. The metal product of claim 8, wherein the metal product exhibits an f15% flexural modulus along the transverse direction of about 0.3 to 1.

0.

15. 9. The metal product of claim 8, wherein the metal product exhibits an internal bend angle of about 10° to 60° after a 10% pre-strain.

16. 9. The metal product of claim 8, wherein the metal product exhibits a surface arithmetic mean height (Sa) of at most 0.60 μm.

17. 9. The metal product of claim 8, wherein the metal product exhibits a yield strength of 90 MPa to 130 MPa in the T4 temper, or 200 MPa to 235 MPa in the T6 temper.

18. 9. The metal product of claim 8, wherein the metal product exhibits an ultimate tensile strength of 195 MPa to 270 MPa in the T4 temper, or 240 MPa to 300 MPa in the T6 temper.

19. 9. The metal product of claim 8, wherein the metal product exhibits a uniform elongation of 20% to 30% in the T4 temper or a uniform elongation of 10% to 20% in the T6 temper.

20. 1. A method for producing a metal product, comprising: Casting an aluminum alloy to produce a cast product, the aluminum alloy comprising Al and about 1 wt. % to 1.5 wt. % Si; up to about 0.35 wt. % Fe; up to about 0.25 wt. % Cu; about 0.05 wt. % to 0.25 wt. % Mn; Approximately 0.2 wt. % to 0.60 wt. % Mg; % Cr; and up to about 0.10 wt. % Ni; Zn up to about 0.20 wt. %; up to about 0.15 wt. % Ti; up to about 0.10 wt. % V; Including, a ratio of the total amount of Mn and Cr to the amount of Fe is greater than 0.7, and at least a portion of the aluminum alloy comprises recycled aluminum alloy inclusions; homogenizing the cast product to produce a homogenized product; hot rolling the homogenized product to form a rolled product; subjecting said rolled product to a final cold rolling process product to produce said metal product; The method comprising:

21. following the hot rolling, subjecting the rolled product to a recrystallization process to produce a recrystallized product, wherein the final cold rolling process cold rolls the recrystallized product to produce the metal product.

21. The method of claim 20.

22. 22. The method of claim 21, wherein the recrystallization process occurs between the hot rolling and the final cold rolling process.

23. subjecting the rolled product to a preliminary cold rolling process after the hot rolling and before the recrystallization process, wherein the recrystallization process occurs between the preliminary cold rolling process and the final cold rolling process; 22. The method of claim 21 further comprising:

24. the recrystallization process comprises: annealing the rolled product at a peak metal temperature of 325°C to 425°C for up to 1 minute to produce a recrystallized product; quenching the recrystallized product; 22. The method of claim 21, comprising:

25. 21. The method of claim 20, wherein the hot rolling exit temperature is 400°C or less.

26. 21. The method of claim 20, wherein the hot rolling achieves a thickness reduction of 90% or greater between the homogenized product and the rolled product.

27. subjecting said metal product to a solution process to produce a solutionized metal product; 21. The method of claim 20, further comprising:

28. subjecting the metal product to an aging or artificial aging process to produce an aged metal product; 21. The method of claim 20, further comprising:

29. 21. The method of claim 20, wherein the aluminum alloy comprises up to 100% recycled aluminum alloy content, or greater than 20% recycled aluminum alloy content.

30. 21. The method of claim 20, wherein the aluminum alloy comprises a 6xxx series aluminum alloy.

31. The aluminum alloy is about 1.2 wt. % to 1.5 wt. % Si; about 0.10 wt. % to 0.35 wt. % Fe; about 0.05 wt. % to 0.25 wt. % Cu; about 0.10 wt. % to 0.25 wt. % Mn; Approximately 0.25 wt. % to 0.60 wt. % Mg; about 0.005 wt. % to 0.10 wt. % Cr; about 0.03 wt. % to 0.10 wt. % Ni; about 0.02 wt. % to 0.20 wt. % Zn; about 0.01 wt. % to 0.15 wt. % Ti; About 0.01 wt. % to 0.10 wt. % V; 21. The method of claim 20, comprising:

32. The aluminum alloy is about 1.35 wt. % to 1.5 wt. % Si; about 0.20 wt. % to 0.35 wt. % Fe; about 0.10 wt. % to 0.25 wt. % Cu; about 0.10 wt. % to 0.20 wt. % Mn; Approximately 0.25 wt. % to 0.60 wt. % Mg; about 0.009 wt. % to 0.10 wt. % Cr; about 0.05 wt. % to 0.10 wt. % Ni; about 0.02 wt. % to 0.15 wt. % Zn; about 0.01 wt. % to 0.15 wt. % Ti; About 0.02 wt. % to 0.10 wt. % V; 21. The method of claim 20, comprising:

33. 21. The method of claim 20, wherein the aluminum alloy contains up to 0.05 wt.% of each of any individual impurities and up to 0.25 wt.% of all impurities.

34. 21. The method of claim 20, wherein the metal product exhibits isotropic strain properties.

35. 21. The method of claim 20, wherein the metal product exhibits a Lankford ratio of greater than or equal to about 0.6 at about 10% strain along the machine, transverse, and diagonal directions.

36. 21. The method of claim 20, wherein the metal product exhibits an f15% flexural modulus along the transverse direction of about 0.3 to 1.

0.

37. 21. The method of claim 20, wherein the metal product exhibits an internal bend angle of about 10° to 60° after a 10% pre-strain.

38. 21. The method of claim 20, wherein the metal product exhibits a surface arithmetic mean height (Sa) of at most 0.60 μm.

39. 21. The method of claim 20, wherein the metal product exhibits a yield strength of 90 MPa to 130 MPa in the T4 temper, or 200 MPa to 235 MPa in the T6 temper.

40. 21. The method of claim 20, wherein the metal product exhibits an ultimate tensile strength of 195 MPa to 270 MPa in the T4 temper, or 240 MPa to 300 MPa in the T6 temper.

41. 21. The method of claim 20, wherein the metal product exhibits a uniform elongation of 20% to 30% in the T4 temper, or 10% to 20% in the T6 temper.

42. The method of claim 20, wherein the aluminum alloy is the aluminum alloy of any one of claims 1 to 7.

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